7 - Cold Handling Operation Manual - Version A

PLTU Kaltim-Teluk Balikpapan
(2110MW) CFB Power Plant

(2110MW)CFB
Cold Handling Operation Manual
PT PERUSAHAAN LISTRIK NEGARA
SINOHYDRO CORPORATION LIMITED
QINGDAO HUAFENG WEIYE ELECTRIC POWER

TECHNOLOGY ENGINEERING CO., LTD
YAN BIN
DOCUMENT NO.
SHCL-KT08-SC-060-2014
CHECKED BY
LI GAOFENG
VERSION
REVIEWED BY
SU YONGDE
DATE 3/16/2015
VOLUME 7 OF 11
EDITED BY
APPROVED BY
O&M Manual for PLTU Kaltim-Teluk Balikpapan Power Plant Project
Foreword
This manual is prepared according to maintenance instructions and relevant

drawings for Coal Handling system provided by the manufacture of Indonesia
2110MW Balikpapan coal-fired power plant. It specifies the general principles
and methods for running, operation, maintenance and accident management of
Coal Handling system of 110MW unit in Indonesia 2110MW Balikpapan coalfired power plant project.
2110MW
2110MW
110MW
CONTENTS
Overview of Coal Handling System ....................................................................................................
.....................................................................................................................................
Coal Unloading Equipment and Equipment of Coal Yard ................................................................... 8
.................................................................................................................................
Fixed Hanging Chain Bucket Ship Unloader ......................................................................................
9
9
2.1.1
.........................................................................................................................
Equipment Overview ...........................................................................................................................
2.1.1
.............................................................................................................................................
2.1.2
Technical Specification ......................................................................................................................
10
2.1.2
...........................................................................................................................................
10
2.1.3
Introduction to Main Components of Ship Unloader ........................................................................
10
2.1.3
.......................................................................................................................
10
2.1.4
Check prior to Startup ........................................................................................................................
12
2.1.4
...........................................................................................................................................
12
2.1.5
Precautions ........................................................................................................................................
13
2.1.5
...................................................................................................................................
13
2.1.6
Basic Requirements for Equipment Application ...............................................................................
13
2.1.6
.......................................................................................................................
13
2.1.7
Ship Unloading Procedures ...............................................................................................................
16
2.1.7
.......................................................................................................................
16
2.1.8
Operation under Working Condition of Ship Unloader .....................................................................
21
2.1.8
21
2.1.9
...............................................................................................................
Operating Instructions of Electrical System ......................................................................................
2.1.9
...........................................................................................................................
25
2.1.10
Operation When the Ship Unloader is not Working ..........................................................................
27
2.1.10
27
2.1.11
...........................................................................................................
Provisions on Inspection Cycle .........................................................................................................
2.1.11
...............................................................................................................................
27
2.1.12
Safety Warning ..................................................................................................................................
28
2.1.12
...........................................................................................................................................
28
2.2
Stacker-reclaimers .............................................................................................................................
30
2.2
...................................................................................................................................
30
2.2.1
Equipment Overview .........................................................................................................................
30
2.2.1
...........................................................................................................................................
30
2.2.2
2.2.2
Technical Specification ......................................................................................................................
...........................................................................................................................................
30
30
2.2.3
Overview of Working Principle and Structure ...................................................................................
36
2.2.3
...........................................................................................................
Maintenance and Safe Operation .......................................................................................................
36
2.1
2.1
2.2.4
9
9
25
27
43
2.2.4
2.2.5
2.2.5
...................................................................................................................
Operation Modes and Characteristics ................................................................................................
43
49
2.3.5
49
...................................................................................................................
Operation Instructions ....................................................................................................................... 55
55
...............................................................................................................................
Electrical Operating Specifications ................................................................................................... 58
58
...........................................................................................................................
Control over Each Mechanism of Bucket Wheel Machine................................................................ 66
66
...........................................................................................................................
Maintenance and Service of Electrical Equipment ............................................................................ 85
85
...................................................................................................................
Failures and Troubleshooting Methods of Bucket Wheel Machine ................................................... 87
87
...............................................................................................................
Fire Prevention .................................................................................................................................. 95
........................................................................................................................................... 95
Safety Rules of Equipment ................................................................................................................ 96
96
.......................................................................................................................
Maintenance and Safety Technologies of Equipment ...................................................................... 102
102
.................................................................................................................
Bridge-type Grab Crane ................................................................................................................... 108
108
.............................................................................................................................
Equipment Overview ....................................................................................................................... 108
......................................................................................................................................... 108
Electrical Control Principle .............................................................................................................. 112
.................................................................................................................................. 112
Notes for Use ................................................................................................................................... 128
......................................................................................................................................... 128
Electrical Inspection System............................................................................................................ 133
................................................................................................................................. 133
Troubleshooting ............................................................................................................................... 135
......................................................................................................................................... 135
2.3.6
Lubrication of Mechanism ............................................................................................................... 142
2.3.6
2.3.7
2.3.7
..................................................................................................................................... 142
Operational Test ............................................................................................................................... 147
......................................................................................................................................... 147
3
3
Equipment for Coaling System ........................................................................................................ 150

................................................................................................................................. 150
3.1
Belt Conveyor .................................................................................................................................. 150
2.2.6
2.2.6
2.2.7
2.2.7
2.2.8
2.2.8
2.2.9
2.2.9
2.2.10
2.2.10
2.2.11
2.2.11
2.2.12
2.2.12
2.2.13
2.2.13
2.3
2.3
2.3.1
2.3.1
2.3.2
2.3.2
2.3.3
2.3.3
2.3.4
2.3.4
2.3.5
3.1
3.1.1
3.1.1
3.1.2
3.1.2
..................................................................................................................................... 150
Equipment Overview ....................................................................................................................... 150
......................................................................................................................................... 150
Main Parameters .............................................................................................................................. 151
......................................................................................................................................... 151
2
3.1.3
Inspection before Operation ............................................................................................................
153
3.1.3
.................................................................................................................................
Preparation before Starting-up .........................................................................................................
153
154
3.1.5
.................................................................................................................................
Commissioning ................................................................................................................................
3.1.5
.................................................................................................................................................
155
3.1.6
Inspection and Adjustment during Operation ..................................................................................
156
3.1.6
.....................................................................................................................
Precautions after Decommissioning ................................................................................................
156
.............................................................................................................................
Failure and Troubleshooting ............................................................................................................
157
.....................................................................................................................................
Vibrating Coal Feeder ......................................................................................................................
158
.....................................................................................................................................
Equipment Overview .......................................................................................................................
163
3.1.4
3.1.4
3.1.7
3.1.7
3.1.8
3.1.8
3.2
3.2
3.2.1
3.2.1
154
155
157
158
163
.........................................................................................................................................
163
163
3.2.2
Technical Specification ....................................................................................................................
164
3.2.2
.........................................................................................................................................
164
3.2.3
Operation of Vibrating Coal Feeder .................................................................................................
164
3.2.3
.............................................................................................................................
Common Faults and Troubleshooting Measures .............................................................................
164
.............................................................................................................................
Double-toothed Roll Crusher ...........................................................................................................
167
169
3.3.1
.............................................................................................................................
3.3.1
.........................................................................................................................................
169
3.3.2
Technical Specification ....................................................................................................................
170
3.3.2
.........................................................................................................................................
170
3.3.3
Crushing Principle ...........................................................................................................................
173
3.3.3
.........................................................................................................................................
173
3.3.4
Operation Method ............................................................................................................................
175
3.3.4
.........................................................................................................................................
175
3.3.5
Precautions for Startup ....................................................................................................................
178
3.3.5
.................................................................................................................................
Safe Operation Rules .......................................................................................................................
178
.................................................................................................................................
Failure and Troubleshooting ............................................................................................................
180
.....................................................................................................................................
182
3.2.4
3.2.4
3.3
3.3
3.3.6
3.3.6
3.3.7
3.3.7
167
169
169
180
182
3.3.8
Crusher Maintenance .......................................................................................................................
183
3.3.8
.................................................................................................................................
Belt-type Electromagnetic iron ........................................................................................................
183
.............................................................................................................................
185
3.4
3.4
3.4.1
185
185
3.4.2
3.4.2
............................................................... 185
Technical Specification......................................................................................................................185
............................................................... 185
3.4.3
Inspection before Equipment Operation............................................................................................186
3.4.3
........................................................ 186
3.4.4
Operation of the Iron Remover..........................................................................................................187
3.4.4
3.4.7
3.4.7
............................................................ 187
Inspection of Iron Remover during Operation...................................................................................189
...................................................... 189
Notes for Shutdown of the Iron Remover..........................................................................................190
...................................................... 190
Iron Remover Faults and the Treatment Methods..............................................................................190
...................................................... 190
3.4.8
Notes for Use......................................................................................................................................192
3.4.8
............................................................ 192
3.4.9
Maintenance........................................................................................................................................193
3.4.9
............................................................. 193
3.5
3.5
Electronic Belt Scale..........................................................................................................................194

............................................................. 194
3.5.1
Equipment Overview..........................................................................................................................194
3.5.1
............................................................... 194
3.5.2
3.5.2
3.5.3
............................................................... 194
Inspection before Operation of Electronic Belt Scale........................................................................194
.................................................. 194
3.5.4
Start, Test and Adjustment..................................................................................................................195
3.5.4
............................................................. 195
3.5.5
3.5.5
Notes for Operation of Electronic Belt Scale.....................................................................................195

.............................................. 195
3.5.6
Electronic Belt Scale Faults and the Treatment Methods..................................................................196
3.5.6
.................................................. 196
3.6
Central Sampling Device of the Belt.................................................................................................197
3.6
3.6.1
...................................................... 197
Equipment Overview..........................................................................................................................197
............................................................... 197
3.6.2
3.6.2
............................................................... 198
3.4.1
3.4.5
3.4.5
3.4.6
3.4.6
3.5.3
3.6.1
246

Nn U

Equipment Components, and Technical Parameters, Structure and Performance of Each Component
198
3.6.3
3.6.4
3.6.4
3.6.5
...................................... 198
Electrical Control System...................................................................................................................205
............................................................ 205
Working Principle...............................................................................................................................206
4
3.6.5
.........................................................................................................................................
206
3.6.6
Operating Process ............................................................................................................................
208
3.6.6
.........................................................................................................................................
208
3.6.7
Maintenance ....................................................................................................................................
209
3.6.7
.....................................................................................................................................
List of Equipment Bearing ..............................................................................................................
209
.............................................................................................................................
Lubricating Materials and Lubricating Requirements .....................................................................
212
3.6.8
3.6.8
3.6.9
3.6.9
212
213
.....................................................................................................................
3.6.10 List of Vulnerable Parts of Equipment ............................................................................................
213
3.6.10
.............................................................................................................................
Flat Bag-type Dust Collector ...........................................................................................................
3.7
216
3.7
217
3.7.1
.............................................................................................................................
3.7.1
.........................................................................................................................................
217
3.7.2
3.7.2
Working Principle ............................................................................................................................
.........................................................................................................................................
217
217
3.7.3
Operation of Bag-type Dust Collector .............................................................................................
218
3.7.3
.........................................................................................................................
Maintenance of Bag-type Dust Collector ........................................................................................
218
.............................................................................................................
Treatment Methods of General Faults .............................................................................................
219
.....................................................................................................................
Fixed Vacuum Cleaning Device ......................................................................................................
220
221
3.8.1
.....................................................................................................................
3.8.1
.........................................................................................................................................
221
3.8.2
Working Principle ............................................................................................................................
221
3.8.2
.........................................................................................................................................
221
3.8.3
Diagram of Power Head Parts and Components of Cleaner ............................................................
223
3.8.3
223
3.8.4
.................................................................................................................
Operation .........................................................................................................................................
3.8.4
.........................................................................................................................................
224
3.8.5
3.8.5
Automatic Protection System ..........................................................................................................
227
227
3.7.4
3.7.4
3.7.5
3.7.5
3.8
3.8
3.8.6
3.8.6
3.9
.................................................................................................................................
Nozzles for Material Suction and Transmission ..............................................................................
.............................................................................................................................
Unloader ..........................................................................................................................................
216
217
217
219
220
221
221
224
229
229
230
3.9
.............................................................................................................................................
231
3.9.1
231
3.9.1
.........................................................................................................................................
231
3.9.2
Working Principle and Structure ......................................................................................................
232
3.9.2
.....................................................................................................................
232
3.9.3
Technical Parameters ....................................................................................................................... 234
3.9.3
234
.........................................................................................................................................
3.9.4
Stroke Adjustment ...........................................................................................................................
3.9.4 .................................................................................................................................
3.10
Warehouse Wall Vibrator .................................................................................................................
3.10
.....................................................................................................................................
3.10.1 Equipment Overview .......................................................................................................................
3.10.1 .........................................................................................................................................
3.10.2 Working Principle ............................................................................................................................
3.10.2 .........................................................................................................................................
3.10.3 Table of Technical Parameters .........................................................................................................
3.10.3 .....................................................................................................................................
3.10.4 Operation and Maintenance .............................................................................................................
3.10.4 .....................................................................................................................................
3.10.5 Common Faults and Troubleshooting Measures .............................................................................
3.10.5 .............................................................................................................
3.11
Air Cannon ......................................................................................................................................
3.11
.............................................................................................................................................
3.11.1 Equipment Overview .......................................................................................................................
3.11.1 .........................................................................................................................................
3.11.2 Main Parameters ..............................................................................................................................
3.11.2 .........................................................................................................................................
3.11.3 Operation .........................................................................................................................................
3.11.3 .........................................................................................................................................
3.11.4 Maintenance and Usage ...................................................................................................................
3.11.4 .....................................................................................................................................
3.11.5 Troubleshooting ...............................................................................................................................
3.11.5 .............................................................................................................................
4
Troubleshooting for the Unloading, Handling and Storage System ................................................
4
.........................................................................................
4.1
Principle ...........................................................................................................................................
4.1
.................................................................................................................................
4.2
Emergency Shutdown ......................................................................................................................
4.2
.........................................................................................................................................
4.2.1 Conditions for Emergency Shutdown ...............................................................................................
4.2.1 .............................................................................................................................
4.2.2
Operating Steps of Emergency Shutdown .......................................................................................
4.2.2 .....................................................................................................................
4.3
Solution for Interruption of Auxiliary Power ..................................................................................
4.3
.........................................................................................................................
4.4
Precautions and Solution for Wet Coal in Rainy Season .................................................................
4.4
.........................................................................................................
4.5
Precautions and Adjustment for Loading Coal with Large Dust Concentration ..............................
6
234
234
234
234
234
234
235
235
235
235
235
235
236
236
238
238
238
238
239
239
239
239
240
240
241
241
245
245
245
245
245
246
246
246
246
246
247
247
247
247
248
4.5
........................................ 248
1
1
Overview of Coal Handling System
The capacity of the Coal Handling system for the Station is designed as 2 sets of 110MW
units. The Coal Handling system is used to unload coal from the coal transporting barges at
the coal unloading wharf of the Station and convey to the coal yard and treat the coal to be
with the particle size required by the boiler and finally convey to the raw coal bunker of the
boiler.
2 110MW
Two ship unloaders of hanging chain buckets are installed at the coal unloading wharf to
unload coal. One transporter grab crane with a span of 24.5m and rated elevating capacity
of 4t (excluding the weight of the grab bucket) is arranged in the dry coal shed.
1
24.5m
4t()
The open coal yard is provided with one stacker-reclaimers and reclaimer with its arm
length of 30m, rated stacking output of 960t/h and reclaiming output of 240t/h to stack coal
and reclaim coal in the open coal yard.
1 30m 960t/h
240t/h
Each belt conveyor of the Coal Handling system is provided with protective devices such as
bidirectional pull switch, bipolar deviation switch, slip switch and speed detection switch.
Both design coal and check coal are Indonesia lignite.
All devices in the Coal Handling system of the Station can guarantee continuous work for
24 hours every day and 7 days every week and adapt to the climate conditions where the
devices are located.
24 7
Coal Unloading Equipment and Equipment of

8
Coal Yard
2
Fixed Hanging Chain Bucket Ship Unloader
5888
Equipment Overview
23
XCJLD800 fixed hanging chain bucket ship unloader is mainly composed of the following
items:
XCJLD800 :
Moving ship system, stand column, cantilever beam, cross traveling trolley, chain bucket
mechanism, belt conveyor, lifting mechanism, counterweight system and electrical control
system, etc.

Safety devices include:
Buffer stopper, limit switch, brake, wind speed alarm, lightning rod, fire extinguisher,
interlock protection device, electric protective device and rain-proof motor cover, etc.
Electric protective devices include:
Main isolator, emergency power off button, short-circuit protection device, over-current
protection device, earthing protection device, no-voltage protection device and zero
protection device.
Operation modes of traveling audible and visual alarm
Various electromechanical devices are mainly operated on the linkage control panel of the
operator cabin and have three states: manual, debugging and stop.
23
Technical Specification
23
23
Introduction to Main Components of Ship Unloader
23
Ship unloader is mainly composed of the following mechanical components:

10
23
Traveling mechanism of cart
23
24
Trolley
23
24
Grab bucket
2.1.3.3
2.1.3.4
Pitching mechanism of boom
2.1.3.4
2.1.3.5
Movable operator cabin, pitching control room of boom and secondary electrical control
room
2.1.3.5
2.1.3.6
Hopper
23
24
Feeding belt conveyor
2.1.3.7
2.1.3.8
Raw coal retaining plate and mechanism
2.1.3.8
2.1.3.9
Lifting and opening & closing mechanism and hauling mechanism of trolley
2.1.3.9
2.1.3.10
Water spraying and dust suppression system
23
24
Elevator, ladder, platform and walkway
Power and control cable coiling apparatus
23
24
Anchoring and hurricane prevention system
Machinery and electric appliance room
23
24
Rope-supporting trolley and hauling system
23
24
Service crane
11
Check prior to Startup
23
23
Before operation, check whether there is any operator or barrier on the travel track and
within the moving range of the ship unloader; check whether the anchoring device, anticreep iron wedge, hurricane prevention mooring and wheel clamp are complete and in
good condition. Relieve the anchoring device, hurricane prevention mooring and anti-creep
iron wedge from anchoring.
23
24
For boarding for shift change, check the ship unloader along the boarding route. Check the
main cable for any warp, appearance damage and looseness; check whether the hopper
system is in good condition; check the connecting pieces of the grab bucket for safety and
the steel wire rope for wear. Timely report is necessary once any abnormality is found.
23
24
Check whether the steel wire rope and its connector are normal and tighten them once any
looseness is found.
23
24
Check the front and rear girders of the ship unloader and confirm whether there is any
barrier on the traveling track and within the moving range of the trolley and ropesupporting trolley and whether the trolley track is normal.
23
24
Check the lifting and opening & closing mechanism and steel wire rope of strainer of
rope-supporting trolley and brake arrestor for their wear.
23
24
Check each lubricating point of the ship unloader for lubrication and check whether the fuel
mass in the fuel tank and reduction box meet the requirements.
23
24
Check each drive, transmission and operating mechanism, electrical circuit, electrical
equipment, protective facility, hydraulic equipment and actuator for any abnormality.
12
23
23
Precautions
23
Both two handles used to operate the linkage control panel have gears in each moving
direction to control the speed of each mechanism. In addition, the linkage control panel is
provided with horn button, stand-alone option switch and emergency shutdown button
which is used to stop the unloader in case of any emergency. Other signal lamps and
buttons are all equipped with corresponding nameplates for identification.
23
24
There are two pedals in front of the operator: the left one is rotating inching foot switch and
the right one is stand-alone pedal.
256
257
Drive the crane over the anchoring pit and anchor the anchoring device into the anchoring
pit in advance in case of gale.
Check the anchoring device for reliability frequently.
Basic Requirements for Equipment Application
5888
Requirements for Operator
Operator:
The ship unloader shall be operated by the following personnel:
A operator passing relevant exams (the operator must pass relevant exams again if
he/she has left for three months before taking his/her post again.)
()
13
Trainees having studied for at least half a year under the direct supervision of the
operator
23
The operator shall comply with the following conditions:

a)
Aged at least 18 and healthy; a)

18
b)
With a visual acuity (including corrected visual acuity) of at least 0.7 and without
achromatopsia;
b) () 0.7 c) With a hearing

that meets the requirements of working conditions; c)
The operator shall be familiar with the following contents:
Structure and technical performance of each mechanism of the ship unloader
Operating standards of the ship unloader and relevant laws;
23
24
Performance of safety and protective devices;
5888
5889 Basic information on prime motor and electric;
Maintenance and basic repair skills
0.0
General Requirements for Safe Operation
Before taking over the shift, the operator shall check the brake, steel wire rope and
safety devices. Any abnormality shall be eliminated before operation.
Ringing and alarm are necessary before startup. Interrupted ring or alarm shall be
given when any person is approaching during the operation.
23
24
Execute any emergency shutdown signal given by anyone immediately.

14
23
24
The main power supply shall not be closed until the ship unloader or its surrounding
area is free of person. If the power supply tripper is locked or equipped with any sign,
relevant personnel shall unlock the tripper or remove the sign before closing the main
power supply.
23
24
The handles of all controllers shall be at the zero position before the main power
supply is closed.
23
24
23
In case of sudden power outage during the operation, the handles of all controllers
shall be put at the zero position; check the action of the ship unloader for any
abnormality before re-operation.
24
Put the chain bucket into the wharf after operation. Stop operation when the wind
speed is larger than 20m/s.

1024
20m/s
0
Safety and Technical Requirements
23
Operation is not allowed in case of any of the following conditions:
The chain bucket mechanism works abnormally.
Any structure or component has any defect or damage that may influence safe
operation such as failure of brake and safety device or damage of steel wire rope that
must be replaced.
23
24
The unloaded materials have particle sizes exceeding 300mm300mm.
23
>300 300
24
The work place is so dark that the site, unloaded materials or commanding signals
cannot be seen clearly.
23
15
The operator shall comply with the following requirements during the operation:
23
The operator shall not stop the unloader through the limiter at the limiting position;
23
24
The operator shall not adjust the brake of the lifting mechanism with load;
23
24
No person is allowed to be under the chain bucket mechanism.
c)
d)
No repair is allowed when the unloader is running.
d)
e)
The steel wire rope on the drum shall have safe number of turns specified by the
design when the cantilever beam is at the lowest position;
23
24
Except in special emergency conditions, it is not allowed to brake by turning the

unloader in a reverse direction.
23
23
Ship Unloading Procedures
23
512
Normal Procedures
Barge docking check before operation request unloading order from the Coal
Handling program control room start manual procedures (putting the operating handle at
the zero position) close the main isolator close air switch of each control cabinet
start the reclaiming belt conveyor after the rear belt conveyors start successively start the
traveling mechanism start the chain bucket mechanism drop the cantilever beam
operation of working status barge emptying and departure
(
)

Barge docking: for barge docking, docking request shall be given to the wharf and the
operator shall check the following items:
5888
16
.0
Check whether the cable crimping device at the wharf is intact;
Check whether the cantilever beam is at the high position;
Check whether the chain bucket mechanism is back to the wharf;
The mariners shall take life chutes.
Prepare for ship unloading and send docking signal to the barge after proper check and
preparation.
Check before operation shall comply with relevant provisions.
5888
5888 Request unloading order: report to the program control room that the barge docking is
completed and the ship unloader is normal and request for unloading order.
23
Put the operating lock in the manual procedure and each operating handle at the zero
position and into the system for interlocking.
23
24
Close the main isolator. When the program control room gives unloading order, check
each operating handle on the linkage control panel and after the button positions are
confirmed to be correct, close the main isolator for power supply and also check the
voltage.
23
24
Close the air switch of each control cabinet and check the voltage.
23
23
Start the reclaiming belt conveyor. Press down the start button of the conveyor to
check the no-load current of the conveyor.
Start the hoist: adjust the variable-frequency power source to adjust the mains
frequency to be 8~15Hz. Press down the moving forward or backward button to start
the hoist and gradually adjust the frequency until the speed reaches 5~8m/min. When
the traveling mechanism reaches the ship head, gradually reduce the frequency and
17
stop the traveling mechanism when the frequency drops to 15~8Hz. Always check the
current and pay attention to the current change during the operation.
5888 815Hz
58m/min
158Hz
5889 Start the chain bucket mechanism and press down the start button of the chain bucket
mechanism to check the current and operating noise of the chain bucket mechanism
for any abnormality.
Start the cross traveling trolley: press down the forward button. Stop the trolley when
it reaches to the transverse center of the barge.
Drop the cantilever beam according to the coal volume in the hopper of the chain
bucket mechanism, generally by inching interrupted operation. Stop dropping when
the excavation depth of the hopper is proper. At this moment, start the traveling
mechanism to continue operation.
Normal coal unloading operation
Barge emptying and departure
After the barge is emptied, lift the cantilever beam to the high position and put the
chain bucket mechanism back to the wharf and stop each mechanism successively.
. When the barge is moved to the wharf center, fix the barge on the wharf bollard
and then loose the cable and roll the cable on the drum of the cable ratchet. Put each
operating handle at the zero position. Take out the operating lock key and disconnect
the air switch of each control cabinet.
18
Working Procedures under Repair
0
Operating procedures: relieve the interlocked operation lock and put at the debugging
position coordinate with the repair personnel for operation. Cut off power for each
mechanism, and hang warning signs when the repair personnel is repairing Repair is
completed. Follow the instructions from the repair personnel to debug the repair parts
independently. Check whether the site complies with the requirements of the safety rules.
1 Operation under Emergencies
Emergencies refer to rainstorms, earthquakes, fire (when fire happens to the belt conveyor,
measures shall be taken according to the fire emergency procedures of the belt and carrier
roller.), equipment blockage, damage, injuries or threats to personal safety. In these
conditions, if normal shutdown procedures do not work, then the master shutdown button
shall be pressed down to stop the equipment.
(
)
Precautions during operation
Before each working mechanism of the ship unloader starts, the belt conveyor system and
the reclaiming belt conveyor shall be started successively through corresponding buttons.

Start the hoist, adjust the positions of ship unloader and barge and move the chain
bucket mechanism to the starting end of the barge. The control operation modes of the
moving ship system include rotating rotary knob to travel forward and backward.
Traveling backward shall start from low speed to high speed gradually. For shutdown
or reversing, the speed shall be reduced gradually until the system stops before
reversing.
5888
19
Before
the
chain hopper is put into operation, no-load debugging after installation is necessary to
check whether each mechanism can work normally within the specified working
scope and whether each indication and limit device is working normally. If no
abnormality or abnormal noise is found and each limit and indication device is
working normally, it shall be considered that the no-load debugging result is good.
Operators of the chain hopper must be provided with relevant training and pass
relevant exams, be familiar with the structure and the maintenance and safe operation
specifications of the chain hopper before operation. Other personnel except the
operators or maintenance personnel shall not climb the chain hopper without approval.
1 Normal working temperature of the chain hopper is +40 and the maximum wind speed
is 20m/s.
0
+40 , 20m/s
Not only the chain hopper but also the working site shall be provided with sufficient
lighting facilities if the chain hopper is working at night.
Lubricating oil, oil cotton yarn and other inflammable and explosive materials shall be
stored in dedicated room properly. No inflammable and explosive material can be
stored in the operator cabin or electrical room.
Proper electrical grounding facilities must be provided for the chain hopper to avoid
lightning stroke. In case of thunderstorm, walking under the chain hopper is not
allowed.

20
The chain hopper shall be managed by dedicated personnel. Other personnel except
the unit personnel shall not enter the operator cabin or operate the mechanism without
approval. Electrical matters shall be in the charge of professional electrical
maintenance personnel.
The operator shall not leave his/her post during the working time.
The operator shall avoid collision with the barge coaming or stopper.
For lager lump coal with diameter of more than 300mm in the barge, excavation is not
allowed but manual hammering is required.
300mm
The grounding resistance of the traveling track shall not exceed 4.
j. 4
Operation under Working Condition of Ship Unloader
Startup Procedures of Ship Unloader
23
Interlocking of the Coal Handling system of the chain bucket ship unloader shall be
closed (open only in case of maintenance). The belt conveyor shall not work until the
coal unloading signal is obtained from the central control room.
(
)
The operator shall check whether all controller handles and various master switches
are at zero position before application. The main power supply switch and the master
key switch shall not be closed until the controller handles and various master switches
are checked to be acceptable. The main power supply switch shall be automatic air
switch and installed in the No. 1 electrical control cabinet and the master key switch
shall be installed on the linkage control cabinet.
21
Startup of belt conveyor
Before each working mechanism of the ship unloader starts, the belt conveyor system
and the reclaiming belt conveyor shall be started successively through corresponding
buttons to avoid blockage.
Start the moving ship system, adjust the positions of ship unloader and barge and
move the chain bucket mechanism to the starting end of the barge. The control
operation modes of the moving ship system include rotating rotary knob to travel
forward and backward. Traveling backward shall start from low speed to high speed
gradually. For shutdown or reversing, the speed shall be reduced gradually until the
system stops before reversing. If both forward and backward buttons are not
disconnected, the operation shall be considered as invalid. The forward speed shall be
in conformity with material reclaiming.
0.0
The First Material Reclaiming
Start the cross traveling trolley to make the chain bucket reach the longitudinal
centerline of the cabin head of the barge before the first material reclaiming. Cross
traveling control is performed by operating the handle of the linkage control panel.
The working mode is controlled by the master switch.
23
24
Start the lifting mechanism to drop the cantilever beam and chain bucket mechanism
which is dropped to the materials. Perform material excavation while dropping the
cantilever beam and chain bucket mechanism until the excavation depth of the hopper
is proper. Operate the handle of the linkage control panel for control. When the handle
is at the middle, it is considered to reach the zero position, i.e. shutdown
position; pulling down leads to lifting and pulling up leads to dropping.
23
22
23
Start the hoist motor to travel forward slowly for continuous materials reclaiming.
When the filling ratio of the chain bucket reaches 110%, the productivity reaches
800t/h during which stable advancing speed shall be maintained. When too many
materials are reclaimed, slow down the hoist or lift the cantilever beam by inching;
when insufficient materials are reclaimed, speed up the hoist or drop the cantilever
beam by inching to increase the reclaiming depth. When the hopper for material
reclaiming approaches the coaming at the tail end of the barge, the speed shall be
dropped gradually. When the hopper is 0.5-1m from the cabin tail, stop the hoist.
23
, 110%
800t/h
0.5-1m
23
The First Reverse
23
After the first excavation of materials, the complete machine will start its first reverse as the
follows:
23
Start the lifting mechanism to lift the head from the top of the material bed.
23
24
Start the hoist motor for traveling backward from low speed to high speed. Generally,
the reversing speed can reach 6-8m/min approximately. When the chain bucket
approaches the coaming at the start end of the barge, the speed shall be dropped
gradually. When the chain bucket is 1m from the coaming at the start end of the barge,
stop the hoist.
23
6-8m/min
1m
23
The Second Material Reclaiming
23
Move the hopper left and right for more than one-hopper width and then stop it. The followup operation is the same as that of the first material reclaiming.
23
23
The Second Reverse
23
The operation procedures are the same as those of the first reverse.
24
The Third Material Reclaiming
23
Move the hopper left and right for more than two-hopper width and then stop it. The followup operation is the same as that of the second material reclaiming.
24
The Third Reverse
23
The operation procedures are same as those of the first reverse.
24
Cabin Cleaning
23
After several material reclaiming operations, remove the residual materials on coamings at
both ends to the centerline of the barge by using a cabin cleaning machine or manually.
Move horizontally for cabin cleaning for 1/4 of the left side and 1/4 of the right side.
1/4 1/4 .
24
After ship unloading, start the lifting mechanism to lift the cantilever beam to make the
hopper opening brake 0.3-0.5m higher than the coaming. Start the cross traveling
mechanism to put the chain bucket into the wharf.
23
0.3-0.5m ,
,
24
Procedures of Barge Docking and Departure
23
24
Before docking and departure, the cantilever beam of the ship unloader shall be at the
highest position and the chain bucket shall be put into the wharf. Both docking and
departure shall comply with relevant provisions of the shipping section and requirements
for safe operation.
24
Operating Instructions of Electrical System
23
After the machineries and electric of the chain hopper are checked to be normal, connect to
the power supply, close QS101 knife switch and QF101 air switch in the control cabinet and
then close QF106-QF112 and control power source switch QF113. Press down SB11. Then
the control power source will be closed and indicator light HL10 will be on. Put SA10 at
the manual gear before operating the ship unloader.
QS101
QF101 QF106-QF112 QF113 SB11
HL10 SA10
Lifting and descending of cantilever beam: Switch the master switch SA12 from zero
position to the lifting gear. Then the motor will start and after time relay of the PLC relay,
the contactor KM17-KM14 will cut off the resistance by stages, thus to lift with increasing
speed. After the motor starts, contactors KM12 and KM13 are energized and brakes YB1
and YB2 are disconnected and indicator light HL11 is on. Switch the master switch SA12
to the zero position before drop gear. Then the motor will start and after time relay of the
PLC relay, the contactor KM17-KM14 will cut off the resistance by stages, thus to drop
with increasing speed.
SA12
PLC KM17-KM14
KM12KM13 YB1YB2
HL11 SA12 PLC
KM17-KM14
After the motor starts, contactors KM12 and KM13 are energized and brakes YB1 and YB2
are disconnected and indicator light HL11 is on. Generally, only SA12 shall be put at the
zero position for shutdown.
KM12KM13 YB1YB2 HL12

