SERRA SUL PROGRAM MINE/PLANT DESIGNN1030-01TITLESERRA SUL PROGRAM MINE/PLANT DESIGNPRODUCT STOCK YARDTEACHING MATERIAL FOR TRAININGBUCKET WHEEL RECLAIMER RC-2092KS-01 TO 04VALE No.DF-MO-2092KS-M-501E-E-002PAGE1/73DHI No.REV.1REVISIONSRP: REVISION PURPOSEA - PRELIMINARYB - FOR APPROVALC - FOR INFORMATIOND - FOR QUOTATIONE - FOR CONSTRUCTIONF - AS PURCHASEDG - AS BUILTH - CANCELLEDRev.RP Revision DescriptionPrep.Che.Appr.Aut.Date0BFOR APPROVALWZJTANMAVM30/07/101ECERTIFIEDWZJTANMAVM21/12/12QLK11000.50 ReclaimerRC-2092KS-01 TO 04TEACHING MATERIAL FOR TRAININGVALEs No. DF-MO-2092KS-M-501E-E-002-R0 Foreword Dear customer, Thank you for choosing our product? For proper erection and installation, safe handling and failure-free operation of the bucketwheel reclaimer/reclaimer, please read carefully Operation Manual for the machine, with special care to the safety warnings and safe specification sections. Please store this Operation Manual for the machine at a convenient place for easy availability and timely reference in case of questions. This Operation Manual is delivered to the equipment user, with preserved proprietary right by DHIDCW Group Co., Ltd. Without our authorization or permission, the provided technical specifications, drawings and sketches may not be all or partly photocopied, distributed, used for competition or provided to a third party. Please properly maintain the Operation Manual within the lifetime of the equipment. This Operation Manual is applicable for bucketwheel reclaimer/reclaimer product. This Operation Manual includes the following parts: Chapter 1 Summary; Chapter 2 Safety; Chapter 3 installation, commissioning; Chapter 4 Usage and operation; Chapter 5 Service and maintenance;This document is electrical part. If your questions can not be answered in this document, please contact us and we will be pleased to provide any help to you.Our contact information: Address: No.169, bayi road, xigang district, Dalian city, Liaoning province Postal code: 116013 Website?http://www.dhidcw.comContact telephone no.:0411-86852188 E-mail:gsbw@dhidcw.comCustomer service center: 0411-62999688 Fax no.:0411-86852553 E-mail:fwzx@dhidcw.comCHAPTER 1 SUMMARYCONTENTS TOC \o "1-3" \h \z \u HYPERLINK \l "_Toc257732334" 1.1 Main application and scope of operation PAGEREF _Toc257732334 \h 3 HYPERLINK \l "_Toc257732335" 1.1.1 Main application PAGEREF _Toc257732335 \h 3 HYPERLINK \l "_Toc257732336" 1.1.2 Scope of operation PAGEREF _Toc257732336 \h 3 HYPERLINK \l "_Toc257732337" 1.1.3 Parameters of reclaimer PAGEREF _Toc257732337 \h 3 HYPERLINK \l "_Toc257732338" 1.1.4 Material and Physical Characteristics PAGEREF _Toc257732338 \h 3 HYPERLINK \l "_Toc257732339" 1.2 Technical Characteristics PAGEREF _Toc257732339 \h 3 HYPERLINK \l "_Toc257732340" 1.2.1 The type of power supply and power PAGEREF _Toc257732340 \h 3 HYPERLINK \l "_Toc257732341" 1.2.2 Capacity of power PAGEREF _Toc257732341 \h 3 HYPERLINK \l "_Toc257732342" 1.2.3 Operating Environment Conditions PAGEREF _Toc257732342 \h 3 HYPERLINK \l "_Toc257732343" 1.2.4 Operating Condition PAGEREF _Toc257732343 \h 3 HYPERLINK \l "_Toc257732344" 1.3 Composition of electrical system PAGEREF _Toc257732344 \h 3 HYPERLINK \l "_Toc257732345" 1.3.1 Drive PAGEREF _Toc257732345 \h 3 HYPERLINK \l "_Toc257732346" 1.3.2 Transformer PAGEREF _Toc257732346 \h 3 HYPERLINK \l "_Toc257732347" 1.3.3 Panel box and desk PAGEREF _Toc257732347 \h 3 HYPERLINK \l "_Toc257732348" 1.3.4 Field instruments PAGEREF _Toc257732348 \h 3 HYPERLINK \l "_Toc257732349" 1.3.5 Light PAGEREF _Toc257732349 \h 3 HYPERLINK \l "_Toc257732350" 1.3.6 Anti fire system PAGEREF _Toc257732350 \h 3 HYPERLINK \l "_Toc257732351" 1.3.7 Vibration management system PAGEREF _Toc257732351 \h 3 HYPERLINK \l "_Toc257732352" 1.3.8 Position and anti-collision system PAGEREF _Toc257732352 \h 3 HYPERLINK \l "_Toc257732353" 1.3.9 Local operation components PAGEREF _Toc257732353 \h 3 HYPERLINK \l "_Toc257732354" 1.3.10 Telecommunication system PAGEREF _Toc257732354 \h 3 HYPERLINK \l "_Toc257732355" 1.3.10.1 CCTV PAGEREF _Toc257732355 \h 3 HYPERLINK \l "_Toc257732356" 1.3.10.2 Access PAGEREF _Toc257732356 \h 3 HYPERLINK \l "_Toc257732357" 1.3.10.3 Communication system PAGEREF _Toc257732357 \h 3 HYPERLINK \l "_Toc257732358" 1.3.11 Safety protection PAGEREF _Toc257732358 \h 3 HYPERLINK \l "_Toc257732359" 1.3.11.1 Interlock between different structures PAGEREF _Toc257732359 \h 3 HYPERLINK \l "_Toc257732360" 1.3.11.2 Process limit PAGEREF _Toc257732360 \h 3 HYPERLINK \l "_Toc257732361" 1.3.11.3 Emergency switch PAGEREF _Toc257732361 \h 3 HYPERLINK \l "_Toc257732362" 1.3.11.4 Anti-collision protection PAGEREF _Toc257732362 \h 3 HYPERLINK \l "_Toc257732363" 1.4 Function of working PAGEREF _Toc257732363 \h 3

SUMMARYAttention: This Instructions is for control and Operation of QLK11000.50 reclaimer only.1 General1.1 Main application and scope of operationReclaimers are widely used for handling and conveying bulk materials such as ore, coal and coke in stockyards of mines, ports, thermal power plants, steel plants, coke oven plants, cement plants and chemical plants. They are large size, high efficiency and mobile mechanical equipment that continuously handle and convey bulk materials. The operators can operate the equipment by way of manual, semiautomatic and automatic operation (unmanned operation) as well as manual unit operation at machine side. 1.1.1 Main applicationThis reclaimer is designed to run on the runway rails in the bulk material stockyard. Itsmain function is to reclaim the material from the stockpile at both sides of rails and conveyit to the designated place via the yard belt conveyer.The manual operation and semiautomatic operation of bucket-wheel reclaimer will beachieved by the operator in the operators cabin or from CCR.It is forbidden that the reclaimer being used for another function, such as auxiliary hauling and hoisting equipment. 1.1.2 Scope of operationQLK1100050 type reclaimer is designed and manufactured for Vale S11D project for reclaiming operation of ore material of the project.While in reclaiming operation, the height of pile is 18m and shall be separated to 3 layers for reclaiming, the thickness of each layer is 6m, each layer of pile shall be reclaimed via the bucketwheel turning.Control modes of the reclaimer include: manual and full automatic (unmanned) operation.1.1.3 Parameters of reclaimerReclaimer capacity?Nominal capacity: 8000t/h Design capacity : 11000t/hSlewing Radius: 50mSlewing Angle: 175Slewing speed: 0-0.14r/minBelt Speed: 4.6m/sLuffing Angle: -14~13Luffing speed(boom tail pulley): 4.5m/minTravelling speed: 0~25m/minMode of power supply: power cable reelMains voltage: 4160 VMains frequency: 60 HzPosition of power supply: middle of whole travel of reclaimer1.1.4 Material and Physical CharacteristicsSort of material: sinter feed/pellet feedGrain size of material: 13+.015/-0.15 mmBulk density: 2.6/2.05 t/m3Moisture content: 10?Angle of repose: 33~381.2 Technical CharacteristicsFor detail please refer to mechanical manual DF-MM-2092KS-M-501E-M-001, item 1.3.31.2.1 The type of power supply and powerpower supply feed to high-voltage power distribution system via HV-cable from substation connecting to cable reel, please refer to the diagram: DF-2092KS-M-501E-E-002----GENERAL SINGLE LINE DIAGRAM. Power supply? AC4.16KV?60Hz LV power supply? AC480V?60Hz Control feeding? AC120V?60Hz Lighting Power Supply? AC380/220V?60Hz Maintenance power supply? AC480V?60Hz AC220V?60Hz PLC feeding? AC120V?60Hz PLC input? AC120V?60Hz PLC output? AC120V?60Hz1.2.2 Capacity of powerTable 1.1Total capacity About1520kWMax.demand1370kW1.2.3 Operating Environment Conditions For detail please refer to mechanical manual DF-MM-2092KS-M-501E-M-001, item 1.4 When the wind speed is more than 80 km/h during operation, the material must beemptied from the equipment system and the ore reclaimer stopped and the rail clamps andwheel brakes in the traveling mechanism are safely applied on the rails.When the wind speed is more that 120 km/h during operation, the ore reclaimer must be driven tothe parking position, and horizontally fixed and dragged. The anchoring devices and rail clamps must be locked in order to ensure that the reclaimer can not be moved by the wind. All the joysticks in the operators cabin are returned to zero. All the power supplies are disconnected and the main circuit breaker is powered off. All the doors and windows are closed. The ore reclaimer can not be used if it is forecasted that the earthquake will occur.1.2.4 Operating ConditionThe following requirements must be met during normal operation of ore reclaimer. If any of therequirements as specified are not satisfied, use of the ore reclaimer is forbidden.The operating environment conditions of equipment are within normal range; All components and parts of mechanical, electrical and hydraulic systems in the equipment are innormal operating condition; The safety and protective devices located in the equipment and on the ground are in normal operating condition; The system area where the equipment is located is in normal operating condition; It must be ensured that there is no risk in the working area of equipment and its components. The reclaimer operator must hold the qualification certification for operating this equipment; Operator of reclaimer/reclaimer should operate strictly in accordance with operaetoian process? It is only allowed to use reclaimer and its onboard equipment for its original functional activities and strictly forbidden to use reclaimer and its onboard equipment for activates irrelevant to reclaiming operation and equipment maintenance; During operation it is strictly forbidden for operator to leave his post, sleep, be absent minded and do other activities, and should make timely treatment in case finding fault. Treatment of fault without any description should follow essential electric common sense and fundamental logic and rational principle, and consultancy to specialized service people and equipment manufacturer should be made. 1.3 Composition of electrical systemReclaimer has 2 E-house,1 cabin,the E-house on under part of machine(+R3) were separated into LV part, MV part and transformer part; the E-house on upper part of machine(+R2) were separated into LV part and MV part, the cabin is located in the top end of boom. All routine operation can be done on the console desk inside cabin, necessary signal for operation and maintenance can be displaied on HMI, all panels were layout in the E-house reasonably. For detail please refer to the drawingsDF-2092KS-M-501E-E-053---- LAYOUT OF UNDER E-HOUSE, DF-2092KS-M-501E-E-045---- LAYOUT OF UPPER E-HOUSEDF-2092KS-M-501E-E-054----LAYOUT OF CABIN

