bucket wheel excavator vabe 400 typical tec

VV AA MM HH Technical Specification Bucket Wheel Excavator VABE 400

BucketWheelExcavator-VABE-400-Typical-TechnDescription-Rev0 30/10/2006 Revision: 0

TECHNICAL SPECIFICATION

BUCKET WHEEL EXCAVATOR

Type VABE 400

VOEST-ALPINE

Materials Handling G.m.b.H.&Co.KG

P.O. Box 2

Alpinestraße 1

A-8740 Zeltweg

AUSTRIA

Phone: +433577755-Ext.

Fax: + 43 3577 756 339

e-mail : [email protected]



Part 1 General Part 2 Technical Description of Mechanical & Structural Assemblies Part 3 Technical Data Part 4 Technical Specification of Electrical Equipment Part 5 General Layout Drawing



Table of Contents

1.1 General 6

1.2 General Design Data 7

2.1 Bucket wheel with Drive 10

2.2 Undercarriage and Crawlers 11

2.3 Superstructure and Turntable 12

2.4 Bucketwheel Boom 13

2.5 Discharge Boom 14

2.6 Operator's Cabin, Control Desk and Transformers 15

2.7 Power Transmission, Electric’s, Control 16

3.1 General 18

3.2 Bucketwheel with Drive 19

3.3 Superstructure and Bucketwheel Boom 21

3.4 Bucketwheel Boom 23

3.5 Luffing Arrangement for Bucketwheel Boom 23

3.6 Discharge Boom 23

3.8 Conveying Line 25

3.9 Crawlers and Undercarriage 28

3.10 Lubrication 28

3.11 Miscellaneous 29

3.12 Power Supply 29

3.13 Motors, Quantity and Rated Power: 30

4.1 General Information 32

4.2 Power Supply and Distribution 34

4.3 Drives 35

4.4 Power Transformer 37

4.5 High-Voltage Switchgear 37

4.6 Resistance Banks 38

4.7 Low-Voltage Switchgear 38



4.8 Local Devices 38

4.9 Signalling System 38

4.10 Operator's Cab Equipment 40

4.11 Miscellaneous Equipment 41

4.12 Lighting 43

4.13 Communication 43

4.14 Slipring Assembly 43

4.15 Cables and Installation Material 44

4.16 Automatic Control System 44

5. General Arrangement Drawing 47



Part 1

General



1.1 General

(a) The bucket wheel excavator will be used to unload copper ore from leaching pads

discharging to a crawler mounted horizontal conveyor (supplied by others). The machine will excavate copper ore at an theoretical capacity of 2000 lm³/h (3000 t/h) or 1450 m³/h (2200 t/h) effective rate (max. density = 1.5 ton/m³ for power calculations). The resulting peak capacity will be kept to a minimum.

(b) The bucket wheel excavator will excavate the copper ore in piles of 7 m in height on

a leach pad system. (c) The machine design includes automatic functions wherever possible / feasible.

Automation is documented in sufficient detail for evaluation of the operational advantages of the offered features.

(d) The equipment is designed to obtain the highest possible degree of standardisation and

interchangeability with respect to the other equipment specified. It is our target that such standardisation cover the complete electrical equipment including motors, couplings, brakes, brake actuators, bearings, plummer blocks and slewing rings. Particulars and feasibility of the above will be elaborated and agreed upon in Contract meetings.

(e) A sketch of the bucket wheel excavator is attached in Part 5



1.2 General Design Data (a) The BWE runs on crawlers. It mainly consist of the complete undercarriage and travel

gear, the slewing assemblies, the superstructure, the bucket wheel boom with bucket wheel, the discharge conveyor, the luffing equipment, the counterweight boom and the complete electrical installation.

(b) Bucket wheel and discharge booms have separate slewing and luffing action. The height

adjustment of the discharge boom will be designed to suit the transfer parameters of the horizontal conveyor and the following grasshoppers.

(c) Transfer points will be designed in such a way that material transfer with minimised spillage

will be ensured and plugging under normal conditions is prevented.

(d) The entire machine will be easily accessible through staircases and walkways so that supervision and maintenance as well as necessary repairs can be easily executed. All parts of the structure including platforms are to be provided with sufficient and effective drainage facilities.

The BWE will be supplied with electric power by hook-up connection from the cable reel of the cable reel car running on the horizontal conveyor.

(e) The maximum operational wind speed will be 72 km/hour, serving as the basis for

structural design. A wind velocity of 130 km/hour has been considered for the out-of-operation load case. Earthquake activity is considered for equipment design as far as applicable.