SA12
Belt conveyor: press down SB22. After the belt conveyor runs normally, indicator light
HL20 will be on to prepare for operation of the chain bucket mechanism. Press down SB23.
Then the belt conveyor motor will stop and indicator light HL20 will be off.
SB22 HL20
SB23 HL20
25
Running of chain bucket: Press down SB16. Then the chain bucket motor will work and
indicator light HL18 will be on. Inch SB18 for reverse and press down SB17 for shutdown.
SB16 HL18
SB18 SB17
Operation of cross traveling trolley: open master switch SA12 to move the cross traveling
trolley left or right. Meanwhile, indicator light HL13 or HL14 will be on. Put master switch
SA12 at the zero position before the cross traveling trolley works to stop the lifting
mechanism. When master switch SA12 returns to the middle position, the cross traveling
trolley will move laterally.
SA12 HL13
HL14 SA12
SA12
Operation of moving ship system: press down SB24. Then the frequency converter will be
electrified and indicator light HL21 will be on. Put SA12 at the forward gear and switch
SA16 to gain different forward speeds. Brake YB5 will be energized and disconnected. Put
SA12 at the zero position before backward gear and switch SA16 to gain different
backward speeds.
SB24 HL21 SA12

SA16 YB5 SA12
SA16
Emergency shutdown: press down each shutdown button for normal shutdown. In case of
emergency shutdown such as failure of belt conveyor, emergency button SB12 can be
pressed down to interrupt power for all mechanisms and turn off all indicator lights. After
emergency shutdown, loose SB12 button by rotating.
SB12 SB12
Operation of lighting system: close air switches QF104 and QF105 to electrify the lighting
section box. For night work, open switches of the floodlights. Keep running lights H12,
H13 and H14 on no matter whether work is performed during night.
QF104QF105
H12H13H14
26
Operation When the Ship Unloader is not Working
Non-working Condition
2.1.10.1
Non-working condition refers to any of the following conditions:

:
a)Wind speed is greater than 20m/s.
a)
20m/s
b)Any failure happens to the operating mechanism or the operating mechanism is under
repair.
b)
c)Emptying for shutdown or temporary shutdown.

c)
d)
Earthquake.
Operation under Non-working Condition
Lift the cantilever beam and put the chain bucket back to the bank.
The cable ratchet releases the pawl to loose the cable for 2-3m to avoid damage of
moving ship equipment during ebb.
2-3m
Cut off power.
Operate in the reverse sequence to relieve the non-working condition.
Provisions on Inspection Cycle
Perform frequent inspection for the following items at least once a month:
Technical performance of ship unloader under normal working condition;
27
b)
All safety and protective devices;
b)
c)
Brake performance and component wear;
c)
d)
Fastening and locking device of each fastener;
d)
e)
Wear of steel wire ropes and fixation of tail ends;
e)
f)Wear, deformation and elongation of chains.

f)
2.1.11.2
Perform periodical inspection for the following items at least once a year:
2.1.11.2
a)Items frequently inspected in 2.1.11.1;

a)
2.1.11.1
b)Deformation, cracking and corrosion of metal structures and connection of welding

joints and bolts;
b)
c)Wear, cracking and deformation of main parts;

c)
d)Reliability and accuracy of indicating devices;

d)
e)Power source and controller.

e)
2.1.11.3
Lubrication
Perform lubrication according to the cycle, kinds and charge volume of lubricating oil
specified on the label.
Safety Warning
Safety warning I:
Do not operate the ship unloader or system in the following conditions, or accidents may
28
happen to personnel, ship unloader system, wharf or unloaded ships!!!
Under non-working wind speed of 20m/s;

20m/
0
The heights of waves along the parallel wharf are > 1m and those for the vertical-face
wharf are > 0.8m.
1m 0.8m
Extraordinary rainstorms have influence on visibility.
Lighting for night work does not comply with the operating conditions.
The unloaded ships are not in conformity with the design ship types.
The ship unloader system is forced to start with failure.
Safety warning II:
Do not operate the ship unloader or system in the following conditions, or accidents may
happen to personnel, ship unloader system, wharf or unloaded ships!!!
The unloaded ship is moored alongside and the empty ship departs from the wharf
when its cantilever beam does not lift to the high point and the chain bucket
mechanism is not put back to the bank.
The ship unloader system is stopped temporarily due to shift change or other reasons
but its cantilever beam does not lift to the high point and the chain bucket mechanism
is not put back to the bank under non-working condition or repair due to failure.
The unloaded ship (with no load or heavy load) is tied to the moving ship trolley
under non-working condition or repair due to failure or suspension of the system
29
under working condition.

0
()
Cabin cleaning is performed under the cantilever beam, and repair and passing are
under the ship loader when the ship unloader system is running.
Safety warning III:
Failure to check and maintain the ship unloader equipment may lead to accidents!!!
0
1 Inspection and maintenance of lifting and balancing steel wire ropes.
b) c)
Inspection and maintenance of moving ship system. c)
d)
Proximity to switch and limit switch for the lifting and descending of the cantilever
beam, moving ship trolley, and cross traveling trolley.
d)
e) Insufficient lubrication of equipment.
Stacker-reclaimers
Equipment Overview
DQL240/96030 stacker-reclaimers and wagon tipper, unloader and belt conveyor of

material yard constitute a system to mechanically and automatically stack and reclaim,
transport and store materials.
DQL240/96030
1536
Characteristics of Materials
30
Type: lignite
Particle size: 0~80mm

080mm
Bulk specific weight: 0.85t/m
0.85t/m Static
angle of repose: 35-40
35-40
Production Capacity
Reclaimed materials: 240 t/h

240 t/h Stacking
materials: 960 t/h
960 t/h
Stacking Height
On the track: 10.5 m

10.5 m Under
the track: 1.5 m
1.5 m
Bucket Wheel Mechanism
Diameter of bucket wheel: 4.36 m

4.36
m Type: cell-less
Rotation speed: 7.3 r/min

7.3r/min
Number of buckets: 8
8 Driving
power: 30kW
30 kW
Boom-type Belt Conveyor

31
Type: common reversible trough type
Belt Speed: 2.5 m/s

2.5 ms
Belt width: 1.2 m
1.2 m
Driving power: 55kW
55 kW
Slewing Mechanism
Slewing radius: 30 m
30 m
Slewing speed: 1/cos variable frequency speed control
1/cos
n0.0400.082 min
Slewing angle: 110
110
Driving power: 2X7.5 kW
2X7.5 kW
Pitching Mechanism
Pitching type: hydraulic type
Pitching angle: -14.81+8.84

-14.81+8.84
Motor: model: Y132M-4
N=7.5 kW
Y132M-4
N=7.5 kW
System pressure: 16 Mpa

16 Mpa
2.2.2.8
Traveling Mechanism
Track gauge wheel base: 6m6m

6m6m
32
Traveling speed: high speed: 20 mmin, low speed: 7 mmin

20 mmin, 7 mmin
Wheel diameter: 600 mm
600 mm
Driving power: 85.5kW
85.5kW
Tripper Car
Structural type
The tripper car is of luffing hydraulic lifting and descending half hanging structure
and mainly composed of tripper, tripper belt conveyor and hydraulic lifting and
descending mechanism.
Structure characteristics
The tripper car has a dip angle of 16and is provided with a bidirectional belt
conveyor mechanism with belt width of 1200 mm and speed of 2.5 m/s. The upper
roller of the belt conveyor has a groove angle of 35 and diameter of 133 mm and
space of 1200 mm. The lower roller has a space of 3000 mm. Both upper and lower
rollers are provided with sufficient centering rollers and have basically same belt
protection device and boom-type belt conveyor.
16 1200
mm 2.5 m/s 35 133 mm
1200 mm3000 mm
The tripper car is provided with double-wheel anti-drift idler wheel at the tail to
prevent the rubber belt from separation when the ground belt conveyor starts. The
communication cable drum and LV power transformation cabinet are set on the
platform of the tripper car where proper passway is arranged to provide convenient
installation and repair of components on the frame.
33
Switching mode of tripper car
Switching of working conditions of the tripper car is driven by hydraulic pressure with
the following switching mode:
Perform following procedures to switch the working mode from material reclaiming
to stockpiling: firstly, separate the main machine from the tripper car coupler to
advance the main machine for about 6.5m and lift the girder driven by the hydraulic
cylinder; then, lay the main machine back for 6.5m to connect with the tripper car
coupler. The emptying point at the tripper car head will align right with the feed
channel on the boom-type belt conveyor to transfer the materials to the belt conveyor
stably, thus to switch to material stockpiling working condition.
6.5 6.5
Perform following procedures to switch the working mode from material stockpiling
to reclaiming: firstly, separate the main machine from the tripper car coupler to
advance the main machine for about 6.5m and decompress the hydraulic cylinder to
lay the girder flat; then, lay the main machine back for 6.5m to connect with the
tripper car coupler. At this moment, the belt conveyor is connected to the transport
system of the main machine through the redirection roller on the tripper car, thus to
switch to material reclaiming working condition
6.5 6.5

Power Supply System
Power supply mode: cable drum
Power supply voltage: 400V

400V
50Hz;
50Hz
34
Communication System
Communication mode: cable drum
Power supply voltage: 230V

230V
Dust Prevention System
50Hz;
50Hz
Water supply mode: the machine is equipped with a water tank with a capacity of ~6.0m3
,
6.0m3 Water pump: model: IS50-32-200
IS50-32-200
Flow: 12.5m3/h
12.5m3/h
MotorY312S1-2
Y312S1-2 Power:
N=5.5kW
N=5.5kW
Rotation speed: n=2900r/min
n=2900r/min
Others
Total installed capacity: ~120MW

210kW
Maximum normal power: ~180 kW
180 kW
Maximum wheel pressure: 250 KN
250 KN
Recommended steel track: P50
P50 Maximum
traveling distance: 110 m
110 m
Maximum wind pressure: under working condition: 250Pa; non-working condition: 400 Pa
250Pa400 Pa
35
Control mode: PLC program control, manual, single-action

PLC
Boundary dimension: length width height63.6m9.07m22m
:63.6m9.07m22m
Total weight: ~260t
260t
Overview of Working Principle and Structure
The machine is mainly composed of 17 parts such as bucket wheel structure, front boom,
boom-type belt conveyor, operator cabin, column, pitching mechanism, traveling
mechanism, gate seat, slewing mechanism, balance mechanism, tripper car, cable drum,
electrical and lubrication system, hurricane prevention and mooring system, central cabling
device and cable suspension device.
17
For material reclaiming, the bucket wheel rotates and the boom revolves round the slewing
center, and the hopper takes materials and discharges on the rubber belt of the boom-type
belt conveyor moving towards the slewing center direction of the machine and then the
rubber belt transfers the materials to the rubber belt of the belt conveyor of the tripper car
through the hopper installed under the column and on the platform and gate seat. The main
machine advances for one material-fed thickness (320mm) within one slewing action of the
3
boom (bulk specific weight is 0.85 t/m and rated reclaiming capacity is 240t/h). Then, the
boom rotates reversely for next material reclaiming. After materials in one layer is
reclaimed, the machine returns to the starting point of another process material layer and
drops or lifts the bucket wheel for 2180mm (radius of the bucket wheel) to repeat the
foresaid movement for material reclaiming. The length of one process material layer is
determined to guarantee that the boom will not touch the material pile. Reclaiming of each
process material layer can be controlled by PLC program after the starting point is
determined manually until all materials in this layer are reclaimed.
36
320mm( 0.85 t/m3, 240t/h )
)2180mm()
PLC
For material stockpiling, the materials are discharged on the boom-type belt conveyor from
the rubber belt of the material yard through the tripper car, and then transported to the head
of the bucket wheel and transferred to the material yard. Material stockpiling mode includes
material stockpiling at fixed point: When the first pile of materials reaches a certain height,
the cart travels for one step to continue stockpiling. When the second pile reaches the
specified height, the cart travels for one step again to continue stockpiling until the preset
pile length is reached. Operating modes of material stockpiling include manual mode and
PLC program control mode. Manual mode is applicable to irregular stockpiling of a small
amount of materials and PLC program control mode is applicable to regular stockpiling of a
large amount of materials.
PLC
PLC
To guarantee uniform material reclaiming, the slewing speed of the boom changes as
1/cos. When angle is larger than 60, the slewing speed of the boom will be large and
the live load born by the structure will increase rapidly, which is harmful to the force status
of the structure. Therefore, the machine is set as follows: when =0~60, the slewing speed
will be n0.040~0.080r/min; when >60, the slewing speed will be n0.080r/min. It can
be seen that the boom would better rotate with an angle of 0~60. Also, the boom can rotate
with constant speed of n 0.040r/min, which is applicable when no strict requirements for
uniform material reclaiming is necessary. (The above-mentioned values are all the ones
when the rated capacity is 240t/h).
1/cos
60
060 n0.0400.080r/min 60 n
0.080r/min 060
(n0.040r/min)(
37
240t/h )
Bucket Wheel Mechanism
As the main actuator mechanism for material reclaiming, the bucket wheel mechanism is
composed of bucket wheel, hopper, arc retaining plate, stripper plate, bucket wheel axle,
bearing pedestal, planetary reducer, fluid coupling and motor. The bucket wheel is cell-less.
The bucket wheel axle is connected to bucket wheel body and planetary reducer through
taper locks.
Boom-type Belt Conveyor
The boom-type belt conveyor is composed of motor, fluid coupling, brake, planetary
reducer, coupling, drive pulley, return pulley, upper and lower roller, rubber conveyer belt
and gravity tensioning gear and installed on the front boom. The rubber belt can operate
bidirectionally. To guarantee safe and effective work, class II anti-sway switch and
emergency pull switch and other necessary safety and protective devices are provided.
Pitching Mechanism
Hydraulic transmission is used for the pitching mechanism which is mainly composed of
motor, oil pump, oil tank, oil pipe, hydraulic lock, all kinds of control valves and two oil
cylinders.
The oil cylinders are connected between the upper balance mechanism and column. The
motor and oil tank of oil pump are installed on the pitching platform of the column.

When the bucket wheel machine is running, the pitching angle of the cantilever crane is
controlled by the electromagnetic conversion valve. The hydraulic system is locked by
38
hydraulic lock and balance valve for synchronizing circuit control and works stably and
reliably during pitching.
Traveling Mechanism
The traveling mechanism is composed of 4 sets of bogies.

The traveling speed includes shunting speed and working
speed which are 20m/min and 7m/min respectively. One track clamping device is installed
on two of the drive bogies respectively to clamp the track automatically when the machine
stops, thus to prevent the machine from rotation when the wind pressure is 400Pa. When
the wind pressure is >400Pa, two traveling anchoring devices must be used to locate the
machine at the preset position at the material yard.
4
20m/min 7m/min
400Pa 400Pa
Slewing Mechanism
The slewing mechanism is located on the column and gate seat and composed of motor, safe
friction clutch, brake, reducer and slewing bearing. This machine is used for slewing drive
of cantilever crane and coordinates with traveling mechanism and pitching mechanism to
enable the machine to reclaim and pile materials at different positions at the material yard.
Metal Structure
Main metal components of the machine include front cantilever crane, column, gate seat,
tripper car and balance mechanism that are also the main bearing components. Their
reliability plays an important role in guaranteeing safe operation of the complete machine.
They have sufficient strength and stiffness according to the calculation results.
39
Lubrication System
Lubricants used for the machine include thin oil and grease. Except the reducer which uses
thin oil for lubrication, all other parts are lubricated with grease. For dry oil, it has many
disperse lubricating points. To guarantee reliable lubrication and reduce workload required
by refueling, lubrication for the machine is performed by areas in a centralized manner and
automatic centralization lubrication is used for the slewing mechanism (including the
slewing bearing and big gear wheel). Manual centralization lubrication is used for traveling
mechanism, bucket wheel mechanism and pitching mechanism of the cart. A set of portable
lube oil pump is provided.
( )
Lubricating grease: GB7324-1994, 2# or 3# lithium base grease.

GB7324-19942# 3#
ISO VG220 low-temperature synthetic oil is applicable to the reducer. After new equipment
is installed and operates for 200 hours, the lubricating oil must be replaced with new oil.
After normal operation of the equipment, the oil must be replaced at least twice a year.
ISO VG220 200
Oil shall be added for the reducer at regular interval.
Auxiliary Devices
Auxiliary devices used by the machine mainly include stockpile height detector, anticollision device of cantilever crane, buffer, track cleaner, traveling anchoring device,
slewing angle detector, slip detection device of belt conveyor, aerovane, gale alarm and
other main safety and detection devices. These components play an important role for safety
and control of the machine and help to realize PLC program control. Therefore, they shall
be inspected frequently to timely eliminate the failures to guarantee all functions of the
machine.
40
PLC
Operator Cabin
The operator cabin is set on the left side of the column. It is spacious and bright and
comfortable. The operator can observe material reclaiming and stockpiling during operation.
It is connected to each part of the main machine with aisles or stairways, which is
convenient for observation and maintenance by the operator.
Tripper Car
The tripper car is composed of main girder I and II, bending mechanism, hopper, LV power
transformation cabinet, traveling wheel, front beam, hydraulic system, hook mechanism,
travel control device, roller, return pulley, ladder, platform and handrails.
I

The belt conveyor of the tripper car and the ground belt conveyor share a rubber belt. The
upper roller is provided with basiconic centering roller and the lower roller is spiral or in
counter-V shape. It is also equipped with protective devices such as anti-sway switch and
bidirectional pull switch. The tripper car is provided with double-wheel anti-drift idler
wheel at the tail to prevent the rubber belt from separation when the ground belt conveyor
starts.
The tripper car is connected with the main machine with hook device. Switching of working
conditions of the tripper car is driven by hydraulic pressure with double cylinders, which is
smooth and reliable.
41
The tripper car is equipped with cable drum.
Switching of working conditions of the tripper car is as follows:
a Switching from material reclaiming to stockpiling:

a
Start the electromagnet of the hook mechanism and keep the hook lifted and
disconnected. Then the main machine moves forward. After the travel control device
touches the travel switch and the hydraulic system acts to lift main girder I to touch
the travel switch, the hydraulic system stops and the main machine moves backward.
After the travel control device touches the travel switch and the electromagnet of the
hook mechanism lays down the hook, the switching of working condition is
completed. Materials are discharged on the boom-type belt conveyor through the
hopper of belt conveyor of the tripper car and then unloaded on the material yard.
b Switching from material stockpiling to reclaiming:

b
Start the electromagnet of the hook mechanism and keep the hook lifted and
disconnected. Then the main machine moves forward. After the travel control device
touches the travel switch and the hydraulic system acts to lift main girder I to touch
the travel switch, the hydraulic system stops and the main machine moves backward.
After the travel control device touches the travel switch and the electromagnet of the
hook mechanism lays down the hook, the switching of working condition is
completed. Materials reclaimed by the bucket wheel are discharged on the belt
conveyor of the tripper car through the central hopper of boom-type belt conveyor and
then conveyed to the specified site by the belt conveyor.
42
Cable Drum
The power cable drum is installed on the platform of the tripper car and used to roll or
unroll cables with the speed synchronized with the traveling speed of the machine.
It is composed of cable drum body, guiding device and support, etc.. The cable drum body
includes operator, electric appliance for drum, gear box and spool. For unidirectional
operation of the motor, long-term stalling is supported with adjustable torque and automatic
braking function and safe and reliable performance.
Inspect the brush periodically and timely replace the worn one.
Maintenance and Safe Operation
Precautions:
For repair of pitching mechanism, if the hydraulic cylinder is required to be disassembled,

the front cantilever crane must be lifted to the horizontal position. Otherwise, it may lead to
major accidents due to excessive force on the column.
For repair of bucket wheel mechanism, if the bucket wheel body or reducer is required to be
removed, the bucket wheel mechanism must be pitched down to the lowest position and the
cantilever crane must be connected to the ground pile (such as the ground track) as a whole
and tightened to avoid excessive force on the column due to turnover of cantilever crane,
leading to major accidents.
()
43
After the machine is installed and put into operation after various tests are performed,
maintenance work shall be carried out according to relevant specifications to guarantee due
production capacity of the machine.
2.2.4.1
Maintenance by Each Shift
Items
Technical Requirements
Inspection of track
Eliminate subgrade settlement and

significant change of track gauge
timely.
Inspection of grounding wire of track
The grounding wire shall be firm and

reliable and with good conductivity.
Removal of dust and scattered and leaked

materials on the machine
Before the machine starts, remove all

dust and scattered and leaked materials
on the platform, at each material
transshipment point on the platform
and on each transmission mechanism
and clean the control board and glass of
operator cabinet.
Inspection of oil levels and pumps of bucket

wheel, belt conveyor, pitching, slewing and
Add new oil when the oil is not

sufficient and repair or replace the
traveling mechanism and reducer
damaged oil pump in a timely manner.
Inspection of various rollers, return pulleys

and drive pulleys of the belt conveyor
Replace the belt conveyor which is

blocked or with failure and adjust the
rubber belt when it is off tracking in a
timely manner.
Inspection of limit switches of slewing,

pitching and traveling mechanisms
Each limit switch shall be flexible to

guarantee safe operation.
Inspection brakes of slewing and traveling

mechanisms and belt conveyor
Each brake shall be reliable to

guarantee good braking performance.
Timely replace the brake with worn
brake shoe influencing the braking
44
Items
performance.
Maintenance and repair of pitching

mechanism
Perform maintenance and repair

according to the operation instructions
of the pitching mechanism.
Inspection of track clamping device
The oil pump shall work normally and

the track clamping device shall be
flexible and reliable.
2.2.4.2
Monthly Maintenance
45
Items
Adjustment of gap and braking
Normal gap between the brake wheel and the brake

shall be 0.5~0.7mm. During braking, the brake shall
be well grounded and act flexibly and reliably.
force of each brake
Re-adjust the braking force according to the braking

requirements.
Inspection of limit switches at

both ends of the material yard
Touch the limit switches with hands to check for

flexibility and then start the machine to travel slowly
used to prevent the machine from
to touch the limit switches and finally stop the
being off the track
machine.
Inspection of cleaning device and
Adjust or replace the cleaning device and the rubbers

of the retaining plate to ensure good contact with the
retaining plate of belt conveyor
belt, thus to guarantee cleaning and blocking

functions.
Inspection of wear-resisting liner

plate and bucket teeth of stripper
Adjust the gap between the hopper bottom and the

arc retaining plate to be 5~7mm and replace
plate and arc retaining plate of
seriously worn liner plate and bucket teeth.
bucket wheel
Maintenance and repair of
pitching mechanism
Perform maintenance and repair according to the

operation instructions of the pitching mechanism.
Inspection of each rod piece and

connector of balance mechanism
Perform timely repair when any abnormality such as

cracking, loose welding or deformation is found.
Inspection of each dry oil
Check each lubrication point to guarantee smooth oil

line and add new oil. Add oil for slewing bearing
lubrication point
once every half month. When old oil is extruded

from the gap, it means that oil has been added to the
proper level.
Inspection of fasteners and

connectors
Tighten all bolts.
Inspection of each distribution

box and relevant electrical
Remove all dust accumulated inside and outside the

distribution box and repair and adjust the electrical
elements
elements for good contact and reliable performance.
4
6
0.50.7mm
57mm
2.2.4.3
Maintenance Once Every Half Year
Items
Repair of all motors
Disassemble the end caps of the motors and remove dust
on the stators and rotors. Check the insulation and replace
with new lubricating grease for the rolling bearing.
Inspection of conductors
Put the conductors and communication wires of the

machine in order. Replace the damaged mark numbers at
ends of the conductors with new ones.
Cleaning of each reducer

(carried out during
Discharge all dirty oil from the reducer gearbox and add
cleaning oil with appropriate amount. Discharge the
seasonal lubricating oil
cleaning oil after the motor has been running for 4~6
replacement)
minutes and then add new lubricating oil.
Repair of all return pulleys

and drive pulleys
Replace with new oil for the rolling bearing which is not
lubricated in a centralized manner. Repair or replace the
47
drive pulley with damaged cast rubber.

Maintenance and repair of
pitching mechanism
Perform maintenance and repair according to the operation

instructions of the pitching mechanism.
Inspection and repair of

track clamping device
Inspect the track clamping device for reliability and adjust

its upper and lower limit switches.
Inspection of all metal
Remove dust on all components and rust. Repaint the

missed parts. Tighten the high-strength bolts connecting
components
the column with torque wrench. The torque shall meet the
requirements. All components with a service life 2~3 years
shall be painted with two layers of anti-corrosive primer
and finish respectively.
(
)
46
23
Safe Operation
Before startup, check whether the anchoring device of the track clamp is loose and
give alarm.
When the wind pressure is greater than 250Pa, stop the machine and cut off power
48
supply and clamp the track. For long-term shutdown, the power supply shall be cut
and the track shall be clamped.
250Pa ,,,
Press down the emergency stop switch to cut off the power supply in case of any
emergency.
During material reclaiming, pay attention to prevent the bucket wheel from being
buried due to collapse. If the bucket wheel is buried by materials, start the machine
immediately to travel slowly to leave the pile. Do not start the pitching mechanism to
lift the cantilever crane.
The motors of slewing mechanism, bucket wheel mechanism, boom-type belt

conveyor and pitching mechanism shall be started with no load.
For quick shunting, put the cantilever crane to horizontal position and lay in the
middle of the track.
Always guarantee favorable conductivity of the grounding wire of tracks and other electric
appliances to avoid electric shock.
Frequently check various auxiliary protection devices and guarantee normal operation.
Operation Modes and Characteristics
Overview of System
One stacker-reclaimers is provided for the Project to pile materials in the dry coal shed and
reclaim materials from the dry coal shed through the rubber belt.
Mechanical Operation Mode and Characteristics

49
Material stockpiling process
Material stockpiling is basically performed by the following ways: traveling, rotating

and stockpiling at fixed points.
Stockpiling by continuous traveling
See figure 1. Material stockpiling is performed by layers and lines and by continuous
traveling at fixed points. Stockpiling starts from the first point of the first line 01-1.
The height of each material pile is detected by a pile height detector (or manually,
similarly hereinafter) with order given to control the jogging of the traveling
mechanism. Materials are piled pile by pile. After the preset piles are completed, the
machine travels to 02-1 for material piling at the next line in reverse direction; when
all lines of the first layer are completed, the machine travels to next layer for
stockpiling until the final pile is completed. Rectangular material piles are formed
through stockpiling process by continuous traveling which has high utilization ratio of
the material yard and benefits environmental protection. The length of piles can be
adjusted according to the conveying load, thus to form regular piles.
( 1)
01-1 ()
02-1
50
Figure 1
1
Stockpiling by continuous rotation
See figure 2. During the stockpiling process, the cantilever crane is always fixed with
the preset piling height for reciprocating stockpiling by continuous rotation. After the
preset times are reached, the traveling mechanism jogs for a preset distance for
stockpiling in the order of 1~2~3. For this process, when the conveying is not
continuous or the conveying load is small, the preset length of the piles can be
adjusted according to the conveying load to form regular piles and guarantee high
efficiency.
( 2)
1~2~3

51
Figure 2
2
Stockpiling at fixed points by discontinuous rotation & traveling
See figure 3. Materials of the first pile are stockpiled in several layers to reduce
swirling dust. Order for layer change is given by the height detector. The height of the
cantilever crane remains unchanged after the final pile is completed. Then the
cantilever crane moves to the second pile to continue stockpiling with the preset
rotating direction and angle. When the rotation limit is reached, the machine jogs for a
preset distance for stockpiling until the preset length of piles is reached and then the
machine stops.
( 3)
52
Figure 3
Stockpiling at fixed points by discontinuous rotation & traveling

3
Material reclaiming process
Material reclaiming processes include reclaiming by layers and by rotation and

reclaiming at fixed points on slopes.
Reclaiming by layers and by rotation
See figure 4. This process has two modes as reclaiming by sections and reclaiming not
by sections based on the pile height.
( 4)
The first mode: automatic reclaiming by layers and sections: Firstly, the operator
operates the bucket wheel machine to travel by single action and the rotating and
pitching devices put the bucket wheel at the starting operation point on the pile top
(single-action operation at fixed points). Then, the machine begins reclaiming by
rotating. When the rotation limit is reached each time, the traveling mechanism moves
for a preset distance (feed). After the first layer is completed according to the preset
length of the feed section Lm (or the preset number of rotation), stockpiling is carried
out for the next layer. The rotating angle for each layer is based on the angle of repose
and number of layers; the pitching height is based on the number of layers and the
traveling distance is based on the feed. For section changer after the materials in the
last layer is reclaimed, put the bucket wheel at the starting operation point on the top
layer of the second section and repeat reclaiming. The length of the feed section Lm
53
shall be set to guarantee that the cantilever crane will not touch the material piles.
()
()
Lm ()
Lm
The second mode: reclaiming by layers and not by sections and by rotation: This
process has the highest efficiency. It can avoid overload of bucket wheel and
cantilever crane due to collapse of material piles. It is applicable to low and short piles
where the cantilever crane will not touch the piles. To achieve layering by rotation
and reclaiming with preset amount, the cantilever cranes rotation speed, under semiautomatic control mode, shall change as 1/COS and change based on the feedback
by the current of the bucket wheel drive motor. Generally, the rotation angel shall be
10~70, and change as 1/COS within the range of 10~60 and as =60 within the
range of 60~70.
1/COS
10~70 10~60 1/COS

60~70 =60
Figure 4
Reclaiming by layers and by rotation

4
Reclaiming at fixed points on slopes (end face reclaiming)

54
()
See figure 5 for reclaiming at fixed points on slopes (end face reclaiming).The first
piling and first reclaiming working process has low work efficiency. During this
process, the piles are subject to collapse, leading to overload of the bucket wheel.
() 5
When the above-mentioned processes are used, the operator shall start reclaiming
from the top layer of the piles and always observe the piles to prevent the head or
bottom of the cantilever crane from touching the piles when the bucket wheel machine
is rotating.
To avoid equipment damage, cart shall not be used for continuous reclaiming by
traveling.
Figure 5
Reclaiming at fixed points on slopes

5
Operation Instructions
Mechanical Operation Instructions
Preparation before operation
After no-load test, various performance indexes of the machine shall meet the production
requirements.
55
Maintenance shall be performed for the machine after various tests to guarantee required
production capacity of the machine.
The operator shall be familiar with the machine after training.
Oil and lubricating greases required by the machine shall be added to the specified
values.
Connect the battery main switch of the machine and check instruments. All parts of
the machine shall response normally.
Firstly, loose the track clamping device and give alarms.
Single-action (local) control

()
Each mechanism of the bucket wheel machine shall start and stop independently.
Switch the operation mode to single-action gear to start and stop each mechanism
independently. At this moment, the protective devices still work. This operation mode
is generally applicable to repair and debugging of bucket wheel machine.
Manual control
Switch the option switch of operation mode to manual position. Then the bucket
wheel machine is under manual control mode where the operator can control the
startup and shutdown of the machine through the operation console. Electric interlock
exists between bucket wheel, belt, traveling mechanism, slewing mechanism and
ground belt and the operator shall not start or stop any of these mechanisms without
approval. Under manual control mode, the operator must start corresponding
mechanism according to the material flow direction during reclaiming and stockpiling,
and operate the mechanism according to the reclaiming and stockpiling processes.
56
Manual control mode is applicable to small-scale uneven and irregular material piles.
,
Semi-automatic control
Switch the option switch of operation mode to semi-automatic position. The

operator adjusts the traveling position of the bucket wheel machine and the angle of
the cantilever crane to the position adaptable to reclaiming and stockpiling. Then the
operator presses down the program control start button and the PLC starts relevant
program for semi-automatic reclaiming and stockpiling. Finally, the operator presses
down the program control stop button to stop the program control work.