Picture 1.1 general layoutLocal operation, semi-automation operation and maintenance operation can be done on the machine. ?Under E-house, MV partMV distribute panel(QD-2092KS-100)-----MV incoming and power feeding for power transformerLighting transformer feeder(QD-2092KS-100)-----Power feeding for illuminate transformer?Under E-house, LV partMCC(MC-2092KS-102)----MCC for clamp,lubrication and other under driving except travelling and cable reel.1,2# travelling panel(RF-2092KS-100/101)Cable reel driver(RF-2092KS-103)2# Illumination panel(QL-2092KS-100)----Power feeding for under part lighting of machineDC Panel(QD-2092KS-102)----Power feeding for MV controlControl panel(QD-2092KS-101)----Power feeding for control systemUnder PLC panel(PL-2092KS-101)Brake resistor(RC-2092KS-01-BR0501/0502)---- Brake resistor for travellingBrake resistor(RC-2092KS-01-BR0505)---- Brake resistor for cable reel125V battery panel(QD-2092KS-103)----Battery for DC panel ?Under E-house, Transformer partPower transformer(TF-2092KS-100)Illuminate transformer(TL-2092KS-100)Ground resistor(RS-2092KS-100)------combined with power transformer ?Upper E-house, MV partMV belt feeder(MC-2092KS-100)----Power feeding for boom conveyor motorMV bucketwheel feeder(MC-2092KS-101)----Power feeding for bucketwheel motor ?Upper E-house, LV partMCC(MC-2092KS-103)----MCC for luffing,lubrication and other upper driving except slewing.1,2# slewing panel(RF-2092KS-102/103)Upper PLC panel(PL-2092KS-100)Brake resistor(RC-2092KS-01-BR0503/0504)---- Brake resistor for slewing ?CabinConsole desk(PO-2092KS-100)1# illumination panel(PI-2092KS-100)----Power feeding for upper part lighting of machine1.3.1 DriveDifferent drivings met matched system, for detail please refer to following table:Table 1.2SystemModelQuantitySpecificationRemarkTraveling Integrated with gear box12AC440V?15kWVVVF drivingClamp motorIntegrated with clamp4AC440V?1.73kWCable ReelIntegrated with cable reel1AC440V?1.5kWVVVF drivingSlewingIntegrated with gear box4AC440V?15kWVVVF drivingBelt conveyor1AC4kV?500kWBucketwheel1AC4kV?400kWLuffingIntegrated with pump3AC440V?55kWTwo for running, another for spareElectric hoist1AC440V?7.8kW1.3.2 Transformer Power transformer?TF-2092KS-100??AC4.16kV/AC0.48kV,500kVA; Illumination transformer?TL-2092KS-100??AC0.48kV/AC0.38kV,50kVA;1.3.3 Panel box and deskTable 1.3No.TagLocationDescriptionreference1+R1Operator cabinDF-2092KS-M-501E-E-0542PO-2092KS-100/200/300/400+R1Operation tableDF-2092KS-M-501E-E-038PI-2092KS-100/200/300/400+R1Illumination panel +C9ADF-2092KS-M-501E-E-0433+R3Under E-houseDF-2092KS-M-501E-E-0534MC-2092KS-102/202/302/402+R3Under MCCDF-2092KS-M-501E-E-033RF-2092KS-100/200/300/400+R3Long travelling panel +C2ADF-2092KS-M-501E-E-034RF-2092KS-101/201/301/401+R3Long travelling panel +C2BDF-2092KS-M-501E-E-035PL-2092KS-101/201/301/401+R3PLC Panel +C6BDF-2092KS-M-501E-E-042QL-2092KS-100/200/300/400+R3Illumination panel +C9BDF-2092KS-M-501E-E-039QD-2092KS-101/201/301/401+R3Control Panel +C0ADF-2092KS-M-501E-E-044QD-2092KS-102/202/302/402+R3DC PanelDC Panel maualQD-2092KS-103/203/303/403+R3Battery PanelDC Panel maualRS-2092KS-100/200/300/400+R3Earthing resistor panelResistor panel maualQD-2092KS-100/200/300/400+R3MV Distribution panelDF-2092KS-M-501E-E-004RF-2092KS-103/203/303/403+R3Cable reel inverter panelCable reel manualTF-2092KS-100/200/300/400+R3Power transformerDF-2092KS-M-501E-E-005TL-2092KS-100/200/300/400+R3Illuminate transformerDF-2092KS-M-501E-E-006RC-2092KS-01/02/03/04-BR0501/0502+R3Brake resistor for long travellingResistor manualRC-2092KS-01/02/03/04-BR0505+R3Brake resistor for cable reelCable reel manual3+R2Upper E-houseDF-2092KS-M-501E-E-053PL-2092KS-100/200/300/400+R2PLC Panel +C6ADF-2092KS-M-501E-E-041RF-2092KS-102/202/302/402+R2Slewing panel +C4ADF-2092KS-M-501E-E-070RF-2092KS-103/203/303/403+R2Slewing panel +C4BDF-2092KS-M-501E-E-071MC-2092KS-103/203/303/403+R2Upper MCC +C5DF-2092KS-M-501E-E-068MC-2092KS-100/200/300/400+R2MV boom conveyor feeding panelDF-2092KS-M-501E-E-061MC-2092KS-101/201/301/401+R2MV bucketwheel feeding panelDF-2092KS-M-501E-E-063RC-2092KS-01/02/03/04-BR0503/0504+R2Brake resistor for slewingResistor manual+FField on machineDF-2092KS-M-501E-E-057/058/046JB-2092KS-120/220/320/420+FLeft LT junction boxJB-2092KS-121/221/321/421+FRight LT junction boxJB-2092KS-123+FTripper car junction boxJB-2092KS-122/222/322/422+FBoom junction boxJB-2092KS-125/225/325/425+FLuffing hydraulic junction boxJB-2092KS-124/224/324/424+FCabin level hydraulic junction boxJB-2092KS-117/217/317/417+FLeft rail clamp local control stationJB-2092KS-118/218/318/418+FRight rail clamp local control stationJB-2092KS-116+FCable reel local control stationJB-2092KS-115/215/315/415+FBoom conveyor local control stationJB-2092KS-119/219/319/419+FCabin level local control stationJB-2092KS-102+FLeft travel maintenance box(AC440V)JB-2092KS-103+FLeft travel maintenance box(AC220V)JB-2092KS-104+FRight travel maintenance box(AC440V)JB-2092KS-105+FRight travel maintenance box(AC220V)JB-2092KS-106+FSlew plateform maintenance box(AC440V)JB-2092KS-107+FSlew plateform maintenance box(AC220V)JB-2092KS-108+FBoom maintenance box(AC440V)JB-2092KS-109+FBoom maintenance box(AC220V)HSS-2092KS-2005/2205/2405/2605+FLeft travel emergency stationHSS-2092KS-2006/2206/2406/2606+FRight travel emergency stationHSS-2092KS-2008/2208/2408/2608+FLuffing emergency stationHSS-2092KS-2009/2209/2409/2609+FBucketwheel emergency stationHSS-2092KS-2007/2207/2407/2607+FSlewing emergency station1.3.4 Field instrumentsSeveral type of instruments were set on the machine for detection and protection, For detail of that please refer to DF-LR-2092KS-M-501E-E-005---MAIN COMPONENT LIST; DF-2092KS-M-501E-E-058---INTERCONNECTION DRAWING; DF-2092KS-M-501E-E-057---TRAVELLING PART LAYOUT; DF-2092KS-M-501E-E-065--- UPPER PART OF SLEWING LAYOUT The instrumentsare listed and described below?1.4No.NameTagFunctionReference1Illumination system1.1Light sensorRS-2092KS-2001Detect light to ON/OFF lights DF-2092KS-M-501E-E-0062Long travelling system2.1FWD operational end limitZS-2092KS-2053Forward operational LS for travellingDF-2092KS-M-501E-E-0082.2FWD emergency end limitZS-2092KS-2054Forward emergency LS for travellingDF-2092KS-M-501E-E-0082.3REV emergency end limitZS-2092KS-2055Backward emergency LS for travellingDF-2092KS-M-501E-E-0082.4REV operational end limitZS-2092KS-2056Backward operational LS for travellingDF-2092KS-M-501E-E-0082.5Left anchor limit switchZS-2092KS-2057NO----left anchor locked OFF----left anchor unlockedDF-2092KS-M-501E-E-0082.6Right anchor limit switchZS-2092KS-2058NO----Right anchor locked OFF----Right anchor unlockedDF-2092KS-M-501E-E-0082.7Left travelling brake limit switch 1~6#ZS-2092KS-2001~2006NO----The brake released OFF----The brake closedDF-2092KS-M-501E-E-0082.8Right travelling brake limit switch 1~6#ZS-2092KS-2007~2012NO----The brake released OFF----The brake closedDF-2092KS-M-501E-E-0082.9Left travelling emergency stopHSS-2092KS-2005Emergency switch on left side of travelingDF-2092KS-M-501E-E-0082.10Right travelling emergency stopHSS-2092KS-2006Emergency switch on right side of travelingDF-2092KS-M-501E-E-0082.111# travelling rotary encoderZT-2092KS-2001Detect the absolute position for travellingDF-2092KS-M-501E-E-0082.122# travelling rotary encoderZT-2092KS-2002Detect the absolute position for travelling(compare the value with 1#)DF-2092KS-M-501E-E-0082.13Derailing detectorZS-2092KS-2119Detect the balance of gantryDF-2092KS-M-501E-E-0082.14RFIDZE-2092KS-2011Detect the section of travelling DF-2092KS-M-501E-E-0083Rail clamp system3.1Left rail clamp valvePV-2092KS-2021?2022When it is acting, the clamp should be openedDF-2092KS-M-501E-E-0093.2Right rail clamp valvePV-2092KS-2023?2024When it is acting, the clamp should be openedDF-2092KS-M-501E-E-0093.3Lifted limit switch for left rail clampZS-2092KS-2069?2071Lifted limit switch for left rail clampDF-2092KS-M-501E-E-0093.4Falled limit switch for left rail clampZS-2092KS-2070?2072Falled limit switch for left rail clampDF-2092KS-M-501E-E-0093.5Oil pressure alarm for left rail clampPS-2092KS-2017?2018Detect high oil pressure and send the signal to PLCDF-2092KS-M-501E-E-0093.6Lifted limit switch for right rail clampZS-2092KS-2073?2075Lifted limit switch for right rail clampDF-2092KS-M-501E-E-0093.7Falled limit switch for right rail clampZS-2092KS-2074?2076Falled limit switch for right rail clampDF-2092KS-M-501E-E-0093.8Oil pressure alarm for right rail clampPS-2092KS-2019?2020Detect high oil pressure and send the signal to