(f) As a minimum the following design parameters will apply: Copper leach pad height 7 m Side slope 60 -65 degrees Face slope 65 degrees Deep-cut below level - 0.5 m Outreach of bucket wheel boom 8.5 m Length of discharge boom 15 m Grade ability in operation 1:20 in transit 1:10



Average ground pressure based on operating weight 100 kpa Slewing range of superstructure related to undercarriage 360 ° Slewing range of discharge boom related to superstructure +/- 105 ° (g) Lighting as specified in this specification for the bucket cutting area will be provided to

permit adequate illumination during night operation.



Part 2

Technical Description of

Mechanical & Structural Assemblies



2.1 Bucket wheel with Drive (a) The bucket wheel will be designed as a cell-less type with suitably connected shaft

arrangement. The bucket wheel shaft will be supported by spherical roller bearings. (b) The drive of the bucket wheel will be effected by electric motor, gearbox arrangement. A

safety coupling (a turbo coupling and an electric overload protector) will be provided between gearbox and motor to prevent overstrain of the bucket wheel gear and separate the flux of forces from the motor to the gear if 1.4 motor momentum is exceeded.

(c) The buckets will be designed with exchangeable cutting tools. (d) The digging teeth are fastened to the buckets in a way which will permit easy and rapid

replacement and which will not loosen during operation. The external rims of the bucket wheel body will be protected by exchangeable wear bars and the bucketwheel chute and ring chute by exchangeable wear places.

(e) The bucket design will provide for continuous cleaning of the buckets during wheel rotation. (f) Considering the material properties, the peripheral speed at the cutting circle of the bucket

wheel will not exceed 75 percent of the critical peripheral speed. (g) The bucket wheel ring chute will prevent preliminary discharge and undue spillage of the

material and will cover a minimum part of about 1/3 of the full bucket wheel running circle from fill to discharge points of the buckets.



2.2 Undercarriage and Crawlers (a) The undercarriage of the BWE will be sufficiently strong and of rigid design. The machine

will be supported by a two-crawler travel arrangement.

The actual bearing surface of the crawler chain, related to the operational machine mass, permits sufficient area contact to ensure that the specified permissible ground pressure of 120 kpa will not be exceeded.

The crawlers are to be equipped with a number of travel rollers in accordance with the load requirements and at chain support saddles in the upper part. The travel rollers are mounted in two wheel bogies to permit some flexibility and equal load distribution.

The crawler frames will be straight, torsion free structures. The crawlers are equipped with a suitable take-up for the crawler chain.

(b) The tension device for the crawler chain will be dimensioned in such a way that in case of

wear in the links of the crawler chain one link can be removed. (c) Lubrication of the crawlers will be effected by central lubrication and life-time lubrication. (d) Each crawler is equipped with a drive arrangement. The crawler drives will be protected

against spillage by covers. Dismantling of bogies and wear elements will be possible by simple means.

(e) For travelling on inclined surface, safe braking of the crawlers must be provided. A ground

clearance of at least 600 mm will be maintained. A turning radius of 10 m will not be exceeded.

(f) Travel speed will be 8 m/min. Interlocking between the BWE and hopper car will ensure

synchronised travel of the various equipment combinations.



2.3 Superstructure and Turntable (a) The superstructure will be of a strong plate design and rigidly stiffened. The basic part will

be the main turntable with firmly connected frame and counterweight boom. The turntable will be supported on the undercarriage by a slewing ring assembly. The slewing drive will consist of two (2) independent drive units. The slewing gear drives are mounted on the superstructure with pinions meshing into the gear rim mounted on the undercarriage.

(b) The slewing gear drives will be equipped with a safety coupling or equivalent which stops

all drives if inadmissible high lateral forces occur. The slewing speed will be indefinitely variable. The slewing ring assembly will be designed for equipment life and suitable lubrication arrangement. Effective protection against contamination will be provided.

(c) The control of the slewing drive will be via AC motor with VVVF control. (d) A separate slewing arrangement for the discharge boom is arranged on top of the main

turntable to permit independent movement of this unit. (e) The counterweight boom will have a rigid connection to the rear end of the turntable. It will

consist of the structure, carrying the counterweight box, electric compartments and transformer. Free movement against the discharge is insured.

(f) The frame, providing the support of the bucketwheel boom, the transfer chute and the

suspension for the discharge boom will be mounted to the front end of the turntable. It will be of a torsion-strong design.