PLC

Hydraulic Operation Instructions
For this hydraulic control system, one pump set is used for oil supply. The oil pumps is
pressure compensation type and can automatically change oil volume under the preset
pressure according to the load flow and guarantee constant pressure of the system.
After the pitching motor starts, the pump begins to supply oil for the system. At this moment, the
solenoid valve is power off and oil supplied by the pump returns to the oil tank directly through
the middle of the solenoid valve. When the control switch is at the luffing rise position, the
solenoid valve is electrified and oil supplied by the pump enters the rodless cavity of the
derricking cylinder through the hydraulic control one-way valve, the one-way valve on right side
of the one-way throttle valve and the hydraulic control one-way valve on right side of each
locking piece to protrude the piston rod of the oil cylinder. Oil in the rod cavity returns to the oil
tank through the one-way valve on left side of the hydraulic control one-way valve and the
solenoid valve. When the control switch is at the luffing
57
drop position, the solenoid valve is electrified and works and the oil flow direction is
opposition to that at luffing rise position.
()
Electrical Operating Specifications
Pre-start Preparations
Relevant preparations must be completed before starting the bucket wheel machine.
Check whether the HV switch cabinet is switched on for power transmission, and
observe the indicating instrument and the indicator light for switching on/off.
Check whether all the emergency buttons are reset.
Power Supply
Startup power supply
About 6kV 50Hz is adopted for startup with power supply from cable drum. The
power supply enters P1 LV distribution cabinet after being transformed by the HV
electrical cabinet inside the box-type substation and two dry-type transformers
(400KVA 6.3Kv/0.4Kv22.5% and 50KVA 6.3KV22.5%); the outgoing line on
the LV side of the 400KVA transformer passes through the busbar of power and
maintenance power supply of the distribution cabinet, and then three-phase 380V
power supply is led out from the main power breaker and the maintenance power
supply is led out from the main switch of the maintenance power supply (maintenance
power supply is equipped with 380V/220V sockets). AC220V lighting power supply
and control power supply are led out respectively from the outgoing line on the LV
58
side of the 50KVA transformer via the distribution cabinet.

~6kV 50Hz
400KVA 6.3Kv/0.4Kv22.5%, 50KVA 6.3KV22.5%

P1 400KVA
380V
( 380V/220V )50KVA
AC220V
Switching on/off of power supply
The main power breaker (-QF101) of the LV distribution cabinet provides power
supply for the motor of each mechanism of the bucket wheel machine. The breaker
can be operated both manually and electrically. Electrical switching on/off is carried
out in the electric room. For switching on, press down the switching-on button on the
P1 cabinet door, the breaker -QF101 will be switched on electrically, and the power
supply is connected. For switching off, press down the switching-off button on the P2
cabinet door, the breaker -QF101 will be switched off electrically. This mode is
applicable to no-load switching off.
-QF101
P1
-QF101 P2
-QF101
Switching on/off of control power supply
V
Switching on of control power supply
Switch on the breaker -QF160 (inside the lower PLC cabinet), -QF161 (on the right control
console in the operator cabin) and the breaker of PLC power supply inside the upper
PLC cabinet first, and the LV AC control circuit, PLC system and DC circuit of the
bucket wheel machine are powered on.
-QF160( PLC )-QF161()
PLC PLC PLC
Afterwards, switch on the breaker -QF191 (inside the lower PLC cabinet), and the
communication circuit between the bucket wheel machine and the central control
59
room is powered on.

-QF191( PLC )
Finally, switch on the breaker -QF192 (on the right control console in the operator cabin),
and the video monitoring system is powered on. At this time, the control system of the
bucket wheel machine can satisfy all the operating conditions. If the control power
supply is in failure, the track clamping device can still work automatically.
-QF192()
Main Electric Layouts
Box-type substation on the platform of tripper cars: HV cabinet room, transformer room and
LV cabinet room are designed;
LV electric room on the platform of tripper cars: LV distribution cabinet, lower PLC
cabinet, traveling frequency conversion cabinet, bucket-wheel belt cabinet and
pitching rotation cabinet.}
PLC
LV distribution cabinet includes main power switches, main lighting circuits and main
maintenance circuits etc.;
Lower PLC cabinet mainly includes main control circuits, PLC slave stations and
relays etc.;
PLC PLC
Traveling frequency conversion cabinet mainly includes traveling and power circuits
of reels etc.;
; Bucket-wheel belt cabinet mainly
includes bucket-wheel circuits and boom belt circuits etc.;
Pitching rotation cabinet and circuits etc.
Left/right control console and upper PLC cabinet are arranged inside the operator
60
cabin. Left/right control sole mainly includes operating switches and indicator lights,
while upper PLC cabinet mainly includes PLC main station, touch screen and relays.
PLC
PLC PLC
Operator cabin
21 left control console: instrument and operating switches are arranged.

21
Instrument: indication of 6kV HV startup power supply;
6kV
Indicator light: indication of switching on/off for HV power supply;
Illuminated button: indication of switching on/off for control power supply;
Illuminated button: indication of switching on/off for power supply;
Button: loosening and tightening of track clamping device;
Button: indication of switching on/off for lighting power supply;
Key switch: indication of switching on/off for control power supply;
Control switch: indication of running and shutdown of wipers;
Master controller: control over forward, stop and backward of carts.
22 right control console: operating switches are arranged.

22
Mushroom button: scram button (emergency stop button);
()
Change-over switch: control over material reclaiming and stockpiling (control
over material stockpiling, stop and material reclaiming);
()
61
Change-over switch: selection of operating mode (single-action, linkage and

semi-automatic);
()
Change-over switch: control over conversion of auxiliary vehicles and tripper
cars (conversion of material stockpiling, stop and conversion of material
reclaiming);
()
Button: alarm of startup and signal reset;
Button: control over running and stop of luffing oil pumps;
Control switch: selection of high/low speed of carts;
Control switch: system interlocking (interlocking and unlocking);

()
Master controller: rotation (left-handed rotation, stop and right-handed rotation);
()
Master controller: luffing (face up, stop and face down)
()
Buzzer: failure alarm.
23 LV control cabinet: PLC remote slave station and auxiliary control circuits
23 PLC
Programmable terminal PT: for equipment monitoring.
PT
Status screen: showing the running status of each mechanism when the bucket
wheel machine is operating;
Position limit screen: showing the actuation for protection limit of each
mechanism when the bucket wheel is operating
Failure list: showing the list of current failure alarms;
62
Parameter setting: setting of lifting times and rotation times during semiautomatic material stockpiling; manual interference during semi-automatic
process and release button ;
Current indication: showing the current of boom tape belt conveyor, tripper car
tape belt conveyor, cart motor and rotation motor;
Digital display: showing the traveled distance, rotation angle and luffing angle
of carts;
Single-action control: single-action control of boom conveyor, bucket wheels,

intermediate hopper baffles, bucket-wheel feed channels, belt conveyor of
tripper cars and oil heaters.

Operation and Sequence during Preparations
Before getting aboard, the operating personnel should lift the anchor manually first, and
then check whether all the breakers inside each control cabinet of the electric room are
switched on. Afterwards, switch on the HV power supply, control power supply and power
supply, loosen the track clamping device and choose a control mode. The specific operating
modes and sequence are as follows:
Lift the anchor
Before getting aboard, the operating personnel should lift the anchor at the bogie on
both sides of the equipment manually first, to switch on the limit switch of the anchor;
Switching on of HV power supply

63
Enter the electric room, to check whether the 6kV HV startup power supply exists on
the voltage display instrument of the HV power cabinet. If the 6kV HV startup power
supply is normal, it is allowed to switch on HV power supply.
6kV
6kV
Press down the Switch on the HV power supply button on the HV electrical cabinet to
complete switching on. After successful switching-on operations, the indicator light
HV power supply is switched on on the cabinet door will be on. At this time, the
HV power supply is switched on.
Switching on of control power supply
The control power supply cannot be switched on unless the HV power supply is
switched on.
Enter the operator cabin, before switching on the control power supply, switch on the
Key switch on the left control console with keys. Afterwards, press down the
Switch on the control power supply button on the left control console, and the
indicator light of Control power supply is switched on will be on, indicating the
control power supply is switched on.

Note: PLC programmable controller and PT programmable terminal which are

powered on for a long term will not be subject to the control of control power supply.
PLC PT
Switching on of power supply
The power supply cannot be switched on unless the control power supply is switched
on.
Press down the Switch on the power supply button on the left control console, and
the indicator light of Power supply is switched on will be on, representing the
64
power supply is switched on.
Loosening of track clamping device
Press down the Loosen the track clamping device button on the left control
console, and on the Status indication screen of the programmable terminal, the
corresponding indicator light of Track clamping device is loosened will be on,
representing the track clamping device is loosened.

Selection of control mode
The control mode of bucket wheel stacker-reclaimer can be classified into singleaction control, manual control and semi-automatic control. The above three control
modes can be converted flexibly. One control mode must be set before equipment
running.
Note: during equipment running, the above three control modes cannot be converted.
Select one of the control modes through conversion of the Select control mode
change-over switch on the right control console, and on the Status indication
screen of the programmable terminal, the corresponding indicator light Singleaction, Manual and Semi-automatic will be on, representing the control mode
has been selected.

After implementing the preparations of the bucket wheel machine as per the above
sequence, the bucket wheel machine can be operated normally.
65
Control over Each Mechanism of Bucket Wheel Machine
Single-action Control
Turn the Select control mode change-over switch on the right control console to
Single-action position, and the whole machine will be under the status of single-action
control. Under single-action control, each mechanism of the bucket wheel machine can start
and stop independently.

Note: this mode is only applicable when each mechanism is under commissioning and
maintenance, and must be approved by the production scheduling personnel. Furthermore,
each mechanism must be monitored and maintained by the operating personnel during
equipment running.
Single-action control of cart traveling
Press down the Speed control of carts control switch on the control console to select the
traveling speed of the cart. One speed must be selected before a cart is running. Traveling at
slow speed is the working speed of carts, while traveling at fast speed is the non-working
speed or is only applicable during shunting. The speed is regulated by the traveling
frequency changer. Note: traveling at fast speed cannot be adopted during normal operation.
Traveling direction is controlled by the operating handle of traveling. If the handle is

switched to Forward or Backward position, PLC will send a command, and relevant
elements will be powered on and actuated. At this time, the brake of traveling motor will be
released, and the fan of traveling motor will be started. After the audible and visual alarm
signals are sent out, the traveling frequency changer will send out running and startup
command after time delay, and the cart will travel in the selected direction and at the
selected speed.
66
PLC
If the traveling must be stopped, switch the operating handle to Stop (zero) position. At
this time, relevant elements will be powered off and actuated, and the traveling frequency
changer will control the uniform deceleration of the traveling motor. Afterwards, the
traveling brake will be activated, and the traveling cooling fan and traveling audible and
visual alarm will stop working.
()
Main protection and detection device of the traveling mechanism: limit switch of forward
and backward, emergency limit switch and incremental encoder.
Control of cable drum
Two sets of torque-type cable drum for power cable and communication cable are equipped
for the machine. The cable drum is driven by motor. When the traveling brake and traveling
fan are powered on, the two cable drums will be started, to ensure that the flat cable on the
drum can satisfy traveling requirements. The traveling motor will not be started unless
corresponding feedback signals are received by the PLC. After the traveling brake is
activated for 3 sec, the two cable drums will stop working.
PLC 3
The major protective device of cable drum is the protection switch for forward and
backward tension of cable. When any of the overtension protection switch is actuated, the
traveling mechanism will stop working immediately, and the traveling brake will be
activated and the machine will stop.
Single-action control of water spraying
67
The control over water spray system is achieved by the operating switch of water spray.
Water spray and dust suppression system is designed for the machine. The solenoid valve
for water spray at material feeding/unloading of the boom belt works during material
stockpiling, while the solenoid valve for water spray at material feeding of bucket-wheel
trough and at lower material feeding works during material reclaiming.
Liquid level detector is designed for the water tank. Operators can observe the liquid level
through visual inspection, and can decide to add water or stop adding water based on the
feedback signal of the liquid level detector.
Rotation control
The rotation motor of boom is driven by the frequency changer, and the rotation of
boom is controlled by the switch on the operating handle of the boom. When the
operating handle of boom is switched to Turn left position, PLC will send a
command, and relevant elements will be actuated. At this time, the rotation brake
will be opened firstly, and the fan of rotation motor will be started
simultaneously. PLC will send out running and startup command to the rotation
frequency changer after time delay, and the boom will turn left/right.
PLC
PLC
When the handle is switched to Stop (zero) position, relevant elements will be
powered off, and the rotation motor will be decelerated to zero uniformly under
the control by the frequency changer. At this time, the rotation brake will be
activated, and the cooling fan of rotation motor will stop working.
()
Control switch of rotation speed is designed on the control console, i.e.

68
Constant speed and Variable speed. Correspondingly, rotation modes at

constant speed and variable speed are designed. Rotation at variable speed
mainly aims at ensuring a stable material reclaiming amount when the bucket
wheel machine is involved in material reclaiming. The speed is controlled by
PLC (regulate the speed as per 1/cos curve). In general, the rotation angle is
0
within the scope of =0 -60 .

0
PLC ( 1/cos =0 -60
Main electric detection and protection device of rotation mechanism: limit switch of
left/right rotation, emergency limit switch; belt limit switch of rotation crossing
the ground; detection of rotation angle (encoder of absolute value)
()
Pitching control of boom
The pitching of boom is controlled by the lever switch. When the operating
handle of boom is switched to Up or Down position, PLC will send
out relevant command to the hydraulic station to lift or lower the boom.
When the operating handle is switched to Stop (zero) position, the front
boom will stop pitching and the oil pump motor in the hydraulic station
will stop running after time delay.
PLC
()
Main detection and protection device of the luffing mechanism of boom: limit
switch of pitching rising/descending, emergency limit switch, limit switch
of height protection for pitching crossing the belt and the angle transducer
of boom.
Control of boom belt

69
When the operating switch of boom belt is switched to Material

stockpiling/reclaiming position, PLC will send relevant command, and
relevant circuit elements will be actuated. At this time, the brake of boom
belt will be disconnected. The boom belt motor will restart after time delay
for several seconds since the brake is disconnected. Afterwards, the bucket
wheel/reclaimer of belt conveyor will start running.
()PLC
()
After the boom belt motor is stopped, band-type brake for boom belt will
be activated after time delay.
2)
3)
Protection of boom belt: to ensure personal and equipment safety, pull

switches, two grade belt anti-sway device, speed (slip) detection switches
and longitudinal rip switches are equipped for boom belt.
3)
()
g) Bucket-wheel control g)
When the bucket-wheel switch is switched to Startup position, PLC will send out
relevant command, and relevant circuit elements will be actuated. At this time, the
bucket-wheel motor will be started, and the bucket wheel machine will start running
(the oil pump of bucket-wheel reducer is powered on and running simultaneously). If
the bucket-wheel switch is switched to Stop (zero) position, PLC will sand out
relevant command, and relevant circuit elements will be powered off and
disconnected. The bucket-wheel motor will also be powered off, and the bucket wheel
machine will stop running after inertial motion (the oil pump of bucket-wheel reducer
is powered off and stop running simultaneously).
PLC
()()
PLC
()
Note: the power of the motor is large, and therefore cannot be started frequently
70
during running.
Central hopper
Two switches are designed for the central hopper to monitor the blockage. Once blockage
occurs, stop the boom belt and bucket wheel machine immediately.
Control of track clamping device
Track clamping device aims at preventing unexpected movement of traveling mechanism

when the bucket wheel machine is idle.
After the power supply of the bucket wheel machine are connected, the power circuits of
track clamping device will be connected, and the oil pump of track clamping device will be
started. At this time, track will be released. When the detector switch for track release is
triggered, representing the track release is completed. At this time, PLC will send out
relevant command, and the oil pump of track clamping device will stop running. However,
since the solenoid valve is still powered on, the track clamping device is under the status of
pressure maintaining.
PLC
Belt of tripper cars
The belt of tripper cars is actually an integral part of the ground belt with displacement
inspection switches and pull switches being designed, to protect the belt system of tripper
cars.
Lift control of tripper cars
Half hanging tripper car: since the tripper car of the machine is of half hanging
structure, the position of tripper cars is different during material reclaiming and
71
stockpiling. For material stockpiling, the tripper car must be lifted to

corresponding position, to unload the material delivered by ground belt conveyor
onto the boom belt; for material reclaiming, the tripper car must be lowered to
corresponding position, to insert the belt head of tripper cars onto the lower
chute of central hopper to receive the material unloaded from the boom belt. The
lifting of tripper cars is controlled by the hydraulic cylinders, and the hydraulic
station of tripper cars is designed on the platform.
Before converting the lifting of tripper cars, the current status and position, and
whether material stockpiling or reclaiming is to be implemented by the bucket
wheel machine must be confirmed. To guarantee safety, all other actions
unrelated to lifting conversion will be stopped during the process. If any
abnormalities are identified at the part to be converted, the bucket wheel
machine will stop running as a whole.
Operations of tripper cars:
Operator cabin
In the operator cabin, turn the option switch for switchover to Material
stockpiling (the position of tripper cars must be switched from material
reclaiming to material stockpiling) or Material reclaiming (the position of
tripper cars must be switched from material stockpiling to material reclaiming)
position, and the equipment will start corresponding switchover. Firstly, the
unhooking electromagnet will be powered on and actuated. The hook will be
opened, and when the hook is in position, the detector switch will send out
relevant signals to PLC. Afterwards, the cart will move slowly, and will stop
72
moving when the limit switch of switchover is triggered. The unhooking

electromagnet will be reset.
(
)()
PLC
If the tripper car is under the status of material reclaiming, switch to material
stockpiling. Afterwards, the tripper car will start rising from a low level. When
the limit switch for rising is switched on, the tripper car will stop rising; if the
tripper car is under the status of material stockpiling, switch to material
reclaiming. Afterwards, the tripper car will start descending. When the limit
switch for descending is switched off, the tripper car will stop descending.
If the rising/descending of the tripper car is in place, the crane will start moving
backward slowly. If the limit switch for moving backward is switched on, the
cart will stop moving backward after time delay. The hook will relock the cart
and tripper car under the effect of collision.
Under the control mode, a specially-assigned personnel must be arranged to

monitor the running conditions of the equipment beside the tripper car, to avoid
accidents.
Local control
To ensure safety and reliability, operators should operate the tripper car at the local
control cabinet. Firstly, switch the control mode switch on the control console to
Single-action position, and then turn the -SA721 switch of local control cabinet to
Local position. Refer to the above for other operating sequences. All the limit
73
switches for protection should work normally during local operations.
-SA721
Anchoring
Before the equipment starts running, the anchoring pin must be pulled out, to lift the anchor
on both sides of the traveling mechanism. Only when the signal of the detector switch for
rising anchors turns to normally off, the PLC system allows the bucket wheel machine to
operate. Before a long-term shutdown or storm, move the bucket wheel machine to the
anchor, put down the anchor, and insert the anchoring pin.
PLC
Pitching control in the operator cabin
The operator cabin of the machine is located at front boom. To improve the operating safety
and comfort of operators in the operator cabin, a pitching mechanism is designed to
maintain the levelness in the operator cabin due to the changes on pitching angle when the
boom is operating. The mechanism is driven by hydraulic system which is shared with the
pitching of boom, and can be controlled by the option switch for pitching in the operator
cabin on the control console.

Anti-collision of boom and detection on height of material pile
Anti-collision of boom
Anti-collision switches are designed on both sides of the boom. When the boom of the
bucket wheel machine is too close to the material pile, the switch will be triggered, and
relevant equipment such as rotation, pitching and traveling will stop for protection.
Afterwards, move the boom out of the protection zone through single-action rotation,
luffing or traveling. Special attention should be paid at this moment.
74
Detection on height of material pile
During material stockpiling/reclaiming, to detect the distance between the front boom and
material pile and to complete material stockpiling successfully, ultrasonic transducers are
designed at the front boom. If the distance between the material pile and front boom reaches
the rated value, the ultrasonic transducer will send out signals of switching value to PLC.
PLC
Semi-automatic Control
Semi-automatic control is involved in material stockpiling and reclaiming. Manual

interference is allowed under semi-automatic running.
Semi-automatic material reclaiming
Note: before semi-automatic control over material reclaiming, the auxiliary tripper car must
be switched to Material reclaiming position.
Semi-automatic operations: drive the cart to the preset coal reclaiming position under the
single-action mode, and then position the head of the bucket wheel machine beside
one layer of material pile of the material pile to be reclaimed (the side adjacent to
track). Afterwards, reset the control switch of luffing, traveling and rotation
mechanisms, and then turn the change-over switch for selection of control mode on
the control console to Material reclaiming position. At this time, the preparations
of program control are completed.

()
;
Switch the option switch for control mode to Semi-automatic position, and wait for
75
the command of material reclaiming from the ground program control room. The
operation starts when the ground belt reclaims the material. Press down the
Semi-automatic start button, and the bucket wheel machine under automatic
control of PLC will start whistling first, and the belt, bucket wheel, rotation and
traveling will be started in order for material reclaiming;
PLC
If no or few materials are reclaimed at the material pile of the bucket wheel machine, the
operator should press down the Parameter setting button to set the end angle for
rotation. At this time, PLC will stop rotation of the boom. Afterwards, start the cart to
move forward slowly to a certain distance, and then start the reverse rotation of the
boom for material reclaiming. In this way, the boom repeats rotation between the start
angle and end angle, and the cart moves forward intermittently until the first layer of
material is reclaimed. At this time, the operator should press down the
Semi-automatic stop button to stop material reclaiming. Afterwards, the operator
should control the bucket wheel machine to back to the original position where
material reclaiming under program control starts manually, and lower the front boom
to a certain distance. At this time, the operator can reclaim the material on the second
layer. The reclaiming methods are the same as above.

PLC
Notes:
Semi-automatic control will not be adopted generally for reclaiming of the material at the
lowest layer.
During semi-automatic control, the control switch of mechanisms such as traveling,

rotation, luffing, belt and bucket wheel cannot be operated. Besides, the operator
should always observe operating conditions, and stop the machine once any
76
abnormalities are identified.
The process of manual material reclaiming is identical to that of semi-automatic material

reclaiming.
C
Semi-automatic material stockpiling
The process for material stockpiling is herringbone material stockpiling at fixed points, i.e.
position the boom at the place where materials are piled. The boom should be distant
from the ground. Afterwards, start material stockpiling. When the material piled
reaches a certain height, rise the front boom to a certain height and keep material
stockpiling. After the material piled reaches the preset height, the boom stops rising.
The material stockpiling will be continued after the cart moves backward for a certain
distance. When the material piled reaches the preset height again, the cart moves
backward again, and moves backward gradually for material stockpiling until all the
materials are stockpiled.
Specific operations: turn the option switch for operation mode to Material stockpiling
position, and then the operator moves the machine to the operation zone, and positions
the front boom at the place where materials are stockpiled. Afterwards,
reset the switch and turn the option switch for control mode to Semi-automatic
position. Press down the Semi-automatic start button after receiving the command
of material stockpiling from ground control room. At this time, PLC will send out
relevant command first, and then start the belt conveyor of boom after whistling.

PLC
When the first pile of materials reaches a certain height, the ultrasonic switch will be
actuated and send out signals of material level to PLC. The boom under automatic
77
control of PLC will rise for a certain distance and keep material stockpiling. When the
material piled reaches the preset height, press down the Parameter setting button,
the boom will stop rising (or otherwise the boom will rise to the highest limit position
gradually). When the ultrasonic switch is actuated again, the cart will move backward
again. Repeat the above until all the materials are stockpiled. After receiving the
command of stopping material stockpiling from ground control room, press down the
Semi-automatic stop button to stop.
PLC PLC
().
To stop operations, stop the bucket wheel machine first. After all the materials on the boom
belt are unloaded onto ground belt, stop the boom belt after about 15 sec. After all the
materials on the ground belt are unloaded, the ground belt will be stopped from the
ground control room. At this time, material reclaiming is completed
15
Notes:
During semi-automatic control, the control switch of mechanisms such as traveling,

rotation, luffing, belt and bucket wheel cannot be operated. During semi-automatic
operations, the operators should always observe material stockpiling, especially
during automatic-receding of the cart.
The process of manual material stockpiling is identical to that of semi-automatic material

stockpiling.
Before material stockpiling, the position of retaining plates of tripper cars and belt
conveyors of boom must be correct.
During fast traveling of the cart, the front boom must be placed beside the parallel position
of ground track.
78
If the bucket wheel machine is idle for a long time, the front boom should be placed at the
horizontal position in the middle of traveling tracks with anchors being inserted.
Interlocking Signal with Ground Communication
The communication interlock between the machine and ground control room is realized by
communication cable and is in the form of relay switch contacts. The power is supplied
from the machine and ground control room. Two pieces of telephone wire cores are
equipped in the cable.
Communication signals between bucket wheel machine and ground control room: material
stockpiling, preparations for material stockpiling, switchover of tripper cars, failures of the
machine, stop command from central control room, material reclaiming/stockpiling of
ground belt, material reclaiming/stockpiling command from central control room.

Lighting System
Power supply of AC220 and 50Hz is adopted for lighting system. Lighting in the electric
room is controlled by its cubicle switches, while lighting in the head of bucket wheel, front
boom and rotation platform is controlled by the switches on the control console in the
operator cabin. The lighting of main accesses is controlled bilaterally by the option switch
at the stairs of the operator cabin and gate seat. The lighting of the lower part and tripper
cars is controlled bilaterally by the option switch at the cab and tripper car.
AC220, 50Hz
Operations after Accomplishment of the Job
Tightening of track clamping device

79
Once the operation is stopped, each operating switch will be reset. At this time, press down
the Switch off the power supply button (+D1-SB104), and the control power supply will
be powered off, and the track clamping device will clamp the track..
+D1-SB104
Switching off of LV power supply
Press down the Switch off power supply button on the control console or in the electric
room, and the main breaker of power supply will be switched off electrically.
Switching off of control power supply
Press down the Switch off control power supply button on the left control console,
and the indicator light of Indication of switching off control power supply will be
on, while the indicator light of Indication of switching on control power supply
will be out. At this time, the control power supply is switched off.

After the control power supply is switched off, take the key of Key switch on the
left control console. Afterwards, the operating personnel can leave the operator cabin.

Fall of anchor
The operating personnel should lower the anchor at the bogie on both sides of the
equipment before leaving, to open the limit switch of anchor on both sides.
At this time, the operating personnel cannot leave unless the stacker-reclaimers are
stopped normally.
Operating and Safety Precautions
Operating Precautions
80
The operators in the operator cabin must follow the command of the commanders, and
always observe the circumstances beside the bucket wheel machine and the
material inside the stock yard. Meanwhile, drivers are not allowed to leave the
operating position when the bucket wheel machine is operating. When the wind
2
pressure exceeds 25Kg/m (above 7-level wind), the bucket wheel machine has
to be stopped immediately and the power supply shall be cut and the track shall
be clamped.. At this time, cut the power supply for track clamping. Also, power
outage for track clamping must be carried out for long-term shutdown. The
boom should be placed on the parallel track where the pressure of pitching oil
cylinders is nearly zero. Press down the emergency stop
button on the machine to cut the power off in case of emergency.
2(
25Kg/m ( 7 )
Before moving the traveling mechanism of the cart, the track clamping device must be
released first with whistling for warning. If the anchor is locked before, it should
be opened in advance. Meanwhile, the track must be always observed before cart
running. Since the running mechanism of the cart is regulated from time to time,
mechanisms such as rotation and luffing cannot be operated when the cart is
running. In addition, the driver should pay attention to the position of transfer
stations during cart running, to avoid collision to the bucket wheel
machine.
The safety device of each component should be checked frequently, and the machine
cannot be started unless the safety device is confirmed normal. The bucket
wheel, front boom belt conveyor and the motor at each part of the pitching
mechanism should be started under no-load status.
81
Favorable conductivity for the grounding wire of tracks and other electric
appliances must always be ensured, to avoid electric shock.
Violent operations should be avoided, to prevent hidden danger for accidents due to
shock and vibrations to the bucket wheel machine and material. Stable
operations must be ensured.
When the bucket wheel machine is reclaiming materials, deep excavation is not
allowed, to avoid accidents due to collapse of material piles.
For rotation, luffing and cart operations, limit switches can not be solely adopted for
shutdown. The limit switch is only a protective device, and severe accidents may
be caused in case the limit switch fails, so the habit of controlling shutdown with
operating switches must be developed.
The door of the operator cabin should be closed for operation in the operator cabin.
Overload must be avoided when the bucket wheel machine is involved in material
reclaiming/stockpiling. The overload occurring for several times cannot exceed
20% of the load.
20%
Inspection items during running of the bucket wheel machine
The person in charge should always check the followings when the bucket wheel
machine is operating, to ensure that the bucket wheel machine is under favorable and
safe working status:
82
Whether abnormal noise, vibrations and heating occur to the motor, bearing, reducer,
coupler and brake; whether fissure or fracture occurs to the reducer, box, reel,
shaft and wheel, especially whether obvious abnormalities can be seen from the
wear of wheels.
Whether the bolt, nut and baffle at shaft end of each part are loose or dropped.
Whether each brake can actuate normally, and the wear of brake shoe.
Whether the amount of lubricating oil inside the reducer is proper, and whether oil
leakage occurs. Whether the lubricating oil is widely distributed at other areas to
be lubricated.
Whether each limit switch is valid.
The delivery conditions of boom tape machine.
Pay attention to the stockpiling of materials scattered. Excessive material stockpiling

may affect the normal operation of the bucket wheel machine and the
transmission accuracy of limit switch signals, and therefore material piles at the
following areas must be cleaned regularly and timely:
Both sides of running track of the cart
Rotation center
Walking board on both sides of the sealing-tape machine of boom.

