3. ___________________________________________________Operation
______________________________________________________________
BI636364 REV 00 5.3
Operation
This chapter contains important information on the operation and
maintenance of the system, an overview of the electrical, hydraulic, and
mechanical components, how to adjust the system, and instructions on
the replacement of wear parts.
Read this chapter carefully and thoroughly paying particular attention to
the safety instructions in Chapter 2, “Your safety”.
How to operate the conveyor system
DANGER!
Incorrect operation endangers yourself and others! Incorrect op-
eration of the system can be the cause of very serious accidents!
Operate the unit only when you have been sufficiently trained on
the system and have read and understood this operating manual.
Should anything be unclear, please contact your immediate super-
visor.
Who is allowed to operate the conveyor system?
The conveyor system is only allowed to be operated by persons with
adequate knowledge of the complete system.
This also includes:
■ what safety devices are installed on the system,
■ where these safety devices are located, and
■ how these safety devices are to be operated.
When can conveying be started?
Operation must not be started until the safe condition and proper func-
tion of the complete system has been checked and the daily mainte-
nance operations have been carried out.
4. Operation____________________________________________________
________________________________________________________________
5.4 BC 200 OMM
Controls and indicators
Drive VFD operator’s station
The Drive controls for the system are located on the VFD cabinet. The
Drive operator’s station (Fig. 9) consists of the following controls and
indicators:
Emergency Stop
Power Disconnect
ACS 800 DTC control
Fig. 9: Drive VFD operator’s station
ACS 800 DTC
programmable
controller
Drive E Stop
Power Disconnect
ACS 800 DTC Programmable controller
NOTICE!
Before preforming any maintenance or service on the drive sys-
tem. The power disconnect must be locked out in accordance with
mine, local and regional rules and laws.
The power disconnect is located to the right of the ACS 800 display and
must be activated in order for the system to function.
Belt conveyor start up sequences vary greatly due to mine conditions,
follow mine supplied sequence for safe startup and shut down.
5. ___________________________________________________Operation
______________________________________________________________
BI636364 REV 00 5.5
This programmable controller (fig:10)has an extensive operations man-
ual covering all features, programing and safety protocols please refer
to vendor manual package and locate the “ACS800 –Firmware Manu-
al—ACS800 Standard Control Program 7.x”
The E STOP (Fig. 10) is used to break the control circuit in emergency
situations. Striking the E Stop with a small amount of force will actuate
the E STOP: all Drive system functions are shutdown immediately.
The system fire suppression system for the belt conveyor is provided
by the mine and follows all applicable mine, local and regional safety,
actuation and resetting rules and laws.
WARNING!
The fire suppression actuator is actuated, the system must be
completely reset before initiating a start sequence on the belt con-
veyor system.
IMPORTANT!
PLC Programing for the drive and feeder systems was completed
by mine personnel. There is no further information available on
parameters or operational settings. All questions and concerns
must be directed to the mine foreman.
E Stop
Fig. 10: ACS 800 Programmable controller
fire suppression
9. ___________________________________________________Operation
______________________________________________________________
BI636364 REV 00 5.9
Starting procedure
After reading the previous descriptions and locating each control and
completing the hands on operator training the operator is ready to oper-
ate the conveyor system. An experienced operator should monitor a
new operator’s indoctrination to the starting procedure.
WARNING!
The system should not be started if it’s core temperature is below
30° Fahrenheit. If the system is started at extremely low tempera-
tures pump and pump motor failure could occur.
IMPORTANT!
Before start-up, check that daily maintenance has been performed
on the system.
WARNING!
Before start-up, check the conveyor for any foreign material or
objects and that all other personnel are within a safe distance of
the system.
Shutdown procedure
The best method for of shutting down the conveyor system is as de-
scribed in operator training.
Allow the system to run until the belt is empty. Continue to run the
system until all material that has been carried back into the return
line has been cleaned out.
IMPORTANT!