2.4 Bucketwheel Boom (a) The bucketwheel boom will be of rigid design with suitable cross bracings to prevent

torsioning. The boom is mounted by shaft connection and hinge bearings to the machine frame. Mounting provisions for the bucketwheel, the bucketwheel drive and the chute arrangements at the front end of the boom are provided.

The bucketwheel boom has a hydraulic luffing arrangement. The hydraulic system is

equipped with check valves or other suitable safety features to prevent a sudden drop of the boom in case of pressure loss or oil leakage.

The transfer end of the conveyor will be provided with a sufficiently strong baffle plate in

order to direct the material stream with minimum spillage to the discharge conveyor. (b) All chutes will be equipped with exchangeable wear plates. (c) The conveyor will have suitable drive arrangements with fluid couplings and brakes or

holdbacks. The drives will be preferably motor-gearbox arrangements mounted on a common base with torque arrester. Flange couplings are used to connect pulleys to gearboxes.

(d) A primary and secondary scraper will be provided at the discharge pulley. A plough scraper

will be installed in front of the return pulley. (e) An electric driven conveyor belt aligner will be provided. The control of the devise will be

from the operator’s cab. (f) Strong overflow guards will be provided along the bucket wheel boom conveyor.



2.5 Discharge Boom (a) The discharge boom will be supported by the discharge boom slewing arrangement.

Luffing will be by hydraulic cylinder. The boom is designed as a torsion-strong steel structure. Safety features have to be provided to prevent the discharge boom from accidentally dropping. Slewing movement against the bucketwheel boom will be controlled by limit switches to avoid collision. The receiving chute of the boom will be provided with an impact table. The chute will have exchangeable wear plates.

(b) Sufficient tensioning distance will be ensured. The discharge end of the conveyor will be

provided with a sufficiently strong baffle plate in order to direct the material stream with minimum spillage to the following equipment.

(c) Transfer points are designed in such a way that plugging will be prevented under normal

operating conditions. (d) The conveyor will have suitable drive arrangements with fluid couplings and brakes. The

drives are shaft mounted motor-gearbox arrangements on a common base with torque arrester. Flange couplings are used to connect the pulley to gear box output shaft.

(e) A primary and secondary scraper will be provided at the discharge pulley. A plough scraper

will be installed in front of the return pulley. (f) An electric driven conveyor belt aligner will be provided. The control of the devise will be

from the operator’s cab. (g) Strong overflow guards will be provided along the discharge boom conveyor.



2.6 Operator's Cabin, Control Desk and Transformers (a) The operator's cabin will be arranged in such a way that the operator has the best possible

visibility over the entire machine. The cabin is equipped with air conditioning, and ventilation.

(b) The windows will be of tinted safety glass with windshield wipers and washers. One

operator will be able to operate the entire machine on his own. From the control desk it will be possible to control all activities of the bucketwheel excavator and the hopper/cable reel car when the beltwagon is not in use.

(c) The BWE will be controlled from the control desk of the machine, but the discharge boom is

also controllable by remote and automated control from the beltwagon. (d) The cabin will be equipped with a suitable chair incorporating arm rests. Enough space will

be provided to allow the operator free movement around the control desk. (e) A slewing angle indicator for the height and position of the bucketwheel and an indicator

monitoring the crawler travel direction (and the corresponding advance steps of a cut as well as the total covered distance) will be in the operator's cabin.

(f) The electric compartment containing the switchgear for the BWE is provided for on the

counterweight boom. (g) Resistance sets are placed separately next to the switchgear house and are weather-

protected. (h) The transformers are placed on open platforms. Below the transformer, oil collecting

troughs with syphons are to be provided. (i) Shelters are to be arranged above the transformers. The shelters will protect the

transformers from being damaged by spillage. (j) A compartment for he storage of spare / wear parts is provided in the vicinity of the

electrical house.



2.7 Power Transmission, Electric’s, Control (a) For the power transmission from the superstructure to the undercarriage a slipring

arrangement is to be provided which permits a slewing movement of 360 degrees. The room for the slipring is to be absolutely water proof, dustproof and protected against vermin.

(b) For electrical interface, refer to Part 4: Technical Specification of electrical Equipment (c) Electrical components are to be designed in accordance with the applicable international

standards.