83
For the inspections above, if any of the abnormalities is identified, stop the
machine immediately, and operations cannot be resumed unless relevant
countermeasures are taken.
The track of the bucket wheel machine must be re-grounded.
Single-action operation is only applicable to equipment commissioning and

maintenance.
The motor of bucket wheel machine, boom motor and traveling motor cannot be
started simultaneously and frequently.
Running mechanisms such as traveling, boom rotation and luffing of the cart for the
bucket wheel machine cannot be stopped immediately during normal shutdown,
and will move due to inertia motion. The operators should bear this in mind
while controlling these mechanisms.
Precautions of storm
When the wind velocity is 20m/s, the bucket wheel machine cannot be operated, and
therefore relevant preparations must be made in case a storm alarm is sent. The bucket
wheel machine must be driven to the anchored parking position, and the track
clamping device of the cart must be clamped. Meanwhile, the anchor must be locked.
The boom must be placed at hurricane-proof piles and be locked. Lock the
door/window in the electric room and the operator cabin, and cut off the power supply.
20m/s ,
84
Maintenance and Service of Electrical Equipment
Regular maintenance and service of electrical equipment is the precondition for normal,
safe and reliable operation of the bucket wheel machine.
The maintenance and service of electrical equipment of the bucket wheel machine can be
classified into routine maintenance, daily maintenance and annual maintenance based on
maintenance cycle.
Each maintenance cycle should be determined as per working conditions and environment
of the bucket wheel machine. The maintenance systems listed below are regulated for
general conditions.
Routine Maintenance
Routine maintenance should be implemented by the operator of the bucket wheel machine
during daily shift, and the maintenance items are as follows:
,
Remove the external attachments of the electrical equipment, such as dust, sludge and oil.
Inspect the heating of motors, electromagnets, controller contacts and resistors by hand.
Check whether oil leakage occurs to the bearing, and whether wire joints of main equipment
are fastened.
Make records on each special circumstance observed.
While opening the handhole cover or enclosure, prevent entry of dust and iron filings into
the equipment.
85
Daily Maintenance
Daily maintenance should be implemented by the electrical serviceman with participation of

the operator of the bucket wheel machine. The maintenance items are as follows:
,
Remove internal attachments of each electrical equipment, such as dust and oil.
Observe the wear of brush carriers, carbon brushes and travelers of the motor.
Monitor whether the noise during running of the motor, electromagnet, relay and
contactor is normal.
Maintain and repair the controller, contactor and switch contacts, and apply a thin layer of
petrolatum oil.
Annual Maintenance
Annual maintenance should be implemented by the electrical serviceman. The maintenance

items are as follows:
:
Disassemble each electrical equipment for cleaning, and maintain the support of each
equipment.
Clean the rolling bearing of the motor and replace with new lubricating grease.
Measure the clearance between the stator and rotor; the rolling bearing should be replaced if
any of the non-uniformities is identified.
Measure the insulation resistance, and implement drying if necessary. According to design
requirements, the machine is protected by the grounding device on the line, and the
track (ground) grounding device is laid by the civil engineering contractor during
construction; the grounding resistance is measured by the test instrument for
grounding resistance; the grounding resistance around the line and head motor should
86
be less than 4; the grounding resistance of electrical device such as lighting device
and transformers cannot be more than 10 and 5 respectively; the machine cannot
be powered on as a whole unless grounding conditions are proven correct and
complete.
()
4 10 5
Insulation resistance between the motor phase windings and insulation resistance from
the phase winding to earth (enclosure): 1M
()1M
Insulation resistance between switches, contactors, control switch contacts and
insulation resistance to earth are 10M; insulation resistance to earth of terminals
for energizing coil is 2M
10M
2M
All the failures identified should be solved during annual maintenance.
The components which cannot be repaired should be replaced during annual maintenance.
The scope of annual maintenance should be determined as per the actual wear and service
period of each equipment.
Failures and Troubleshooting Methods of Bucket Wheel Machine
Failures and Troubleshooting Methods of Belt Conveyor of Boom
S/N
Failure
Reasons
87
Troubleshooting Methods
S/N
Failure
Reasons
Failures and Troubleshooting Methods of Belt Conveyor of Boom and Tripper Car
a)
Belt deviation
The belt
drum;
b)
drum;
Materials
attached on the
surface of
transmission
drum and
turnabout drum
b)Adjust the position of turnabout
c)
Adjust the self-aligning roller;
d)Check whether the belt is severely

deformed/damaged;
e)
Clean each surface of the drum.
a)
Replace the roller or bearing;
The roller
bearing is
damaged.
Belt slipping
Adjust the position of transmission
tension is
non-uniform.
a)
a)
b) The roller
support is
deformed.
c)
The belt
b)Calibrate or replace the roller

support;
c)
Adjust the tension of tension device.
a)
Replace the damaged parts and
tension is
insufficient.
a)
The
components of the sweeper;
Material
cleaning device
is invalid.
b) The
b)
Replace the sweeper;
attached to
materials are too
c)
Control the humidity of incoming
the belt
wet.
c)
Excessive
materials in the stock yard;

d) Eliminate the failure of excessive
materials
dropped.
materials dropping.
The belt is
4
sliding
forward or
backward
when the belt
conveyor stops
The hydraulic
push rod of the
brake is damaged
or too loose.
Regulate or replace the brake.
8
8
S/N
Failure
Reasons
Failures and Troubleshooting Methods of Lubrication System

a)
No oil at the
lubricating
point
The
pipeline is
blocked or
leaked;
a) Open the joint at the end of each tube,
b) No oil at the
drying oil station;
c)
The
to determine the leakage or blockage

source, and then eliminate.
b) Fill in lubricating grease of a given
lubricating pump
is damaged;
amount.
c) Replace the damaged parts or replace
d) The oil
feeder is
damaged;
e)
Air in the
d) Maintain or replace the oil feeder.
system;
f) Straighten the folded section.
f)
with a new manual lubricating pump.
e) Exhaust the air.
The
lubricating
grease is folded
in the rubber
hose.
a) The
Insufficient
oil amount
lubricating
point is too
distant from
the oil feeder
with large
resistance.
b) Excessive oil
outlets of oil
feeders.
c) Excessive
a) Increase the amount of oil feeders, and

clean the oil outlet of oil feeders.
b) Increase the amount of dry oil stations
or increase the pressure of dry oil
stations.
lubricating
points.
3
Excessive oil
The pipeline fails
contamination
to be cleaned
89
a) Clean the pipeline.
S/N
Failure
Reasons
or the filter is
damaged
during
installation.
b) Replace the filter.
Failures and Troubleshooting Methods of Traveling Mechanism

a)
The cart fails

1
to travel
Failure in
the reducer.
b) The
a)Figure out the reasons, and replace

relevant damaged parts and components.
bearing of
traveling wheels
is burned.
b)Figure out the reasons, and replace

the bearing.
c)
Failure in
electrical
control.
Failure in
a)
The limit
reversing of
the cart
during
traveling (at
the point of
material
discharging)
travel switch is
damaged
b) The control
a)Replace with a new travel switch.
wiring is
disconnected
disconnected, and connect the control
braking
b) Figure out the section

wiring
Failure in
3
c) Figure out the reasons as per relevant

requirements of the electrical
instructions, and then eliminate.
a)Check whether oil exists on the

a)
Failure in
brake block. If any, clean the oil.
the brake
b)Check whether the brake block is

overworn. If any, replace it.
b)
Adjust the elastic force of spring.
The brake
cannot be started
c)
The motor
is burned.
Figure out the reasons; repair or replace

the motor.
Failures and Troubleshooting Methods of Rotation Mechanism

1
a) Check whether the brake wheel and brake
9
0
S/N
Failure
Failure in
rotation
Reasons
a)
Failure
in the motor
ring are burned. If any, repair or replace.
b)Check whether the motor bearings are
burned. If any, figure out the reasons and
replace.
c)
Check whether motor windings are
burned.
b)
Failure
in torque
limiter
c)
The sliding torque set is incorrect, and reset.
The
electrical
control
circuit is
disconnected
.
Connect the circuit.
a)
The brake is
2
invalid
The pressure spring is broken, and
replace it.
a)
Failure
in the brake
b) Clean the oil on the brake wheel (ring).

c)
Check whether the brake wheel and
brake ring are damaged and invalid.
b)
Failure
in rotation
limit switch
c)
Replace the limit travel switch, and adjust the

traveling distance.
Failure
in electrical
control
circuit
Check one by one as per the electrical

instructions and eliminate.
a) Check whether the slewing bearing is of
Abnormal
Failure in
noise in the
slewing
bearing
the roller of
slewing
bearing
9
1
favorable lubrication; fill in lubricating

grease or replace the lubricating grease in
case of unfavorable lubrication.
b) Check whether the slewing bearing is of
favorable lubrication; if the lubrication is
proven in good conditions, check whether
S/N
Failure
Reasons
the slewing bearing roller is normal, to
determine whether the roller or bearing
needs to be replaced.
Failures and Troubleshooting Methods of Pitching Mechanism of Boom

Oil cylinder
1
still actuates
after the
boom is in
place
The limit
switch is
damaged
The support
The oil line is
of oil
cylinders is
unstable
blocked or the
throttling hole
is too large
Replace with a new travel switch, and adjust

the operating position.
Clean the oil pipelines of the oil cylinder

actuated slowly, and adjust the throttle valve.
The sealing
Oil leakage.
gasket or joint
is damaged,
or the
interface
surface is
misfit
Replace or repair the element timely
The boom
cannot be
controlled,
and is
rising/descend
ing
automatically
Check whether impurities exist on the

Oil leakage in
the system
interface surface of the balance valve and

check valve, and whether the
pressure-regulating spring cannot return
a)
b)
a)
b)
9
2
c)
d)
e)
a)
a)
b)
b)
c)
c)
a)
a)
b)
b)
c)
c)
d)
a)
a)
b)
1
c)
d)
e)
f)
b)
c)
d)
e)
f)
a)
9
3
a)
b)
c)
a)
b)
b)
a) a)
b)
b)
c)
c)
a)
(
a)
2
b)
b)
a)
a)
b)
b)
c)
a)
a) b)
c)
b)
c)
9
4
a)
b)()
a)
c)
b)
c)
a)
b)
Fire Prevention
Only dry-type fire extinguishers are allowed to be equipped on the bucket wheel
95
machine, and the most common one is carbon tetrachloride fire extinguishers. Foam
extinguishers are not allowed. Dry sand can only be used to put out the fire of
conductors instead of motors.
The power supply should be cut off first in case of fire. At this time, the emergency switch
or button can be used to disconnect the general contactor or general breaker inside the
distribution cabinet. If the conductor in front of the power supply cabinet is on fire,
cut off the breaker or fuse of incoming line of the bucket wheel machine first, or
disconnect the switch of feeder line of ground system.
Once the bucket wheel machine caught fire, it must be cleaned out and wiped and all
electrical equipment and wiring must be dried and inspected, which shall not be used
until it is qualified after repair.
Safety Rules of Equipment
Safety Rules
The operator must be trained full-time personnel who are qualified in the examination.
Prohibit working beyond the stacking and reclaiming capacity, the pitch angle range, the
rotation angle range and the other limited ranges under control specified in the
instructions.
The stacker-reclaimer can run normally only when the ambient temperature is +5
~+50 and below 7-level wind. Check frequently whether the limit switches are in
correct position and whether braking of the brake is reliable. Prohibit moving limit
96
switches or adjusting the brake without authorization.

+5 ~+50
Since track clamping device and traveling mechanism can only brake when the wind
velocity is less than 25m/s, the bucket wheel machine can only work when the wind
velocity is less than 25m/s. Once the bucket wheel machine is blown away by the
wind, re-braking will be harder. In conclusion, the track clamping device must always
be maintained well, and the reliability of the warning system of wind should be
checked regularly. The following regulations must be observed during working:
25m/s
25m/s
When the wind velocity exceeds 25m/s, and the warning system sends out alerting
signals, stop working immediately.
25m/s
Personnel in the control room should ensure sufficient time to drive the bucket wheel
machine to the anchored position for anchoring and track clamping in advance
when the predicted wind velocity may exceed 25m/s. Meanwhile, the bucket
wheel should be landed quickly and the boom should be locked.
25m/s
When the wind velocity exceeds 25m/s, stop working immediately, and drive the
bucket wheel machine to the anchored position for anchoring and track
clamping. Meanwhile, the bucket wheel must be landed and the boom be locked.
25m/s
When unexpected power failure occurs to the equipment, or line voltage fluctuates greatly
during operation, the operator shall cut off the general power switch as soon as
possible and reset all control switches to zero.
Oil filling, cleaning and maintenance are not allowed during working; the power must
97
be cut off during shutdown for maintenance.
Relevant tools and spare parts must be stored in the special cabinet; casual placement is not
allowed; combustible and explosive objects cannot be stored on the machine or in the
operator cabin/electric room; dry-type fire extinguishers should be equipped.
The oil contaminations, rainwater, snow and scattered coal and coal dust on the
ladder/platform should be cleaned regularly.
Full-time personnel should be assigned to check and maintain the electrical part.
Furthermore, the electrical operating specifications should be strictly followed.
The grounding performance of the motor and other electrical equipment should be kept
well.
i)
j)
Users should formulate specifications for safe operations and maintenance.
j)
k)
Operate as per the specifications above, and make records of the conditions
before/after operation.
k)
l)
Responsibilities of drivers
Be familiar with the structure, working principle, technical parameters, assembly and
operation and maintenance methods of the machine. Safety rules should be strictly
followed.
Preparations before operation
Pay attention to climate change as per weather forecast, especially the strong wind, to
ensure the safety of the bucket wheel machine.
Before starting, the followings need to be checked in addition to implement as per the
98
specifications of the power plant:
Whether obstacles can be seen within the running scope of tracks and equipment.
Whether obstacles can be seen on the cable or within the collection/release scope of the
cable.
All the fixed devices should be released.
The power voltage is within the scope of +5%~-15% of the rated voltage.
+5%~-15%
Special Precautions of Rotation
Forward or reverse rotation of each driving device is not allowed in a split second. A shortterm pause should be ensured for reversing. Furthermore, stable running should be ensured.
Luffing, traveling and rotation limit switches are only used for emergency shutdown in case
of failures. The switch (button) on the control console should be used for normal
shutdown. A short-term pause should be ensured for reversing. Furthermore, stable
running should be ensured
()
The operator should focus on operations and observations, especially during rotation and
luffing, to avoid damages to the bucket wheel machine due to collision between the
boom and coal pile or construction facilities. During automatic material
stockpiling/reclaiming, the operator should strengthen monitoring on relevant
operations.
Stop the machine with the emergency shutdown switch in case of unexpected failures
during operations.
99
Excessive coal cumulated at the head of the boom may affect normal luffing, and therefore
the cumulated coal should be cleaned timely.
Patrol inspection of equipment operation
For the machine, patrol inspection personnel should be assigned in addition to drivers, to
check the followings during operations:
Whether abnormal noise, vibrations and heating can be identified in the bucket wheel
reducer, motor, bearing, transmission device and oil cylinders of hydraulic device.
Whether the bolt, nut, end cap and cardboard at each part of the machine are loose or
damaged.
Any structural member and the weld should be free from fissure and obvious deformation.
The reducer filled with oil should be free from oil leakage, and all other parts should be
lubricated fully.
Stop the machine with emergency shutdown switch or the pull switch of the sealing-tape
machine in case of failures.
Precautions during Hydraulic Operations
Oil filters are provided at the oil suction and oil return header of pumps in the system, to
prevent damages to the element due to entry of contaminated particles in the oil.
Alarm signals will be sent out automatically once the oil return filter is blocked. At
this time, the oil pump motor must be stopped immediately and cannot be resumed
unless the filter element is cleaned or replaced.
100
b)Observe frequently whether the pressure, speed and temperature are normal during
operation (normal working temperature is within 55C~65C). If not, find out reasons
timely and restart after it is repaired.
b)( 55C~65C )
c)Observe frequently whether oil leakage occurs to joint surface of elements, pipelines
and the oil line and whether abnormal noise can be heard during operation. If any of
the above occurs, figure out the reasons timely with proper solution.
c)
d)The switch should be located at Stop position during shutdown.

d)
2.2.12.4
Post-storm Inspection
2.2.12.4
When the wind velocity exceeds 25m/s, check the followings immediately after the storm.
25m/s
a)Whether obstacles can be seen on the running track of the machine.
a)
b)Whether the anchoring device on the traveling mechanism, the anchoring base on the
ground and the locking device of boom are damaged.
b)
c)Whether fissures can be seen on the main mechanism structure (such as gate post,
counter-balanced carriage, boom, gate seat, rack and outrigger).
c)()
d)Whether the electrical equipment and elements in the operator cabin/electric room are
humidified or damaged.
d)
e)Whether the power supply cable and cable drum are damaged.
e)
After the bucket wheel machine is identified normal, refuel all the lubricating points. Firstly,
operate under no load at low speed, and then operate at full speed when each limit switch
can work normally.
101
Post-earthquake Inspection
When the machine is hit by an earthquake, check the followings, and restart after all the
damaged components are replaced or repaired:
. >Whether obstacles can be seen on the track, and the track accuracy should satisfy the
requirements of Appendix I.
.
Whether fissures can be seen on the weld of structural members.
Whether the operator cabin/electric room is damaged.
Whether the electrical component is missed or damaged.
After the bucket wheel machine is identified normal, fill lubricating oil to each lubricating
points. Firstly, operate under no load at low speed, and then operate at full speed when each
limit switch can work normally.
Maintenance and Safety Technologies of Equipment
Special prompt
While repairing the pitching mechanism, the replacement of oil cylinders must be installed
before releasing the pitching oil cylinders, or otherwise significant accidents may be
caused due to overturn of the machine.
While repairing the bucket wheel mechanism, the boom and ground piles (such as ground
tracks) must be integrated and fastened with wire cable before disassembling the
bucket wheel body or the planetary reducer, to avoid significant accidents due to
overturn of the boom.
102
(
)
While repairing the rotation mechanism, the rotation platform can only be lifted at the
position where the pressure of pitching oil cylinders is nearly zero (at this time, the
eccentricity is the lowest). However, relevant operations should be made by the
personnel of the manufacturer, or otherwise significant accidents may be caused due
to overturn of the machine.
()
Machine Maintenance
Refer to the table below for the maintenance and service of machine per shift.
()
S/N
1
Items
Rail inspection
If subsidence or obvious changes are identified

on the track, eliminate timely
Check the grounding wire of
The grounding wire of tracks should be firm with
the rail
favorable conductivity
Before starting the machine, clean the dust and
Clean the dust and scattered

3
materials on the machine
scattered materials on the

platform, walking
board, transshipment points
and transmission
mechanism first, and then wipe up the glass on
the control console and in the operator cabin.
Check the oil level of

4
reduction
gearboxes
of
mechanisms such
as the If the oil amount is insufficient, fill oil timely.
boom, belt conveyor of
tripper cars, rotation and
traveling
Check
all
the
rollers, If the roller, turnabout drum and driving drum
turnabout drums and driving

drums of the boom and belt
conveyor of tripper cars
103
are identified clamped or

inflexible, replace
timely. If off tracking is identified, calibrate
immediately
Check the limit switch of

6
mechanisms such as rotation, Each limit switch should actuate flexibly, to

pitching,
pitching of tripper ensure running safety
cars and traveling
Check
the
brake
of
mechanisms such as rotation Each brake should actuate reliably, to

and traveling
and
belt favorable braking effect
conveyor
ensure
Check
luffing
the
pitching Check base on the instructions of
mechanism
mechanism
Monthly Maintenance and Service of Machine (see table below)

()
S/N
Items
104
The normal clearance between the brake wheel

1
Adjust the clearance and and brake is 0.5-0.7mm; the brake

is properly
braking force of each brake
contacted and can be operated flexibly; readjust
the braking force as per braking requirements
Check
the
switch Trigger the limit
cleaning device Adjust or replace the
and retaining plate of

conveyor
belt
cleaning device and the
rubber of damper plate and the cleaning device,

to ensure proper
contact with the belt and
effective cleaning and retaining.
of Adjust the clearance between the hopper bottom
Check the chuting plate

4
switch manually first to see
whether it can work flexibly. Then start the belt

conveyor and make it run at low speed to trigger
limit switch till belt conveyor stops
located on both sides of the

coal yard
Check the
limit
the bucket wheel, and the

and arc retaining plate to 5-7mm; replace the
wear-resistant lining
plate
worn lining plate; replace the worn bucket tooth
and bucket tooth of
the
with a new one
annular trough
Check each lubricating point, to ensure a smooth
grease pipeline. Fill in grease, and the great

bearing for rotation should be filled with grease
half a month; when the existing grease overflows
from the gap, the grease feeding reaches a proper
level.
Check each grease

lubricating point
Check each power
Clean
the dust inside/outside the distribution
cabinet; repair and adjust the electrical elements,

to ensure a favorable contact performance and
reliable operation
distribution cabinet and

relevant electrical elements
Check the fastening parts
All the bolts should be fastened
Check the lubrication of
The slewing bearing
slewing bearings and the

torque limiter
lubrication; adjust the pressure of torque limiters,

so as to satisfy the requirementsof overload
protection
Check the luffing
Check base on
mechanism
mechanism
105
the
should be of favorable
instructions of
luffing
0.5-0.7mm
5-7mm
Semi-annual Maintenance and Service of Machine (see table below)

()
S/N
Items
Disassemble the end cap of the motor, to remove
Check all the motors
the dust on the stator and rotor; check the

insulation; replace with new lubricating grease
for the rolling bearing
Clear up the conductor and communication line
Check the conductor
of the whole machine; if the label on the end of

each conductor is damaged, replace if necessary;
check whether the slide line and collector is of
favorable contact performance
106
Clean each reduction
Discharge all the contaminated oil in the
gearbox (replace the

lubricating oil as per reason
characteristics)
reduction gearbox; fill into cleaning oil as per the

volume discharged; exhaust the cleaning oil after
the motor is started and operated for 4-6 min, and
refill lubricating oil
Replace the oil in the roller and bearing which
Check all the turnabout

drums and driving drums
will be subject to centralized lubrication per

month; if the cast rubber of the driving drum is
damaged, repair timely or replace with a new one
Check the luffing
Check base on the instructions of luffing
mechanism
mechanism
Clean the dust on all the structural members;
Check all the metal parts
(
3
eliminate the rust, and repaint. Check whether

the pull rod of upper structure, boom and
weighting arm are connected firmly. Check the
connected part with high-strength bolts;
re-tighten with a torque spanner, to ensure that
the torque can meet relevant requirements. All
the structural members should be re-painted
every 2-3 years; the anti-rusting primer and
finishing coat are required to be painted twice

4-6
107
2-3
Bridge-type Grab Crane
Equipment Overview
The crane consists of the bridge, trolley hoisting mechanism, cart traveling mechanism,
operation room, electrical control equipment, and the bridge is made up of main beam, end
beam and walking board. Tracks are erected for running of the trolley on the main beam,
and walking boards are erected outside the two main beams. One is for installing and
repairing the traveling mechanism of the cart, and the other is for installing the conductive
device of the trolley. All-in-view operation room equipped with linkage control console or
single controller is hung below the main beam. Inclined escalators are erected for the
operation room and walking boards, to facilitate the walking of operating and maintenance
personnel from the operator cabin to the walking boards on the bridge. The main beam is
connected to the cross beam firmly with the high-strength bolt.
Independent driving is adopted for the traveling mechanism of the cart (Figure 1-1). Four
wheels are generally equipped for the crane cart. For the crane with large lifting capacity,
the crane should be of bogie structure with 8 or above cart wheels. The wheel and the
angular bearing box with rolling bearings should be installed on both ends of the end beam
after assembly.
( 1-1)
108
The trolley of the crane is made up of trolley frame, hoisting mechanism (Figure 1-2) and
trolley traveling mechanism (Figure 1-3). Dual-limit-protection (two sets of limit switches
for hoisting safety are installed) and single limit protection are adopted for the hoisting
mechanism; single hooks and double hooks are adopted for hoisting with single braking and
double braking for the hoisting mechanism.
( 1-2)( 1-3)
()
()
Power for the trolley is supplied from the suspension-type conductive cable (the track for
cable pulleys are made of joist steel, round steel and angle steel) and safe slide wires.
()
Opened and closed operation rooms are designed. The closed operation room is equipped
with electric heaters, air coolers and air conditioners if required by the user.

109
110
111
Electrical Control Principle
The electrical circuit of the crane is made up of distribution protection circuits, main
circuits of each mechanism, control circuits and lighting signal circuits.
Distribution Protection
XQC-type protection box is adopted as the distribution protection device of the whole
112
machine with the disconnector DK and main contactor XC as the main power switch. The
main circuit and control circuit of each mechanism are led out from the rear of XC.
XQC DK
XC
XC
The following operations and protective elements are cascaded in the coil circuit of the
main contactor XC:
XC
DS()
Electric lock DS: a button with a key, to ensure that only the responsible operator can
operate the crane (interlinked control console).}
Startup button QA is connected to the main contactor XC generally.
QA XC
Emergency switch JK will cut off the main contactor XC, and the power supply of the
whole machine in case of emergency, to avoid worsening.
JK XC
Zero linkage contacts KX, Kd, Kf and ks (1-2) of each mechanism: to ensure that the main
contactor XC cannot be switched on unless the operating handle of each mechanism is
located at zero, so as to avoid automatic startup of the mechanism once the power
supply is resumed, and can also prevent the motor from starting up when the rotor
resistance is cut off.
KXKdKfks(1-2) XC
Safety switches 1AK, 2AK and 3AK of safety gate: if the handrail door is opened and the
safety contact is switched on, the main contactor XC will be disconnected and cannot
be started, to avoid human injuries due to unexpected startup while getting on/off.
1AK2AK 3AK
XC
the normally closed contacts LJ and (1-5) LJ for the general overcurrent breaker and the
overcurrent breaker of each mechanism: when one mechanism is overloaded, or the
line is short circuit, the main contactor XC will be disconnected and the power supply
will be cut off.
113
LJ (1-5)LJ
XC
Limit switches 1XS, 2XS, 1Xf, 2Xf, 1Xd, 2Xd, 1Xx and 2Xx of each mechanism: when one
mechanism reaches the limit position, the main contactor XC will be disconnected to stop
the running. Both of the limit switches of the hoisting mechanism are for rising. Two
switches are adopted to strengthen the reliability and reduce accident rate. The two
switches are of different structure. One is of heavy punching structure, and the other is of
rotation structure. Limit protection is unnecessary for the descending of common cranes. If
limit protection for descending is required in case of special conditions, special ordering
requirements should be proposed.
1XS2XS1Xf2Xf1Xd2Xd1Xx2Xx
XC
Control Principle for Traveling Mechanism of Trolley
The trolley traveling mechanism of the crane is driven by a single motor with 5 gears at
front and back. To improve the starting stability, 1-phase open circuit of motor rotor
st
resistance control is adopted for the 1 gear. See Figure 3-1 (Schematic Diagram on Wiring
of Rotor Circuits) for details. This is an example of motor rotor circuits cascading with
asymmetric resistance, which means that one of the phase resistances (R 8) is infinite, and its
equivalent resistance is the sum of the two phase resistances, i.e. R=R 1+R2. When there is a
great difference between the rated resistance of the motor and the equivalent resistance, the
mechanical characteristics curve of which can approximately be shown in a straight line.
Refer to Figure 3-2 for the Schematic Diagram on Mechanical Characteristics Curves of the
Five Gears. Three taps are equipped for the RK-type resistor. When the rotating speed is
zero, three working conditions of level-0.35, level-0.5 and level-0.7 can be obtained by the
st
starting torque of the 1 gear through regulating the taps of resistors. One of the three can
be selected as per actual needs. For box folding, chucking, assembly and installation
occasions which require stable startup and low-speed running can select level-0.35. For
other common transportation sites which are frequently used, level-0.7 can be selected to
improve the productivity. A common control program of motor rotor circuits
114
cascading with asymmetric resistance for step-by-step startup is adopted for the 2
sec
rd
,3 ,4
th
th
and 5 gears. Push the handle step-by-step, and the cam contact will be in short circuit with
the resistance step-by-step. Accordingly, the motor will be started step-by-step. The
resistance is not short circuited at the last position. Two sections of the resistance are
connected to the phase-1 after parallel connection. If the motor is working at curve 5, drive
the trolley at a speed slightly lower than the rated one.
5
(3-1)
(R8)
R R1+R2
(3-2) RK
0.350.5 0.7
0.35
0.7
115
Control Principle for Traveling Mechanism of Cart
st
Except that the sliding gear is added for the 1 gear, the control principle of the traveling
mechanism for the cart is the same as that of the trolley. After the sliding gear is added,
st
switch to 1 gear before stopping. At this time, the motor will be powered off instead of the
brake. The traveling mechanism can still keeping sliding, and then return to zero after
reaching the destination. The brake will be powered off and be braked, to stop the traveling
mechanism. In this way, the cart brake can be adjusted more firmly, to ensure stable
stopping and braking of the cart. Switch to the zero directly in case of emergency, to ensure
safety.
Control Principle of Hoisting Mechanism
The control principle of controlling motor rotor circuits cascading with asymmetric resistance
for step-by-step startup with cam controllers is basically identical to that of the traveling
st
mechanism of the cart/trolley. General asymmetric resistance is adopted for only the 1 gear
instead of 1-phase open circuit of rotor resistance. While descending the load, since it is a
potential energy load, the load will drive the motor to rotate, making the motor speed exceed the
synchronous speed and go into the status of regenerative braking. At this
116
time, the speed will be accelerated if the resistance is cascaded in the rotor. In conclusion,
excessive durations at the front gears should be avoided while descending the load, or
otherwise galloping may be caused.
The principle of controlling the motor through the XQR2-type control box with the main
contactor is as follows:
XQR2
Line characteristics:
Reversible asymmetric line;
Gears of the main contactor: 3-0-3

3-0-3
The starting resistance is grade-4; grade-1 and grade-2 resistance can be cut off manually,
while others should be cut off by the accelerating contactor controlled by the timedelay relay.
st
Descending of the 1 gear is plug braking, to realize slow descending of the heavy load
(larger than 0.5 times of the rate one).
( 0.5 )
Descending of the 2
sec
gear is single-phase braking, to realize slow descending of the light
load (less than 0.5 times of the rate one).

( 0.5 )
Descending of the 3
rd
gear is compulsory descending or descending with regenerative
braking, for rapid descending of various loads.
The brake should be powered off first while stopping and then the motor after 0.6 sec, to
avoid hook sliding.
0.6
117
To avoid interphase short circuit during reversible conversion of the main contactors ZCDC and DC-FC, reversing relay ZDJ should be adopted.
ZC-DCDC-FC ZDJ
The line is provided with overload, short circuit, limit, zero and no-voltage protection.
The disconnector 1DK, reversing contactor ZC and FC, single-phase braking contactor DC,
overcurrent relay 1LJ and 2LJ and braking contactor ZDC are connected in the stator circuit
of the motor. The power of brakes is supplied from ZDC. Different from direct control by
the cam contact over the motor, since the brake is directly linked to the motor in parallel,
plug braking, single-phase braking and regenerative braking are adopted in the descending
direction of the line. Each braking is controlled by its own line contactor. During the
descending, the three contactors are changed over repeatedly. The motor is powered off at
the moment of change-over. If the brake is directly connected to the motor in parallel, the
brake will also be powered off for braking at the moment when the motor is powered off,
which is adverse for running. In addition, during single-phase braking, since the motor is
provided with only two phases of power supply, the brake cannot work reliably. In
conclusion, the brake must be powered independently.
1DK ZC FC
DC
1LJ 2LJ ZDC ZDC

Grade-1 reversing resistance, grade-3 acceleration resistance and grade-1 softening
resistance are connected in the rotor circuit of the motor.
Since the loading direction is different to the driving direction for the hoisting mechanism,
to improve service performance, different working characteristics are designed for the
rising/descending of the lime. See Figure 3-3 for details. For rising, characteristics 1, 2 and
st
3 correspond to the 1 , 2
sec
and 3
rd
gear on the main handle, to ensure stable running.
Characteristics 1 and 3 are automatically transited by the time-delay relay, so stable running
cannot be guaranteed. These characteristics are obtained through cascading different

resistances in the rotor circuit, and are mainly used for motor startup and speed regulation
118
(since the resistance characteristics are soft, light load cannot be used for speed regulation).
However, the resistor is designed as per startup conditions, and therefore long-term usage is
not allowed, and is only applicable to short-distance slow rising of heavy load.

(3-3) 123 123
1 3

(
)
While descending, there are three stable working characteristic curves 1, 2 and 3, and two
,
,,
transition characteristic curves 3 and 3 .