If material is very wet or sticky, it is recommended that the return
line be flushed with water and the conveyor be allowed to run and
clean out the return line before shutting the system down.
10. _____________________________________________Electrical system
______________________________________________________________
BI636364 REV 00 5.10
Electrical system
The following pages contain a brief description of the major electrical
components and assemblies that are on the conveyor system.
The system receives electrical power through a heavy-duty cable. Be
sure that the box connector is correctly identified and is securely con-
nected; also check that the cable entrance is in good mechanical condi-
tion. Walk along the cable from the power center to the conveyor sys-
tem and check the condition of the cable. Give special attention to
points most apt to cause damage, such as corners, intersections, and
where cable may be run over by moving equipment. Never use a cable
with exposed wires or splices which heat up or spark under load.
WARNING!
This section is intended only to familiarize the user with the major
electrical components of the conveyor system. All electrical
maintenance should be performed only by a qualified electrician
with the knowledge of the function of the components involved.
WARNING!
Before removing the cover from the starter enclosure and attempt-
ing any maintenance or troubleshooting on the system, the main
power must be disconnected and locked and tagged out at the
main power center.
Fig. 14: Major electrical component locator
Drive VFD Incoming Power Connection
Take Up VFD Incoming Power Connection
11. Electrical system _____________________________________________
________________________________________________________________
5.11 BC 200 OMM
Drive panel - front side
The Drive panel (Fig. 15) is accessed by opening the door on the en-
closure. Located on the Drive panel are: ACS 800 controller, relays,
transformers, circuit breakers and the main disconnect.
Fig. 15: Drive panel (front side) and main circuit breaker
Main Disconnect Main Disconnect is the main power control for the drive system. The
control knob on the front of the enclosure panel is used to control the
disconnect when the enclosure door is closed
When looking directly at the main disconnect, when the shaft “T” han-
dle is horizontal the power is ON. When the main disconnect “T” han-
dle is vertical the power is OFF .
10A
Breaker
Control Relays
Profibus communication adaptor
Main fuses
DIN
Terminal
blocks
Heavy Duty
Bus chopperTransformer
Regulated
Power supply
Main
Disconnect
20A
Breaker
12. _____________________________________________Electrical system
______________________________________________________________
BI636364 REV 00 5.12
Drive panel - front side
The Take up Panel (Fig. 16) is accessed by opening the doors on the
enclosure. Located on the Take Up panel are: ACS 800 controller, re-
lays, transformers, circuit breakers and the main disconnect.
Fig. 16: Take Up panel
(inside view)
Main Disconnect
Main Disconnect is the main power control for the drive system. The
control knob on the front of the enclosure panel is used to control the
disconnect when the enclosure door is closed
When looking directly at the main disconnect, when the shaft “T” han-
dle is horizontal the power is ON. When the main disconnect “T” han-
dle is vertical the power is OFF .
Control Relays
Profibus
communication adaptor
Main fuses
DIN
Terminal
blocks
Heavy Duty
Bus chopper
Transformer
Regulated
Power supply
Main
Disconnect
Breakers
Configurable
Input/ Output
Communication Module
13. ____________________________________________ Hydraulic system
______________________________________________________________
BI636364 REV 00 5.13
Hydraulic system
The following pages contain a brief description of the hydraulic compo-
nents and assemblies that are on the conveyor system.
The Manual hydraulic system for this system has been designed to pro-
vide manual hydraulic power for the Feeder Take up
WARNING!
This section is intended only to familiarize the user with the hy-
draulic components of the conveyor system. All hydraulic mainte-
nance should be performed only by a qualified technician with the
knowledge of the function of the components involved.
WARNING!
Never disconnect a hydraulic hose if the circuit is pressurized or if
there is a load on the circuit. If a hose is disconnected while the
circuit is pressurized or a load is on the circuit, the load will fall
causing damage to the system or serious injury or death to you or
other workers.