Part 3

Technical Data



3.1 General Type of bucketwheel excavator Compact Type -

Heavy Duty Version Effective capacity 1450 lm³/hr 2200 t/h Theoretical capacity 2000 lm³/hr 3000 t/h Leach pad height max. + 7 m Deep-cut above level - 0.5 m Side slope 60 -65 degrees Face slope 65 degrees Travelling speed 8 m/min. Minimum turning radius related to crawler outer edge 12 m Gradeability - in operation 1:20 - in transit 1:10 Average ground pressure based on operation weight 120 kpa



3.2 Bucketwheel with Drive Bucketwheel Type of bucketwheel cell-less Diameter (related to cutting circle) 5.6 m Number of buckets 10 Discharges per minute high speed 66 per min Cutting speed 1.94 m/sec Revolutions per minute - maximum 6.6 rpm - minimum (maintenance) approx 0.3 rpm Bucket capacity (I1) 0.325 m³ Ring space capacity (I2) 0.150 m³ Rated bucket capacity (In) 0.400 m³ Rated output at the above number of bucket discharges with buckets filled 100% 1,880 lm³/h Max. Cutting force 171 N/cm² Tilt of bucketwheel - related to horizontal plane 8 degrees - related to vertical plane 0 degrees Bucketwheel Shaft Type/design hollow shaft Material 42CrMo4V Bearings - Type/Number spherical roller bearing - Lubrication grease-central lubrication Bucket Wheel Drive Motors - Type Squirrel cage - Number 1 - Capacity of each motor - nominal (Nn) 110 kW Rated Speed 1500 rpm



Bucketwheel Reduction Unit Type planetary gear Number 1 Number of oil pumps 1 Overload Safety Device Mechanical Type fluid coupling Overload 1.5 -fold Electrical Type electronic / PLC Overload 1.4 -fold Chutes Inclination of chutes 55-60 degrees Type of wear protection high resistant wear plates - Thickness for ring chute 16 mm - Thickness for fixed chute 12 mm



3.3 Superstructure and Bucketwheel Boom Main Slewing Assembly Slewing angle of superstructure to undercarriage infinite Maximum slewing speed related to centre of bucketwheel 36 m/min Type of slew bearing slew bearing - Material specification 42CrMo4V Fastening - with superstructure bolted - with undercarriage bolted Type of sealing V-type Lubrication grease, central lubr. Type of rolls for slewing race cylindrical rollers Slewing Drive Units Number of slewing drives 2 Type of slewing drive frequency controlled Type of motors electrical Voltage 400 V Rated power of each motor 11 kW Pinions per unit 1 Type of safety clutch magnetically Overload factor 1.3 Type of brake double shoe brake Number of brakes on each slewing drive 2 Acceleration in operation 0,05 m/sec² Deceleration - in operating 0,05 m/sec² - at emergency stop 0,15 m/sec² Safety Devices Type of gripping device double shoe brake - Quantity 2 - Location slew drive



Slewing Assembly for Discharge Boom Slewing angle of discharge boom related to the superstructure +/- 105 degrees Slewing speed related to centre of discharge pulley 15 m/min Type of slewing race slew bearing - Material specification 42CrMo4V - Type of sealing V-type - Lubrication grease, central lubr. Type of slewing drive electrical Power of slewing drive 2 x 11 kW Type of slewing gear planetary gear - Lubrication oil Type of brake brake motor



3.4 Bucketwheel Boom Length of system from slewing centre to centre of bucketwheel 8500 mm Conveying angle - in highest position +18 degrees - in lowest position -15 degrees Adjusting speed, related to centre of bucketwheel - raising approx. 5 m/min - lowering approx. 5 m/min 3.5 Luffing Arrangement for Bucketwheel Boom Number of hydraulic cylinders 1 Pressure of each cylinder - Operating pressure 220 bar - Maximum pressure 280 bar Type of luffing drive hydraulical Power of luffing drive 45 kW 3.6 Discharge Boom Dimensions Length in horizontal position from the slewing centre to the centre of material discharge 16 m Length from centre of drive pulley to centre of discharge pulley approx. 17 m Height of centre discharge pulley related to travelling level - in highest position 7.6 m - in lowest position 3.2 m



Conveying angle, maximum + 12 degrees - 5 degrees Lifting and lowering speed of discharge boom 3 m/min Luffing Arrangement Number of hydraulic cylinders Pressure of each cylinder 180 bar Operating pressure 250 bar Type of luffing drive hydraulical Power of luffing drive 45 kW ( same as BW hoist )