123 3 3
st
Plug braking is adopted to descend the 1 gear. At this time, the contactor ZC is switched
on, and the motor torque is in the direction of rising. Since a large resistance is cascaded in
the rotor, the motor torque is small. If the load is more than 55% of the rated load (heavy
load), the motor will be pulled down by the load, and will rotate in the direction contrary to
the magnetic field, i.e. plug braking.
ZC
55%()

Plug braking cannot be used for a long-term, and is only applicable to short-distance slow
descending under heavy load.
119
Single-phase braking is adopted to descend the 2
sec
gear. At this time, the contactor DC is
switched on. Single-phase braking not only overcomes the disadvantages of rising under
light load for plug braking, but also supplemented the shortcomings of lacking of low speed
sections for regenerative braking. If a proper additional resistance is selected for the rotor,
characteristics of slow descending under light load can be obtained.
DC
Wiring for single-phase braking should be made as per the methods in Figure 3-4. After the
two phases of stator winding are connected in parallel, the motor should be cascaded to the
two phases with the other phase. At this time, the voltage applied to the three phases of the
motor stator is asymmetric. Asymmetric voltage can be further classified into positive
sequence voltage and negative sequence voltage.
(3-4)
The positive sequence voltage and negative sequence voltage (

of the network voltage)
are equivalent through analysis and calculations. Since the motor torque is in direct
proportion to the square of the voltage, the maximum torque of the positive sequence and
negative sequence generated in positive sequence voltage and negative sequence voltage
1
(
of the maximum torque during normal operation of the motor) is equivalent.
Figure 3-5 is the curve of mechanical characteristics when the rotor traveler is in short
circuit as per the wiring methods in Figure 3-4. Curve 1 is for positive sequence torque,
while curves 2 and 3 are for negative sequence torque and composite torque respectively.
The composite torque is electric torque in the first and third quadrants. If the rotation speed
120
is zero, the composite torque is also zero. This feature cannot be started automatically, and
also cannot be used for descending braking. In conclusion, a proper resistance must be
applied in the motor rotor circuit, to soften the feature. Turn the composite torque into
braking torque through rotating from the first and third quadrants to the second and fourth
quadrants to obtain the characteristics of sing-phase braking. See Figure 3-6 for details.
(3-5)(3-4) 1
2 3
(3-6)
Single-phase braking is adopted for slow descending in case the load is less than 55% of the
rated load (light load). This gear should not be adopted if slow descending is unnecessary.
121
st
If slow descending under a load more than 55% of the rated one is required, 1 gear, i.e.
plug braking should be adopted. If the load cannot be estimated, try hanging first before
hoist. Large current can be identified during single-phase braking, among which the current
of one phase can reach 1.6-2.1 times of the rated current. This is mainly associated with the
rotor resistance. Currently, 67% of the rated resistance is adopted. Excessive resistance will
make the characteristics curve steeper and the descending speed faster. However,
insufficient resistance will cause excessive current.
55%()
55%
1.62.1 67%
The gears above are used for slow descending, i.e. regulatory movement, and cannot be
used for a long time, to avoid damages to the motor and resistor due to overheating.
Compulsory descending or descending with regenerative braking is adopted for descending

rd
of the 3 gear. At this time, the contactor FC is switched on, and the motor torque is in the
direction of descending. While lowering the unloaded hook or light load (the load is so light
that the frictional resistance of the driving device cannot be overcome), the motor will put
down the unloaded hook and light load. If the working curve is at the third quadrant, the
strength is weakened. While lowering heavy load, the load will drag the motor and increase
the rotation speed. When the rotation speed is larger than the synchronous speed, the motor
will turn the loaded potential energy into power as a motor connected to the power grid in
parallel. Afterwards, it will feedback relevant information to the power grid. If the working
curve is at the fourth quadrant, regenerative braking for rapid descending of various loads is
adopted.
FC
()
The three contactors ZC, FC and DC are electrically interlocked, i.e. the normally closed
122
auxiliary contacts of two other contactors are cascaded in the coil circuit of one contactor,
which can realize the effect of interlocking normally, so as to avoid short circuit in power
supply. However, if the normally closed auxiliary contacts are not well regulated, or the
contact is started after frequent switching on of power supply, arc short circuit may be
caused in case the arc of one contactor is still on, and the other contactor is powered on, so
reversing relay ZDJ is adopted in the line. The normally closed contact of ZDJ is cascaded
in the coil circuit of ZC and FC, while the normally opened contact of ZDJ is cascaded in
the coil circuit of DC, thus increasing the reversible conversion time and the arc short
circuit is avoided accordingly. Meanwhile, the temporary time delay of ZDJ is utilized.
When the main handle is pushed downward to 3 rapidly from zero, or is pushed back to
zero from 3, DC will not move, thus relieving the work of DC.
ZCFC DC
ZDJ ZC FC ZDJ DC
ZDJ
ZDJ 3 3
DC
DC
Reversing resistance occurs under the status of transition during rising for preparation. The
time-delay normally closed contact of time-delay relay 2LSJ is cascaded in the coil circuit of
the reversing contactor FJC. When the main handle is located at zero, the coil of 2LSJ will
be powered on, and then open its normally closed contact connected in the coil circuit of
FJC. When the handle is pushed upward to 1, since the ZC is powered on, open its normally
closed auxiliary contact connected in the coil circuit of 2LSJ, to cut off the power supply of
2LSJ coil. After time delay of 0.2 sec, switch on its normally closed contact, to provide
power supply for FJC coil. Cut off the reversing resistance, and the mechanical
characteristics will be transited to working characteristics 1 from transition characteristics 1
automatically.
FJC
2LSJ
2LSJ
,,
FJC 1 ZC
2LSJ 2LSJ 0.2
FJC 1
123
1
For descending with single-phase braking or regenerative braking, since the reversing
resistance will not participate in relevant actuations, it can be cut off. Therefore, the
normally closed contact of 2LSJ in the coil circuit of FJC is connected with the normally
opened auxiliary contact of DC and FC in parallel. When DC or FC is powered on, 2LSJ
will not work. The FJC is powered on through the auxiliary contact of DC or FC, thus
cutting off the reversing resistance.
FJC
2LSJ DC FC DC FC
2LSJ
DC FC FJC
When the handle is pushed to rising 2, the accelerating contactor 1JSC will be powered on.
Once the grade-1 accelerating resistance is cut off, the motor will be accelerated, and will
operate on working characteristics 2. Since the normally opened auxiliary contact of FJC is
cascaded in the coil circuit of 1JSC, 1JSC cannot be powered on unless FJC is powered on,
to ensure stable step-by-step acceleration of the motor.
2 1JSC
2 1JSC FJC FJC

FJC 1JSC
When the handle is located at rising 3, 2JSC will be powered on. Once the grade-2
accelerating resistance is cut off, the motor will be accelerated again, and will operate on
,
transition characteristics 3 . However, since the time-delay normally closed contact of timedelay relay 3LSJ is cascaded in the coil circuit of 2JSC, 2JSC should be powered on after
0.6 sec when 1JSC is powered on. After 2JSC is powered on, disconnect its normally closed
auxiliary contact connected in the coil circuit of 4LSJ, to cut off the power supply of 4LSC
coil. Switch on its normally closed contact after 0.3 sec, to provide power supply for 3JSC.
Once the grade- 3 accelerating resistance is cut off, the motor will be accelerated again, and
will operate on working characteristics 3.
3 2JSC
3 2JSC 1JSC 0.6 2JSC
3LSJ 2JSC
4LSJ 4LSC 0.3
3JSC 3
To avoid hook sliding of load during stopping, the brake is switched on first, and then motor
is powered off during design, to ensure that a rising torque of the motor can be
124
guaranteed while stopping, thus relieving hook sliding. The series loop made up of the main
contact 5 and the normally opened time-delay contact of 1LSJ is connected to the main
contact 4 in parallel. When the handle is pushed back to zero from rising 1/descending 1,
the contact 5 is switched on, and 1LSJ is powered off since ZDC is released. Open the
closed contact after 0.6 sec. At this time, ZC is powered on, while ZDC is powered off, thus
realizing the requirement of Brake first, and then stop the motor.

5
1LSJ
4 1
1 5 1LSJ ZDC 0.6

ZC ZDC
All the three gears in the descending direction of the line are independent.
The order of 1
2
3 needs not to be followed during operation. Chose the
correct gear as per load weight, descending speed and distance.
1
Rapid descending of various loads: push the handle to descending 3 directly from zero, and
then implement compulsory descending or descending with regenerative braking on
working characteristics 3. The step-by-step startup of the motor is controlled by 3LSJ and
,
,,
4LSJ automatically. Transition characteristics 3 and 3 exist in the middle.

3 3
3LSJ 4LSJ
3 3
Slow descending with light load: push the handle directly to descending 2 and working
characteristics 2 from zero for descending with single-phase braking.
2 2
Slow descending with heavy load: push the handle to descending 2/3 first from zero, and
then back to descending 1 and working on characteristics 1, and descending with plug
braking.
2 3 1
1

If the distance between heavy load and the drop point is relatively high, push the handle to
125
descending 3. If the heavy load is close to the drop point, push the handle back to
descending 2/1 as per load weight, thus reducing the running time of sing-phase braking or
plug braking and avoid the heating of the motor and resistor.
3
2 1
To avoid rising while descending the light load, if the handle is pushed to descending 1
from zero, the mechanism will not operate. Only when the handle is pushed back to
descending 1 from descending 2/3 can the descending with plug braking be made. In
conclusion, for heavy load, push the handle to descending 2/3 first cannot meet the
requirements of slow descending, which is realized through the interlock relay 1LSJ. When
the handle is at zero, 1LSJ will not be powered on. When the handle is pushed to
descending 1 from zero, 1LSJ still cannot be powered on. ZC and ZDC also cannot be
powered on due to the two normally open contacts of 1LSJ. At this time, the mechanism
cannot be operated. However, when the handle is pushed to descending 2/3, since DC or FC
is powered on, 1LSJ can also be powered on, thus switching on the normally open contact.
At this time, if the handle is pushed back to descending 1, since 1LSJ is switched on, ZDC
can also be powered on. On the contrary, since ZDC is switched on, 1LSJ can also be
powered on, thus realizing mutual protection. Since 1LSJ is powered on, ZC and ZDC can
also be powered on for descending with plug braking. To ensure that rising will not be
affected by this link, the normally open auxiliary contact of ZC is connected on 1LSJ
contacts in the coil circuit of ZDC in parallel. As long as ZC is powered on, ZDC can also
be powered on.
1
2 3 1
2 3 1LSJ
1LSJ 1 1LSJ
ZC ZDC 2 3
DC FC 1LSJ
1ZDC 1LSJ 1LSJ ZDC
1LSJ ZC ZDC
ZDC 1LSJ ZC
ZC ZDC
Lighting Signal Circuits
126
The disconnector 3ZK of lighting signal circuits, connected to the main disconnector DK in
parallel, is designed inside the protection box. If DK is cut off during maintenance, the
lighting signal circuit can still work.
3ZK DK
DK
Lighting can be classified into lighting in operation room, portable maintenance lighting
and underbridge lighting. Safe voltage of 12V is adopted for portable maintenance lighting,
while voltage of 220V is adopted for lighting in operation room and underbridge lighting
with power supply from the 380/220 and 12Vsecondary dual winding transformer. All the
lamp switches are installed inside the operation room.
12
220V 380/22012V
GC-29 shockproof lamps (500W bulbs) are adopted for underbridge lighting. Three lamps
should be installed in case the bridge span is more than 16.5m, while two for others.
GC-29 500W16.5m
The bell of safe voltage is adopted as sound signals.
A 220V socket for connection with electric fans and a 12V socket for maintenance lamps
are equipped. If required in the order contract, electric fans, electric heaters, air coolers or
air conditioners can be supplied.
220V 12V
Operations
All the operating elements are installed inside the operation room with the controller, start
button, emergency switch and bell for each mechanism around the operation room
reasonably, to facilitate operations.
Controllers controlling mechanism operation, power indicators, electric locks, start/stop

buttons, emergency switches and pedal bell switches are installed on the interlinked control
127
console.
The traveling mechanism of the cart/trolley is controlled by one handle, and mechanisms
such
as
longitudinal/lateral
control
over
trolleys
can
be
operated
independently/simultaneously.
The traveling mechanism of main/auxiliary hooks for the double crane is controlled by two
handles.
Notes for Use
Safety and technical Rules
The safety and technical rules must be followed while using the crane:
The crane should be operated by full-time personnel.
Obvious marks (maximum hoisting load, span, working class and manufacturer) must be
signed on the sides of the crane.
No standing at any other position except for the operation room when the crane is
operating.
The crane must be powered off during tests or repair.
The hook should be 2.5m (the height of one person) from the ground when the crane is
operated without heavy load.
2.5 ()
No one shall stand below the objects when the crane is hoisting heavy objects.
The distance between the lowest point of the heavy objects and the highest obstacle on
128
the running line should be at least 0.5m when the crane is operating with heavy load.
0.5
Manned hoisting is not allowed.
Dropping of objects from the crane in any methods is not allowed.
Tools, spare parts, fasteners and sundries must be stored inside the special box; casual
placement on the crane is not allowed, to avoid falling.

While hoisting liquid metal, harmful liquid and essential objects, the load should be hoisted
for 150-200mm first regardless of the weight. Hoist after the reliability of the brake is
verified.
150200mm
Combustibles cannot be stored on the crane; work concerning fire protection should
be implemented.
The crane for outdoor service should be stopped in case the wind is more than 6-level.
6
While stopping the crane for outdoor service, the crane must be fixed firmly (hang ground
anchor to the hook; apply wedge liner to wheels), to avoid unexpected accidents due
to blow-off of the crane.
(
)
Implement regular safety inspection to the crane, including testing the dead load and live
load with test load, and then record relevant results for filing.

Safety and technical rules for maintenance of electrical equipment:
The electrical maintenance of the crane should be completed by full-time electrical

personnel.
129
Portable spotlight with voltage below 36V must be used during maintenance.
36
When live maintenance is required, rubber insulating gloves and boots must be worn, and
tools with insulating handles must be used. The electric switches should be protected
by the specially-assigned personnel; cut off the power supply immediately in case of
emergency; all the areas adjacent to the conductive part must be isolated with barriers.

All the metal areas with potential conductivity hazards of the motor, electrical
equipment and electrical enclosure must be grounded.
Responsibilities of Operators
Be familiar with the purpose of the crane, equipment operation methods and service
rules.
Strictly observe the safety and technical rules.
The followings should be made before operating a crane:
Know well the power supply; the crane cannot be started in case the power voltage (voltage
among conductors of the cart) is lower than 90% of the rated value.
( ) 90%
Test the crane when the general switch is disconnected; check the connection and usage
conditions of main parts; implement necessary adjustments to several mechanisms.

Check whether any tools or other objectives are left, to avoid personal injuries or
equipment damages due to falling during operation.
130
4) Fuel each lubricating point of the equipment as required. 4)
5)
Proper hurricane-proof measures should be taken to the outdoor crane which is not
working.
5)
d)
Before the main switch is powered on, the operator must turn the all the handles of the
controller to zero. No one shall stand on the bridge and cart tracks when the crane is
operating.
Warning signals for startup (bell) must be given before the crane is started each time.
()
The weight of the objects to be hoisted cannot exceed the rated overweight.
The operator must coordinate with the flatman closely. Movement and hoisting of the heavy
objectives should follow the signals of the flatman. However, the crane should be
stopped immediately once the signal of Stop is given.
The heavy objectives to be hoisted must be upright. The cart/trolley cannot be moved to
drag the objectives.
If the crane and trolley are close to the edge, move at the slowest speed, and then
close gradually as long as they don't collide with the retaining support.
The interlinked control console of the crane should be controlled step-by-step; before a
machine is stopped wholly, the interlinked control console cannot be turned to
reversion position for braking from positive rotation position directly. However, this
can be used as emergency measures sometimes to avoid accidents. However, the
st
interlinked control console can only be pushed to 1 reversing gear, and then relevant
work cannot be continued unless no damages to the mechanical components are
identified through inspection.
131
An operator must avoid collision with another crane. Only when one crane fails can another
crane be allowed to push the crane in failure. Under this circumstance, both of the two
cranes must be under no load and move with the slowest speed.
In case of obvious decreasing in voltage and power outage, the main switch must be
disconnected, and all the control handles must be placed at zero.
In case of unexpected power outage in the crane motor or obvious decreasing in line
voltage, all the control handles must be placed at zero, and the main switch in the
operator room must be disconnected timely. The operator should notice the flatman to
stop working with signals. If heavy objectives are hung on the hook of the crane
during power outage, the operator and flatman should warn anyone of walking below
the hook.
When heavy objectives are hung on the crane or while lowering the lifting appliance, the
operator cannot leave the operation room.
When the crane is out of service, the lifting appliance should be hoisted to upper position;
push the control handle to the zero, and disconnect the main switch.
After all the operations are completed, the operator must switch off the main switch and cut
off the power supply.
p)
Service the crane as required after each operation; check whether the equipment is
132
complete and make recordings.
The operator on duty should hand over the log book to the next operator on duty while
shifting, and report all the failures identified during operations to relevant departments
and the next operator on duty.
Before an operator leaves a crane, the crane must be parked at the specified point and
be fixed.
Electrical Inspection System
Regulations on repair cycle are determined in accordance with working condition of the
crane. Inspection and repair system list in the following is applied to normal circumstance.
Crane drivers conducts daily inspection when they shift duty. Scope of repair is as following:
clear off attached materials outside of electrical equipment, like dust, dirt and oil; detect
heating of motor, controller contact and resistor by hand; check whether oil is leaked in the
bearing and whether wire connection of main equipment is tight; prevent dust and iron
scraps from entering into the equipment when handhole cover or enclosure is open; and
record all special circumstances obtained through observation.
Electrician takes charge of ten-day check (or dual-week check) in the presence of the driver.
Scope of repair is as following:
()
Clear off attached materials insides of electrical equipment, like dust and dirt; observe wear
of brush carrier of the motor and slip ring of carbon brush and whether noise made during
the operation of motor, relay and electromagnetic switch is normal; check and repair the
contact of controller and switch.
133
Electrician takes charge of annual inspection and repair or overhaul. Scope of repair is as
following:
Dismantle all electrical equipment and clear it up, inspect and repair the support of all
equipment, clean out rolling bearing of the motor and replace with new lubricating grease,
measure the gap between stator and rotor and replace rolling bearing once unevenness is
found out. Measure insulation resistance and dry it when necessary. All errors must be
repaired during annual repair and the components which are unable to be repaired shall be
replaced. Annual repair or overhaul scope depends on actual wear or aging extent of all
equipment.
The crane must be furnished with and only adopts dry fire extinguisher (carbon
tetrachloride extinguisher is most frequently used), however, foam extinguisher is not
allowed to be used. Dry quicksand is only used to put out fire on the conductor rather than
fire on the motor.
Where fire accident happens, power supply shall be timely cut off at first by emergency
switch or knife switch on protection panel. When the conductor in front of the protection
panel catches fire, knife switch on feeder line should be cut off.
Once the crane caught fire, it must be cleaned out and wiped and all electrical equipment
and wiring must be dried and inspected, which shall not be used until it is qualified after
repair.
134
Troubleshooting
Failure on Control Circuit

2.3.5.1
Failure condition
Failure cause
Troubleshooting method
protection panel is closed,
One phase on function
Eliminate grounding
fusible cutout on function
circuit is grounded
condition
Such phase is grounded
Eliminate grounding
When knife switch on
circuit is burnt out.

Fusible cutout on incoming
line is burnt out after main
condition
contactor is closed.
1 Setting value of
overcurrent relay is
Automatic switch is actuated
controversial
following the controller.
One part of
mechanical component
Adjust current of the
relay to make it 225-250% of

rotated current of the motor;
2
Check mechanical part
Inspect and adjust the

brake mechanism;
is clamped
1
Rated power of the motor is
unable to be achieved and the
motor rotates slowly.
The brake is not
completely opened;
2
The resistor is
actuated, corresponding motor

is still charged with electricity.
1 The circuit with

limit switch is short
circuited;
2
connected;
135
reduction;
3
Correct connection of
the resistor;
Check the conductor
that is connected to limit
Wiring to the
controller is disorderly
Remove the reason
which causes voltage
circuit decreases;
incorrectly connected;
When lever of limit switch is
Voltage in the
switch;
2
Check the wiring;
The contactor does not fall
1 Grounding or
short circuit of function
1The disconnection may
circuit;
be found out by tramegger
Contact of the
and then repaired;
when the power supply is cut
contactor is fixed by
2Remove the failure that
off.
welding;
the contactor is welded;
3It is clung by
3Clear off greasy dirt
greasy dirt on contact
attached on contact surface;
surface of armature;
225-250%
1 1
2 2
3
3
136
AC Motor
2.3.5.2
Failure condition
Failure cause
1
Check working load of
the crane which must carry
Actual working load
exceeds rated level and

The whole motor is
overheated evenly.
causes overload;
2
Network voltage
decreases;
3
Resistors are not
matched;
Local short circuit occurs
Local overheating of the core
of the stator
between steel discs of the

iron core;
Poor contact
out work in accordance with

required working level;
2
Recover network
voltage;
3
Replace resistors;
Remove burr or other part

that incurs short circuit and
then paint with insulation
varnish;
1
Check all welding
parts and remove external
between winding tip and
flaws;
the temperature of the rotor
neutral point or between
increases, the stator is
parallel windings;
between winding and slip
impacted by large current
ring;
and full speed of the motor
slip ring of the winding;
could not be reached under
brushes;
rated load.
brushes;
that connects contactor of
Poor connection of
Poor contact of
Poor contact of rotor
circuit;
Inspect connection part
Inspect and adjust
Check rotor contact
the conductor or controller

and starting resistance;
Motor vibrates during

operation.
1
Motor reel and
reducer shaft share no
1
2
core;
replace the bearing;
137
Align the motor;

Check and repair or
2
3
Bearing abrasion;
Deformation of the
3Check and shape the

rotor;
rotor;
1
Displacement of
phase position of the
stator;
2Iron core of the
The motor makes abnormal
stator is not tightly
sound during operation.
compressed;
3
Rolling bearing
abrasion;
4
Slot wedge
expansion
Check the stator,
compress and overlap iron

core or the stator again;
3
Replace the bearing;
Cut off expanded
wedge and replace the

shrinking one;
system;
Check connecting
2
3
4
2
3
3
4
1
2
138
1
2
2.3.5.3
2.3.5.3
Linkage Control Panel
Failure condition
Failure cause
Hand shank is clamped
1
The contact is
welded;
1
Remove failure and
repair the contact;
during operation.
The contact is severely

burnt;
Failure happens to
Check and repair
locating mechanism;
steady pin;
1Poor contact of the

contact;
1
Adjust pressure and
location of the contact;
Overload of the
controller;
Change working
specification or replace the

controller;
1
2
1
2
1
2
1
2
AC Braking Electromagnet
Failure
condition
Failure cause
Coil is
Traction overload of
139
Adjust spring pressure or
overheated.
electromagnet;
2Gap exists between portable
position of the hammer;

2
Adjust mechanical part
components and static components of
of the brake to remove the
electromagnet at working position;
gap;
1Adjust spring pressure or
change the position of the
1Overload of the electromagnet;

Loud noise is
2Working surface of magnetic
generated.
conductor is contaminated;
hammer;
2Remove dirt on the
surface of magnetic
conductor;
3Magnetic conductor is bent;
Adjust mechanical part
to eliminate bending of
magnetic conductor;
1
2
1
2
AC Contactor and Relay
Failure condition
Coil is
overheated.
Failure cause
The coil is overloaded;
Portable part of
1
Reduce the pressure of portable
contactor spring;
magnetic conductor is
unable to contact with static
part;
Great noise is
generated.
1
2
Eliminate reasons that cause
abnormality of portable part of

magnetic conductor, such as bending,
blocking and contamination;
The coil is overloaded;

Working surface of
140
1
Reduce the pressure of portable
contactor spring;
magnetic conductor is
contaminated;
2
3
conductor;
Magnetic
conductor is bent;
Remove the contaminations;

Adjust the position of magnetic
Remove additional friction;
away from static part;
Shorten the distance between
two parts;
Automatic adjustment
system of magnetic
conductor is clamped;
1
Portable part of
magnetic conductor is far
Slow action;
Upper part of the
baseboard of the machine is
Make the device vertical;
Increase spring pressure of the
expanded compared with

lower part;
Magnet does not
fall in case of
power failure;
1
Insufficient pressure of
the contact;
2
Much greasy dirt on
contact surface of armature;
contact;
2
Remove the dirt;
The contact is
1
Portable contact
applies minor pressure to
Adjust spring pressure;
overheated or
static contact;
Remove the dirt or replace
burnt down;
sliding block on the contact;
The contact is
contaminated;
1
2
1
2
()
1
2
3
4
141
2
3
4
1
2
1
2
Lubrication of Mechanism
The lubrication condition of crane equipment directly affects the normal operation of crane
mechanism and is closely related to extending the service life of the mechanics and
promoting safety in production. Therefore, the use and maintenance personnel must carry
out regular checks on all lubrication points and fuel on time with oil gun through oil cups of
the lubrication points (painting method is not frequently adopted because grease is hard to
enter into lubricating surface)
)
Distribution of Lubricating Points for the Crane
Hook pulley spindle
Steel wire rope
Speed reducers
Bearing housing (including wheel parts)

()
Motor bearing
142
Nodes and axle bolts of brake
Fixed sliding wheel shaft on the trolley

()
Piston of long-stroke electromagnet (MZS type)
(MZS )
Pulley bearing of electric cable
Gear couplings
Lubricating Conditions and Materials
Proper lubricating grease must be applied to hoisting equipment, to lubricate it at regular

intervals and timely replace lubricating grease. Lubricating devices and points must keep
clean. Table 1 specifies general provisions for lubricating time of main components of each
mechanism and recommended lubricating materials.
Table 1
1
S/N
Components
Requirement
Generally
lubricating once
in every 15-30
1
Steel wire
days, which is
rope
determined by
actual utilization
of the lubricating
grease
Lubricating
conditions
1
Heat
lubricating
grease to 80
grease Q/SY152-65
-100 and
implement
calcium soap lubricating
dip-coating till it
grease (SYB1450-65) or
is saturated.
other lubricating grease
for steel wire rope
Paint it
without heating;
143
Lubricating materials
Wire-rope flax wick
Paint with compound
Replace it in
every quarter at
Summer
first and then

2
Apply HL30 gear oil

(SYB1103-62)
Speed
replace it in every
reducer
half to a year
Winter
based on
(temperature no
cleanliness of
lubricating grease
less than -20 )
Apply HL20 gear oil

(SYB1103-62)
Gear
coupling
Once a month
1
Working
temperature:
1
Lubricating grease
that uses any element as
Rolling
bearing
Once in every 3 6 months
-20 - 60
its primary structure
without mixed usage No. 1
Sliding
bearing
As the case may

be
Inner fluted
Fill up with
while No. 3 and 4

lubricating materials are
disc of reel
lubricating grease
favorable in summer
during each
overhaul
grease (QSY1110-65), No.
More than
and 2 lubricating materials
50
3
Less than
-20
are preferred in winter,
Lithium lubricating
1 in winter and No.2 in

summer
3
No 1 and 2 special
lubricating grease
(Q/SY1119-70)
1
Normal
motor
7
Motor
Annual repair or
Class H
overhaul
insulation and
damp and hot
zone
144
Compound
aluminium-base grease
(Q/SY1105-66)
2
No.3 lithium
lubricating grease
1
15-30 80 -100
2
(SYB1450-65)
HL30 (SYB1103-62)
(
-20 )
1 Q/SY152-65
1
-20 -60
HL20 (SYB1103-62)
2 50
12 34
3 -20
(QSY1110-65) 1
2
3-6
3 12
(Q/SY1119-70)
Note:
145
1
2 H
1
(Q/SY1105-66)
2 3
The listed Q/SY series in table 1 is the emblem mark and code of Lubricating Oil and
Grease Factory in Yingkou City, Liaoning Province, SYB is the ministerial standard
code of the Petroleum Department.
1 Q/SY SYB
Regulated lubricating time shall be added or reduced based on working level (light, medium
or heavy), working district and condition. Lubricating time listed in the above
table is determined in accordance with medium working level.
( )
Owning to strong hydrophilia, sodium soap grease may not be applied to humid zone.
One essential condition to ensure that the equipment is sound is to frequently inspect
lubricating condition of the equipment and fill each lubricating point with lubricating
grease at regular intervals.
According to surveys, some units strictly abide by such conditions. Although the crane works as
long as 15 years, its mechanical components are still in perfect condition and still
implement normal operation. On the contrary, some units do not pay attention to
lubricating conditions. Therefore the gear of the coupling is worn out, which is usually
replaced in every 1 -2 years or in every 2 months under more severe condition. Severe
consequence is generated as a result of detachment between the motor and relevant
mechanism.
15
Lack of necessary lubricating grease, is the main reason, to quickly wear out steel wire rope,
rolling bearing and the gear.
Failure to fill grease cup with lubricating grease mainly results from unqualified
146
grease cups. Rubber on oil gun nozzle is likely to be worn out, which shall be replaced
frequently.
Operational Test
Preparation and Inspection before Commissioning
Cut off all circuits and check whether each fastener is tightly connected, whether each
transmission part is assembled correctly and flexibly and whether metal structures are
deformed and check the tangling of steel wire rope on pulley and reel.
Check whether the installation and erection of the crane meets relevant provision.
Commissioning could not be conducted until electrical equipment finishes the

following works.
Use megohmmeter to inspect insulation resistance of electric system and all electrical
equipment;
When power circuit is cut off, check whether the control circuit is correctly connected and
inspect whether the rotating part of all commanding apparatus is flexible and reliable
(apply lubricating grease when necessary).
()
Ensure electrical equipment is reliable and carries out normal operation, pay attention that
limit switch, safety switch and emergency switch must be reliable and pay attention to
the phase sequence of the motors of traveling mechanism that are separately driven, to
make the two motors rotate towards the same direction.
No-Load Commissioning
147
Rotate the brake wheel of each mechanism by hand, to avoid clamping during the rotating
of axletree or reel shaft and then power on for commissioning without load (each
mechanism should carry out normal operation). When the trolley is operated, driving
impeller should contact with the track in the whole course and each limit switch shall be
inspected, to see whether it is safe and reliable.
Load Commissioning
Loaded commissioning is allowed after no-load commissioning passes the test. Loaded
commissioning is divided into two, in which dynamic commissioning is conducted after
static commissioning is completed.
a) Inspection content of loaded commissioning

a)
Bolted connection, riveting or welding mass of each joint of metal structure of the crane,
especially joint mass of main end beam;
Strength an rigidity of mechanical equipment, metal structure and lifting appliance as well
as strength of crane track;
Motor brake shall be flexible and reliable and the lifting hook bears no defect, like residual
deformation and cracks.
Reducers bear no abnormal noise or screaming;
Lubricating components are greatly lubricated and temperature rise of the bearing is still
under regulated value;
All mechanisms and components are stable and bear no vibration;

148
If defect is found, commissioning shall not be conducted until such defect is

overcome;
Static-load commissioning
The trolley gradually increases to rated load from starting load, shuttling around the whole
cable tray and its performance shall be inspected, to verify whether meets design
requirement. Remove the load, to make the trolley stop in cable tray; determine datum mark
and start it by using 1.25 times of rated load to suspend it in a place, 100 mm away from the
ground for 10 min and then remove the load; next check whether cable tray is permanently
deformed. Drive the trolley to the end of the stride when the cable tray forms no permanent
deformation after maximum three inspections. Actual arch value is more than 0.7L/1000
through inspection. Finally, still stop the trolley in cable tray. Deflection of main beam is
less than S/800 (calculated based on actual arch value) through inspecting rated load for
lifting.
()
1.25
100mm 10
0.7L/1000
S/800(
)
Dynamic-load commissioning
Apply 1.1 times of rated load as starting load to implement dynamic-load commissioning.
Meanwhile, start up two mechanisms to operate towards different directions. Time for
suspension shall be reserved in accordance with working level. Commissioning shall be
maintained for 1h. Each mechanism shall be flexible, stable and reliable. Furthermore,
inspect limit switch and its protection as well as reliability of interlocking device.
1.1
Inspection items specified in electrical component test
Continuous and repeated operation for mechanisms of the crane shall be maintained
149
up to 15min, therefore such mechanisms are preferred to implement crossover

operation. Reverse operation is not allowed until mechanisms completely halt.
15
When hand shanks of linkage control panel are placed in different positions, check whether
the motor is under normal operation.
Check whether the action of limit switches, safety protection devices and interlocking
devices is correct and reliable.
Failures occurred during the operation of electrical equipment shall be removed. Neither
temperature rise of motor and electrical equipment exceeding regulated value nor
moving contact burning is not allowed, furthermore, abnormal noise or vibration of
the equipment is also prohibited.
Equipment for Coaling System
Belt Conveyor
Equipment Overview
Belt conveyor C01A/B (belt conveyor on the wharf) adopts A/B parallel arrangement; C1
and C2 belt conveyors are arranged in the open air; C3 and C6A/B belt conveyors are
arranged indoors; head and tail of C4A/B and C6A/B belt conveyors are arranged indoors,
while the middle part is arranged in the open air.
C01A/B()A/B C1C2
C3C6A/B C4A/BC6A/B
C3 belt conveyor is furnished with vibrating coal feeder.
C3
150
C2 belt conveyor is furnished with wiper. Its head adopts retractor device, while its tail is
compressed by hydraulic pressure. C2 belt conveyor, which could be operated reversely,
shall be used in cooperation with stacker-reclaimers at coal yard.
C2
C2 ,
C2,C4A/B and C5A/B belt conveyors are provided with de-ironing separator, under which 4
sets of non-magnetic idler set are installed. C01A/B and C5A/B belt conveyors are provided
with electronic belt scale.
C2C4A/BC5A/B
C01A/BC5A/B
C01A/B and C6A/B belt conveyors are provided with plow discharger. It should be used in
cooperation with ship unloaders on the wharf without reverse operation.
C01A/BC6A/B ,
Bulk density of fire coal is 0.8 t/m 1.0t/m ; particle size of the fire coal carried by C5A/B and
C6A/B belt conveyors 15mm, while that carried by other belt conveyors 70mm.
3
0.8 t/m 1.0t/m C5A/BC6A/B 15mm

70mm
3
Bulk density of fire coal is 0.8 t/m 1.0t/m ; particle size of the fire coal carried by C5A/B and
C6A/B belt conveyors 15mm, while that carried by other belt conveyors 70mm.
3
0.8 t/m 1.0t/m C5A/BC6A/B 15mm