PLCDF-2092KS-M-501E-E-0094Cable reel------please refer to the manual of cable reel Under lubrication system5Under lubrication system5.1Travelling 1# lubrication station alarmZS-2092KS-2181Fault signal of 1# travelling lubrication stationDF-2092KS-M-501E-E-0125.2Low oil level travelling 1# lubrication stationZS-2092KS-2182Low oil level of 1#travelling lubrication stationDF-2092KS-M-501E-E-0125.3Travelling 2# lubrication station alarmZS-2092KS-2183Fault signal of 2# travelling lubrication stationDF-2092KS-M-501E-E-0125.4Low oil level travelling 2# lubrication stationZS-2092KS-2184Low oil level of 2#travelling lubrication stationDF-2092KS-M-501E-E-0125.5Travelling 3# lubrication station alarmZS-2092KS-2185Fault signal of 3# travelling lubrication stationDF-2092KS-M-501E-E-0125.6Low oil level travelling 3# lubrication stationZS-2092KS-2186Low oil level of 3#travelling lubrication stationDF-2092KS-M-501E-E-0125.7Travelling 4# lubrication station alarmZS-2092KS-2187Fault signal of 4# travelling lubrication stationDF-2092KS-M-501E-E-0125.8Low oil level travelling 4# lubrication stationZS-2092KS-2188Low oil level of 4#travelling lubrication stationDF-2092KS-M-501E-E-0125.9Traveling lubrication end pressureZS-2092KS-2010~2013Over normal End pressure DF-2092KS-M-501E-E-0126Substructure auxiliary system6.11#funnel thruster extend LSZS-2092KS-2120DF-2092KS-M-501E-E-0136.21#funnel thruster shrink LSZS-2092KS-2121DF-2092KS-M-501E-E-0136.32#funnel thruster extend LSZS-2092KS-2122DF-2092KS-M-501E-E-0136.42#funnel thruster shrink LSZS-2092KS-2123DF-2092KS-M-501E-E-0136.5Left chute thruster extend LSZS-2092KS-2124DF-2092KS-M-501E-E-0136.6Left chute thruster shrink LSZS-2092KS-2125DF-2092KS-M-501E-E-0136.7Left chute jammed LSZS-2092KS-2109DF-2092KS-M-501E-E-0136.8Left rip cord detector for ground beltZS-2092KS-2101~2104DF-2092KS-M-501E-E-0136.9Right chute thruster extend LSZS-2092KS-2126DF-2092KS-M-501E-E-0136.10Right chute thruster shrink LSZS-2092KS-2127DF-2092KS-M-501E-E-0136.11Right chute jammed LSZS-2092KS-2110DF-2092KS-M-501E-E-0136.12Right rip cord detector for ground beltZS-2092KS-2105~2108DF-2092KS-M-501E-E-0137Slewing system7.11#slew brake openZS-2092KS-2065The signal of brake openDF-2092KS-M-501E-E-0147.22#slew brake openZS-2092KS-2066The signal of brake openDF-2092KS-M-501E-E-0147.33#slew brake openZS-2092KS-2067The signal of brake openDF-2092KS-M-501E-E-0147.44#slew brake openZS-2092KS-2068The signal of brake openDF-2092KS-M-501E-E-0147.5Slew left operational end limitZS-2092KS-2025Left operational LS of slewingDF-2092KS-M-501E-E-0147.6Slew left emergency end limitZS-2092KS-2026Left emergency LS of slewingDF-2092KS-M-501E-E-0147.7Slew right operational end limitZS-2092KS-2027Right operational LS of slewingDF-2092KS-M-501E-E-0147.8Slew right emergency end limitZS-2092KS-2028Right emergency LS of slewingDF-2092KS-M-501E-E-0147.9Slew across belt limit switchZS-2092KS-2064If it is avaliable combined with the signal ZS-2092KS-2063---Luff level limit switch, slewing across belt shoud be forbiddenDF-2092KS-M-501E-E-0147.10Over temp70---slew 1# reduction gearTS-2092KS-2002The signal of over temp of 1# slewing reducerDF-2092KS-M-501E-E-0147.11Over temp70---slew 2# reduction gearTS-2092KS-2003The signal of over temp of 2# slewing reducerDF-2092KS-M-501E-E-0147.12Over temp70---slew 3# reduction gearTS-2092KS-2004The signal of over temp of 3# slewing reducerDF-2092KS-M-501E-E-0147.13Over temp70---slew 4# reduction gearTS-2092KS-2005The signal of over temp of 4# slewing reducerDF-2092KS-M-501E-E-0147.14Slew emergency stopHSS-2092KS-2007Emergency switch near slewing systemDF-2092KS-M-501E-E-0147.15Slew 1# encoderZT-2092KS-2003Detect the absolute angle for slewingDF-2092KS-M-501E-E-0147.16Slew 2# encoderZT-2092KS-2004Detect the absolute angle for slewing(compare the value with 1#)DF-2092KS-M-501E-E-0148Luffing system8.1Luff local emergency stopHSS-2092KS-2008Emergency switch near luffing systemDF-2092KS-M-501E-E-0158.2Luff up operational end limitZS-2092KS-2059Luffing up operational LSDF-2092KS-M-501E-E-0158.3Luff up emergency end limitZS-2092KS-2060Luffing up emergency LSDF-2092KS-M-501E-E-0158.4Luff down operational end limitZS-2092KS-2061Luffing down operational LSDF-2092KS-M-501E-E-0158.5Luff down emergency end limitZS-2092KS-2062Luffing down emergency LSDF-2092KS-M-501E-E-0158.6Luff level limit switchZS-2092KS-2063See Item 6.7DF-2092KS-M-501E-E-0158.7Luff 1# ball valve stateZS-2092KS-2137For detail refer to the manual of hydraulic systemDF-2092KS-M-501E-E-0158.8Luff 2# ball valve stateZS-2092KS-2138For detail refer to the manual of hydraulic systemDF-2092KS-M-501E-E-0158.9Luff 3# ball valve stateZS-2092KS-2139For detail refer to the manual of hydraulic systemDF-2092KS-M-501E-E-0158.10Luff 4# ball valve stateZS-2092KS-2140For detail refer to the manual of hydraulic systemDF-2092KS-M-501E-E-0158.11Luff 5# ball valve stateZS-2092KS-2141For detail refer to the manual of hydraulic systemDF-2092KS-M-501E-E-0158.12Luff 6# ball valve stateZS-2092KS-2142For detail refer to the manual of hydraulic systemDF-2092KS-M-501E-E-0158.13Luff pump 1# butterfly valve stateZS-2092KS-2131For detail refer to the manual of hydraulic systemDF-2092KS-M-501E-E-0158.14Luff pump 2# butterfly valve stateZS-2092KS-2132For detail refer to the manual of hydraulic systemDF-2092KS-M-501E-E-0158.15Luff pump 3# butterfly valve stateZS-2092KS-2133For detail refer to the manual of hydraulic systemDF-2092KS-M-501E-E-0158.16Luff pump 4# butterfly valve stateZS-2092KS-2134For detail refer to the manual of hydraulic systemDF-2092KS-M-501E-E-0158.17Luff pump 5# butterfly valve stateZS-2092KS-2135For detail refer to the manual of hydraulic systemDF-2092KS-M-501E-E-0158.18Luff pump 6# butterfly valve stateZS-2092KS-2136For detail refer to the manual of hydraulic systemDF-2092KS-M-501E-E-0158.19Oil return filter jammedPS-2092KS-2007For detail refer to the manual of hydraulic systemDF-2092KS-M-501E-E-0158.201# High pressure filter jammedPS-2092KS-2008For detail refer to the manual of hydraulic systemDF-2092KS-M-501E-E-0158.212# High pressure filter jammedPS-2092KS-2009For detail refer to the manual of hydraulic systemDF-2092KS-M-501E-E-0158.22Temperature measuring hydraulic stationTS-2092KS-2007Analog signal of hydraulic station temperatureDF-2092KS-M-501E-E-0158.23Pump exit pressure measuringZS-2092KS-2002Analog signal of output pressure of pumpDF-2092KS-M-501E-E-0158.24Oil level measuringPS-2092KS-2089Analog signal of oil levelDF-2092KS-M-501E-E-0158.25Pressure measuring 1 left hydraulic cylinderPS-2092KS-2003Analog signal of pressure of left hydraulic cylinderDF-2092KS-M-501E-E-0158.26Pressure measuring 2 left hydraulic cylinderPS-2092KS-2004Analog signal of pressure of left hydraulic cylinderDF-2092KS-M-501E-E-0158.27Pressure measuring 1 right hydraulic cylinderPS-2092KS-2005Analog signal of pressure of right hydraulic cylinderDF-2092KS-M-501E-E-0158.28Pressure measuring 2 right hydraulic cylinderPS-2092KS-2006Analog signal of pressure of right hydraulic cylinderDF-2092KS-M-501E-E-0158.29Luffing 1# encoderZT-2092KS-2005Detect the absolute angle for luffingDF-2092KS-M-501E-E-0158.30Luffing 2# encoderZT-2092KS-2006Detect the absolute angle for luffing(compare the value with 1#)DF-2092KS-M-501E-E-0158.311# Spill valvePV-2092KS-2001DF-2092KS-M-501E-E-0158.322# Spill valvePV-2092KS-2002DF-2092KS-M-501E-E-0158.33Directional control valvePV-2092KS-20034/3 way directional valveDF-2092KS-M-501E-E-0158.34Directional control valvePV-2092KS-20044/3 way directional valveDF-2092KS-M-501E-E-0158.35Proportional valvePV-2092KS-20054/3 way proportional valveDF-2092KS-M-501E-E-0158.36Proportional valvePV-2092KS-20064/3 way proportional valveDF-2092KS-M-501E-E-0159Boom conveyor system9.1Boom conveyor left anti collision switchZS-2092KS-2051Anti collision signal ---left side of boomDF-2092KS-M-501E-E-0169.2Boom conveyor right anti collision switchZS-2092KS-2052Anti collision signal ---right side of boomDF-2092KS-M-501E-E-0169.3Belt misalignmentZS-2092KS-2077~2080Signal of belt misalignmentDF-2092KS-M-501E-E-0169.4Speed sensorSS-2092KS-2001The signal of belt speedDF-2092KS-M-501E-E-0169.5Belt tension LSSS-2092KS-2111The signal of belt tensionDF-2092KS-M-501E-E-0169.6Boom conveyor brake openZS-2092KS-2021DF-2092KS-M-501E-E-0169.7Boom conveyor brake closedZS-2092KS-2022DF-2092KS-M-501E-E-0169.8Under speed switchSS-2092KS-2002The signal of lower speed of beltDF-2092KS-M-501E-E-0169.9Overhaul bracket limit switchZS-2092KS-2116DF-2092KS-M-501E-E-0169.10Oil temp measuringboom belt reduction gearTS-2092KS-2006The analog signal of belt reducer temperatureDF-2092KS-M-501E-E-0169.11Coupling temperature sensorTS-2092KS-2001The analog signal of belt coupling temperatureDF-2092KS-M-501E-E-0169.12Distance measuring device ZS-2092KS-2115The signal of pile heightDF-2092KS-M-501E-E-0169.13Safty pull line on left sideHSS-2092KS-2001Emergency switch on left side of beltDF-2092KS-M-501E-E-0169.14Safty pull line on right sideHSS-2092KS-2002Emergency switch on right side of beltDF-2092KS-M-501E-E-01610Bucketwheel system10.1Bucketwheel emergency stopHSS-2092KS-2009Emergency switch near bucketwheel systemDF-2092KS-M-501E-E-01710.2Brake LSZS-2092KS-2023The signal of brake openDF-2092KS-M-501E-E-01710.3Reducer oil flow detecterPS-2092KS-2023DF-2092KS-M-501E-E-01710.4Reducer filter jammingPS-2092KS-2024DF-2092KS-M-501E-E-01710.5Oil temp measuring bucketwheel reducerTS-2092KS-2010DF-2092KS-M-501E-E-01710.6Coupling temperature sensorTS-2092KS-2009The analog signal of bucketwheel coupling temperatureDF-2092KS-M-501E-E-01711Cabin level system11.11# ball valve statecabin levelingZS-2092KS-2143The