3.8 Conveying Line Bucketwheel Boom Belt speed 4.2 m/sec (820 fpm) Belt width 1200 mm (48”) Troughing angle - Upper belt 35 degrees - Lower belt 15 degrees Length measured from centre of return (take-up) pulley to centre of discharge pulley - minimum 10.000 mm - maximum 10.500 mm Belt clearance to steel structure on each side 100 mm Number of pulleys 2 Diameter of pulley (wo. lagging) 630 mm Face width of pulley min. 1450 mm Type of lagging herringbone rubber Thickness of lagging Drive pulley min. 20 mm (3/4”) Tail pulley min. 15 mm (~1/2”) Type of bearing spherical roller bearing Make of drive Type of drive electrical via gear box Number of drives 1 Drive power 75 kW Type of brakes double shoe brake Type of take-up hydraulic cylinder Take-up length 500 mm Type of carrying idlers 3-roller garlands Number of idlers per set 3 Spacing of idler sets max. 1200 mm Diameter 127 mm Type of bearing ball bearing Type of sealing labyrinth + V-type



Type of return idlers 2-roller garlands Number of idlers per set 2 Spacing of idlers sets max. 3000 mm Diameter of idler tube 127 mm Type of bearing ball bearing Type of sealing labyrinth + V-ring Type of impact idlers garlands Number of idlers per set 3 Troughing 35 degrees Number of idler sets at transfer point 8 Spacing of idler sets max. 380 mm Diameter of idler tube 152 mm Type of bearing ball bearing Type of sealing labyrinth + V-ring Type and number of belt cleaners 1 primary belt scraper 1 secondary belt scraper

1 plough scraper Bucket wheel chute Type of wear protection wear resistant steel plates Thickness of wear protection 12 mm Discharge Boom Belt speed 4.2 m/sec (820 fpm) Belt width 1200 mm (48”) Troughing angle - Carrying belt 35 degrees - Return belt 15 degrees Length of discharge boom between pulley centres - minimum 16 m - maximum 16.5 m Belt clearance on each side 100 mm Number of pulleys 2



Diameter of pulley (wo. lagging) 630 mm Face width of pulley min. 1450 mm Type of lining herringbone rubber Thickness of lining Drive pulley min. 20 mm (3/4”) Tail pulley min. 15 mm (1/2”) Type of bearing spherical roller bearing Type of drive electrical via gear box Voltage 400 V Number of drives 1 Type of brakes double shoe brake Drive power 75 kW Type of take-up hydraulic cylinder Take-up length 500 mm Spacing of idler sets max. 1200 mm Diameter of idler tube 127 mm Type of bearing ball bearing Type of sealing labyrinth + V-ring Type of return idlers Number of idlers per set 2 Spacing of idlers sets max. 3000 mm Diameter of idler tube 127 mm Type of bearing ball bearing Type of sealing labyrinth + V-type Type of impact idlers garlands Number of idlers per set 3 Troughing 35 degrees Number of idler sets at transfer point 8 Spacing of idler sets 400 mm Diameter of idler tube 159 mm (6 in.) Type of bearing ball bearing Type of sealing labyrinth + V-ring Type of belt cleaners 1 belt scrapers

1 plough scraper



Number of belt cleaners 2 Angle of chute walls 55 – 60 degrees Type of wear protection wear resistance plates Thickness of wear protection 16 mm 3.9 Crawlers and Undercarriage Number of crawlers 2 Track gauge 6000 mm Type of support 4-point Ground clearance 500 mm Average ground pressure at service weight 120 kpa Length of crawler measured from centre of drive tumbler to centre of return tumbler 5,980 mm Take-up distance 300 mm Width of crawler plate 1,700 mm Load bearing surface 20.4 m² Number of track wheels per crawler 8 Lubrication grease-central lubr. Number of drives per crawler 2 Drive power per crawler 45 kW 3.10 Lubrication Automatic grease lubrication -Type dual line system -Location platform - Number of grease pumps 2 - Number of points of lubrication appr. 108



3.11 Miscellaneous Walkways - Type of flooring grating - Inside width, minimum 500 mm Stairs - Type of flooring grating - Inside width, minimum 500 mm 3.12 Power Supply Power supply from: Supply voltage 4.16 kV HV - Motor voltage 4.16 kV LV - Motor voltage 400 V Control voltage 24 V Lighting voltage 230 V Frequency 50 Hz



3.13 Motors, Quantity and Rated Power:

Qty Installed Average Power (KW) Consumption (each) each (KW)

- Travelling gears 2 45 15 - Bucketwheel drive 1 110 72 Bucket Wheel Gear - oil pump 1 2.2 2