70mm
Main Parameters
List of basic parameters
Convey
Rated
Belt
Belt
Horizont
Hoisting
Referenc
or No.
transport
widt
velocit
al
height /
e power
capacity
conveyor
angle (m)
(kW)
(t/h)
(mm
(m/s)
length
9.65/10.13
200
)
C01A/B
960
1200
Remarks
(m)
2.5
L=491.83
Vertical
tensionin
151
g
C1
960
1200
2.5
L=60.25
5/0
75
Vertical
tensionin
g
C2
960
1200
2.5
L=198.12
12/14
275
Tensionin
g by
hydraulic
pressure
C3
240
800
2.0
L=39.0
4.5/6.6
30
Tensionin
g by the
screw
C4A/B
240
800
2.0
L=93.9
18.3/12
45
Vertical
tensionin
g
C5A/B
240
800
2.0
L=146.1
39.4/15.1
90
Vertical
tensionin
g
C6A/B
240
800
2.0
L=89.5
0/0
37
Vertical
tensionin
g
(t/h)
(mm)
(m/s)
(m)
C01A/B
960
1200
2.5
L=491.83
9.65/10.13
200
C1
960
1200
2.5
L=60.25
5/0
75
C2
960
1200
2.5
L=198.12
12/14
275
C3
240
800
2.0
L=39.0
4.5/6.6
30
C4A/B
240
800
2.0
L=93.9
18.3/12
45
152
(m)
(kW)
C5A/B
240
800
2.0
L=146.1
39.4/15.1
90
C6A/B
240
800
2.0
L=89.5
0/0
37
Inspection before Operation
Power supply control cabinet bears no Prohibit Operation Board , indicator light for tripping turns on and
selector switch is located at Program Control position.
Both on-site lighting, calling device, bell and camera used to monitor industrial television are sound.
Fastening screws on the roller of motor, reducer, coupling, holdback and belt are fully equipped and tight;
protective covers are integrated without damage; no obvious looseness
and detachment are found in foundation bolt at each position.
Reducer has normal oil level and the oil has great quality without impregnation or leakage and the air hole is
not blocked.
The holdback is integrated; brake shoe and brake wheel have smooth surface and even contact surface.
Junction box of the motor are integrated and the ground lead is greatly connected.
Belt lacings and rubber surface have no glue or tearing failure. No coal is accumulated up or below the belt,
at head or tail of the roller or tension device.
Roller used to adjust the core shall be flexible in rotation without detachment or severe caking of coal.
Cleaning device functions well with fine wiping performance and free of severe caking of
coal.
153
No caking of coal and wastes are accumulated inside of coal chute; air lock is flexible and sound without
caking of coal and wastes.
The surface of coal guide trough is in perfect condition; inspection door of coal chute should be closed;
electric switching baffle shall not be severely blocked by caking of coal.
Check whether coal plough and wiper are elevated.
Knife edge of coal plough shall be smooth, integrated without severe abrasion, connecting
rod bears no detachment and limit switch is integrated.
Belt sway switch, dual-direction pull switch, belt speed detector, material flow signal detector, protective
devices for chute blockage signal and longitudinal tear of conveyor belt shall be integrated.
Tension device shall be integrated, steel wire rope bears no fracture, jamming and derailment and de-ironing
separator and dirt catcher are integrated and stand by.
Drainage ditch and drain pit under the basement are smooth without obstruction and sewage pump functions
well in drainage.
Coal wiper at each part is flexible and functions well and mental clamping plate shall not directly contact
with the belt.
Preparation before Starting-up
Bucket wheel machine, double girder crane or ship unloader is integrated and stands by.
Three-way baffle within the selected procedure is flexible, functions well and is located at
154
correct position.
Coal plough is flexible to rise and fall and functions well without contacting with the coal.
The belt bears no water, wastes, severe abrasion, glue failure, coal leakage with proper tension.
Belt weigher and de-ironing separator function well.
Dust-extraction unit could be put into operation.
Coal breaker is integrated and could be put into operation.
Commissioning
Manual Commissioning without Load
Select efficient procedure on DCS screen after system inspection is finished. Alarm window
on the screen displays the instruction that allows start-up. Turn on the equipment one by one
in accordance with reverse direction of coal flow. The next equipment can not be started
until the previous equipment is under normal operation. No-load commissioning shall be
implemented at least for 2h after the system is started and under normal operation.
DCS
Program Controlled No-load Commissioning
Shift to procedure control position from DCS screen after system inspection is finished and
select efficient procedure. When clicking for pre-startup three-way baffle is in place,
alarm window on the screen displays the instruction that allows start-up. Click startup
procedure on DCS screen and then the system could start up the equipment one by one in
accordance with reverse direction of coal flow.
DCS
155
DCS
Interlocking Commissioning
When any equipment halts during the course of manual or program control commissioning
without load, the equipment operated in front of such equipment immediately halts, while
the equipment operated following such equipment continues to work.
When wiring, belt deviation, chute blockage, belt tearing signals are tested during the
course of manual or program control commissioning without load, operating equipment in
front of the signal equipment halts, while the equipment operated following such equipment
continues to work.
Loaded Commissioning
Loaded commissioning shall be implemented after manual or program control startup. 20%50%-80%-100% of rated load shall be gradually added and the commissioning under
various loads shall be maintained for at least 2h. Determine whether full-load startup and
operational test shall be carried out under 110%-125% of rated load in accordance with
technological process requirement of the system.
20%-50%-80%-100% 2
110%-125%
Inspection and Adjustment during Operation
Check whether operational parts are touched and worn out. If it is found, timely adjust it, to prevent the belt
from damaging.
Check whether conveyor belt is deviated. If deviation exceeds 5% of the belt width,
adjustment shall be implemented.
5%
156
Check whether abnormal noise or vibration exists at the equipment.
Check whether oil leakage happens to reducer, fluid coupling and other lubricating parts.
Check whether temperature rise of lubricating oil and the bearing is normal.
Check whether scraper blade of the cleaner contacts with conveyor belt in normal manner.
Inspect whether jamming happens when tension device is working.
Check whether bolts connected to the foundation and components are loose.
Check whether belt weigher bears overload. If it happens, stacker-reclaimers, double girder crane or ship
unloader shall be notified to reduce coal quantity.
Precautions after Decommissioning
Turn off the belt after on-site man on duty affirms that no coal is accumulated on the belt. If manual
shutdown is adopted, shut down the equipment one by one in accordance with the
direction of coal direction, however if program control is adopted, directly press down stop
button.
Check whether accumulated coal or dust exists in the system. If it exists, timely clean out it.
Check whether caking of coal happens within coal chute, diversion trench and coal breaker. If it exists, clean
out it.
Safety alarm device shall be integrated.
No obstructions are stored in the passage accessing to emergency shutdown switch.
157
Illumination on loading position shall be great.
If abnormal operation of the equipment is found by operator or patroller, relevant records must be filled and
specified to his successor.
Failure and Troubleshooting
Failure and troubleshooting for belt conveyor
Failure
Belt slipping
Causes
Treatment
1
Water contains on roller
surface or non-working
1
Clean out accumulated water
and operate for several minutes
surface of the belt
under no load
Excess coal quantity
The belt is not
feeder
Reduce coal quantity of coal
sufficiently tensioned
fails, notify relevant personnel to
Failure exists on
rotating machine
Adjust tension device. If it
repair and handle it

4
Inform maintenance
personnel for treatment.

Belt deviation
1
Coal is accumulated in
coal chute or mass coal exists
1
Dredge coal chute and adjust
coal falling point
in coal guide trough
The baffle is worn out
Inform maintenance
and deformed
Remove accumulated coal
Remove accumulated coal
A great amount of coal
is accumulated under the belt
and improve the efficiency of the
and contacts with the belt
sweeper
Idler or roller is attached
Change the angle of idler,
with coal
however if it fails, inform
maintenance personnel for
Centering idler does not
work
treatment
158
6
7
Misaligned feeding
Drum roll is not parallel
with tail drum
6
Adjust discharge position, to
make the coal fall exactly over the
center of sealing-tape machine
7
Adjust the supports on both
sides of the roller, to make equal

tension
Belt scratching or
tearing
1
Sharp hard objects are
located under coal chute or
1
Conduct emergency
shutdown, maintain current
between the roller and belt, to
situation and notify the monitor
scratch the belt
personnel
Sweeper, coal plough,
Notify the maintenance
metal knife rest on feed

channel damage the belt
Belt fracture
1
2
Belt aging
The belt operates with
overload for a long term
1
Inform maintenance
2
Prohibit operation under
overload and inform maintenance

personnel for treatment
Coal blockage of
the coal chute
1
Large coal quantity and
extremely wet coal
1
2
personnel
Interlocking protection
fails
3
The baffle is located at
wrong place or not in place

4
Adjust coal quantity

Notify the maintenance
Reset the baffle
Clean out foreign matters
Eliminate slipping of the belt
Reduce the load

Inform maintenance
Foreign matters get
stuck in the coal chute.

5
Slipping occurs to
downstream belt
Motor overheating
and with excess
1
Belt conveyor heavily
bears overload
1
2
current
Mechanical parts get
stuck
3
3
Two-phase operation of
the motor with low voltage

159
Inform maintenance

4
Reduce the load and then try
Loaded startup
to start it up
Huge vibration and

abnormal noise
1
2
Foundation bolt is loose

The center of the
1
Shut down the reducer and
tighten the screw
from the reducer
coupling lacks alignment
The bearing is damaged
and the gear is worn out
Inform maintenance
Inform maintenance

The reducer bears
excess temperature
1
Operation under
load for a long term
heavy 1
2
Reduce the load

Fill up with oil based on
Excess or mere oil level
regulated value
Unqualified oil quality
Replace the oil
Mechanical failure
Notify
the
maintenance
personnel
Push
brake
rod of
does
the 1
not 2
work
Push rod get stuck

The shelf of the brake is
1
Manually
move the push
rod, to make it resume work
damaged
3
Rectifying
device
Inform
maintenance
is personnel for treatment.
delayed for a short time or
damaged
Oil shortage
Inform
maintenance
Fill up with oil
The
band-type 1
Brake shoe does not 1
Inform
maintenance
brake is loose
uniformly contact with brake
wheel
2
Lining leather
Inform
maintenance
of the personnel for treatment.
brake shoe is severely worn
Clean out water and oil
out
3
Brake shoe
and brake
wheel contain with water and

oil
Motor startup fails
1
Option
interlocking switch
switch, 1
Put switches or baffle in
or the correct position
position of the baffle is not
Reset
correct
Reset
160
2
3
Pull switch is cut off

Reset is not carried out
after
the
operation
4Make clear of the reason and

remove the failure
of
thermocouple
4
Such
eliminated
failure
after
is
not
protection
action of the belt is carried

out
Belt
conveyor 1
Power supply is cut off
automatically stops or fuse is burnt out
1
Notify
the monitor and
replace with new fuse protector
during operation
Protection action of the
Reset
it
in
motor
thermocouple
Interlocking action
inform maintenance personnel for
Protection action of belt
treatment in case of other
conveyor
action,
case
of
however
electrical protection action

3
If interlocking
action is
incurred by failure shutdown of

the system, follow the instruction
of the monitor.
4Make clear of the reason and
remove the failure
4
5
,,
161
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
162
1
1
1
2
1
2
Vibrating Coal Feeder
Equipment Overview
Hut for storing dry coal is furnished with coal bucket to cooperate with transporter grab
crane. Each coal bucket is provided with a vibrating coal feeder, through which coal is
supplied to belt conveyor in coal filling system.
1
ZGM series vibrating coal feeder consists of trough, vibration body, vibration motor,
damping device, abrasion-resistance lining plate and regulating gate.
ZGM
163
Operation of Vibrating Coal Feeder
Inspection before Operation of Vibrating Coal Feeder
Operators read duty records before work.
Check whether components are reliably connected and whether attachment bolt is tight.
Check whether the bolt of the motor is tight and whether detachment happens. Check
whether objects surrounding vibrating coal feeder will interfere with the operation of
coal feeder.
Check whether caking of coal exists within coal feeder.
Startup of coal feeder, which has no load, shall comply with the sequence of process system.
Startup, Test and Adjustment
Startup
Close manual coal gate, and start it up after vibration motor switches on and check whether
the rotation direction of the motor is correct (the rotation direction is deemed to be correct if
two motors rotate towards opposite direction). Self-synchronizing inertial vibrating coal
feeder of the series allows direct startup and shutdown under full load and rated voltage. In
order to make stable parking and quickly pass through resonance region, brake stop is
allowed and adapts to various electric braking modes.
164
()
Idle running of the equipment
Start up the motor and operate it under no load after all is ready. Stop the motor 5 10min
after startup and check whether the attachment bolt of all components is loose or whether
other abnormities exist. Observe and carry out necessary inspection to coal feeder after
operation for 2h under no load. Check temperature rise of the bearing and exciter and check
whether components are correctly connected. Coal feeder itself is not allowed to crash into
surrounding objects in case of startup and stop. Amplitude and current are stable except
change along with network voltage during commissioning.
510
Loaded operation
First start up vibrating coal feeder and then open coal gate by hand in case of loaded
operation; when the equipment is shut down, first close manual coal gate and then shut coal
feeder.
The method to adjust feeding quantity is as follows:
Adjust frequency of frequency converter, to achieve feed quantity through stepless

control without shutdown.
Adjust included angle of eccentric block of inertial vibrator after the equipment is shut
down and change exciting force to achieve stepless control of coal feeding.

Adjust the opening of coal gate and change thickness of feed layer, to achieve
165
the purpose of adjusting feeding quantity.
Inspection during Operation of Vibrating Coal Feeder
Inspect whether proper feeding quantity of coal feeder is supplied through electronic belt
weigher.
Check whether bolt at all parts is loose and check whether the surface of the machine
is worn out.
Check whether the bolt of the motor is tight and whether detachment happens.
Shutdown of Vibrating Coal Feeder
First notify operator of double girder crane to stop supplying coal before it is determined to
stop feeding.
Determine whether raw coal on C8A or C8B belt is empty through industrial television and
electronic belt weigher.
b) C8A C8B
c) Shut down vibrating coal feeder until it contains no coal. c)
d)
Move the cursor, click the screen showing coal feeder is operated in the system and
then a dialog box is displayed, next move the cursor and click on stop , finally
vibrating coal feeder is immediately shut down.
Check whether the current of coal feeder returns to zero after shutdown operation is
finished.
Notify the patroller and affirm whether coal feeder is shut down on site.
166
Common Faults and Troubleshooting Measures
Common faults and troubleshooting measures for vibrating coal feeder
S/N
Fault phenomena
Coal feeder shows no

1
vibration after switching

on
Reasons
1) Circuit breaker is
tripped.
2) Power line is
disconnected or the phase
Troubleshooting
measures
1)
Close the circuit
breaker
2)
Check the wiring
is lost
1) One of the two
inertial vibrators does not
Amplitude is small with
work of operates in one
huge lateral oscillation
phase
after startup
2) Two inertial vibrators

rotate towards the same
direction
1) Bearing heating
2) Single-phase
Excess temperature rise

of inertial vibrator
operation
3) Internal frication
between rotor and stator
4) Interturn short circuit
One terminal of the

vibrator is heated
The machine generates

loud noise
1) Inspect the inertial

vibrator that does not
work and handle the
failure of phase loss
2)
Exchange a
vibrator and connect

wire on any of the two
phases
1)
Repair or replace
the bearing
2)
Handle phase loss
3)
Repair the rotor
4)
Repair the stator
The bearing is worn out

and heated
Select matched bearing
1) Bolt on the bottom of

the vibrator is loose or
1) Tighten and
replace the bolt
breaks
2)
2) Internal components
of the vibrator are loose
3) Internal fracture
167
Repair inertial
vibrator
3)
Repair or replace
the chute
exists in the chute

4) Internal component
4)
Repair the reducer
of the reducer crashes
Current increases
1) Inspect the inertial

vibrator that does not
2)
work
The machine bears
excess load
2)
3)
of feed layer
The bearing get stuck
Reduce thickness
or lacks oil
3)
4)
bearing or fill up with
Single-phase
operation or interturn short
oil
circuit
4)
Replace the
Repair the stator
The opening of the hopper
No-load commissioning
shows normal
7
1)Only one of the two

vibrators works
has improper design, to
circumstance, however
make the trough bear
amplitude is greatly
excess load implemented
reduced when load is
by stock column
added
Redesign or improve the

opening of the hopper
or reduce the pressure
of stock column
1)

1)
2)
1)
2)
2)
1)
2)
1)
2)
1)
2)
3)
3)
4)
4)
1)
1)
2)
168
2)
3)
4)
1)
2)
1)
2)
3)
3)
4)
4)
3)
4)
Double-toothed Roll Crusher
Equipment Overview
HL2PG.5 series crusher mainly consists of main frame, power unit, working device, lubricating
system and concession device. As the support and installation foundation for the whole
equipment, main frame ensures safety and reliability of the equipment when it crushes allowable
materials. Power unit provides essential power for the equipment. Crushing component, toothed
plate of working device, is crucial to achieve crushing function of the crusher. Lubricating
system ensures that all rotating parts are lubricated and protected. When small (below 40mm)
objects that are hard to be crushed, like metal block and wood block, entry into the crusher and
working device quickly withdraws, concession device makes it possible to access to the crusher.
Then working device automatically restores the normal position without the need to adjust it.
When relatively large (40 60mm) objects that are hard to be crushed, like metal block and
wood block, entry into the crusher, the safety of main components and parts of the crusher is
effectively protected through the damage of safety pin and long-distance concession of working
device. Meanwhile, in order to protect the crusher for safety operation, it is furnished with travel
switch for quick retract, to ensure travel switch works and the crusher is shut down so as to avoid
great damage when excess flash-retract distance exists on one side due to dissymmetry of the
equipment, which is caused by the entering of huge objects that are hard to be crushed.
Meanwhile,
169
service life of the toothed plate of the crusher shall be extended, to ensure that discharging
granularity of the crusher is stable and uniform.
HL2PG.5
,
(40mm )()
(4060mm)()
Name: double-toothed roll crusher

Quantity: 2 sets

Type: HL2PG-300

HL2PG-300
Rated output: 300t/h

300t/h
Material: lignite coal

Main Specification for the Equipment
Applicable material: coal

Feeding size: 70mm
70mm
Discharging granularity: 15mm (the buyer must provide feeding size curve, while the
seller must meet the requirement of the curve for coal size in the boiler when it is designing
170
and manufacturing.
15mm(
)
Rated output: 300t/h
300t/h
Service voltage: 400V
400V
Electrical control systems are capable of achieving local operation and remote control of the
crusher.
Equipment Parameters
3.3.2.3
Type specification: HL2PG-300B1

Maximum feeding size 70 mm
output per hour:
discharging granularity
Equipment external dimensions (L W

H) mm
t/h
15 mm
540048703920
Weight (kg)
21800
Maximum external dimension for lifting

(L W H) mm
269023001420
Maximum hoisting weight (kg)
(frame + working device) 13000
Maximum repair dimension (L W H)

mm
21001100
Maximum repair weight (kg)
Main motor
300
4200
Model
Voltage
Power
Quantity
External Dimension
(mm) (L W H)
Y315M-6
400V
90
1300645845
Y315M-6
400V
90
1300645845
HL2PG-300B1
70 mm
300
t/h
15 mm
540048703920
()mm
21800
(kg)
171
269023001420
(
)mm
(kg)
(+)13000
21001100
()mm
4200
(kg)
mm()
Y315M-6
400V
90
1300645845
Y315M-6
400V
90
1300645845
Precautions: rated output could only be achieved when materials are evenly distributed on
working surface of the crusher.
List of Main Components and Materials
S/N
Name of components
Texture
Frame
Q235A
Toothed plate
Manganese steel
alloy
Insert
Q345B
Bearing pedestal
ZG35
Main shaft
40Cr
Belt pulley
HT200
Irregularly shaped pulling plate
ZG35
Side joint, adjustment screw rod, and

back-end joint
40Cr
Baffle plate and the enclosure of distributing

device
Q235A
10
Safety pin
35
11
Sliding block locker
45
Q235A
172
Remarks
Casting
parts
Q345B
ZG35
40Cr
HT200
ZG35
40Cr
Q235A
10
35
11
45
Crushing Principle
Class I crushing principle is adopted to break down the particle with size of 70MM - 15MM
and the crushing principle and procedure are as follows:
70MM 15MM
Material with size of no more than 70MM enters into the equipment through pipe.
70MM
25N narrow V-shape belt excited by the motor achieves relative rotation under high speed
and material is crushed through the principle of breaking, snapping, squeezing
and grinding when materials pass through the toothed plate.
25N V
Discharging granularity is controlled through control upon space width, to ensure that the
granularity 15MM.
15MM
173
Fig.1 Schematic diagram

Precautions: feeding direction of the material is vertical to working roll, to ensure service
life of the toothed plate, therefore materials are required to evenly fall along the direction of
working roll.
174
Operation Method
Local Control
Switch the local control, debugging and remote control to local control , and close each
breaker. The power indicator and the local indicator are on. The system is ready.
//
The crusher shall not be started up until its feeding system is initiated and under normal
operation. Press down startup button of 1# main machine electrically controlled by the
crusher after its discharging system is started up and under normal operation, then 1#
main machine is started up. It is automatically shifted to full-pressure operation after
certain time of startup and operation indicator light of 1# main machine turns on; then
press down startup button of 2# main engine, then 2# main machine is started up. It is
automatically shifted to full-pressure operation after certain time of startup and
operation indicator light of 2# main machine turns on. The crusher reaches normal
operation after 1# and 2# main machines are under normal operation.
1#
1#
1# 2# 2#
2#1#2#
Shutdown procedure: first 2# main machine halts, then 1# main machine halts, next
operation indicators turn off. power supply is cut off when pin roll of the crusher
completely stops, then power supply indicator turns off and the crusher stops.
c) 2# 1#
Remote Control
Switch the local control, debugging and remote control to remote control , and then
remote indicator is on and selection signal for remote control is transmitted to remote
175
control system, in which the user inputs startup and shutdown signals through remote
control interface and starts up and shuts down the equipment in accordance with startup and
shutdown procedure. Remote control interface maintains outputs signals (electrical
independent contact), like remote startup and shutdown (long signal; electrical independent
contact is needed), operation status of main machine and alarm status signals, for custom
use. Once remote control is started up, other buttons for local control, except for scram
button, change-over switch between local control, debugging, and remote control, do not
work. Interlocking function of relay worked in local control is also functional in remote
control, therefore the following procedures must be in conformity with: operation after
discharging startup of 1# main machine operation of 1# main machine startup of
2# main machine operation of 2# main machine allowed startup sequence of feeding
signal and opposite shutdown sequence.
//
()
()
//
1#1#2#2#
Debugging Control
When switch shifting between local control, debugging and remote control is turned to
debugging and debugging indicator light is turned on, both 1# and 2# main machines are
capable of independent startup and shutdown for the convenience of overhaul.
//1# 2#
Note: debugging could only be adopted during equipment overhaul.
Lubricating System
If lubricating motor is provided, it should be controlled solely. Lubricating motor could only
be started up after more than half hours operation of the crusher, which lasts about
2min. Lubricating motor could be started up and shut down by hand for lubrication when
176
either local control, remote control or debugging is adopted. Lubricating motor could
implement lubrication by itself through time switch when the crusher is operated for about
100h. Lubricating motor automatically halts 2 min after startup.
100
2
Alarm and Alarm Processing
Alarm devices set up by electronic control are different based on different crusher type and
agreement of the Contract. If it is provided, the following instruction could be consulted:
Alarm for quick retract
When minor objects that are hard to be crushed is encountered during crushing, working
device automatically withdraws, to make electric control cabinet give out sound-light alarm.
At that time the crusher automatically halts despite of system condition and it shall be
started up again after the reason for such failure is removed.

Locked-rotor alarm (velocity measurement)
()
Whether the crusher is under manual or automatic status, when rotating speed of pin roll is
less than its setting value (theoretical experience value, which is set up before delivery and
adjusted in accordance with actual condition of equipment operation) after normal operation,
electric control cabinet will give out sound-light alarm. At that time the crusher
automatically halts despite of system condition and it shall be started up again after the
reason for such failure is removed.
(
Temperature alarm
177
For crushers with different types, different temperature monitoring points are set up to
detect the temperature of the crusher. Electric control cabinet gives out sound-light alarm
when the temperature on any monitoring point exceeds setting value (setting temperature of
the equipment is 80 when it is released). Alarm points could be looked over through the
parameters of temperature controller). At that time the crusher automatically halts despite of
system condition and it shall be started up again after the reason for such failure is removed.
( 80 )(
)
Vibration alarm
For crushers with different types, different temperature monitoring points are set up to
detect the amplitude of bearing pedestal. Electric control cabinet gives out sound-light
alarm when the amplitude on any monitoring point exceeds setting value (the deviation of
the equipment is 0.35mm when it is released). Alarm points could be looked over through
the parameters of vibration itinerant detector). At that time the crusher automatically halts
despite of system condition and it shall be started up again after the reason for such failure
is removed.
( 0.35mm)(
Precautions for Startup
Operators shall check the machine based on specified procedure, be familiar with and abide by Safe
Operation Rules before startup.
If the equipment is not tightened to the foundation, it is not allowed to open the shield or
inspection window.
All rotating components of the equipment must be provided with protective cover and it is
178
prohibited to touch the rotating part when the equipment is under operation.
It is prohibited to conduct any overhaul when the equipment is still under operation or the power supply is
not cut off.
Electromagnetic deironing device must be installed, to effectively remove metal substance in raw material.
Material whose pressure is more than 80MPa, especially steel block and large wood
block, is not allowed to enter into the crusher.
80MPa (
).
Overall delivery volume of the belt is operated up to 5-10% of designed capacity of the crusher. When
material is fed during the operation of the crusher, its overload time shall be maintained for
5min to the greatest extent, otherwise blockage will happen.
5-10% 5
It is prohibited to open any window, cover or protective cover, carry out any adjustment, observe feeding
hole, discharging hole or inspection window by anyone, remove materials and enter
inflammables and explosives.
.
When the equipment is employed, the user must set up electric interlocking control for transmission system
of the crusher. The feeder carries out work when crusher motor is started up under rated
voltage and operated for 5min. the crusher motor stops 5min after the feeder is shut down,
to avoid loaded startup in the next time.
5 5
Distributing device is unable to bear the crash of an object falling from more than 1.2m. If the elevation for
feeding is too high, buffer device must be provided, otherwise its service life would be
shortened.
1.2
Low-temperature operation: supply the first feeding when distributing device is operated for 5 10min with
no load under -10 , with 30% of rated feeding volume; after 5
179
10mins operation, supply the second feeding, which reaches 60% of feeding volume; total
feeding is supplied in the third time after 5 10min.
-10 5-10
30% 5-10 60%
5-10
Uniformly distribute the material along the axis of pin roll, to ensure service life of toothed plate and even
discharging granularity. Uniformly distribute the material along the axis of pin roll, to
ensure service life of toothed plate and even discharging granularity.
Fasteners may become loose during the operation process of the equipment. Unless otherwise specified, shut
down the machine and tighten up all bolts after new equipment is
operated for 7 days and then tighten them up again after 15 days.
7
15
It is prohibited to use both new and old toothed plates, otherwise vibration and noise would increase and
discharging granularity is unable to be guaranteed.
It is prohibited to use new and old belts, otherwise uneven force of the bolt will impact the output and
speed up abrasion of the belt.
Clear off all materials in the crusher after each time's usage.
If the quantity of coal gangue exceeds 20%, it will speed up abrasion of the toothed plate, impacting service
life of the bearing and output of the crusher.
20%
Safe Operation Rules
It is prohibited for anyone to climb, stride across or stand on the equipment when it is operated or its power
supply is not cut off.
,
It is prohibited to start up the equipment after all personnel within operation zone of the equipment are
notified.
180
It is prohibited to start up the equipment after all precaution and protection facilities are installed in place.
It is prohibited to start up the equipment when it gives out abnormal noise.
It is prohibited to start up the equipment under load and materials could only be fed after the equipment is
started up and under normal operation.
It is prohibited to crush other materials beyond regulations by the equipment.
It is prohibited to open any window, cover or protective cover when the equipment is operated.
It is prohibited to conduct any overhaul when the equipment is still under operation or the power supply is
not cut off yet.
It is prohibited to open any window, cover or protective cover, carry out any adjustment, observe feeding
hole, discharging hole or inspection window by anyone, remove materials and enter
inflammables and explosives.
Only debugging personnel could observe observation window on both sides of the
equipment under inclination angle of 45
45
It is prohibited to crush other materials by the equipment except for regulated utilization scope.
Materials are allowed to enter into the crusher until metal substance and large wood blocks are effectively
removed.
It is prohibited to freely increase working gap of class I working device. Otherwise, the
181
class I handling capacity increases, class II handling capacity lags behind, and the
equipment will be blocked and damaged.
Feeding under overload could only be maintained up to 5min.

5
It is prohibited to use new and old belts at the same time.
A working device could not use new and old toothed plates at the same time.
Special personnel are assigned to control electric control cabinet in case of initial
commissioning in the presence of special command staff.
All lubricating parts must be lubricated before initial commissioning.
Initial commissioning could be conducted until it is affirmed that working device does not
contact with the gear.
Failure and Troubleshooting
S/N
Failure
Vibration during
rotating
Particles with large
size
Material blockage
Causes
Foundation bolt is loose;
Bearing pedestal of the
equipment shares no center;
Tighten up foundation bolts;

Adjust bearing pedestal;
Excess gap between pin rolls

of working device
Adjust such gaps;
Quick feeding, small gap
Adjust gap between pin rolls

and remove blocked
between pin rolls, or blocked

upper discharging hole
Solution
materials, to keep it
unblocked.
Abnormal noise is
given out during
Ultrahard objects get stuck

on the tooth
Remove foreign materials

and start it up again;
operation
Teeth are close with each
Adjust gap between pin rolls
182
other
of working device;
Toothed plate is loose
Check the sliding block and

tighten up the nut
Teeth of toothed plate are

worn out
Repair and grind toothed

plate
Crusher Maintenance
Lubrication
In normal circumstance, the bearing and bearing pedestal that have no automatic lubricating
system should be washed with kerosene till it rotates for 1000h. After washing, fill up the
gap of the bearing with lubricating grease that is listed in lubricant table.
1000
Lubricant table
183
Lubricating part
Raw material of the

lubricant
Standard
code
Lubricatin
g period
Lubricating
method
Bearing of working
device
MOS2- lithium
lubricating grease
GB7324-94
300h
Filled up by
oil pump
Huge belt wheel
MOS2- lithium
lubricating grease
GB7324-94
300h
Filled up by
oil gun
Tensioning device
MOS2- lithium
lubricating grease
GB7324-94
300h
Injection
MOS2-
GB7324-94
300
MOS2-
GB7324-94
300
MOS2-
GB7324-94
300
Note: the temperature of dropping point of lubricating grease is 160 , applicable to

working temperature of -20120 .
160 -20120
Precautions:
Check whether attachment bolt of bearing pedestal and adjusting screw of belt tensioning
device are loose on each day.
Daily Maintenance
Frequently check, clean lubricating points, fill up with lubricating oil by rule, to
ensure fine lubrication of the equipment. If ambient temperature is less than -20 or
working temperature exceeds 120 , pay attention to replace lubricating grease in oil
pump and select and use such lubricating grease that is applicable to the temperature.
a)
-20 120

Check fastening bolt and nut and ensure they are tight in each shift.
184
Regularly check gap between pin rolls of working device, to ensure fine particles are
generated.
Regularly check abrasion of pin rolls of the working device, judge the performance of
distributing device and determine whether to adjust gap of working device and
rotating speed of distributing device.
Regularly check whether bearing temperature of the equipment is normal.
Belt-type Electromagnetic iron
Equipment Overview
RCDD air-cooling self-unloading electromagnetic iron, using internal and external oil
circulation radiating tube and the unique technology for internal excitation coil, is installed
at the head or middle part of the belt conveyor. The belt can correct the direction
automatically, and carry out cycled iron unloading through motor-driven belt and its scraper.
To be used together with all types of conveyors, it can remove 0.1~35kg tramp iron from
diffused non-magnetic materials, with the applicable belt speed 2.5m/min.
RCDD
0.1~35kg 2.5m/min
Model o f the Iron Remover
RCDD -12T1 air - coo lin g self - unlo ading electromagnetic iron RCDD
-12T1 .
Table of Technical Parameters

185
App
Appli
cable
Model
belt
width
(mm)
Magnetic
field
intensity
mT
Mater
Excit
ial
thickn
ess
ation
power
mm
kw
Driv
ing
pow
er
kw
External Dimension (mm)
licab
le
belt
spee
d
Weig
ht
kg
m/
s
RCDD-12
1200
70
300
6.7
4.0 4.5
4250 336 203 128 174 175
T1
mm
mT

mm
kw
kw
RCDD-12
1200
70
300
6.7
T1
mm
kg
m/
4.0 4.5
4250 336 203 128 174 175

0
Inspection before Equipment Operation
Check whether there is no Prohibit operation mark on control cabinet in the site, the ammeter reads
zero, the power indicator light is on, and the voltmeter is normal.
Check whether the location of each option switch is correct, and each button indicator light can be normally
on and off.
Check whether the connecting screws at each rotary part and overhead crane part become loose or fall off.
There shall be no sundries on the iron remover, the iron piece shall be
186
clean, and the hanging rings shall be fixed firmly.
Check whether there is no barrier in the travel of the overhead crane, and whether the location of the
iron remover is correct.
Check whether the power wiring of the iron remover is in perfect condition, and whether it has a good
grounding device.
Check that the belt for waste iron is free from tear, deviation, clamping, scraping, or being too tight or too
loose, and whether the belt joint and scraper for waste iron are well fixed.
Operation of the Iron Remover
Trial Operation and Adjustment
Switch on the power supply, the green signal light on the panel of control cabinet will
be on, and the control cabinet will be standby.
Press down the start button, the red signal light will be on, and the voltmeter will indicate in
the range of rated voltage; when the reading on the ammeter rises to a stable value, the
control cabinet and iron remover can be put into normal operation.
Switch on the power supply, carry out trial operation of the iron remover for as least 2
hours. Observe its operation, if the operation is completely normal, the iron remover
can be put into trial operation for production.
2
Check the overall operation state of the iron remover and iron attraction and
discarding capacity of the iron remover.
187
To check the iron attraction and discarding capacity as well as the removing rate of the
mainframe, tramp iron of different weight and different shape can be deliberately
added to the materials to be convoyed, and when necessary, the lifting height or tilt
angle can be adjusted (In the test, overweight or oversharp tramp iron shall not be
used). During the continuous trial operation for 24 hours, if there is no problem
occurred, it can be put into operation in formal production.
(
) 24
Local Operation
Put the changeover switch SA in Local state, switch on the power supply, close the
switches QF1, QF2, QF3 and QF4, the Power indicator light will be on.
SA QF1QF2 QF3QF4
Press down the Excitation button, the iron remover will start to conduct excitation, with the
Excitation light on. Press down the Run belt button, with the Run belt light on,
the belt will start to operate, and the iron remover will start normal operation.