state of 1# ball valve for cabin levelDF-2092KS-M-501E-E-01811.22# ball valve statecabin levelingZS-2092KS-2144The state of 1# ball valve for cabin levelDF-2092KS-M-501E-E-01811.3Feed back oil filter jammedPS-2092KS-2022DF-2092KS-M-501E-E-01811.4Cabin level detecterZS-2092KS-2118The analog signal of cabin levelDF-2092KS-M-501E-E-01811.5Station Temp/level measuringTS-2092KS-2008DF-2092KS-M-501E-E-01811.6Spill valve for cabin levelPV-2092KS-2007DF-2092KS-M-501E-E-01811.7The valve for cabin luffing upPV-2092KS-2008The valve for cabin luffing upDF-2092KS-M-501E-E-01811.8The valve for cabin luffing downPV-2092KS-2009The valve for cabin luffing downDF-2092KS-M-501E-E-01812Upper lubrication system12.1Slew lubricate station alarmZS-2092KS-2191Alarm signal of slewing lubricationDF-2092KS-M-501E-E-01912.2Slew lubricate station low levelZS-2092KS-2192The signal of low oil level of slewing lubricationDF-2092KS-M-501E-E-01912.3Boom lubricate station alarmZS-2092KS-2193Alarm signal of boom lubricationDF-2092KS-M-501E-E-01912.4Boom lubricate station low levelZS-2092KS-2194The signal of low oil level of boom lubricationDF-2092KS-M-501E-E-01912.5Bucketwheel lubricate station alarmZS-2092KS-2195Alarm signal of bucketwheel lubricationDF-2092KS-M-501E-E-01912.6bucketwheel lubricate station low levelZS-2092KS-2196The signal of low oil level of bucketwheel lubricationDF-2092KS-M-501E-E-01912.7slewing lubrication end pressurePS-2092KS-2014Over normal End pressureDF-2092KS-M-501E-E-01912.8Boom lubrication end pressurePS-2092KS-2015Over normal End pressureDF-2092KS-M-501E-E-01912.9Bucketwheel lubrication end pressurePS-2092KS-2016Over normal End pressureDF-2092KS-M-501E-E-01913Anemometer system13.1AnemometerST-2092KS-2002The analog signal of wind speedDF-2092KS-M-501E-E-02213.2Wind direction sensorST-2092KS-2001The analog signal of wind directionDF-2092KS-M-501E-E-02214Belt scale system14.1Belt scale controllerWT-2092KS-2001DF-2092KS-M-501E-E-02414.2Weighting sensorWT-2092KS-2002DF-2092KS-M-501E-E-02414.3speed sensorWT-2092KS-2003DF-2092KS-M-501E-E-0241.3.5 Light For the location of all lights please refer to the drawing DF-2092KS-M-501E-E-055---- ILLUMINATION LAYOUT.1.3.6 Anti fire systemThe wire temperature detectors are set in the cable closet of MCC, it can detect the high temperature of power cable and send the signal to fire fighting system(For detail of fire fighting system please refer to the appendix 3-manual of wire detector and drawing DF-2092KS-M-501E-E-023--- FIRE DETECTER SYSTEM). The terminal connectors are located in CONTROL PANEL +C0A. In case cable temperature in MCC cable room gets too high,the terminal connector will send out alarm signal to fire fightingsystem, fire fightingsystem will automatically send out alarm and start to extinguish fire. SHAPE \* MERGEFORMAT Picture 1.2 Application example of wire temperature detector1.3.7 Vibration management systemSome vibration/temprature detectors are set for important part of machine,it can detect abnormal temperature rise and vibration change. Please refer to the table 1.5 and drawing DF-2092KS-M-501E-E-067--- V/T DETECTOR LAYOUT and DF-2092KS-M-501E-E-029--- ASSET MANAGEMENT DIAGRAM for detail position of sensors. For detail of system, please refer to the manual.Table 1.5 vibration detectorsNO.POSITIONSIGNALSENSOR MODELQUANTITYTAG1BEND PULLEYAccelerometerCMPT23104*6VE-2092KS-3001/3201/3401/3601 TO 3006/3206/3406/3606Accelerometer/Temp.CMPT2310T4*6UE-2092KS-3001/3201/3401/3601 TO 3006/3206/3406/36062TAKE UP PULLEYAccelerometerCMPT23104*2VE-2092KS-3007/3207/3407/3607 TO 3008/3208/3408/3608Accelerometer/Temp.CMPT2310T4*2UE-2092KS-3007/3207/3407/3607 TO 3008/3208/3408/36083BOOM CONVEYOR DRIVE PULLEYAccelerometerCMPT23104*2VE-2092KS-3009/3209/3409/3609 TO 3010/3210/3410/3610Accelerometer/Temp.CMPT2310T4*2UE-2092KS-3009/3209/3409/3609 TO 3010/3210/3410/36104BOOM CONVEYOR DRIVE REDUCERAccelerometerCMPT23104*4VE-2092KS-3011/3211/3411/3611 TO 3014/3214/3414/3614Accelerometer/Temp.CMPT2310T4*2UE-2092KS-3011/3211/3411/3611 TO 3012/3212/3412/36125BOOM CONVEYOR DRIVE MOTORAccelerometerCMPT23104*2VE-2092KS-3015/3215/3415/3615 TO 3016/3216/3416/3616 Accelerometer/Temp.CMPT2310T4*2UE-2092KS-3013/3213/3413/3613 TO 3014/3214/3414/36146SLEWING DRIVE REDUCERAccelerometerCMPT23104*4VE-2092KS-3017/3217/3417/3617 TO 3020/3220/3420/3620Accelerometer/Temp.CMPT2310T4*4UE-2092KS-3015/3215/3415/3615 TO 3018/3218/3418/36187BUCKET WHEEL MOTORAccelerometerCMPT23104*2VE-2092KS-3021/3221/3421/3621 TO 3022/3222/3422/3622Accelerometer/Temp.CMPT2310T4*2UE-2092KS-3019/3219/3419/3619 TO 3020/3220/3420/36208BUCKET WHEEL SHAFTAccelerometerCMPT23104*2VE-2092KS-3023/3223/3423/3623 TO 3024/3224/3424/3624Accelerometer/Temp.CMPT2310T4*2UE-2092KS-3021/3221/3421/3621 TO 3022/3222/3422/36229BUCKET WHEEL DRIVE REDUCERAccelerometerCMPT23104*4VE-2092KS-3025/3225/3425/3625 TO 3028/3228/3428/3628Accelerometer/Temp.CMPT2310T4*2UE-2092KS-3023/3223/3423/3623 TO 3024/3224/3424/36241.3.8 Position and anti-collision systemRedundant encoders are provided for position detecting of travelling (ZT-2092KS-2001/2002), slewing(ZT-2092KS-2003/2004) and luffing(ZT-2092KS-2005/2006). Position signals are communicated to CCR via optical fiber ethernet(the radio is set for spare). CCR can learn the exact position of each machine and calculate the distance between two machines on the same rail, CCR should command the machine to stop, if its distance is within dangerous scope.Two wire type protectors(ZT-2092KS-2051/2052) are also provided along both side of the boom, they can act when boom is going to touch some obstruction. When the boom luffs down, the pile laser detector---( ZS-2092KS-2115) can detect if the boom shall be touching the pile and send the signal to control system to stop the action.1.3.9 Local operation components ?Console deskPicture 1.3 Console deskConsole desk is in operators cabin, arrangement refer to drawing DF-2092KS-M-501E-E-054---LAYOUT OF CABIN. For console top arrangement please refer to Picture 4 and 5 as shown below. Left desk

Picture 1.4 Left desk-JS1201,1301 is joystick for boom luffing and slewing, the symbol is same with that in the circuit diagram. -SB0201,0202 are pushbuttons for main LV power ON/OFF. Right desk

Picture 1.5 Right desk -JS0501 is joystick for long travelling.-SA2401 is turnbutton for rain wiper ON/OFF, -SA2402 is turnbutton for wash sprayer ON/OFF.-SE0202 is emergency mushroom button, when the operator finds danger, he can push it to cut off all power. All other function can be operated or displayed on HMI,Please refer to chapter 4. ?HMIHMI model is ABB PP865, In addition to the founction of joysticks and the buttons above, all operation, monitoring and trouble shooting can be done on HMI, which can also display history record print report and shoot fault etc, the start picture is showed below, for detail please refer to chapter 4.

Picture 1.6 Start picture of HMI1.3.10 Telecommunication system1.3.10.1 CCTVThere are 6 cameras on the machine, all the cameras are controled by CCR via Ethernet, and the pictures are displayed on the screen in CCR, please refer to the picture below. For detail please refer to the manual of CCTV.

Picture 1.7 Scheme of CCTV1.3.10.2 AccessFor the layout of access system, please refer to.DF-2092KS-M-501E-E-053----LAYOUT OF UNDER E-HOUSE.DF-2092KS-M-501E-E-045----LAYOUT OF UPPER E-HOUSE.DF-2092KS-M-501E-E-054----LAYOUT OF CABIN.For detail please refer to the manual1.3.10.3 Communication systemNormally the communication between machine and CCR should be done via optical fiber, the automation systen and telecom system are separated by using different optical fibers. There are two sets of radio on the machine as spare, one for automation and the other for telecom, which should be avaliable in case the optical fiber fails. For detail please refer to the drawing DF-2092KS-M-501E-E-036---PLC AND TELECOMMUNICATION ARCHITECTURE. Main components of communication system ?Switch for automation: Model: RS30-16020606SDAEHC, specification: 16*100Mbit ports, 2*1000Mbit uplink ports(for optical fiber). ?Switch for telecom:Model: WS-C2960-8TC-L, specification: 8*100Mbit ports, 1*1000Mbit uplink ports(for optical fiber). ?Radio setsModel: AIR-LAP1522AG-A-K9?specification: Ethernet TCP/IP, Data transfer rate54Mbps, Operating frequency5.8 GHz1.3.11 Safety protection1.3.11.1 Interlock between different structures? Interlock between drive and brake, all the drives must be started after respective brake opens ? Interlock between Travelling, cable reel, anchor, clamp and boom positionThe anchors and clamps must be open, the cable reel must be started, before travelling starts; the boom must be parallel to rail when the machine travels in high speed.? Interlock between slewing and luffing, when the switch ZS-2092KS-2063----LUFF LEVEL LIMIT SWITCH is available, slewing should be limited to the right part or left part of rail, cant slew across the ground belt(ZS-2092KS-2068---- SLEW ACROSS BELT LIMIT SWITCH should be available, the boom slewing across the ground belt is restricted), if the operator want to slew across the ground belt, he must lift the boom up untill the signal of LUFF LEVEL LIMIT SWITCH is eliminated. ? Interlock between boom belt, Bucketwheel and ground belt.When reclaiming is started, the boom belt cant be started untill the ground belt running; the bucketwheel cant be started untill the boom belt running. If the ground belt is failed to running, the boom belt must stop immediately, and same between boom belt and bucketwheel.1.3.11.2 Process limit ?Long travelling Forward operational LS for travelling----------------------- ZS-2092KS-2053 Backward operational LS for travelling--------------------- ZS-2092KS-2056 ?Slewing Left operational LS of slewing------------------------------- ZS-2092KS-2064 Right operational LS of slewing------------------------------ ZS-2092KS-2066 Slew-across-belt limit switch-------------------------------- ZS-2092KS-2068 ?Luffing Luffing up operational LS------------------------------------- ZS-2092KS-2059 Luffing down operational LS--------------------------------- ZS-2092KS-2061 Luff level limit switch----------------------------------------- ZS-2092KS-20631.3.11.3 Emergency switch ?Boom conveyorEmergency switch---- HSS-2092KS-2001,2002, these wire switches are provided along both sides of belt, when the person on the boom notice danger, he can pull the wire to stop the conveyor immediately. ?Long travelling Left side emergency button station------------- HSS-2092KS-2005 Right side emergency button station----------- HSS-2092KS-2006 Forward emergency LS for travelling----------------------- ZS-2092KS-2054 Backward emergency LS for travelling--------------------- ZS-2092KS-2055 ?Slewing Slewing emergency button station--------------- HSS-2092KS-2007 Left emergency LS of slewing-------------------------------- ZS-2092KS-2065 Right emergency LS of slewing------------------------------ ZS-2092KS-2067 ?Luffing Luffing emergency button station -------------- HSS-2092KS-2008 Luffing up emergency LS------------------------------------ ZS-2092KS-2060 Luffing down emergency LS-------------------------------- ZS-2092KS-20621.3.11.4 Anti-collision protectionAnti-collision detector---- ZT-2092KS-2051/2052, these wire detectors are provided along both sides of boom, when it touchs some obstacle, a signal will be sent to the control system to stop boom slewing.Traveling encoder(ZT-2092KS-2001/2002), slewing encoder(ZT-2092KS-2003/2004) and luffing encoder(ZT-2092KS -2005/2006) respectively detects traveling distance, slewing angle and luffing angle, and sends signal to CCR, centeral control system will determine based on such information if the machine is going to run into any obstacles and send stop order to the reclaimer in advance to prevent accidents. 1.4 Function of working Abbreviation PLC-------------Programmable Logic ControllerHMI-------------Human Machine Interface. A graphical personal computer system providing operator controls, Alarms and status indication. E-House------Electrical SwitchroomLCS------------Local Control Station, which is the individual control station adjacent to each drive or drive system. CCR-----------Central Control Room The discription for the code on all drawing: Function code: =XXXX Position code: +XXXX Component code: ?XXXXTable 1.6System drawing NO.Function codeEnglish descriptionChinese description DX01=HVHigh voltage system??????DX02=LV Low voltage system??????DX03=IL Illuminating system??????DX04=PC PLC control system PLC????DX05=LT Long travel system??????DX06=RCRail Clamp system???????DX07=WHCWheel Clamp system???????DX08=CR Cable reel system????????DX09=DS Dust suppression system????????DX10=LBBSubstructure lubricate system????????DX11=ASBSubstructure auxiliary system????????DX12=SL?RK?Slewing?Rake? system??(??)????DX13=LF?TR?Luffing?Trolly? system??????????DX14=BCBoom conveyor system????????DX15=ICIntermediate Conveyor system????????DX16=BTBelt tension system????????DX17=BWBucket wheel system ??(??)????DX18=TCTripper car system??????DX19=YCLYard conveyor lifting system???????DX20=CMCar moving system????????DX21=CLCabin levelling system?????????DX22=LBPSuperstructure lubricate system????????DX23=ASPSuperstructure auxiliary system????????DX24=WSWashing system??????DX25=AMAnemometer system???????DX26=FRFire Detection system????????DX27=BSBelt scale system???????DX28=CSCommunication system??????DX29=ITVIndustrial TV system??????DX30=ASMAsset management system??????DX31=ASMAccess control system????Table 1.7 Position codeCode NO. of box, console and cabinetFunction code English descriptionChinese description+R1=SRCabin???+R2=SRUpper E-house???????+R3=SRUnder E-house???????????+D1=SRLeft console desk????+D2=SRRight console desk????+C0=SRControl panel???+P1=SRInstrument panel???+C1=SRLV distribute panel?????+C2=SRTraveling driving panel?????+C3=SRAuxiliary driving panel?????+C4=SRSlewing driving panel???????????+C5=SRLV Belt & luffing driving panel???????+C6=SRPLC panelPLC???+C7=SREngineer station?????(PC????)+C8=SRLV Bucketwheel driving panel?????+C9=SRIllumination panel?????+HA01=SRMV income panel?????????+HA02=SRMV distributing panel?????????+HA03=SRMV belt driving panel?????+HA04=SRMV Bucketwheel driving panel?????+HA05=SRMV illumination feeder?????+HA06=SRPower fact compensation?????+MB1=SRMaintenance box?????+MB2=SRMaintenance box?????+MB3=SRMaintenance box?????+GB1=SRMV yard power junction box???????+CB1=SRYard control junction box???????+OB1=SROpital Junction box?????+TEJB=SRLT Encoder Junction box????????+SEJB=SRSL Encoder Junction box????????+LEJB=SRLF Encoder Junction box????????+SL.JB=SRSL Junction box?????+LF.JB=SRLF Junction box?????+LT.JB1=SRLT Junction box 1???????+LT.JB2=SRLT Junction box 2???????+BC.HEAD=SRBC HEAD Junction box???????+BC.TAIL=SRBC TAIL Junction box???????+CL.JB=SRCL Junction box????????+DS.JB=SRDS Junction box?????+CRP.JB=SRCRP Junction box???????+CRC.JB=SRCRC Junction box???????+IL.JB=SRIL Junction box?????+LF.LCS=SRLocal Control Station?????+BC.LCS=SRLocal Control Station?????+BW.LCS=SRLocal Control Station?????+LT.LCS=SRLocal Control Station?????+SL.LCS=SRLocal Control Station?????????+CRP.LCS=SRLocal Control Station???????+CRC.LCS=SRLocal Control Station???????+RC.LCS=SRLocal Control Station??????+YCL.LCS=SRLocal Control Station?????+DS.LCS=SRLocal Control Station?????+IL.LCS1=SRLocal Control Station???????+IL.LCS2=SRLocal Control Station???????+LF.LES=SRLocal emergency station??????+BC.LES=SRLocal emergency station??????+BW.LES=SRLocal emergency station??????+LT.LES1=SRLocal emergency station????????+LT.LES2=SRLocal emergency station????????+SL.LES=SRLocal emergency station??????+YCL.LES=SRLocal emergency station??????+R2.LES=SRLocal emergency station???????+R3.LES=SRLocal emergency station???????+LF.HB=SRLF Hydraulic box???????+YCL.HB=SRYCL Hydraulic box?????+CL.HB=SRCL Hydraulic box???????+RC.HB1=SRLeft RC Hydraulic box????????+RC.HB2=SRRight RC Hydraulic box????????+BW.HB=SRBW Hydraulic box???????+BW_CH.HB=SRBW chute Hydraulic box??????????+IC_CH.HB=SRIC chute Hydraulic box??????????+CT_CH.HB=SRCenter chute Hydraulic box?????????CHAPTER 2 SAFETYCONTENTS TOC \o "1-3" \h \z \u HYPERLINK \l "_Toc257733363" 2.1 General description PAGEREF _Toc257733363 \h 3 HYPERLINK \l "_Toc257733364" 2.2 Items to be complied with and forbidden PAGEREF _Toc257733364 \h 3 HYPERLINK \l "_Toc257733365" 2.3 Definition and position of warning signs and warning labels PAGEREF _Toc257733365 \h 3 HYPERLINK \l "_Toc257733366" 2.3.1 Definition of signs and labels PAGEREF _Toc257733366 \h 3 HYPERLINK \l "_Toc257733367" 2.3.2 Positions for hanging indication and sign PAGEREF _Toc257733367 \h 3 HYPERLINK \l "_Toc257733368" 2.3.3 Symbols for instruction reader PAGEREF _Toc257733368 \h 3 HYPERLINK \l "_Toc257733369" 2.4 Indication of hazardous areas and cautions for entering such areas PAGEREF _Toc257733369 \h 3 HYPERLINK \l "_Toc257733370" 2.5 Notes for safe operation PAGEREF _Toc257733370 \h 3 HYPERLINK \l "_Toc257733371" 2.6 Notice before operation PAGEREF _Toc257733371 \h 3 HYPERLINK \l "_Toc257733372" 2.7 Safety notice during operation PAGEREF _Toc257733372 \h 3 HYPERLINK \l "_Toc257733373" 2.8 Safety notice when operation is finished PAGEREF _Toc257733373 \h 3 HYPERLINK \l "_Toc257733374" 2.9 Other safety notice and measures PAGEREF _Toc257733374 \h 3

SAFETY2.1 General descriptionThe safety content specified in this part is to ensure equipment and personal safety, so as to realize safe production. During operation of the equipment, in addition to the terms listed by such specification, the regulations specified by the national law and regulations related to the equipment also must be complied with. Using, checking and servicing of the electrical devices on the equipment must comply with requirement specified in law and regulations of corresponding trade.2.2 Items to be complied with and forbiddenCompanies undertaking site installation and commissioning and end user should comply with the following items:Only personnel who have received proper training of reclaimer operation and understand basic safety and accidental prevention specification are authorized to operate this equipment. Operators must be professionals who have been trained and passed the examination. Other unauthorized people should stay away from the equipment and installation area. and professional may operate the equipment only when it is necessary for the job and should strictly follow all operation procedures.Only personnel who have relative knowledge on safe operation of equipment and have read and understood the safety regulations and warning notes in this documents are authorized to work on reclaimer. Other unauthorized people should stay away from the equipment and installation area.This equipment is to be operated by professional operators, either in mode of onboard operation and remote operation. Therefore without permission, no one should stay in the perimeter of the equipment, even when the equipment is not in operation, because the equipment may start and operate at any time.During installation, commissioning, and operation, unauthorized people should stay away from the equipment and equipment working area.For the authorized personnel working on reclaimer, the