- Bucketwheel boom Slewing drive 2 11 13 Hoisting unit (Hydraulic Power Pack) 1 45 15 Conveyor belt 1 75 62 - Discharge boom Slewing drive electrically Hoisting unit hydraulically (same as BW Hoist) Conveyor belt 1 75 62 Others - Grease pumps 2 0.7 1 - Air Conditioning 2 7 5 - Others lighting, fans... 3

Total Installed Power appr. 450 KW Average Power Consumption appr. 255 KW

*Average Estimated Consumption = Average Load X Duty Cycle (% of time)



Part 4

Technical Specification of

Electrical Equipment



4.1 General Information 4.1.1 Operation Conditions Ambient Temperature min. +0° C outdoor max. +35° C Altitude: 900 m 4.1.2 Standards

Design, manufacture and testing of the electrical equipment will be in accordance with the international codes and standards



4.1.3 General Data of Electrical Equipment Supply voltage: 4.16 kV, 3-phase Frequency: 50 Hz Allowable range of rated voltage: ±10% Motor voltage: 4.16 kV,, 3-phase 400 V, 3-phase Control voltage, general: 24 V, 1-phase PLC voltage: 24 V, DC Indications lamp voltage: 24 V, DC Grounding: - 4.16 kV-Network ungrounded, with earth-leakage monitoring located in substation of the open pit mine - 400 V Main distribution network ungrounded, with earth-leakage monitoring - 400 V Auxiliary network B ungrounded, with ear-leakage monitoring - 230/400 V Auxiliary network A grounded neutral



4.2 Power Supply and Distribution

The 4.16 kV power supply of the BWE will come from the belonging belt wagon or directly from the cable reel car via the cable loop at the discharge boom to the 4.16 kV-Switchgear in the superstructure E-House. The 4.16 kV-power supply and switchgear can be isolated by switching-off the 4.16 kV-Loadbreak switch on the cable reel car.

For the power distribution on the BWE a - main distribution network - auxiliary network A - auxiliary network B will be provided.

The auxiliary network A will comprise all the consumers (such as lighting, heating, main control and monitoring voltages, but not drives) which will remain powered after emergency-off. The auxiliary network B will comprise the consumers which are necessary for repair purposes, such as cranes and oil pumps, etc. In case of necessity, these consumers can be disconnected.



4.3 Drives

The drive motors with their data are specified in the motor list. This list also contains information about the control details as well as associated brake thrustors. The superstructure slew drive will be furnished with A.C. Motors. The motors are parallel-connected and fed by a frequency converter. The actual speed values are measured by one tacho-generator, which is attached to one motor. All squirrel cage rotor motors will be started directly, the slipring motors will be started by time-delayed gradual variation of the rotor resistance. Unintentional starts of drives after power voltage failure and recovered is prevented by suitable design of the control system. The drives of bucket wheel, the conveyors 1 and 2 are electrically interlocked among each other and with the associated conveyor route, that they allow being started in a segment only in a sense reverse to the direction of conveyance. Should anyone of these drives fail, all other feeding conveyors will be cut out immediately. In case of locally switch-on the conveyors by means of interlocking release, the drives cannot be started from operator's cabin. In addition, an interlocking will be provided for normal operation to allow connection of the excavator drives, hoist, slew and travel and only then will the bucket wheel drive be connected. For transportation of the excavator, the interlocking can be by-passed in the main operator's cabin by means of an unlocking switch. In this case, the bucket wheel drive cannot be started. Oil pump and grease pumps will be started in accordance with the main drives. The starting of the conveyor route from the operator's cabin is only possible, when the according conveyor system is running. This will be indicated by a signal-lamp on the operator's cabin. The main breaker will be opened with time lag with regard on the slew converter (also be emergency-off).



The following protection and monitoring equipment will be provided:

- Short circuit and overload protection, - Insulation monitoring, - Overcurrent monitoring. - Speed monitoring devices for some drives, - Slip monitoring device and Belt deviation monitoring for conveyor drives.

The heater for the bucket wheel drive gear will be interlocked with the oil pump. The heater will be disconnected in case the oil pump is disconnected. The thermostat-controlled heaters will remain in operation. A.C. motors will be employed for the slewing drive. The slewing speeds will be controlled according to the function of l/cos alpha in the automatic mode.



4.4 Power Transformer

The bucket wheel excavator will be equipped with a vibration-proof power transformer suitable for vibration and inclination applications. The transformer tank will be of a welded plate design and resistant to pressure. Supply of the transformer will include the first oil filling. Bushing insulators and port insulators will be outdoor types of the relevant voltage class. Cable Terminal Boxes will be of protection IP 54. Voltage Tap-changing will be provided in variation of the voltage tap changer: ±2.5%, ±5%, Voltage tap-changing be of off-load type. Oil conservator with oil level gauge and air dryer (silicagel filling) will be provided as well as thermometer pocket and drainage valve.