,,
To stop the operation, press down De-excitation and Stop belt buttons, the iron
remover will stop the excitation operation and stop the belt operation. The
Excitation and Run belt indicator light will be off, waiting to be started next time.
Remote Control
Put the changeover switch SA in Remote state, switch on the power supply, close the
switches QF1, QF2, QF3 and QF4, the Power indicator light will be on.
SA QF1QF2 QF3QF4
Input Remote start signal in program control room, the iron remover will start excitation
and convey its belt, the Excitation and Run belt indicator lights will be on, and
the iron remover will be in normal operation state.
188
Input Remote stop signal in program control room, the iron remover will be nonmagnetic, with the stop of belt, the Excitation and Run belt indicator lights will
be off, and the iron remover will stop operation. It will be standby for the operation
next time.
,
Inspection of Iron Remover during Operation
The starter of the iron remover shall be in good work condition, without abnormal sound and scorched
flavor, the indicated voltage value shall be normal, and it shall have normal iron
attraction capacity. During the operation, pay attention to the work condition of the
magnet, after it is in normal operation, the operating personnel can leave.
During the operation of belt conveyor, the magnet shall not be pulled out, and the power supply shall not
be interrupted. If it is required to carry out those operations, the belt
conveyor shall first be stopped, and then the iron remover can be pulled out.

During the operation of the electromagnetic iron, the temperature shall be lower than 100 . Strictly prohibit
watering on the iron remover or cleaning the equipment with wet cloth, and
the equipment shall maintain clean.
100
Frequently check whether the connecting bolts of the magnet and cabinet bracket are loose, and the
connecting bolts shall be fastened timely. Check whether the self-unloading tape scraper is
damaged, if so, it shall be changed timely.
189
Notes for Shutdown of the Iron Remover
The electromagnetic iron shall be shutdown after the stop of belt conveyor.
For operation, the belt conveyor shall be started after the startup of the iron remover; while for shutdown, the
iron remover shall be shutdown after the stop of the belt conveyor.
In the operation of the iron remover, hot current shall be less than cold current.
Tension bolts of self-unloading belt have been adjusted before leaving the factory, unless in special
circumstances, they shall not be adjusted randomly.
When measuring the turning direction of self-unloading belt conveyor, it shall not turn over
two circles.
During the operation of the iron remover, there is strong magnetic field nearby, and the materials which
are easy to be magnetized such as watches and instruments shall not keep near to the
field.
Iron Remover Faults and the Treatment Methods

3.4.7
Fault Description
Causes Analysis
Troubleshoot
Method
Weakened iron attraction and

discarding capacity
Changed lifting height or

tilt angle
Adjust the lifting

height or tilt angle
Poor contact with the connecting
Vibration in iron attraction

and discarding or other
Reconnect the cable
cable of junction box
factors
Stronger vibration of the

equipment, with upgraded noise
Loose fastenings
Fix the fastenings

again
Manual traveling trolley fails to

move
There are foreign matters

between the track and
Check the condition

of track
190
traveling wheel, or the track

is deformed
After being connected to the

power supply, the iron remover
is not started, and it doesnt
conduct excitation.
1
The section switch
isn't closed.
2
The operation of
thermal relay is
unrecovered.
3
The cutout of control
loop is fused.
is started, but when it starts to
conduct excitation, the automatic
control switch trips.
Close the
section switch.
2
Recover the
thermal relay.
3
Replace the
cutout.
1
Breakdown of silicon
rectifier, and the voltmeter
1
Replace the
silicon rectifier.
is not normal.
repair the direct
Short circuit at direct
Check and
current side, and the
current excitation
ammeter is not normal.
loop.
1
Check and
repair the
temperature control
1
is started, but it doesnt conduct
excitation.
Temperature control
relay is open.
2
Failure of cooling fan.
Overtemperature of
exciting winding.
relay.
2
Check and
repair the cooling

fan.
3
After the
cooling down of the

winding, recover the
temperature control
relay.
The motor is overload
or the bearing is damaged.

The motor speed reducer sounds
abnormal.
speed reduction box.

3
Severe wear in the
No oil in the speed
reducer.
191
1
Check whether
there is debris stuck
on the belt, and
replace the bearing.
2
Add oil to the
speed reducer to the

specified gauge
level.
1
2
1
1
Notes for Use
If it has been shutdown for a long period, electrical performance of the speed reducer and
192
connected circuit shall be checked when it is used again.
In normal operation, the cables shall not be damaged, impacted or tensioned. The cable connector shall
be connected or disconnected after the power is disconnected.
During the operation of the iron remover, there is strong magnetic field nearby, so the
instruments such as magnetic cards, clocks and watches shall not be put around.
Maintenance
Unless special failure is occurred, routine inspection and maintenance for the iron remover mainly include
frequent cleaning of dusts around the machine, regular oil filling for the
bearing, weekly inspection of oil level in transformer, which shall be short of oil.
Apart from the replacement of power lines, unless in special conditions, the power control cabinet shall not
be opened randomly, to prevent the insulation and aging of coils and electrical apparatus
elements. When replacing the power lines, cables with the same specification shall be
used. After the cover of control cabinet is opened, it shall be dry enough with firm wiring,
and screw up all bolts to recover its original state.

Regular inspection shall be carried out for iron unloading belt and power line, once the damage is
found, it shall be replaced timely.
The desiccant connected to the top of oil conservator is used to clean and dry the debris and moisture in the
air entering the transformer oil conservator due to the change of transformer oil
temperature, to ensure the insulation strength of transformer oil. Check the swelling amount
of the desiccant every month, and the desiccant shall be replaced if the water
193
content is too large.
Electronic Belt Scale
Equipment Overview
ICS electronic belt scale mainly consists of four parts: weighing bridge, weighing sensor,
speed sensor and weighing instrument.
ICS
3.5.2
3.5.2
3.5.3
Inspection before Operation of Electronic Belt Scale
3.5.3
Weighing roller and scale bracket shall be clean, and there shall not be debris such as coals between the
scale bracket and belt.
The scale bracket shall be intact, free from fracture, open weld and deformation.
The four groups of rollers in front of and behind the scale bracket shall be intact, and the speed
measuring drum shall not be loose or fall off.
The fastening screws of the sensing elements such as speed sensor and weighing sensor shall not be
loose or fall off.
194
Start, Test and Adjustment
Connect to the power supply, and carry out following operations when the power is affirmed to be
normal.
Define the unit of weight: default unit: ton, alternative unit: kilogram.
Select the unit of rate: default unit: t/h, alternative unit: t/h.
t/ht/h
Define maximum weighing capacity rate: default: 10.0, minimum: 1.0, maximum: 200,000.0. Select
maximum capacity rate, and select scale division: default: 1, alternative: 0.1, 0.01, 0.001,
1.
10.01.0200,000.0
1 :0.1,0.01,0.001,1
Speed input type: default: external, alternative: external, analog.
Select calibration mode: default: electronic calibration, alternative: electronic calibration, chain
calibration, weighing calibration.
Input calibration constant: maximum: 1000, minimum: 0, default: 1.

1000 0 1
Make the display return to zero and determine the span.
Start the belt scale and put it into operation.
Notes for Operation of Electronic Belt Scale
In the operation, belt side skid shall not occur in weighing section, otherwise, it shall be adjusted in time
to ensure accurate measurement.
Overloading and unbalance loading working conditions are not allowed, to prevent damaging the
weighing sensor of the belt scale.
195
If the rollers in weighing section and the four groups of rollers in front of or behind the scale bracket are
damaged or do not operate, it requires to be checked and repaired in time.
The belt scale shall not be cleaned during the belt operation, to prevent damaging the speed measuring and
weighing measuring elements.
If emergency shutdown of the scale with heavy load occurs, treatment measures shall be taken as soon as
possible to empty the coal on the belt, to prevent fatigue damage of the weighing sensor.
When it is found that the electronic belt scale is inaccurate, the coal quantity is not displayed, or the
accumulative value doesn't change, it shall be solved in time by the thermo technical
personnel.
Anyone shall not adjust the integrator of the belt scale at will.
Electronic Belt Scale Faults and the Treatment Methods
Faults
Causes
Zero drift
Dusts and materials are
Treatment Methods
1
The operating personnel
shall clean timely the dusts
accumulated on scale
and materials that are
bracket.
accumulated on the scale
bracket.
Stones are stuck on
scale bracket.
other debris.
Failure of electronic
measurement elements
Eliminate stones and
Inform maintenance

Interval drift
1
Change of tension of
conveyor belt.
196
1
Inform maintenance
2
Failure of measuring
system.
2
Inform maintenance
Severe overload of
weighing sensor.
volume.
Failure of electronic
measurement elements.
Adjust the coal delivery
Inform maintenance
1
2
Central Sampling Device of the Belt
Equipment Overview
Mechanical automatic central sampling device of the belt is based on the sampling theory
and error theory of probability theory. The subsamples from the sampling device are
strongly representative.
Programmable logic controller is used as the main control component for electrical control,
to carry out automatic random sampling, which eliminates the human factors and provides a
reliable method for modernization management of the enterprises.
197
Table of Main Technical Parameters of the as Fired Coal Sampling Device
Type
Main Technical
Parameters
Item
Unit
Parameter
Applicable belt
speed
m/s
1.5-4
Sampling speed
m/s
Speed of conveyor belt
Sampling quantity
Kg/time
>5
Applicable
moisture content
15%
Sampling time
control
Min
Any time period < 30
m/s
1.5-4
m/s
Kg/
>5
15%
Min
< 30
Equipment Components, and Technical Parameters, Structure and

Performance of Each Component
SDCY-Z Central Sampling Head

SDCY-Z
Main Technical Parameters
198
Model
Belt
Width
(mm)
Supporting
motor (KW)
SDCY-Z1200
1200
45.5
(mm)
(KW)
SDCY-Z1200
1200
45.5
Dimension of
Sampling
Remarks
Scraper
Structure and Performance (Attachment I)

()
SDCY-Z Central Sampling Head is located across the middle part of the belt conveyor,
consisting of brake motor, helical gear speed reducer, rotary C-type sampling head,
approach switch and steel structure bracket with protective cover. Rotary C-type sampling
head is made from stainless steel, and is equipped with balancing weight. At its end, wearresistant rubber plate or steel wire brush is installed to ensure sampling in the entire section
without damaging the tape. The brake motor is installed on steel structure bracket to drive
and stop the C-type sampling head. C-type sampling head will carry out continuous
sampling and continuous material unloading in each rotation, and complete material
unloading at the end point of its travel, with the approach switch controlling the travel
termination. Protective device is set to ensure that the sampling head can be stopped
correctly. The interval for sampling is controlled by PLC and selected through the switch.
SDCY-Z C
C C
PLC
SDCY - W1 Stage I Coal Feeder

SDCYW1
199
Belt Width (mm)
Motor Power (kW)
Belt Speed
(mm/s)
400
1.1
180
(mm)
(KW)
mm/s
400
1.1
180
Structure and Performance (Attachment II)

()
SDCY - W1 Stage I Coal Feeder is a kind of completely enclosed belt conveyor, with good
sealing capacity, which ensures little loss of water content of coal samples. Motor speed is
controlled by cycloidal pin wheel speed reducer, and the belt speed is 180mm/s, with
regular coal feeding, which prevents the coal blockage resulting from irregular coal feeding
caused by the impulse coal feeding of the sampling head. External sweeper is installed
outside the material unloading drum for sweeping the materials attached on the surface of
conveyor belt after material unloading.
SDCY-W1
180mm/s
SDCY-PCH03 Ring Hammer Crusher

SDCY-PCH03
Discharging
Feeding material
size (mm)
material size
(mm)
<200
6--13
(mm)
(mm)
Supporting
Output
(t/h)
200
(t/h)
motor power
(KW)
7.5
(KW)
Rotate speed
of the
crusher
(r/min)
900
r/min
<200
6--13
7.5
900
Structure and Performance (Attachment III)

()
The ring hammer crusher consists of rotor, fixed lower cover, upper cover which can
be completely open, and regulating mechanism.
The motor directly drives the rotor through belt wheel and inertia wheel. The ring
hammer crusher is a kind of impact rotor crusher with rotary hammer. The ring
hammer can not only rotate with the rotor, it can also swing with around the hammer
pin. When the materials enter the crushing cavity, they will be crushed under the
impact effect of ring hammer, and the crushed materials will gain the force from the
ring hammer at the same time, which makes them rush to the crushing plate in high
speed and be crushed for the second time. Then, they will drop down to the screen and
be further crushed from the squeezing and grind by ring hammer, and be discharged
out through the screen hole. The debris that can not be crushed will enter the metal
collector and wait to be periodically cleaned later. The material size can be adjusted
by adjusting the quantity of screen to meet the requirement for discharging material
size.
SDCY W2 Stage II Coal Feeder

SDCYW2
Belt Width (mm)

400
Motor Power (kW)

1.5
201
Belt Speed (mm/s)

130
(mm)
400
(KW)
mm/s
1.5
130
Structure and Performance (Attachment IV)

()
Stage II Coal Feeder is a kind of completely enclosed belt conveyor, with good sealing
capacity, which ensures little loss of water content of coal samples. Motor speed is
controlled by cycloidal pin wheel speed reducer, and the belt speed is 130mm/s, with
regular coal feeding, which prevents the coal blockage resulting from irregular coal feeding
caused by the impulse coal feeding of the sampling head. External sweeper is installed
outside the material unloading drum for sweeping the materials attached on the surface of
conveyor belt after material unloading.
130mm/s
SDCY-XF Rotary Divider

SDCY-XF
Applicable belt
width (mm)
400
(mm)
400
Motor
Sampling
power
speed
(kW)
(m/s)
0.55
1.6

(KW)
(m/s)
0.55
1.6
Sampling
quantity
Scraper
width of
each time
sampling
(kg)
head (mm)
>0.1
40
1:3 1:100
adjustable
(kg)
(mm)
>0.1
40
Division ratio
1 31 100
Structure and Performance (Attachment V)

202
()
The rotary sampling divider stretches across the conveyor belt of Stage II coal feeder. After
the coal samples are crushed by the crusher, they will pass the divider through the conveyor
belt of Stage II coal feeder, and the divider will carry out division sampling according to the
setting time interval. The structure size of the rotary sampling divider is less than that of
central sampling head, while the both have the same structure and performance.
SDCY-S4(6, 8)Sample Collector

SDCY-S4(68)
a)
Collector volume (L)
Motor power (kW)
Rotate speed of
rotary table (r/min)
4-10
0.37
(L)
(KW)
(r/min)
4-10
0.37
Structure and Performance (Attachment VI)

()
The sample collector consists of rotary table, vessel, brake motor, speed reducer, approach
switch and supporting bracket.
Through the speed reducer, the brake motor drives the rotary table to rotate, with
four/six/eight 8L sample collectors on the rotary table. The termination position of the
angular displacement of the rotary table is controlled by the approach switch. When the
vessels are not at the packing location, a sealing cover shall be put.
468 8

SDCY-D100 Bucket Elevator
203
SDCY-D100
Structure and Performance (Attachment VII)

()
The bucket elevator has a simple structure, with smooth and stable conveying capacity. The
motor drives the speed reducer to make the bucket on the conveyor belt continuously
excavate the waste coal, with the bucket movement speed of 1.4m/s, the motor power of
2.2KW and the treatment capacity of 3t/h, and the maximum feeding material size of 25mm.

1.4m/s 2.2KW 3t/h 25mm

SDCY-L20 Screw Conveyor
SDCY-L20
It shall be determined whether the equipment is needed according to the return type of
excessive materials from the sampling equipment.
a)
a)
Conveying
Diameter of screw
Motor power
Rotate speed of
blade (mm)
(kW)
screw blade (r/min)
200
1.5
63
(mm)
200
(KW)
(r/min)
1.5
63
capacity
(t/h)
Maximum
conveying
material size
(mm)
25
(t/h)
3
(mm)
25
Structure and Performance (Attachment VIII)

()
The screw conveyor uses rotary screw reamer to move the conveying materials inwards
within the fixed cover to complete the conveying work. The length of the screw conveyor is
determined according to the requirement on site. The motor drives the speed reducer to
204
make the blades on screw shaft to rotate. Its treatment capacity is 3 t/h, with the motor
power of 1.5 KW.
3t/h1.5KW
c Steel Frame c
It is the structure connecting all the equipment on the fixed sampling device, which is
welded by structural steel and sheet material. The steel frame is used for routine
maintenance and observation of the equipment operation condition on the device.
Electrical Control System
Power Supply
Power loop: AC 380V, 415V

380V415V
Control loop: AC 220V
220V
3.6.4.1
three phases 50HZ

50HZ
single phase 50HZ
50HZ
Control system
The sampling device uses independent power distribution system, equipped with
undervoltage, short circuit, overload, and default phase protective devices, which have good
protective functions. Reliable interlocking and mutual locking are installed for each
equipment of the device. The control system uses PLC to carry out programmed control,
and it has two control modes, on-site manual control and remote automatic control. On-site
manual control mode is used for test and adjustment, service and maintenance, and standalone start. In automatic working condition, each equipment of the sampling device can be
started or stopped automatically along with the conveyor belt and carry out sampling
automatically; Deblocking option can be selected, and the operator can select to start or stop
the sampling system based on the operating condition of the conveyor belt. (The operation
can be carried out on the IPC or electrical cabinet in central control room.)
205
PLC
)
The control system has the function to check the working condition of the equipment
automatically. It checks the working condition of the equipment according to the signals of
sensor on the equipment, and if a fault is found, it will alarm immediately. When alarms are
given, the equipment at the upper part of the fault position is shutdown immediately, and the
equipment at lower part of the fault position is shutdown after time delay set by the process,
to prevent coal blockage. System operation and fault condition are controlled by electrical
cabinet to facilitate orientated troubleshooting.

A timer or touch screen is set on the electrical cabinet panel to adjust the sampling interval
and division interval. Based on different types of coals and different coal quality, the timing
setting can be adjusted to make PLC adjust the working condition of the system
automatically, to ensure that the quantity and quality of the subsamples can meet the
requirements of relevant standards.

PLC
Working Principle
The central sampling head which spans across the belt conveyor revolves a circle on the belt
conveyor based on the setting time interval and takes coal samples of a complete section,
and the coal samples will directly drop into the stage I coal feeder through the discharge
pipe. The coal samples then will be sent continuously and regularly by the coal feeder into
the ring hammer crusher to be crushed, and the crushed coal samples whose size
206
is less than 6-13mm will be sent into the feed channel of the stage II coal feeder. After
passing through the feed channel and the coal adjusting gate, the coal samples with uniform
thickness will continuously enter the rotary sampling divider on the stage II coal feeder.
According to the setting time interval, the rotary sampling divider will revolve a circle on
the conveyor belt of stage II coal feeder to take a complete coal sample and gain a
subsample, and the subsample will enter the sample collector through coal discharge pipe.
The divided excessive materials will enter the bucket elevator under the gravity, and the
elevated excessive materials will drop into the screw conveyor through coal discharge pipe,
and then return to the main conveyor belt through the screw conveyor. If no screw conveyor
is used, the excessive materials will directly drop on the belt conveyor through the coal
discharge pipe after being elevated by the bucket elevator.
6-13mm
.
Remote automatic control and the belt conveyor are interlocked, when the belt conveyor is
started, the equipment in the sampling device will automatically start operation in the
sequence as follows:
Screw conveyor Bucket elevator Stage II coal feeder Rotary sampling divider ring
hammer crusher Stage I coal feeder Central sampling head.
When the belt conveyor is stopped, the equipment in the sampling device will automatically
stop operation in the opposite sequence of start sequence.
207
Operating Process
Each equipment shall be turned for several rounds after installation, and the trial operation
shall be carried out after it is confirmed that each rotary part is flexible and free from
jamming. Carry out no-load trial run for 2 to 4 hours and loaded trial run for 5 to 6 hours of
each equipment on site, and when it is confirmed that the no-load trial run and loaded trial
run are normal, the operation can be carried out by manual control or automatic control.
2-4 5-6
Manual Control:
Turn the manual/automatic option switch to Manual, and the start and stop of each
control loop will be controlled by the buttons in on-site control box. Except that forward
rotation and reversal rotation are interlocked, the control loops are independent, and there is
no control logic relation between them.
/
Automatic Control:
Automatic Interlocking:
Turn the manual/automatic option switch to Automatic location, and turn the
interlocking/deblocking option switch to Interlocking , and the sampling system will start
or stop its operation along with the conveyor belt.
//
Automatic Deblocking:
.
Turn the manual/automatic option switch to Automatic location, and turn the
interlocking/deblocking option switch to Deblocking location. After conveyor belt A and
conveyor belt B is selected, press down the start button, and the system will conduct
208
sampling on the selected conveyor belt A or B. The start of the entire sampling system is not
interlocked with the conveyor belt, and the sampling time can be selected automatically, the
sampling system will automatically stop when the conveyor belt stops.
//
During the operation of the sampling system, the program will check the condition of the
system at any time. If a fault is checked out, it will alarm immediately and stop the
equipment according to the process, it will also indicate the alarm content.
Maintenance
It is the key factors for the normal operation of the system to know the technical
performance of each part of the sampling device, to be familiar with the equipment and
electrical operation process and to carry out regular inspection and maintenance of the
equipment on the device.
General Requirements for Maintenance of the Equipment on the Device:
Regularly check whether the fasteners on each equipment are all reliably fastened.
Each shift shall check the oil level in the cycloidal pin wheel speed reducer and helical gear
speed changing box of each equipment, if it is lacking of oil, the lubricating oil shall
be filled timely.
During the normal operation of the equipment of the system, if abnormal sound is found or
if some operating part is abnormally hot, the equipment shall be shutdown
immediately to figure out the cause of the fault, and it shall be restart after
troubleshooting.
209
Maintenance of Each Part of the Device
Central sampling head, rotary sampling divider
Each shift shall check the discharge condition of the discharge hole of rotary C-type
sampling head.
C
Each shift shall check the fastening condition of approach switch, and the rotary C-type
sampling head shall be able to rotate flexibly and return to its original location
accurately.
C
Regularly check the wear condition of the wear-resistant rubber installed at the end of rotary
C-type sampling head. If it has been worn out, it shall be adjusted or replaced
immediately to ensure sampling of the whole section.
C
The temperature-rise of bearing shall not exceed 45 , and the maximum temperature
at bearing shall be less than 70 .
45 70
Stage I and stage II coal feeder
Regularly check the rotation condition of upper and lower roller and anti-sway device.
The wear-resistant plate on the sweeper of discharge hole shall keep contacting to the drive
belt. If the sweeping wear-resistant plate is damaged or unable to completely scrape
the coal, it shall be adjusted or replaced in time.
Adjust the tensioning gear timely to maintain the reasonable tensioning of the driving drum,
return drum and drive belt.
4)
Regularly check the condition of feed channel, and the wear condition of
210
wear-resistant rubber on the feed channel. If coal leakage is found, the equipment
shall be adjusted or replaced immediately to ensure the tightness of conveyor belt.
The temperature-rise of bearing shall not exceed 45 , and the maximum temperature
at bearing shall be less than 70 .
45 70
Ring hammer crusher
Regularly check the wear condition of the wear-resistant parts such as crushing hammer
plate, and screen plate.
1)
2) Frequently clean the foreign materials in collecting cavity of the crusher.
2)
3) If the discharging material size from crusher can not meet the requirement, the
crushing hammer plate and screen plate shall be replaced.
3)
Sample collector
Each shift shall check the rotating position of the collecting tank.
Coal leakage shall never occur during the operation of the sample collector.
Each shift shall check the fastening condition of approach switch, and the rotary C-type
sampling head shall be able to rotate flexibly and return to its original location
accurately.
Screw conveyor
Each shift shall check the feeding and discharging condition at upper and lower feeding and
discharging holes.
Regularly check and eliminate the accumulated materials and impurities in the screw drum.
211
Bucket elevator
Each shift shall check the feeding and discharging condition at upper and lower feeding and
discharging holes, and timely eliminate the accumulated materials at lower part of the
bucket elevator.
Regularly check and adjust the tightness of drive belt to make it free from side skid to
prevent coal blockage.
Electrical cabinet
Regularly check the condition of all the switch contactors, and they shall be intact, with
good contacting capacity, and the contacts shall be smooth and free of pocking marks.
Regularly check whether all the buttons and indicator lights are reliable.
Regularly check whether the wiring terminal blocks, switches and the wiring of contactors
are fastened without falling off.
Regularly eliminate dusts on the surface of each electrical components (with the power off),
and the electrical cabinet shall be dry.
()
List of Equipment Bearing
Name of
Standard
Equipment
No.
Name
Specifications
Quantity
and Model
(set)
Central sampling
head
Insert bearing with

pedestal
P210
Stage I coal
Insert bearing with

pedestal
UCF208
1208
feeder
Bearing
212
Ring hammer
GB/T281-
crusher
94
1208
1314
208
UCP208
7213
UCFC212
UCF209
UCP209
()
P210
UCF208
1208
1208
1314
208
UCP208
7213
UCFC212
UCF209
UCP209
2
2
Stage II coal
Bearing
Insert bearing with
feeder
Screw conveyor
Aligning roller bearing
pedestal
GB297-84
Tapered roller bearing

Insert bearing with
pedestal
Insert bearing with
pedestal
Bucket elevator
Bearing with pedestal
GB/T28194
GB297-84
Lubricating Materials and Lubricating Requirements
Name of
Lubricating
Requirement
213
Lubricating
Lubricating
Equipment
Point
Materials used in
Winter
Materials
used in
Summer
Central
sampling
Oil filling hole

of speed
head
reducer
Stage I coal
Oil filling hole

of speed
feeder
Stage II
coal feeder
Screw
conveyor
Bucket
elevator
First, please
strictly follow
First, please
strictly follow
First, please
the operation
strictly follow
instruction or
the operation
operation manual
instruction or
provided by the
operation manual
manufacturer of
provided by the
speed reducer to
manufacturer of
operate. Second,
speed reducer to
replace it every
select the
quarter when
specified model
initially using it,
of lubricating oil.
Oil filling hole
and later, replace
Second, apply
of speed
it every half a
N22 gear oil.
reducer
year.
reducer
Oil filling hole
of speed
reducer
Oil filling hole
of speed
reducer
the operation
instruction or
operation
manual
provided by
the
manufacturer
of speed
reducer to
select the
specified
model of
lubricating
oil. Second,
apply N46
gear oil.
Central
sampling
Lubricating grease filling hole of

insert bearing with pedestal
2
First, please
strictly follow the
First, please
strictly follow
head
positions
operation
the operation
Stage I coal

4
instruction or
instruction or
operation manual
operation
positions
provided by the
manual

4
manufacturer of
provided by
speed reducer to
the
positions
operate. Second,
manufacturer

4
fill the lubricating
of speed
grease in or
reducer to
positions
replace it every
operate.
feeder
Stage II coal
feeder
Bucket
elevator
214
Ring
hammer

2
crusher
positions
3-6 months
Second, apply
the calcium
soap or
lithium soap
Install two 7213 tapered roller