Fig. 17: Hydraulic component locator conveyor system
Feeder
Manual
Hydraulic
Take Up
14. Hydraulic system _____________________________________________
________________________________________________________________
5.14 BC 200 OMM
Major hydraulic components
The hand pump is located on the side of the take up section of the sys-
tem, and is used to manually extend and retract the take up cylinders.
The hydraulic cylinders are located on the feeder take up system.
Each cylinder is individually controlled by the 4 way valve on the hand
pump.
WARNING!
Do not replace the take up hydraulic cylinders with different style
cylinders or the system may fall. The system could be damaged
or you or other personnel could be seriously injured or killed by
the failing system.
Take up hydraulic cylinders
take up hand pump
16. Mechanical assemblies ________________________________________
________________________________________________________________
5.16 BC 200 OMM
Feeder power unit
The feeder power unit drives Feeder(s) (Fig. 19). It consists of a 55KW
electric motor coupled to a gearbox via fluid coupling. The power unit
has been assembled as a unit and can be removed as a unit or as indi-
vidual components (see Replacement of wear parts section of this
chapter).
Fig. 19: Feeder power unit main components
Motor (125 HP)
Connecting tube
Gearbox
Rigid Coupling
Fluid Coupling
18. Mechanical assemblies ________________________________________
________________________________________________________________
5.18 BC 200 OMMConveyor chain not shown
Drive power unit
The drive power unit (Fig. 21) drives the belt. It consists of a 150 HP
electric motor coupled to a reducer. The power unit has been assem-
bled as a unit and can be removed as a unit or as individual compo-
nents (see Replacement of wear parts section of this chapter).
Fig. 21: feeder power unit
Motor (125 HP)
Connecting tube
Gearbox
Rigid Coupling
Fluid Coupling
19. _______________________________________ Mechanical assemblies
______________________________________________________________
BI636364 REV 00 5.19
Take Up Assembly
The Take Up assembly (Fig. 22) attaches to the end of the Feeder sys-
tem frame. It consists of a return belt pulley, pillow block bearing and
take up cylinders. The belt runs around the belt pulley and over the
impact bed.
The take up cylinders are used to tension the belt to correct for misa-
lignment between the belt and the conveyor system.
The take up assembly, when attached to the conveyor system, pro-
vides a means for quickly tensioning the belt.
Fig. 22: Take up assembly
Take up cylinder
Pillow block bearing
Belt pulley
20. Mechanical assemblies ________________________________________
________________________________________________________________
5.20 BC 200 OMM
Carriage assembly
The carriage assembly (Fig. 23) attaches to the storage unit of the con-
veyor system. It consists of pulley carriage and pulley.
The carriage assembly is used to tension the belt during system
advancement and retreat.
Fig. 23: carriage assembly
Upper belt
spreader cylinder
Pillow Block Bearing
Winch Connection
Carriage Pulley Greasing Manifold
V-Groove Tracking wheel Assembly
Pulley Carriage Frame
21. ________________________________________________ Maintenance
______________________________________________________________
BI636364 REV 00 5.21
Instructions on the maintenance
Maintenance at regular intervals increases the operational safety and
prolongs the service life of the system. In particular, observe the safety
instructions in chapter 2 “Your safety”.
Important notes
Please observe the following:
■ In order to avoid individual components not being serviced or being
only inadequately serviced during maintenance work on the system
as a whole, we recommend that a general maintenance plan be
drawn up. You can, for example, draw up a checklist using this
operation manual and the manuals of the other components.
■ Inadequate maintenance can result in system damage which leads
to considerable costs.
■ Use only suitable and approved tools for maintenance work.
■ Use only original Caterpillar spare parts when replacing
components.
■ All electrical work must be supervised and inspected by a certified
electrician.
■ Anyone performing maintenance on this equipment must be trained
to operate it and be familiar with this Caterpillar guide.
Before maintenance
Please observe the following:
■ Disconnect the electrical power. The circuit breaker must be in the
“OFF” position and the power should be disconnected at the main
power source. Follow all Federal and mine safety regulations for
lockout/tagout procedures.