4.5 High-Voltage Switchgear

A high-voltage switchgear will be provided in the superstructure E-House with a - Transformer feeder consisting of a fused load-break switch - Motor feeder for bucket wheel main drive consisting of a - fused load break switch with motor drive and under voltage trip (switched off in case of emergency-off) - Contactor - Current transformers with overload relay and ammeter - Power capacitor for compensation of lower factor, located locally The power capacitor will be parallel connected with the B.W. motor so that it is switched on and off by the stator contactor together with the B.W. motor. The reactive power of the capacitors will be approximately 90% of the no-load reactive power consumption of the motor. The power capacitors will be anti-vibration and suitable for outdoor operation.



4.6 Resistance Banks

The resistance banks consist of cast iron elements or wire grids enclosed in standard sheet metal boxes in protection class IP 12.

4.7 Low-Voltage Switchgear

A low-voltage switchgear will be provided consisting of different cubicles with circuit breakers, contactors, auxiliary relays, PLC, special relays, instruments etc., details are shown on the single line diagrams.

4.8 Local Devices

The safety-and limit-switches and the supervising devices are compiled in the list of local control devices as well as by-pass switches, proximity switches, shaft encoders etc.

4.9 Signalling System

A signalling system will be provided for transmitting all required information concerning malfunction and operating conditions of the machine. All detected malfunctions and operating conditions will be displayed on a monitor in the operator's cab as single or collective indication. The control signals between BWE and central control station will be transmitted via the nearest belt conveyor control substation (switch station at head drive station).

(1) Signals from BWE to the central control station: - Ready for operation; - BWE in operation; - BWE malfunction; - BWE out of operation. (2) Signals from central control station to BWE: - Ready for operation; - Running signal, conveyor; - Stop excavation.



Among others, the following indications are envisaged: - Circuit breaker on/off - Control voltage on/off - Operational limit switch - Safety limit switch - Emergency stop - Fuse supervision (conveyor route) - Oil pressure supervision - Ground connection - Wind warning The rest indications are mentioned in the list of local control devices.

A PLC (Programmable controller) for control and processing of annunciation signals, with all necessary components, interface, I/O racks, special cables, remote I/O adapters for remote I/O in operator's cab and/or control rooms, etc. will be provided. The PLC will perform all necessary operations as timing, counting, arithmetic operations, comparisation, data manipulation etc. The PLC will be provided with required power source and battery back-up to maintain memory contents during power loss. The required special relays of proximity switches, ground fault relays, lubricating system malfunction relays, selsyn indication units, inclination monitoring devices, will be provided.



4.10 Operator's Cab Equipment

Operator's Desks 1 Control desk for operator's cabin, consisting of left and right side panel and driver's chair, containing: Control and master control-switches for the drives of the excavator. Further controls are:

• 1 Interlock release switch • 1 Key switch for control voltage • 1 Push button for warning signal • 1 Emergency stop button • 1 Switch for air conditioning • 1 Switch for lighting • 1 Microphone • Operating devices for communication equipment

Indication- and Instrument Panels 1 Monitor panel, containing:

• 1 Monitor • also for indications of • - crawler position • - slew position • - hoist position • - total distance travelled • - step advance • - slew speed • - wind speed • 1 Voltmeter for 6 kV • 1 Ammeter for bucket wheel drive • 1 Clock • 1 Loudspeaker for communication equipment



4.11 Miscellaneous Equipment

The main items are specified in the list of local control devices. Among other the following items will be provided: Lever-type limit switches, heavy duty design. Inclination measuring device, with indication in the operator's cab, alarm and stop at inclinations of 1:10 (change of location) and 1:20 (operation). Anemometer indicating wind velocity, with alarm and stop at max. wind velocities (visible and audible alarm at a wind pressure of approx. 20kg/m², max. wind pressure at 80 kg/m² with equipment at standstill), anemometer transducer with heating, make: Lamprecht or equal; stop is effected when the maximum wind pressure persists for a period in excess of 6 seconds. Air-conditioning units for the cab, including intake filter and accessories. Miscellaneous emergency stop buttons with red mushroom-type button, to be unlatched by turning, type of enclosure IP 56, heavy iron-clad design, to be distributed over the machines. Required heating elements for gearing, cab, electrical room, etc. including the necessary accessories, such as thermostats, switches etc. Miscellaneous power plugging devices for connecting of vulcanising equipment, welding equipment and tools. Several high-power floodlights, suitable for outdoor use, also for illuminating of the BWE digging area of the bucket wheel. Several lighting fixtures with fluorescent lamps, complete with reflector, ballasts, starter, as required for adequate illumination of the walkways, stairways, suitable for outdoor installation. Several plastic fittings for fluorescent lamps, complete with glass well, reflector, ballasts, starter etc., for adequate illumination of the cab and E-house and collector ring room, workshops. Miscellaneous items for lighting and heating circuits, such as switches, push-buttons Several signal horns for outdoor installation, also for start-up alarm.