end user and installation and commissioning company will provide necessary safety protection equipment (safety helmet, safety harness, working suit, gas mask, special protection equipment, etc.), and provide special instructions.Personnel working on the reclaimer should comply with the requirement and put on safety protection equipment, the best is do not ware long hair (long hair is to be done up) and do not ware loose suits or jewelries, because these items may easily caught up by the equipment and result in personal injury. End user and installation and commissioning company should check from time to time if their workers comply with safety operation regulations.End user and installation and commissioning company should ensure safety documents are always stored on the reclaimer for reference on occasions. End user and installation and commissioning company should provide instructions about laws and other accident prevention and environmental protection safety specifications to be followed (e.g. Specifications for handling hazardous materials, etc.).End user and installation and commissioning company should supplement the documents with other internal instructions of the company(e.g. Supervision and reporting function, factory features, working organization, working cycles, employed personnel, etc.). Regularly check if all safety devices are installed correctly and in proper working condition.During operation of the equipment, it is forbidden to stay within the following dangerous area: areas within reach of the boom; front of the equipment; material transit area; belt conveyor area. Under the following condition, the safety devices may be dismantled: after confirming power for the mechanism is shut down; when taking appropriate measures, the reclaimer is sure not to have accidents again; being maintenance or serviced by trained professionals; all existing safety devices must be regularly checked.Do not take fire lightly, it may happen occasionally. Make sure fire extinguishers are provided in inflammable area, and working personnel onboard must exactly know the position of fire extinguisher (operators cabin, electric room, hydraulic room, and hydro-chamber).Make sure reclaimer is in safe condition and at good technical level, which are the basic conditions for safe operation, make sure all safety equipment and devices (safety protective device, safe position limit, emergency stop pushbutton, sound damper, explosion proof facilities, etc.) Are in normal mounting position and running normally before the reclaimer is allowed to be started.Before starting reclaimer, make sure no one is likely to be hurt when reclaimer is started and running.Check external hazards warning indications?and safety devices are working normally, at least once a day.Any potential changes, including change of operation situations, should be immediately reported to responsible person of respective sections. If necessary, immediately stop the machine and protect the reclaimer (e.g. Shut off main switch or push down emergency stop switch, etc.).In case of fault, immediately cut off main switch of the reclaimer, and take proper measures to prevent reconnection of reclaimer main switch, immediately eliminate the fault.Comply with specification in the document; follow switching procedures of indicator lights and indicator, etc.After starting the controller, keep hands away from all switches or pushbuttons, lest pushing causes mal-operation. During normal operation of the reclaimer, do not turn on any safety devices.Installation, commissioning, maintenance, etc. of the electrical equipment of the reclaimer should only be done by qualified electricians, or by personnel who have received proper training under the supervision of a qualified electrician, according to electrical engineering specification and regulation.Regularly check electrical equipment of reclaimer, tighten all loose connections, and replace any aged or damaged cable.Always keep electrical cabinet locked and only authorized personnel with keys or relevant tools may open the electrical cabinet. Certified fuse product with appropriate ampere must be used.In case of power failure or power outage, immediately shut off mains control box of the reclaimer.Before making service, maintenance or repair work to equipment components, the components must be discharged. First use electrical instruments to check if the components have finished discharging, then earth it and short circuit it, to separate with adjacent electrified components.Working on electrified components is fatal. If it is a must, then there must be the presence of another person, and in case of emergency, this person should press down emergency shutoff switch or cut off main switch, to shut down power. The working area should be enclosed by warning line and warning sign must be provided. Insulated tools must be used for operation.For carrying out installation and maintenance, shop should be provided with relevant tools necessary for the work.Timely make specified adjustment, maintenance and service to the equipment, which should be done by qualified personnel.Before commencing any service or repair work, operator must be noticed and one supervisor appointed for the work.During maintenance, service and repair, power supply for the reclaimer should be cut off and proper measures taken to ensure no mal-operation will reconnect the power. Procedures as below:lock main control device, take away the key to be kept by the personnel doing maintenance or repair.if due to some reasons the main control device can not be locked, the main switch and emergency cutoff switch should be cut off, with warning signs provided at both switches. at necessary positions, warning line should be used to enclose the maintenance area.If it is necessary to mount or replace single component or large item, it must be carefully tied to appropriate lifting equipment and protected to ensure no danger will happen. It is a must to use suitable lifting equipment and tools and ensure they have enough load carrying capacity and are in good technical condition. It is not allowed to stand below the lifted item or to work under the lifted goods. The specified lifting equipment in installation manual must be used for lifting up goods.The goods must be tied by experienced person, and instructions are sent to crane driver. The person giving instructions must be able to see the operator or must be able to get in contact with the operator.When doing mounting work in the air, ladders, platforms and other climbing tools should be used to ensure safety. It is not allowed to climb onto components or equipment. During assembly or inspection, proper measures should be taken to protect the installed or dismantled components and tools to prevent it from falling.If it is necessary to remove safety device/safety equipment in order to carry out installation, maintenance or repair, then the safety device/safety equipment must be reinstalled as soon as the maintenance or repair work is finished, also must check if they are in good working condition. make sure all loosened bolts connections are retightened; make sure the consumables and replaced items are handled in proper and safe situation; protect the switches and control devices to prevent from influence by water or dust;it is mandatory to use tools of qualified performance, appropriate tools and under some circumstances specified tools (such as electrical installation tools, etc.);all rotating or open components may cause dangers of crushing or jamming, so special attention should be paid; tools or other external materials should not be stored on the equipment.Due to danger of fire and explosion, it is only allowed to weld, flame cut or grind on the reclaimer when there is definite requirement for it, and with approval of safety department and monitoring by safety personnel. Before making any welding, flame cutting or grinding, clean the reclaimer and its adjacent area, remove all scale or inflammable material, and keep good ventilation. During welding work, earthing must be directly connected to the welding position; otherwise electrical component may be damaged. For working in narrow areas, current national laws and regulations should be complied with.When handling oil, glycerol and other chemical materials, pay attention to the current safety regulation and requirement of the product.2.3 Definition and position of warning signs and warning labels2.3.1 Definition of signs and labelsDuring installation, commissioning and operation of the reclaimer, some positions are necessary to put on relative warning signs and attention labels in order to prevent safety accidents, symbols and definitions refer to table 2.1. Table 2.1 Symbols and definitions of warning signs and attention labels A sign that safety helmet must be worn, and if not followed, head or other part of the body may have danger of bruising or scuffing by fallen items from height, or by equipment edges or corners, in serious cases may jeopardize life. A sign that working suit must be worn, and if not followed, clothes may burn, leak or be scraped, other part of the clothes may have danger of being sucked in by rotating parts, in serious cases may jeopardize life. A sign that flame is forbidden, and if not followed, surrounding flammables may catch fire, equipment or person may be hurt, in serious cases may jeopardize life and damage equipment. A sign that flame is forbidden, and if not followed, surrounding flammables may catch fire, equipment or person may be hurt, in serious cases may jeopardize life and damage equipment. A sign that touch is forbidden, indicating no direct or indirect contact with item is forbidden, and if not followed, there will be danger of electric shock, liquid corrosion, burning, sucked in by rotating part, or scuffed by such items, etc., in serious cases may jeopardize life and damage equipment. A sign that passing through is forbidden, indicating such area is dangerous, and if not followed, there will be potential personal injury, in serious cases may jeopardize life. A sign that safety should be noted, the appearance of such sign means there are danger or possibility to have danger in such area or during operation process, and if not followed, there will be danger that equipment or person may be hurt, in serious cases may jeopardize life and damage equipment. A sign that falling should be noted, and if not followed or not careful, there will be danger of falling from platform, handrail, high level platform, in serious cases may jeopardize life. A sign that fire should be noted, indicating the area or articles are possible to catch on fire, and if not followed, there will be fire, and in serious cases may jeopardize life and damage equipment. A sign that electric shock should be noted, indicating the area or articles are possible to be electrically charged or leaking, and if not followed, there will be electric shock, causing equipment short circuit and personal injury, and in serious cases may jeopardize life and damage equipment. A sign that corrosion should be noted, indicating the articles are possible to corrode equipment, human body, environment, etc., and if not followed or noted, there will be possibility of equipment damage, personal injury, and environment pollution, and in serious cases may jeopardize life and damage equipment. 2.3.2 Positions for hanging indication and signPositions for hanging indication and sign refer to table 2.2, and indication and sign should be provided by Installation Company or end user. Table 2.2 Positions for hanging indication and signs Indication and signsDescription Hanging position Ware safety helmet, wear working suitAll stairs entry to the reclaimer Caution of falling, note safetyBy the edge of all platform, passage and handrail No flame, no smokingOperators cabin Note safety, caution of fireElectric room Caution of electric shock, no touching High temperature and inflammable, caution of corrosionHydraulic room Caution of electric shock, no through passingAll stairs entry to power supply devices No through passingUnfinished areas such as platform and handrail, lifting area, mechanism moving area and passage area where component assembly is carrying on overhead, etc., and use warning line to isolate. 2.3.3 Symbols for instruction readerThis instruction will include the following symbols, please learn carefully about the definition and purpose of all indication symbols, see table 2.3. Table 2.3 Definition and purpose of indication symbolsIndication symbols Definition Appearance of such symbols indicates there are important content to warn relevant people, if not followed it may result in installation fault, equipment damage during equipment installation, commissioning, operation and maintenance, and in serious cases injury or death may happen. Appearance of such symbols indicates there are important content to warn relevant people, if not followed it may result in equipment damage or personal injury during equipment installation, commissioning, operation and maintenance. Appearance of such symbols indicates there are important content to warn relevant people, if not followed it may result in major equipment damage or personal injury accident during equipment installation, commissioning, operation and maintenance. Appearance of such symbols indicates there are proposing content to warn relevant people, if not followed it may result in unsatisfactory operation of equipment, improper maintenance, untimely service, etc. 2.4 Indication of hazardous areas and cautions for entering such areasPersonnel authorized to work on reclaimer must know about the hazardous areas of the equipment, learn by heart the location of such areas to prevent personal injury. Hazardous areas of the reclaimer see table 2.4. Table 2.4 hazardous areas of the reclaimerHazardous areas Location Cautions to prevent dangerPotential injuryBelt conveyorNotice operating belt conveyorSlewing deviceNotice operating slewing deviceLuffing deviceNotice operating luffing deviceTraveling deviceNotice operating traveling devicePotential falling dangerAll stairs to the equipmentHold on handrail tightEdge of all platforms close to handrail Never extend your body out over top of the handrail Potential jammingMaterial transmit areaNo entry into such area during operationPotential electric shockingTransformer room, inside electric cabinet in electric room, external electric components No touching of electric components Potential dust explosionMaterial transmit areaNo welding allowed during operation, no smoking and flame allowed in the periphery, maintenance only allowed after thoroughly clean the dust and keep ventilation. Inflammables existsInside hydraulic room(if use flammable hydraulic oil) No smoking and flame allowed regularly check wire for ageing signs. Around lubrication pumpNo smoking and flame allowed regularly check wire for ageing signs. 2.5 Notes for safe operationOnly personnel with relevant operation qualification are allowed to operate this reclaimer.If current for traveling, slewing, luffing and belt conveyor are obviously larger than normal value, relevant leader should be reported to timely.In case of abnormal situation of reclaimer (such as intense vibration, operator in the operators cabin can feel apparent vibration),operator should notice service personnel to find out the reason after finishing this operation cycle, to determine if the problem is electrical, mechanical or hydraulic issue.In case of the following situations, the reclaimer operator must immediately report to his manager, to get it handled by service people: Severe vibration, complete machine power outage and switch tripped, luffing goes down by itself, reclaimer slides off in stopped state, etc.Do no push down emergency stop pushbutton at will unless in special situation. No people other than operators are allowed to go aboard the reclaimer before permitted by the onboard operator.Accessing and alighting from the reclaimer are only allowed when reclaimer is in idle state.Operator should not let irrelevant people go aboard the reclaimer.In case of major fault of reclaimer, no one is allowed to operate the reclaimer before the fault is eliminated, and the reclaimer should be in a locked status.Requirement for electrical service people:It is forbidden to operate with out qualification or service by people without full scale professional training, and service must be done by professional technicians.It is forbidden to short circuit with power switched on.It is forbidden to use megohmmeter to directly measure insulation on thyristor /IGBT. Before touching circuit board, personnel should discharge to earth to prevent static electricity from damaging circuit board.Only when operator has confirmed all power supply and signal indications are normal, can reclaimer operation be carried out.It is forbidden for personnel without HV operation certificate to service or maintain on HV electrical equipment such as HV transformer, HV switchgear, etc., otherwise it may cause personal injury, death and equipment damage.All rectifier, inverter and relevant equipment must be earthed.It is forbidden to service rectifier and inverter with power switched on. If fault searching involves internal structure of modules, motor or motor cable, then main power must be cut off for at least five minutes, until intermediate circuit capacitor has finished discharging before making operation on converter, motor or motor cable. It is the best to check if converter has finished discharging before conducting work (use voltmeter).When main power is switched on, no matter the motor is running or not, the VF motor cable terminals are always with dangerous high voltage.When main circuit of converter is cut off, inside converter, dangerous voltage from external control circuits still exists. Great prudence and attention should be paid during operation. Otherwise neglecting these safety instructions would cause personal injury or death.Do not make any measure, change of spares or other service work other than those referred to in converter manual.2.6 Notice before operation Check reclaimer traveling rail and ground make sure there are no obstacles.Check drive part for any obstacles, check fastening of brake, coupling, etc., brake should make good braking. Check reclaimer track: if that the track is level and normal, ground brush is good.Check if metal structure and all mechanisms are normal, check if there are loose bolts, nuts fallen on the platform. Check lubrication of reclaimer, check if hydraulic pipeline leaks oil. Check if reclaimer is interlocked with central control. Check if switches and joysticks of all electrical devices are at normal position. Check if reclaimer initial position status information is correct.Check if reclaimer power voltage is normal, if voltage exceeds normal value by10??the machine must be stopped.Only when it is sure the reclaimer is in normal status before the machine can be started for operation.2.7 Safety notice during operationDuring normal operation it is not allowed any people (including operators) to be at reclaimer track, belt conveyor, stockyard, if there is any one, all operation must be stopped to prevent personal injury accident.Under any circumstances, operator must pay special attention to warning system, to prevent damage of equipment. Before start reclaimer traveling, operator must send out photo acoustic alarm signal and real time warning.Even when belt conveyor, slewing and traveling operation are in automatic operation mode, the operator should also carefully observe the operation status.2.8 Safety notice when operation is finishedWhen finishing operation, operator should make sure of the position of long travel, slewing angle, luffing angle before cutting off main switch, and in addition to that, cut off motor power as necessary. Before operator leaving reclaimer, the machine must be stopped, and all tasks to be done for stopping of the machine must be properly done, operator should make proper operation log and other records.When stopping the machine under normal situation, reclaimer should be parked at a position that boom is parallel to the track. Properly shut the door and windows of hydraulic room, electric room, operators cabin and turn off illuminating light.If without hydraulic system warning and oil cylinder speed has obvious change, the system should be stopped after this cycle of operation and service people for hydraulic system should be requested to come to site to check and only after problem has been dealt with before restarting of the equipment is allowed.2.9 Other safety notice and measuresDuring operation, the operator should follow instruction of central control room personnel and the interlocked information of central control room. Only when especially emergent situation happens at site, can operators take relevant measures based on specific situation.Overloading during commissioning is only a testing operation, and carried out with all preparations, so it does not mean the machine can be overloaded during operation. In case of overloading at any mechanisms, operation should be stopped in time, and only when fault has been dealt with and situation is normal before operation can be continued.When safety limit switch of a mechanism is loose, technicians should be requested to deal with the accident immediately to find out fault reason and only after fault has been eliminated before the fault signal is by-passed by the bypass switch installed in control cabins of all mechanisms, and restart power, move the fault mechanism in opposite direction, to move out of safety limit switch activating area, then reset the bypass switch and resume normal operation.During operation the operator should always pay attention to abnormal phenomena such as abnormal noise, vibration and heating, etc., in case of such abnormal phenomena happening, operation should be immediately stopped and reason is to be found out before making any relevant handling or operation.The operation limit switch of reclaimer is to ensure safety, during operation, the operator should not only use limit switches to control movement of mechanisms, but to stop movement before the mechanism arrives at finish position. After the mechanism moves into deceleration area, operator should put joystick to low speed position to prevent failure of deceleration from causing fault. Operator should not leave operation position when reclaimer is in operation.During operation of reclaimer, it is not allowed to fill oil, make adjustment, repair or carry out cleaning and service work. Only after power switch is cut off, can electric equipment be serviced, and signs warning do not switch on should be hanged at the switch. It is not allowed to make separate movement of reclaimer without the permission of central control interlocking information; otherwise it would cause major accidents. Reclaimer must be immediately stopped in case of fault. When reclaimer is in operation at night, the outdoor illuminating lamp should be turned on.CHAPTER 3 INSTALLATION,COMMISSIONINGCONTENTS TOC \o "1-3" \h \z \u HYPERLINK \l "_Toc258479334" 3.1 Installation conditions and technical requirement PAGEREF _Toc258479334 \h 3 HYPERLINK \l "_Toc258479335" 3.1.1 Inspection before installation PAGEREF _Toc258479335 \h 3 HYPERLINK \l "_Toc258479336" 3.1.2 Cable reel PAGEREF _Toc258479336 \h 3 HYPERLINK \l "_Toc258479337" 3.1.3 Installation requirement for electrical control cabinet and junction boxes PAGEREF _Toc258479337 \h 3 HYPERLINK \l "_Toc258479338" 3.1.4 Installation requirement for field instrumrnts and limit switchs PAGEREF _Toc258479338 \h 3 HYPERLINK \l "_Toc258479339" 3.1.5 Technical requirement for resistor installtion PAGEREF _Toc258479339 \h 3 HYPERLINK \l "_Toc258479340" 3.1.6 Wire, cable and laying requirement PAGEREF _Toc258479340 \h 3 HYPERLINK \l "_Toc258479341" 3.1.7 Laying of wire conduit and cable tray PAGEREF _Toc258479341 \h 3 HYPERLINK \l "_Toc258479342" 3.1.8 Protection earthing requirement PAGEREF _Toc258479342 \h 3 HYPERLINK \l "_Toc258479343" 3.1.9 Limit switch PAGEREF _Toc258479343 \h 3 HYPERLINK \l "_Toc258479344" 3.1.10 Lighting equipment PAGEREF _Toc258479344 \h 3 HYPERLINK \l "_Toc258479345" 3.1.11 Other electrical equipment PAGEREF _Toc258479345 \h 3 HYPERLINK \l "_Toc258479346" 3.2 Installation procedure, method and cautions PAGEREF _Toc258479346 \h 3 HYPERLINK \l "_Toc258479350" 3.2.1 Assembly of electrical equipment PAGEREF _Toc258479350 \h 3 HYPERLINK \l "_Toc258479385" 3.2.2 Fixing of electrical equipment PAGEREF _Toc258479385 \h 3 HYPERLINK \l "_Toc258479386" 3.2.3 Fixing of cable and wire conduit and laying of cable in cable tray and metal conduit PAGEREF _Toc258479386 \h 3 HYPERLINK \l "_Toc258479387" 3.2.4 Earthing PAGEREF _Toc258479387 \h 3 HYPERLINK \l "_Toc258479388" 3.2.5 Wire and cable connection PAGEREF _Toc258479388 \h 3 HYPERLINK \l "_Toc258479389" 3.2.6 Wiring inspection and insulation test PAGEREF _Toc258479389 \h 3 HYPERLINK \l "_Toc258479390" 3.2.7 Drawing and document for installation PAGEREF _Toc258479390 \h 3 HYPERLINK \l "_Toc258479391" 3.2.8 Installation and acceptance requirement PAGEREF _Toc258479391 \h 3 HYPERLINK \l "_Toc258479393" 3.3 Commissioning condition, cautions and commissioning method PAGEREF _Toc258479393 \h 3 HYPERLINK \l "_Toc258479394" 3.3.1 Commissioning condition PAGEREF _Toc258479394 \h 3 HYPERLINK \l "_Toc258479395" 3.3.2 Cautions PAGEREF _Toc258479395 \h 3 HYPERLINK \l "_Toc258479396" 3.3.3 Commissioning method PAGEREF _Toc258479396 \h 3 HYPERLINK \l "_Toc258479397" 3.3.3.1 Commissioning preparation PAGEREF _Toc258479397 \h 3 HYPERLINK \l "_Toc258479398" 3.3.3.2 Circuit test PAGEREF _Toc258479398 \h 3 HYPERLINK \l "_Toc258479399" 3.4 Items, method and criterion of acceptance test after commissioning PAGEREF _Toc258479399 \h 3 HYPERLINK \l "_Toc258479400" 3.5 Preparation before test run, start of test run and test run PAGEREF _Toc258479400 \h 3 HYPERLINK \l "_Toc258479401" 3.5.1 Preparation before test run PAGEREF _Toc258479401 \h 3 HYPERLINK \l "_Toc258479403" 3.5.1.1 Power system PAGEREF _Toc258479403 \h 3 HYPERLINK \l "_Toc258479404" 3.5.1.2 Hydraulic system PAGEREF _Toc258479404 \h 3 HYPERLINK \l "_Toc258479405" 3.5.1.3 Lubrication system PAGEREF _Toc258479405 \h 3 HYPERLINK \l "_Toc258479406" 3.5.1.4 Initial position of all systems PAGEREF _Toc258479406 \h 3 HYPERLINK \l "_Toc258479407" 3.5.2 Start of test run, test run PAGEREF _Toc258479407 \h 3

INSTALLATION,COMMISIONING3.1 Installation conditions and technical requirementThis section only gives general requirement for installation of electrical equipment of reclaimer. For some electrical equipment with special requirement, refer to additional drawing and electrical system instruction delivered with machine.3.1.1 Inspection before installationa) Clean and remove dirt and defects from electrical equipment and components, replace damaged parts and components;b) All movable parts and components should move freely without jamming, sticking or loosing phenomenon;c) All wiring fasteners are complete, and wired screws should be tightened;d) Nonmetal part of electrical equipment installation fasteners, structures, steel pipe and joint, connecting parts, electricity conducting device, supports, etc. Should all be galvanized or coated for corrosion prevention or galvanized product should be used.3.1.2 Cable reelPower supply of this machine is fed on board by flexible cable through cable reel, cable reels are provided on the platform of the tripper car, and interlocked with travel drive device. Cable reels include two sets, one is power cable reel and the other is control cable reel, both are magnetic hysteresis type, for detail usages see cable reel instruction. A) Arrangement, installation and connection of cable reel assembly should follow design drawing.B) Installation of cable reel should comply with the above mentioned regulations, and in addition, HV cable should make withstand voltage test before connection and installation and should company with relevant specification of current issue of electrical equipment handover test standard for electrical device installation project.3.1.3 Installation requirement for electrical control cabinet and junction boxes A) Installation of control cabinet (panel) should comply with relevant specification of VALEB) Control cabinet (panel) should be installed inside electric room and operators cabin according to mechanical arrangement drawing. C) Installation of control cabinet (panel) should be secure and reliable, to minimize its vibration during equipment operation, and if necessary, bracing should be added. Screen of control cabinet (panel) should have verticality error less than 12.D) use 500V megohmmeter (working voltage?48V) or 250V megohmmeter (working voltage