WARNING!
Before performing maintenance on the system, the circuit breaker
must be in the “OFF” position and the power should be discon-
nected at the main power source. Follow all Federal and mine
safety regulations for lockout/tagout procedures. Electrical shock
and accidental system movement can cause serious injuries or
even death to you or the maintenance person.
■ Test the controls to ensure that the unit will not move.
WARNING!
Do not move any hydraulic control lever unless you are certain
that everyone is completely clear of any system movement. Acci-
dental system movement can cause serious injuries or even death
to you or the maintenance person.
22. Maintenance _________________________________________________
________________________________________________________________
5.22 BC 200 OMM
■ Do not perform maintenance on a hydraulic cylinder while there is a
load resting on the hydraulic cylinder. Loads must be securely
blocked if maintenance is to be performed with a load on the
hydraulic cylinder. Follow all Federal and mine safety standards for
blocking the load.
WARNING!
Never disconnect a hydraulic hose if the circuit is pressurized or if
there is a load on the circuit. If a hose is disconnected while the
circuit is pressurized or a load is on the circuit, the load may fall,
causing damage to the system or serious injury or death to you or
other workers. Always block or place a mechanical lock on the
load. Follow all Federal and mine safety standards for blocking
the load.
WARNING!
You could be seriously injured or even killed by falling loads. Ob-
serve the safe working load limits of lifting or blocking devices
and keep a safe distance from suspended loads.
■ Do not perform maintenance in a congested area. This could
endanger the maintenance person or others in the vicinity.
■ Whenever a potential problem is uncovered during a periodic
maintenance check, it is imperative that it be corrected immediately
by a qualified maintenance technician.
■ Cleanliness can not be overemphasized as the essential ingredient
of a good maintenance program. System should be kept as free as
possible of dirt and debris which could impede performance or
infiltrate systems and cause premature wear or failure.
23. Maintenance _________________________________________________
________________________________________________________________
5.23 BC 200 OMM
Lubrication and inspection
Maintenance includes:
■ lubrication of the system in accordance with the lubrication
schedule.
■ inspection of the system for faults and proper function.
■ inspection of wear parts.
Lubrication
IMPORTANT!
The is equipped with lubrication manifolds on the system.
The manifolds (Fig. 24) are located through out the conveyor system.
This allows the following to be easily lubricated from a central point; he
pulley bearings, and idler bearings.
Fig:24 grease manifold
lubrication manifold
Grease Manifold
24. Maintenance _________________________________________________
________________________________________________________________
5.24 BC 200 OMM
Inspection of the conveyor system
CAUTION!
During inspection, report any damage, missing parts or other
faults to your immediate supervisor.
Prior to each shift the following points should be inspected:
Clean and remove any foreign material from the operator’s station.
Inspect all electrical cables, conduits, hydraulic hoses, fittings and
warning devices for signs of wear or damage.
Visually inspect the condition and readability of all tags, labels and
reflectors.
Check the “STOP” button (s) for correct operation.
Check oil level in all reducers.
Inspect the condition of all electrical and hydraulic components.
Check for proper conveyor belt tensioning.
Lubricate per the lubrication schedule.
Check power input cable to power source insuring that the voltage
and breaker settings are correct.
Check that all covers are installed and secure.
Check the tightness of all connecting elements.
25. ________________________________________________ Maintenance
______________________________________________________________
BI636364 REV 00 5.25
Inspection of wear parts on the conveyor
In order to be able to determine in good time when a repair shift has to
be scheduled, and to avoid damage to other components, it is essential
to inspect all the following wear parts as to their degree of wear:
■ the conveyor tail pulley
■ the idler rollers
■ the return rollers
■ the belt wipers
■ the belt cleaners
■ the plugged chute sensor
Inspection of fire suppression system on the conveyor
system
To provide maximum assurance that your fire suppression system will
operate effectively and safely, the system should be inspected weekly,
in accordance with mine safety procedures.