Several fans and filters for the electrical room. Magnetic powder couplings for BWE superstructure slew drive, approx. 60 v, Amp., D.C. Slewing angle indicator with accessories for BWE slew drive, indication in operator's cab. Boom hoist height indicators mounted at pivot points, with indication of height from the ground to the bottom of bucket wheel, indication in operator's cab. BWE travel indication, indicating the travel distances and advance steps of the cuts and the total covered distances, indication in operator's cab. All necessary control valves, 24 V, DC (for hydraulic systems) Pull cord switches, 2 per conveyor and for cable tension monitoring of cable to other machine, including necessary ropes and accessories. Proximity limit switches for speed control and position limitation. Belt alignment switches.



4.12 Lighting

Outdoor lighting will be divided into general and operational lighting. Quick ignition floodlights will be used for illumination of the boom and crawler areas. The operational lighting will be provided for the important working areas, such as on the surface areas around the machine and the belt conveyor transfer point, etc. The general lighting will only be provided for the walkways, platforms and stairs etc., so that safety conditions will be guaranteed for operations and inspections. The E-house and operator's cab will be equipped with lighting installations according to the respective illumination requirements.

4.13 Communication

The following communication equipment will be provided for the BWE: - Telephone systems for internal communications - One loudspeaker calling system - Space will be reserved for radio communication system between BWE and central control station.

4.14 Slipring Assembly

A slipring assembly will be provided in the slewing centre of the BWE. All cables running between the superstructure and substructure are connected to the rings and brush holders of this slipring assembly.



4.15 Cables and Installation Material

Cables 4.16 kV power cables type NTSCgEwöu will be used for the infeeding primary side of power transformer and B.W. main drive motor. For LV power transmission rubber sheathed flexible cable will be used. Control cables will also be rubber sheathed flexible cable with a conductor cross Part of at least 2,5mm² as well as special cable, also shielded cables. Installation Material Fastenings and small installation material including terminal boxes, cable trays, conduits, cable grips, cable shoes, switches for lighting and heating, will be provided.

4.16 Automatic Control System

An automatic control system will be provided for a) Automatic operation Consisting of automatic control of bucket wheel main drive, conveyor drives, hydraulic pump, oil pumps, grease pumps, slew drive frequency converter. b) Automatically adjusting of bucket wheel height c) Automatic control system of slewing angle d) Automatic control of slewing speed e) Automatic cutting depth control The detail principles of the automatic height adjustment and slewing angle control are as follows:



Automation of Wheel Height Adjustment The wheel boom luffing angle relative to the excavator superstructure is determined digitally with a shaft encoder. The determined angle value can be corrected digitally in order to fix the grade level as zero reference for the boom lift. The angle value is converted to elevation values which indicate the difference in elevation between the lowest peripheral point of the bucket wheel and grade level. The desired luffing height is adjusting by hand on a digital setpoint station. Signal lamps indicate when the pre-stop position is reached. Automatic Slewing Angle Control System The wheel boom slewing angle relative to the crawler is determined digitally with an absolute angle coder or similar device. The angle obtained is recorded in order to represent the slewing angle alpha T and alpha S as defined. The zero point can be adjusted digitally within reasonable limits. When a predetermined pre-stop position is reached, the slewing speed is reduced, and the slewing mechanism is stopped when the setpoint stop position is reached. The momentary slewing angle is indicated. Setpoint adjustment can be effected by making the first slewing pass through the slice by manual control. The actual limiting slewing angle values are used as setpoint input by pressing a key when the slewing mechanism is at a standstill. The boom movement will then stop when the stored set point values are reached.



Part 5

General Layout Drawing



5. General Arrangement Drawing Dwg. No. 415.33951.000 A

bucket wheel excavator vabe 400 typical tec

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