Screw
bearings, two UCFC212 bearings
conveyor
with pedestal, and one suspension
lubricating
grease,
No.1-2 in
winter, and
bearing
No. 3-4 in
summer.
N22
N46
3-6
50%~60%
7213 2
UCFC212 2
215
1-2
3-4
List of Vulnerable Parts of Equipment
Name of
Equipment
Name of
Vulnerable
Specificati
ons
Part
Manufacture
Quantity
Stage I coal
feeder
400mm wide
belt
=8mm
Stage II feeding
machine
400mm wide
belt
=8mm
Stage I or stage
Sanyuan
Electric
Roller
II coal feeder
Power
Company
Ring hammer
Hammer head
180X60
( 28) 1 set
crusher
Sanyuan
Electric
Power
Company
Ring hammer
Screen plate
crusher
328X40X1
Sanyuan
Electric
Power
Company
Bucket elevator
Bucket
Based on the height
Sanyuan
Electric
of the elevator
Power
Company
Bucket elevator
150mm wide
belt
=5mm
216
400mm
=8mm
400mm
=8mm
180X60
328X40X1
0
150mm
( 28)1
=5mm
Flat Bag-type Dust Collector
Equipment Overview
JJPBC flat bag-type dust collector mainly consists of dust filter box, ash cleaning
mechanism, draft fan, ash hopper and ash discharge device. The filter bag uses 729
polyester dacron as the filter material, and according to the installation type, it can be
divided into several types, including right 90 degree, right 180 degree, left 90 degree and
left 180 degree. It has two series, series A and series B, and series A has no lower box
(including ash hopper, supporting leg, ash discharge valve and ash discharge motor).
JJPBC
729 90 180
90 180 AB A (
)
Working Principle
The unit consists of draft fan, filter box, frame-type bag and ash cleaning and vibrating
217
device, and it can automatically operate controlled by the program. When it is started, the
dust filter chamber is under negative pressure due to the draft fan, and intake the dusty air
into the filter box through air inlet. The dust will attach to the exterior surface of the bag
after being filtered in the bag, and the clean air will enter the clean room through the filter
material and be sent to the outdoor atmosphere by the draft fan. Thus, the air will be
purified or the solid particles will be collected from the dusty air.
With the operation of the unit, there will be a gradually increasing number of dusts attached
on the exterior wall of the bag, and there will be a sharp increasing resistance of the unit.
The differential pressure alarm apparatus will cause the stop of draft fan, and meanwhile,
the mechanical vibrating ash cleaning mechanism will start its operation to force the
accumulated ashes to drop. The ashes will be discharged after passing through the ash
hopper and ash discharge bucket. Some setting time later, the vibrating motor will stop its
operation, and an ash cleaning circle is completed.
Operation of Bag-type Dust Collector
Manual Control
Switch to Manual control, use the buttons to control the start/stop of the draft fan, the
start/stop of vibration, and the start/stop of electrical heating. The three processes are
mutually locked with each other, and they cannot work at the same time. Switch the unit
control box to Local control, start the unit, and check its working timing sequence. During
the operation, the dust collector will clean the ashes every 45 minutes or when the
differential pressure switch is on. During ash cleaning, the vibrating motor and ash
discharge motor will be started, and the draft fan will be stopped.
///
218
45
Program Control
When switching to Program control, the program control interlocking will be started and the
draft fan will be started. The interlocking device stops the draft fan, and 30 seconds after the
stop of the draft fan, the vibrating ash cleaning will operate for 30 seconds and stop, and
then the electrical heating device will operate for 20 minutes and stop, then the vibrating
ash cleaning device will operate for another 30 seconds and stop. This is a flow process, and
the unit will be standby for next interlocking start. Check whether the forced pressure of the
draft fan is normal. Use clamp meter to test the draft fan and vibrating motor, check whether
the current value of the ash discharge motor is normal. Check whether there is abnormal
sound of vibration of the unit.
30
30 20 30
Maintenance of Bag-type Dust Collector
During the operation of the dust collector, the air passing through the unit shall be maintained around the
rated air volume, and try to lessen the fluctuation of air volume. Frequently check the
tightness of each inspection door. The motor and draft fan bearing shall be filled with oil in
the operation every 1000 hours. Regularly eliminate the ashes and dusts and other
impurities in the unit body and air discharge pipe for rust protection. Frequently check
whether the air at the air discharge hole is clean. If ashes and dusts are found discharged
from the air discharge hole, it shows that the bag is damaged, and it shall be replaced
immediately. Service of the unit shall be carried out in shutdown state. When it is
controlled by program, vibrating and electrical heating will be interlocked in the operation,
and the draft fan can not be started. After vibrating and electrical heating are completed,
the draft fan can be started. In local operation, vibrating and electrical heating
shall not be operated for too long, and they shall be stopped for some while.
219
1000
Generally, it is impossible to lose the program. During the service, it shall be checked whether the wires of
each part are well connected instead of doubting that the program is in failure. Frequently
check and clean the filter screen bag. If many ashes and dusts are found, carry out vibrating
and ash cleaning immediately.
Treatment Methods of General Faults
Fault
Cause
Small air
Wrong wiring connection

of draft fan, and the
volume
service door is not closed

tightly.
The bag is too dirty.
Poor purifying
effect
Treatment
1 Adjust the power wiring of the
draft fan.
2 Close tightly the air-tight door.
3 Clean or replace the bag.
4 The service door is

not closed tightly.
5 Close tightly the air-tight door.
The resistance of the dust
6 Enlarge the positive pressure at
removal system is
the outlet of the draft fan to reduce the
relatively large, and the air
system force.
volume is declined.
Overload of the
draft fan
1 Phase loss of the

motor
2 The bearing has not
been filled with oil for a
long time.
Check the causes and carry out

troubleshooting, and then press down
the reset button for thermal protection.
Add oil or replace the bearing.
220
7
8
10
11
12
3
4
Fixed Vacuum Cleaning Device
Equipment Overview
HV 840 cleaner consists of the followings: Maintenance platform power head

ground control box gate valve maintenance and explosion-proof door (optional)
hopper stairs. HV 840 cleaner is equipped with four filter cartridges and two air
blowback tanks.
HV 840
() HV 840
Working Principle
HV 840 is a large vacuum cleaner. A rotary vacuum pump with rated capacity is used to
pump air from the hopper under the power head. Negative pressure will be formed in the
hopper and air attached with materials will enter into the hopper through collection hose
and hose system. Later, air will be separated from the materials in the machine. Clean air is
emitted into the atmosphere while materials are left in the hopper.
HV 840
Rotary vacuum pump with rated capacity (Roots pump) is the heart of the system. It is
221
driven by the triangle belt and belt pulley. The belt is connected to the driving shaft of the
motor.
()
Roots pump consists of two blade discs whose rotation directions are opposite to each other.
Gaps between two blade discs, and blade disc and the shell are extremely small. When the
blade disc rotates, air with fixed volume is captured and driven out of the outlet of Roots
pump. Passing through exhaust silencer, air is emitted back into atmosphere. To prevent
materials residue (and dust generated during transmission) from entering into the
atmosphere, HV 840 cleaner is equipped with a pair of filter cartridges. Before entering the
Roots pump, the air attached with materials must pass through the filter cartridges which are
able to filter 100% dust. In this way, clean air to be emitted is guaranteed and vacuum pump
is protected.
(
)
100%
Grade I centrifugal separator is set before materials and dust enter the filter cartridge.
Firstly, materials have to enter into the centrifugal separator which rotates the air and
materials to separate materials from air flow. Secondly, separated materials enter into the
hopper under the power head. Light materials left in the air will be brought to filter
cartridges. In the filter cartridges, dust will be separated and attached to the external surface
of cartridge. Compressed air will blow into the inside of the filter cartridge every 4 to 15
seconds. Therefore dust residue attached to the external surface of the filter cartridge will be
blown off to keep the cleanness of the external surface. An ultrasonic level meter is installed
to measure the height of materials accumulated in hopper. The machine will stop when the
hopper is full, and start again only when it is not full. A gate valve is installed at the bottom
of hopper for material discharge. Usually, the valve is manually opened. Since the material
suction requires negative pressure in the hopper, normally, the machine must be stopped
before the discharge valve is opened. Options for discharge valve: consecutive discharge. If
the star-shape rotating valve (also called air-lock valve) is adopted, automatic discharge is
possible though the machine is not stopped and is taking materials
222
consecutively. If the hopper is full, the machine will automatically stop and open the valve
to discharge materials. After the valve is closed, the machine will automatically restart (a
switch on the electric control cabinet can be used for automatic discharge and restart ).
4 15
()
("-" )
Pneumatic control or electric control is available for HV 840 cleaner.
HV 840
Diagram of Power Head Parts and Components of Cleaner
1 silencer 2 electric control cabinet 3 vent valve 4 Roots pump 5 motor 6 suction valve 7
head cover 8 material level detector 9 air blowback tank 1 2 3
4 5 6 7
8 9
223
Operation
Inspection Procedures Prior to Startup
Only when the power head is closed, connection or removal of vacuum hose and its parts
can be applied to material inlet valve or hose system. Improper operation may injure
the operators.
Check all the liquid levels including oil level of the vacuum pump (rear shaft end of the
machine) before starting the machine.
()
Liquid level shall be at the middle of the glass oil pointer.
Check whether there is abrasion, cut and fracture of all the lead wires, before starting
the machine.
If there is any, repair and or replace the lead wire.
Check whether the guide pipe and its parts are defective before starting the machine.
Check whether the rotation direction of the Roots pump and motor are correct.
Watch the vent cover of the silencer and press Start Roots pump button, and then press.
""
Stop Roots pump button
If the cover of silencer is lifted and air is emitted from silencer, the rotation direction
is correct.
If the cover of the silencer does not move (i.e. air is sucked into the silencer), the
rotation direction is wrong.
224
()
Corrections are as follows: confirm whether the lead line of power supply is powered off,
and then reconnect the lead line on the top of breaker.
Startup Rules
3.8.4.2
Drive the Motor
a)
Complete the inspection procedures prior to startup.
a)
b)
Check whether the vacuum hose and its parts are well connected and whether the
nozzle is clean. Make sure that the vacuum pump is started without load.
b)
Note: connect or remove the vacuum hose and nozzle before the vacuum pump is started.
Improper operation may injure the operators.
c)
The door of the electric control cabinet must be closed and locked.
c)
d)
Turn the breaker to on in a clockwise way.
d)
"on"
e)
Press Start air compressor button until the pressure indicator light is off, press Start
/Reset Roots pump button, and then the Start Roots pump button.
e)
"""/"
""
Note: If the vent cover of the silencer is lifted and the air is emitted from the silencer, the
rotation direction of Roots pump is correct.
The Hi-Vac is prepared now; check the instrument panel to confirm the operation is normal.
Hi-Vac
f)
Slowly plug the nozzle into the materials to be sucked.
Stop Rules
225
Manual Stop
Remove the nozzle of the vacuum hose from materials and make the pump suck for 2-3
minutes to clean the material residue inside the hose.
1)
23
Keep the vacuum pump sucking air without load for two minutes to cool the pump, if
time allows.
Press Stop/Reset vacuum pump button.

"/"
Pull the breaker anticlockwise to "OFF".
"OFF"
Automatic Stop
Hi-Vac equipment will automatically stop in case of the followings: Press Stop/Reset
vacuum pump button on the electric control cabinet to reset and restart the pump, after the
problems are corrected.
Hi-Vac "/
"
Full hopper
A material level detector that leads to the hopper is installed under the power head. When the
hopper is full, the equipment will stop and the indicator light Full hopper on the electric
control cabinet will light up. Empty the hopper and restart the equipment for suction.
""
Low pressure of the compressed air
The compressed air is used to clean the filter cartridge. Without blowback by the
compressed air, the filter cartridge will quickly absorb a large quantity of dust, resulting in
the increase of resistance. Therefore, it was set to stop when the pressure of the compressed
air is low.
226
If the device stops when there is air pressure, check whether the air pressure is too low.
Excessive differential pressure leading to stop
With the differential pressure switch, the equipment will stop when the differential pressure
of the clean surface and dirty surface of the filter cartridge reaches over 1016mm of the
water column height. This indicates that the filter cartridge is very dirty. Switch to manual
pulse for blowback and inspect the timing panel and magnet valve to make sure the pulse
blowback is working. If the differential pressure still remains excessively high after
blowback, replace the filter cartridge. The intervals of pulse blowback should be 8-15
seconds (adjustable based on different materials). Interval was set as 15 seconds on the
timing panel in the factory.
1016mm
8-15 ()
15
Automatic Protection System
Cases listed here may severely damage the vacuum pump. Hi-Vac protects the vacuum
pump from the listed potential damages with following measures.
Hi-Vac
.
Excessive Vacuum
On the sea, the maximum allowed vacuum is 16 inches of the column of mercury
(0.054MPa).
16 (0.054MPa)
When the vacuum reaches the maximum value, the vent valve on the spring at the
inlet pipe of the vacuum pump opens.
227
Air will directly enter into the pump. In this way, the vacuum pump will not be overloaded.
When the vacuum decreases to a certain degree, the vent valve will automatically close.
Protection System of Filter Cartridge
Differential pressure switch and differential pressure gauge
The filter cartridge collects dust during the operation of Hi-Vac. When the dust on the dirty
surface of the filter cartridge increases, air resistance increases.
Hi-Vac
The resistance will lead to the increase of differential pressure between two surfaces.
To avoid the overload of vacuum pump caused by excessive differential pressure, and the
damages resulted from the excessive load of the filter cartridge, Hi-Vac is equipped
with differential pressure switch and differential pressure gauge.
Hi-Vac
It will be automatically stopped when the differential pressure reaches 40 inches (1016mm)
of the water column.
40 (1016mm)
Temperature protection
When the temperature of the vacuum pump exceeds 170 , the butterfly valve will open
to compensate air and reduce the temperature. When the temperature decreases to 140 ,
the butterfly valve will close.
170
140
Protection of vacuum pump at the low oil level
When the oil level of the vacuum pump is lower than the standard, light indicating
excessively low oil level will light up and the equipment will automatically stop.
228
Nozzles for Material Suction and Transmission
Material suction of Hi-Vac requires different nozzles suitable for different occasions.
Hi-Vac
Suction of large quantities of materials requires a large air force. Without sufficient air
force, materials are likely to be accumulated in the pipe, forming a blockage.
In light of the large quantities of material, big nozzles should be used to maximize the suction rate of the
materials. The terminals of the big nozzles can be buried into material piles. The air will be
automatically sucked from the top of the nozzle. For a better effect, Hi-Vac should be
operated within the mercury of 13 inches to 15 inches (0.044-0.058Mpa). Vacuum is shown
in the negative pressure gauge. It is normal that the vacuum fluctuates. Vacuum fluctuation
is caused by the unevenness of the materials and air in the nozzle and
pipe. Use the air-feeding hole on the nozzle to handle this.
Hi-Vac 13 15 (0.044-0.058Mpa)
Notice:
Large quantity of air + small quantity of material = low vacuum

+ =
Small quantity of air + large quantity of material = high vacuum
+ =
No air + no material = blockage
+ =
For the unmovable material, move the nozzle back and forth in the materials to ensure that certain
quantities of air and material enter into the nozzle, in order to obtain a large suction
volume.
229
Reduce the leakage of the hose, for example, replace the worn hose, tight and compact the joint, to
minimize leakage.
Keep the hoses straight, and avoid bending and abrupt bending. The best methods to avoid dead bend are as
follows:
Pull the nozzle across the working place until the hose is straightened, and then pull it back.
No hot and wet materials should be transmitted. Water vapor can condense on the filter cartridge, resulting
in lump that cannot fall off. If this happens, manually remove the lump from the filter
cartridge.
Correct nozzle usage:
Big nozzles are used to suck large quantities of material.
Thin nozzles are used for common cleanup, including cleanup of corners.
Flat nozzles are used to clean narrow places between machines, and places under them.
Fan-shaped nozzles are used to clean large areas whose depths are no more than 6 inches
(152.4mm).
6 (152.4mm)
The indented edge is able to remove the lumped materials.
Handwheel ground nozzles are used to clean the accumulated dust on the ground, wall and
irregular surface.
Unloader
230
Equipment Overview
The DLS electric plow unloader is installed at the center of C01AB of the coaltransportation system dock and C1 belt conveyer. There are four unloaders, i.e. 1 left-side
coal unloader and 3 right-side coal unloaders. Corresponding belt conveyer: B 1200
mmV= 2.5 m/s.
DLS C01AB C1 1
3 4 B1200 mmV= 2.5 m/s
22 single-side plow unloaders are installed on the C6AB belt conveyer in the coal handling
system, i.e. 11 left-side unloaders and 11 right-side unloaders. The corresponding belt
conveyer: B800 mm and coal particle 15mm.
C6AB 22 11 11
B800 mm15mm
The unloader features the followings:
1 Combined main and auxiliary plowshares are adopted, and the moldboard is made from
wear-resistance materials with small head angle and arc tail.
1
2 The entire plowshare can be adjusted up and down, and the angle can be adjusted by
the pull rod.
2
3 The whole machine has high strength and has no shaking.
3
4 The remote collective control and site operation can be simultaneously carried out to
realize collective control and remote control.
4
5 Applicable particle width of materials: 0~350mm.
5 0~350
6 Applicable belt speed: 0.8~3m.
6 0.8~3
231
Working Principle and Structure
Working principle
Power of the unloader comes from the electric pushing rod. Under the preparation status,
the plowshare is lifted, roller and other carrying roller are at the same level, the moving
roller is with trough angle and the electric pushing rod is retracted. Under the working
status, the electric pushing rod stretches out. The drive frame will move the pushing rod to
put down the plowshare, and push the cam frame to raise the moving bracket for unloading.
After the trough angle of the moving roller disappears, the unloader enters into working
status. Upon the completion of unloading, the unloader enters the preparation status.
232
Single-side
Mo
del
Speci
ficati
800
1150
450
150
1700
515
300
980
270
10
1200
1600
500
180
2300
650
470
1200
360
15
DZ
C
800
1150
450
150
1700
515
300
980
270
10
1200
1600
500
180
2300
650
470
1200
360
15
on B
DZ
C
800
DZ
C
120
0
800
DZ
C
120
0
Funnel for air lock (single side)

()
233
B1
b1
H1
L1
L2
L3
800
1150
400
450
1000
760
100
1400
1450
1650
1200
1450
450
500
1200
870
120
2000
2050
2260
B1
b1
H1
L1
L2
L3
800
1150
400
450
1000
760
100
1400
1450
1650
1200
1450
450
500
1200
870
120
2000
2050
2260
Technical Parameters
3.9.3
3.9.4
Stroke Adjustment
Loosen and adjust the screw to loosen the collision block.
Adjust the distance between the collision block and the contact of the stroke switch to set
the block on the designated place.
3.9.4.3
Adjust and tighten the screw to secure the collision block. Power on and test until the
optimal working condition is reached.
Silo Wall Vibrator
Equipment Overview
LZDF warehouse vibrator is also called vibration anti-blocking device. It takes the vibration
motor as its excitation supply, and eliminates the blockage and humping inside the
warehouse by high-frequency vibration and impact force.
LZDF
,
234
Working Principle
When the warehouse vibrator is working, the vibration motor is rotating at a high speed,
causing periodic high-frequency vibration to the warehouse wall. The periodic highfrequency vibration disconnects the materials and the warehouse wall, and eliminates
friction between the materials and the warehouse wall. The materials affected by alternating
speed and acceleration are unstable, effectively overcoming the friction and gathering force
of the materials, and eliminating relative stability between materials in the warehouse. In
this way, materials will be smoothly discharged.
Table of Technical Parameters
3.10.3
3.10.4
B1
b1
H1
L1
L2
L3
800
1150
400
450
1000
760
100
1400
1450
1650
1200
1450
450
500
1200
870
120
2000
2050
2260
Operation and Maintenance
Bolts on the chassis of the vibration motor should be tightened once a day in the beginning
and once a week after two weeks, because tightness may be reduced due to the loosening
caused by the friction between bolts, nuts and chassis. Oil supplementation for bearing of
the vibration motor should be regularly conducted (2# lithium saponify), normally once
every ten days of consecutive operation. Oil is supplemented from the oil nipple with oil
gun after the vibration motor is not in the operation status. The first oil supplementation
should be 15g20g, and after that 10g is enough.
Minor repair every 4~6 months and overhaul every year are required for the vibration motor.
Minor repair is to clean the dust accumulated on the external surface of the shell for better
235
heat dissipation. It is prohibited to wash the motor with water. Besides, inspection of the
insulation resistance of the coil and the tightness of the wiring should be conducted to
eliminate dangers. Overhaul is made to clean the inside and outside of the motor with
compressed air, replace the lubricating oil and check whether bearing is worn.
(2#) 10
15g20g
10g 46
Common Faults and Troubleshooting Measures
Fault Phenomena
Likely Causes
Troubleshooting Measures
1).Interphase short-circuit of
stator winding, open-circuit
1).Inspect where open-circuit and

short-circuit are, and repair them.
I. Motor fails to
and grounding of stator
2). Inspect and correct the
start after the
winding
winding wiring.
power supply is
2).Wiring errors of stator
3). Reduce the load and eliminate
connected.
winding
blockage.
3).Rotor is overloaded or
blocked.
1). Overload
2). Short-circuit of winding
1). Reduce the load or replace

motor.
3). Error of winding wiring
2). Repair the short-circuit.
II. Temperature of
4). Winding grounding or
3). Inspect and correct the
motor increases
turn-to-turn short-circuit
winding wiring.
excessively or the
5). Broken rotor bars of the
4). Find and repair the fault.
motor smokes.
motor
5). Replace the rotor.
6). Friction between stators
6). Measure air gap of the motor,
and rotors
inspect and repair assembly and

abrasion of the bearing.
236
III. Bearing
overheating
1). Abrasion or quality

problems of the bearing.
1). Replace the bearing.

2). Adjust lubricating grease.
2). Too much or too little
3)If it is too loose, additionally
bearing grease, wrong type
weld a lap of metal for
or poor quality.
reprocessing; if it is too tight,
3). Too loose or too tight
process the bearing guard again.
coordination of the bearing
4). If it is too loose, expand the
inner ring and bearing.
bearing housing; if it is too tight,
4). Too loose or too tight
reprocess the bearing housing.
coordination of the bearing
5). Dismantle and then
outer ring and end cap.
reassembly to ensure that the
5). Poor assembly of the end
bearing bears a uniform force.
cap and inner bearing cap.

1). Poor grounding.
2). Winding insulation is
1). Find the cause and repair it.

2). Repair the insulation;
IV. The electrical
damaged.
immerse it into paint and dry it.
shell of the motor
3). Winding is damped.
3). Dry or dry after immersing it
is charged
4). Wiring board is damaged
into paint.
or the dust is too much.
4). Replace the wiring board and

clean the dust and dirt.
V. The support leg

is broken.
1). Anchor bolt is not tight.

2). The installation plane is
1). Tighten the bolt.

2). Reprocess the installation
not smooth.
plane.
1)
1)
2)
2)
3)
3)
237
1)
2)
3)
1)
2)
3)
4)
4)
5)
5)
6)
6)
1)
1)
2) 2)
3)
4)
4)
5)
1)
2)
3)
3)
5)
1)
2)
3)
4)
4)
1)
2)
1)
2)
Air Cannon
Equipment Overview
There are 2 boilers, each of which has 2 coal bunkers. Each coal bunker has 3 coal hoppers,
each of which has 3 air cannons of 150L.There are 36 air cannons in total, 9 for each coal
bunker.
2 2 3 3
238
150L 9 36
Main Parameters
3.11.2
Type:
Capacity:
KT-150
KT-150
150L
150L
Operating pressure:
0.4~0.8MPa
0.4~0.8MPa
Impact force:
4500/10000N
4500/10000N
Explosion energy:
20400 kgfm
20400 kgfm
Weight
130Kg
130Kg
Temperature of compressed air:
50
Oil content in compressed air:
50
1ppm
1ppm
Operation
Operation of air cannon includes manual and pneumatic control of a single air cannon;
electric control of a single air cannon, and release of air cannons in groups; timed automatic
release and so on. Firstly, open the hand-operated ball valve to automatically input the air.
Then, when release is needed, press the startup button to give pulse signal or air signal to
the reverse flow valve. Air cannon will eject strong impact air current through the vent and
automatically recover to the inflation status after the energy is released and is ready for the
second run. The release procedure of the air cannon starts from the lower layer and then the
upper layer to facilitate material discharge.
239
Manual operation of the air cannon is completed through the small handle on the reverse
flow valve. Electric control is achieved through the operation button and automatic control
through automatic control instrument of the air cannon. Central control procedure can be
carried out, to release air automatically at the preset time.
Maintenance and Usage
Preparation:
After installation and careful inspection of the air cannon, if no problems are found, the air
cannon can be inflated. If the air cannon is qualified for the seal test, air release test can be
carried out. Test with lower pressure and then with higher pressure to check whether there
are some problems. The air cannon can be put into use after it is qualified for security check.

Monthly Inspection
Check whether there is loosening or air leakage in all the air pipelines and their joints.
Check whether the pneumatic elements are normal and flexible.
Inspection Every Half Year:
Check the appearance to see whether there is structural damage in the air cannon.
Close the air supply, release air in the cannon, and dismantle the drain plug to
discharge all the accumulated water, put the drain plug back and tighten it.

240
Check the joints of the suspension device and supporting device of the air cannon, check
whether there is damage and loosening of bolts.
Abnormal phenomenon.
Under normal operation, if leakage is found in the air cannon, clean and replace the sealing
ring (type O) or the piston. Note: before the cleaning and replacement, close the air
supply and release air in the cannon. In light of both cleaning and replacement,
replace a new O sealing ring as long as the piston is taken out. The piston and
sealing ring must be lubricated with oil before installation.
O
Inspect the flange gasket between the head and body of the cannon, if damage is
found, replace the gasket, and install and tighten all the components.
Check whether there is loosening, abrasion or fracture of the wiring.
After the completion of inspections mentioned above, connect all the air pipes and
power supply. Put them into use after confirming that all the connections are correct
and reliable.

Troubleshooting
Phenomena
Causes
Troubleshoot Methods
1. The air cannon
1. One-way valve is improperly

installed.
1. Change its installation

direction.
2. Air leakage occurs at O

sealing ring.
2. Wash the piston or replace

the sealing ring.
cannot be
inflated. -
241
3. Cannon body is full of water

or filth.
3. Discharge water and the

filth.
4. Loosening and leakage occurs

at drain plug.
4. Tighten the drain plug.
5. Air source pipeline leaks or is
5. Inspect and repair the

pipeline to ensure that it is
impeded.
smooth.
6. The magnet reverse flow

valve is improperly installed or
6. Inspect and correct the

installation location, wash or
damaged.
repair the valve.
1. The magnet reverse flow
1. Eliminate the electric, air

and signal faults. Inspect and
valve does not work.
repair the magnet reverse flow

valve.
2. Installation of the magnet

reverse flow valve is wrong.
2. Correctly connect the valve.
2. The air cannon
3. Failure of magnet reverse
cannot be released.
flow valve occurs.
3. Find the causes of failure.

Maintain, repair or replace the
4. The piston is locked.
valve.
4. Wash the cylinder and
replace the damaged parts and
components.
5. The pneumatic valve is far

from the cannon.
3. Low release
ability of the air
cannon.
5. Adjust the distance between

the pneumatic valve and the
cannon; keep it within 15m.
1. Excessively low air pressure.
1. Inspect and increase

pressure of air source.
2. Insufficient inflation of the air

cannon.
2. Properly extend the

inflation time.
3. There is water or filth in the

cannon.
3. Discharge filth and water in

the cannon.
4. Air leakage occurs at the

piston and O sealing ring.
4. Replace the piston and

sealing ring.
242
5. Large resistance of air current

in the injection pipeline.
5. Reduce the resistance.
6. Pneumatic valve is far from
6. Adjust the distance between

the pneumatic valve and the
the cannon.
4. Inflation of the
air cannon is slow.
cannon; keep it within 15m.
1. Small diameter of the outlet of

air source pipeline.
1. Replace it with a large

diameter pipeline.
2. Small exhaust gas volume of

the air compressor.
2. Increase the exhaust

amount.
3. Air source pipeline is
3. Find causes of the

impedance and eliminate the
impeded.
impedance.
1. The diaphragm of
quick-release solenoid valve is
5. KZK air cannon
damaged.
does not work
2. The air flow guide of the

quick-release solenoid valve is
properly.
1. Replace the diaphragm.
2. Clean the air flow guide.
blocked.
3. Valve is too dirty.
3. Remove the dirt in the

valve.
2O
1.
243
2 3
15
6
6
15
244
5KZK
Troubleshooting for the Unloading, Handling and

Storage System
4
Principle
To timely limit expansion of the accident, eliminate threat to people and equipment, isolate
or eliminate the cause, it is essential to keep normal operation of the device.
When accident occurs, operators on duty should find the faulty equipment and check the
protection action of the equipment, and the signal as well as the instrument panel swiftly.
Besides, operators on duty are supposed to identify the scope and nature of the accident and
find the cause.
The operators should report the accident to the shift supervisors and leaders in time.
Operators shall abide by the order of the shift supervisors when handling the accident. Shift
supervisors order is superior to other orders, when any conflicts appear. Executive shift
supervisors order may be rejected due to the threat to people and equipment, but an
explanation should be given.
Emergency Shutdown
245
Conditions for Emergency Shutdown
Apply shutdown when any of the followings occurs during equipment operation of the coal
handling system.
Operating equipment is related to personal injury and death as well as severe fire accident.
Sparking of the operation box, abnormal current indication, and any abnormal sound, vibration,
smoking, or catching a fire occurs.
Vibration and temperature exceed the allowable upper limits.
The belt is stuck, jammed or the coal is blocked. Severe sway of the belt may probably lead
to tripping. Belt may be damaged or broken.
Abnormal sound of the coal crusher during operation is heard and the vibration exceeds the vibration value.
Failure to lift the coal plough may be caused by blockage.
Sharp metal jammed in the belt may possibly damage the belt.
Much coal leakage in the bunker affects belt operation.
Operating Steps of Emergency Shutdown
Where emergency shutdown occurs, operators on duty should precisely identify the
accident, and take measures. Then, report to the team leaders.
246
When fault and emergency shutdown occur, standby equipment should be started to continue coal
loading. Report to the shift supervisors and team leaders.
After the faulty equipment stops, the team leaders shall check the accident at the site swiftly,
and make efforts to find accident causes with operators on duty to eliminate the fault as soon
as possible. Report to the shift supervisors and record it.
.
Cut off the power supply of the fault equipment and adopt protection measures, when the fault is severe.
If it is fire accident, apply emergency shutdown and cut off power. Besides, swiftly put off the
fire according to firefighting regulations, and report to team leaders and shift supervisors.
Solution for Interruption of Auxiliary Power
Phenomena
The equipment comes to a full stop, the current is zero, lights are off and there is no
indication on the simulation panel.
Solution
Operators on duty should restore the operation switch and button to standby position.
Operators on duty should report to the ream leader and start equipment according to
operation steps after power recovery.
Precautions and Solution for Wet Coal in Rainy Season
Since wet coal in rainy season may lead to coal blockage in coal chute during
247
unloading, prepare tools for cleaning blockage in advance and reduce loading load.
Caking coal of the turnabout roller and parallel roll may cause to belt sway. Inspection and
adjustment to the sweeper should be conducted timely.
Since the caking coal of the crusher and blockage of screen holes may result in overloaded
coal crusher, current should be monitored.
If disheveled coal or coal supply interruption in the boiler raw coal bunker occurs, please
contact local staff and operators of boiler to enhance monitoring.
Precautions and Adjustment for Loading Coal with Large

Dust Concentration
Team leaders and operators of remote control must inform operators on duty in each section
to prepare for loading in advance. They can identify the abnormity by hearing while
operators in each section are supposed to observe coal loading at a place where
dust concentration is relatively small. Remote operation rather than field operation
is used to protect operators from being injured by the rotating machine.
Dust mask and necessary labor protection are required in the handling site.
Smoking or fire welding which could cause explosion is prohibited in the handling site
during loading. Accumulated coal powder should be cleaned and watered for fire
prevention before using electric or fire welding. Kindling materials should be
eliminated after welding. Operators on duty should scrutinize the handling site in case
that any residue of kindling materials causes fire accident.
248
To prevent fire accident caused spontaneous combustion of accumulated coal, overall and
thorough cleanup should be conducted to the cleaning zone once a week by each team,
including motors and cables, especially where the temperature is relatively high(e.g.
coal bunker ).
()
Operating equipment is not allowed to be cleaned and swept, especially the head and tail of
the roller or the inside of the belt in each section, to prevent anyone from being
injured by the belt.

Team leaders and operators of remote control are supposed to keep in touch with operators
on duty and shift supervisors, and tell them about causes of heavy dust and loading
quantity as well as loading time in advance.
Operators on duty in each section should ensure that dust collector, ventilation facilities and
firefighting equipment are available before operation.
Operators of remote control must concentrate when working on the control panel. Once any
abnormity is found, correction and reports to team leaders and shift supervisors should
be conducted.
249

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PLTU Kaltim-Teluk Balikpapan

(2110MW) CFB Power Plant

PT PERUSAHAAN LISTRIK NEGARA

SINOHYDRO CORPORATION LIMITED

QINGDAO HUAFENG WEIYE ELECTRIC POWER

O&M Manual for PLTU Kaltim-Teluk Balikpapan Power Plant Project

This manual is prepared according to maintenance instructions and relevant

O&M Manual for PLTU Kaltim-Teluk Balikpapan Power Plant Project

Overview of Coal Handling System ....................................................................................................

Coal Unloading Equipment and Equipment of Coal Yard ................................................................... 8

Technical Specification ......................................................................................................................

Introduction to Main Components of Ship Unloader ........................................................................

Check prior to Startup ........................................................................................................................

Basic Requirements for Equipment Application ...............................................................................

Ship Unloading Procedures ...............................................................................................................

Operation under Working Condition of Ship Unloader .....................................................................

Operation When the Ship Unloader is not Working ..........................................................................

Safety Warning ..................................................................................................................................

Equipment Overview .........................................................................................................................

Technical Specification ......................................................................................................................

Overview of Working Principle and Structure ...................................................................................

O&M Manual for PLTU Kaltim-Teluk Balikpapan Power Plant Project

Lubrication of Mechanism ............................................................................................................... 142

Equipment for Coaling System ........................................................................................................ 150

Belt Conveyor .................................................................................................................................. 150

O&M Manual for PLTU Kaltim-Teluk Balikpapan Power Plant Project

Inspection before Operation ............................................................................................................

Inspection and Adjustment during Operation ..................................................................................

Technical Specification ....................................................................................................................

Operation of Vibrating Coal Feeder .................................................................................................

Technical Specification ....................................................................................................................

Crushing Principle ...........................................................................................................................

Operation Method ............................................................................................................................

Precautions for Startup ....................................................................................................................

Crusher Maintenance .......................................................................................................................

O&M Manual for PLTU Kaltim-Teluk Balikpapan Power Plant Project

Inspection before Equipment Operation............................................................................................186

Operation of the Iron Remover..........................................................................................................187

Notes for Use......................................................................................................................................192

Electronic Belt Scale..........................................................................................................................194

Start, Test and Adjustment..................................................................................................................195

Notes for Operation of Electronic Belt Scale.....................................................................................195

Electronic Belt Scale Faults and the Treatment Methods..................................................................196

Central Sampling Device of the Belt.................................................................................................197

O&M Manual for PLTU Kaltim-Teluk Balikpapan Power Plant Project

Operating Process ............................................................................................................................

Working Principle ............................................................................................................................

Operation of Bag-type Dust Collector .............................................................................................

Working Principle ............................................................................................................................

Diagram of Power Head Parts and Components of Cleaner ............................................................

Automatic Protection System ..........................................................................................................

Equipment Overview .......................................................................................................................

Working Principle and Structure ......................................................................................................

O&M Manual for PLTU Kaltim-Teluk Balikpapan Power Plant Project

Technical Parameters ....................................................................................................................... 234

O&M Manual for PLTU Kaltim-Teluk Balikpapan Power Plant Project

O&M Manual for PLTU Kaltim-Teluk Balikpapan Power Plant Project

Overview of Coal Handling System

Both design coal and check coal are Indonesia lignite.

Coal Unloading Equipment and Equipment of

O&M Manual for PLTU Kaltim-Teluk Balikpapan Power Plant Project

Fixed Hanging Chain Bucket Ship Unloader

Safety devices include: