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Operating Manual DBT - Control valve block 10 functions Doc. no.: 8154 059 000 BA 00

DBT GmbH Industriestraße 1 D-44534 Lünen

Telefon: +49 (0) 23 06 / 709 - 0 Telefax: +49 (0) 23 06 / 709 - 421

Email: infodbt@dbt.de Internet: www.dbt.de


Amendments and alterations to this publication are not subject to notification. DBT GmbH (DBT) reserves all rights to this publication. Its content is protected by copyright laws, both domestic and international. No part of this publication may be reproduced or transmitted in any way or form without the prior written approval of the DBT. DBT declines all liability for direct or indirect consequences of printing errors. DBT GmbH, Lünen 2002 E


1. About this manual Before starting work . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3

Who is this operating manual intended for? . . . . . . . . . . . . What is the purpose of this operating manual? . . . . . . . . . Characters and symbols used . . . . . . . . . . . . . . . . . . . . . . .

1.3 1.3 1.4

2. Your safety Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4

Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unauthorised Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 2.4

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5

Overview of the safety instructions . . . . . . . . . . . . . . . 2.10

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3. Storage and Transport Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3

Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storage Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storage Periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 3.3 3.3

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5

Transport Crates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions and Weight of the Control Block . . . . . . . . . . . Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 3.5 3.5

4. Installation Removal of the Control Block . . . . . . . . . . . . . . . . . . . . . . . . Installation of the Control Block . . . . . . . . . . . . . . . . . . . . . .

4.3 4.4

5. Operation

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Operation and Function of the Pilot Valves . . . . . . . .

5.3

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 5.3

Filter Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4

Replacing the Filter Cartridge . . . . . . . . . . . . . . . . . . . . . . . .

5.4

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6. Technical Data Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Materials Employed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 6.4 6.4 6.4 6.5 6.5 6.5 6.5

Power Supply to the Pilot Control Valves . . . . . . . . . .

6.6

Connection Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6

Hydraulic flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6

Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7

Hydraulic Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Supply / Tank Line . . . . . . . . . . . . . . . . . . . . . . . . .

6.7 6.7

Hydraulic Fluids of Group HFA . . . . . . . . . . . . . . . . . . .

6.8

Our Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3

Service address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Referenced Standards and Guidelines . . . . . . . . . . . . . . . .

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7. For Your Information


1

About this manual



Before starting work

About this manual This chapter contains important information which will simplify work with this manual for you. In addition, it contains information about the structure of the manual and on the characters and symbols used.

Before starting work If you use an operating manual which has not been written for your control block, you will endanger yourself and others. Ensure that the data on the control block correspond to those in the operating manual. This operating manual belongs to the: DBT Control Block (10-functions) with the Order No.: 8154 059 000 00 00 The operating manual is to be used only for control blocks of this type! An operating manual must always be available for the control block. Send for a new manual immediately if this manual is no longer complete or has become illegible. DBT GmbH, Lünen 2002

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Who is this operating manual intended for? This operating manual is intended for all persons involved in the J installation, J maintenance, J repair, J operation and J dismantling J of the control block.

In addition, the supervisory personnel instructing and/or supervising the above activities must observe this operating manual.

What is the purpose of this operating manual? This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all the activities related to the control block. Read this operating manual completely and carefully. In particular, pay attention to the safety instructions. Note the appearance and meaning of the safety and warning symbols. Pay particular attention to the chapter ”Your Safety”. It contains important information drawing your attention to possible sources of danger. Observe the information and follow the instructions contained in this operating manual. This is the only way to minimise operating costs. Failure to follow these instructions will invalidate all warranty claims.

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1.3


Before starting work Characters and symbols used The following characters and symbols are used for safety instructions and important information in the operating manual. Pay particular attention to these points. DANGER! Points in the text marked with this symbol draw your attention to immediately impending danger. Possible consequences are: Very serious injury or even death. WARNING! These points contain information on dangerous situations. Possible consequences are: Very serious injury or even death.

IMPORTANT! Points in the text marked with this symbol contain useful tips and information intended to facilitate work for you. They do not warn about harmful or dangerous situations. J

Lists are marked with bullets.

Sub-lists are marked with a long dash at the start of the line.

.

1.4

Points in the text marked in this way describe individual work steps. Follow these instructions step-by-step. They will help you carry out your work faster and, more importantly, safer.

DBT - Control valve block, 10 functions

DBT GmbH, Lünen 2002

NOTICE! Points in the text marked with this symbol draw attention to harmful situations. Possible consequences are: Minor machine damage or damage in the immediate vicinity.

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CAUTION! This symbol draws attention to dangerous situations. Possible consequences are: Light to moderately serious injuries and machine damage.


2

Your safety



Personnel

Your safety For your safety

This chapter contains important information for your safety. Please read this chapter particularly carefully in order to avoid dangers for yourself and others.

State of the art

The control block has been manufactured to the state-of-the-art and in accordance with recognised safety engineering regulations. Dangers can nevertheless not be completely ruled out. Please observe also the general safety and accident prevention regulations: J of the mine, J of the Mines Inspectorate and J of the mining supervisory authorities

Personnel Installation of the control block and the associated operations may only be carried out by qualified personnel.

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Training

The electro-hydraulic and hydraulic controller may only be operated by persons who can demonstrate that they have been trained to do so. The reading of the operating manual, in particular of the chapter ”Your safety”, must form part of this training. The personnel must have and be able to demonstrate adequate knowledge of the J Mechanics, J Hydraulics and J Control engineering

Repair work on the: J Control block J Working valves J Pilot control valves J Safety components (e.g. pressure relief valves, etc.)

may only be carried out by service engineers from DBT or by specially qualified personnel of the mine. As a fundamental rule, repair work may only be carried out by personnel who have been adequately trained for this particular work and who can demonstrate such knowledge.

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2.3


Operating Conditions Operating Conditions Intended Use The control block has been designed and manufactured purely as a component of the control unit for shield-type supports. It may only be employed in conjunction with a controller (e.g.: PM 4). Use the control block only for its intended purpose! The intended uses are: J Together with the electro-hydraulic controller (e.g.: PM 4), the

control block forms a control unit with which shield-type supports in hard coal mines can be operated. DANGER! When you press the push--buttons of the pilot valves, the shield is controlled directly, i.e. the shield moves as soon as you press the buttons on the valves. Be sure to observe the safety instructions for operation of the shields during repair work! J The control block serves also as a repair controller. Moving of

the supports is thus also possible even if the controller is locked out or has failed.

Use of the control block for any purpose other than that defined under ”Intended Use” is an unauthorised use. Unauthorised use includes, e.g.: J Controlling the shields only via the push-buttons on the pilot

valves is an unauthorised use. Control of the neighbouring shield is therefore not possible. Direct control of the shields must remain the exception, e.g. for repair work on the shield. In such cases, be sure to observe the special safety instructions. DANGER! Unauthorised use of the control block endangers not only yourself but also others. Unauthorised use can result in serious injury or even death. Use the control block only for its intended purpose!

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Unauthorised Use


Safety Instructions Safety Instructions Basic rules: General

Always observe the operating manual of the support and controller in addition to the instructions given here. Always familiarise yourself with your working environment. Never stand under an unsupported shield. Always wear your personal protective equipment. Pay attention to acoustic and optical start-up warnings. In particular, pay attention to the start-up warnings of the conveyor and mining machine.

Prerequisite

Employ only control blocks which are in a technically good and safe condition.

EMERGENCY STOP

Press the EMERGENCY STOP switch immediately in the event of faults or irregularities in operation. Report any peculiarity to your superior so that necessary measures can be taken immediately.

Support blocking switch

If the shield is equipped with an electro-hydraulic controller, you must lock out the shield by actuating the support blocking switch (repair switch). The shield can then not be operated via the controller.

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Actuate the support blocking switch before: J Maintenance operations J Inspection operations J Repair operations J Prolonged periods in the shield Moving parts

Never allow parts of your body to come between parts which could move. This applies in particular to: J Gap covers J Skids J Control arms (lemniscates) J Hydraulic props and cylinders J Front cantilevers

Storage and Transport Do not store materials in the travel route or in your working area. In order not to hinder or endanger the face working crew, defective components must be transported from the face immediately. Do not store defective parts alongside good parts in order to avoid the risk of defective components being installed again by mistake. Pass on defective parts for repair. Maintain the prescribed storage periods and observe the storage instructions.

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2.5


Safety Instructions Installation Always depressurise the hydraulic systems before starting work on them. Always support all moving components mechanically before relieving the pressure in the hydraulic system. Ensure that no dirt enters the hydraulic system. Remove the dust caps on the ports only immediately before installing the control block. Operation Operate the repair controller only when it is absolutely essential. Whenever possible, control the shields with the controller of the neighbouring shield. Check whether all protective devices on the shield are in place and properly functional. Ensure that no other persons remain in the vicinity of the controlled shield. Observe the are of movement of the shield in order to be able to recognise and avert dangers in good time.

Cordon off your working area with sufficient space to work in order not to endanger yourself or others. Cordon off your working area for the mining machine. Shut off the mining machine and conveyor. Secure the system to prevent it from being switched on again inadvertently. Secure the shield mechanically to prevent it from lowering under its own weight before starting work, e.g. by: J Supporting the canopy bar J Positioning wooden wedges between the control arms (lemnis-

cates).

Stop work on the shield immediately if conveying and mining work is being carried out in your working area. Install any removed safety devices immediately after completing the work and check that they are functioning correctly. Ensure that the prescribed maintenance and inspection intervals are observed. See also chapter: ”Operation: Maintenance Schedule” Original spare parts

Use only spare parts which satisfy the specified technical requirements. This is only ensured with original DBT spare parts. Please refer to the spare parts folder for the order numbers. Do not carry out modifications or conversions. Modifications and conversions must be approved by the DBT. Never use the control block without a filter cartridge. Without a filter, the level of soiling will become so high that it can result in the failure of the complete system.

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DBT GmbH, Lünen 2002

Inform the supervisory personnel and the face working crew of any maintenance and repair operations. Give them information on the intended operations and the anticipated duration.

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Maintenance


Safety Instructions

Handling of hydraulic fluids

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Maintenance, repair

permissible tubing

Hydraulics Avoid direct contact between the skin and hydraulic fluids. Hydraulic fluid can penetrate the skin and cause serious infections. Never use hydraulic fluids for rinsing or cleaning. Hydraulic fluids represent a very serious danger to health. Only persons who have and can demonstrate a special knowledge of hydraulics may be allowed to work on the hydraulic system. Carry out a visual inspection of all the hydraulic components at regular intervals. In particular, pay attention that: J The hoses are not pinched or trapped. J The hoses have no bubbles or blisters. J The hoses or the outer sheathes of the hoses are not abnormally rigid or hard. J The outer sheath of the hoses is not damaged. J The connectors are securely inserted into the sockets. J The connections are leak-tight. Ensure that no dirt enters the hydraulic system during repair work. Dirt in the hydraulic system can cause serious damage in the whole system! Flush out the hydraulic lines thoroughly before connecting. If hydraulic hose couplers are difficult to disconnect or cannot be disconnected, the hydraulic line may still be pressurised. Be sure to depressurise the line before disconnecting couplers. Secure the connectors of the hydraulic elements only with the proper coupling clamps. Always fasten the clamps completely and with both sides. Never use nails, wire or similar materials for securing. After finishing repair work, check all connectors and connections for leaks before pressuring the system again. Use only hydraulic hoses approved for the prevailing pressures. Do not use any hydraulic hoses with damaged connectors or worn O-rings. Replace hydraulic hoses only with hoses of the same or a higher quality. Observe the date of manufacture stamped on the hydraulic hoses. Never use hydraulic hoses which are more than 2 years old, even if they have no visible signs of damage. Fig. 1:

Example: 4SP hydraulic hose, designation

3

2 1

6 4 1 hose type 2 nominal diameter 3 date of manufacture

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5 4 manufacturer 5 flame-resistant and antistatic 6 standard

2.7


Safety Instructions Never try to hold a jumping hydraulic hose. Depressurize the line in question immediately. Never try to repair damaged hydraulic hoses. Replace hydraulic hoses at the first suspicion of damage. installation of hydraulic tubing

Lay the hydraulic hoses properly behind the brackets and clamps provided for them. Always lay hydraulic hoses so that they: J always have a little slack. Fig. 2:

Laying of hydraulic hose lines, slack WRONG

RIGHT

J are not twisted. RIGHT

WRONG

J are not bent directly behind the connections

(distance min. 1.5 x nominal diameter). Fig. 4:

Laying of hydraulic hose lines, bend RIGHT

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WRONG

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Laying of hydraulic hose lines, twist DBT GmbH, Lünen 2002

Fig. 3:


Safety Instructions J cannot chafe. Fig. 5:

Laying of hydraulic hose lines, crossing RIGHT

WRONG

J Are not kinked. J Do not have to withstand tensile strains. J Are protected against thermal radiation. J Are accessible at all times.

Push hydraulic hoses into the sockets only by hand. Never try to drive the hydraulic hoses in with a tool as this will damage the connections. When installing the hydraulic hoses, ensure that they cannot be: J Torn out, DBT GmbH, Lünen 2002

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J Kinked, J Crushed, J Driven over or J twisted by the movement of the machine (Fig.: 6). Fig. 6:

Laying of hydraulic hose lines, connections at movable parts RIGHT

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WRONG

2.9


Overview of the safety instructions Overview of the safety instructions This is a summary of all the safety instructions which have to be observed in the following chapters. This summary is intended only to give you an overview of all the instructions. In some cases, there is no logical relationship between the individual instructions. Chapter 3: Storage and Transport CAUTION! There is a highly danger of hardly damaging or destroying the hydraulic components, if you do not replace the emulsion by an suitable anti-corrosive fluid. The emulsion possibly will change its properties within short time - caused e.g. by microbial attack - to an aggressive acting fluid. Flush the hydraulic components respectively system carefully and replace the emulsion completely by an suitable anti-corrosive agent.

Chapter 4: Installation DANGER! If the couplers cannot be removed or are very difficult to remove, the hydraulic line may still be pressurised. Jumping hydraulic hoses can cause serious injury or even death! Be sure to depressurise the hydraulic hose. Jumping hydraulic hoses can cause serious injury or even death. Secure the couplers only with coupler clamps. Hook into the clamps completely with both sides of the clamp. Never use nails, wire or similar items. WARNING! Improper or incorrect installation endangers you and others. Carry out the installation only when you have the necessary special knowledge to do so and can evidence this knowledge! Release the shield for operation again only when you have checked the function and observed no malfunctions. CAUTION! Prior to assembly, sockets and nipples of the plug-in O-couplers must be treated with a type B3 lubricating paste according to EWN 7068, which is free of molybdenum disulfide. See chapter 6, section “Recommended Lubricating Greases and Pastes”. NOTICE! Do not secure the control block with chains or steel ropes in order to avoid any danger of injury. Use only transport belts as they fit closely to the control block and prevent slipping.

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DBT GmbH, Lünen 2002

IMPORTANT! Ensure when storing that any new supplies are stored separately from existing stocks in such a way that on removal, old stocks are always taken first.

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NOTICE! Dirt in the hydraulic system can result in failure of the whole support system and necessitate costly repairs. Remove the plugs only immediately before installation and connection of the control block.


Overview of the safety instructions Chapter 5: Operations and Maintenance DANGER! Do not operate the controller of the shields unless you have a good knowledge of the operating elements and their fundtions. You must have been instructed on the controller installed. Blocking the push-buttons can result in uncontrolled movements of the shields. These could lead to serious injury or even death! Therefore never block the push-buttons. WARNING! Hydraulic fluids escaping under high pressure can cause serious injury or death. Be sure to depressurise the hydraulic system before starting work. The pressure must be relieved at ports P or Pw. CAUTION! Use each filter cartridge only once and do not try to clean them. Soiling in the hydraulic system is a frequent cause of costly repairs. Always use only new filter cartridges and seals.

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Soiling in the hydraulic system can result in serious damage to the whole hydraulic system! Always ensure that your working area is clean. IMPORTANT! The filter cartridge is soiled with emulsion residues and deposits. Dispose of the filter cartridge in accordance with the environment protection regulations! Chapter 6: Technical Data WARNING! As soon as the current drops to a level below 25 mA, the switching positions become unstable. This results in malfunctions or even failure of the controller. NOTICE! Use only hydraulic fluids approved by DBT! These fluids have been tested at DBT and guarantee a reliable operation of the hydraulic system. IMPORTANT! Please use the spare parts folder supplied when ordering spare parts. We expressly point out that the approval of the listed products relates only to the pure technical use in our hydraulic systems. Only the manufacturers are responsible for the constituents used in the hydraulic fluid concentrates. Be sure to observe the manufacturer’s instructions for use. Further information is contained in DIN 24320.

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3

Storage and transport



Storage

Storage and Transport This chapter contains important information on the correct storage and transport of the control block. Observance of the instructions and tips will increase the service life and availability of the control block.

Storage corrosion protection

The components of the control block are made of non-corrosive materials. Additional the internal parts are coated by a protective film of remaining testing fluid. A testing fluid with anti-corrosive characteristics (e.g. HYDROCOR CV 50 *) is used for testing purpose at DBT site. After draining the testing fluid, the remaining fluid forms an anti-corrosive protective coating, which protects the internal parts for around six month, if the control block will be stored and transported in appropriate manner.

Storage of new Equipment

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On principle, control blocks must not be stored outdoors. Control blocks always must be stored indoors in a well ventilated, dry room. no direct exposure to sunlight

Protect the equipment against direct exposure to sunlight. Store the electrical equipment, electronic components, spare parts of rubber or plastic - such as seals and hoses - and hydraulic fluids only in closed rooms at temperatures of 15° C to 25° C.

moisture and dirt

All parts of the stored hydraulic equipment must be protected against penetration of moisture and dirt. Hydraulic plug connectors and the connectors of the electrical cables must be protected with the caps and plugs supplied.

long-term storage

If the hydraulic components are to be stored for more than six months, they must be completely filled with a corrosion inhibiting/ frost-proofing fluid such as e.g. HYDROCOR CV 50.

natural ageing

Even with proper storage, seals and hoses are subject to natural ageing. A storage period of approx. two years is therefore quoted as an indicative value for these parts.

random sample inspection

After a storage period of approximately two years, a random sample inspection must be performed to determine whether the measures taken and the method of storage has prevented damage. On request, the inspection can be carried out by DBT.

HFA fluids

Regarding storage of concentrates for hydraulic fluids, the manufacturer and / or supplier instructions must be observed first. Additional information are to be found in chapter 6, section “Hydraulic Fluids of Group HFA” of this manual. IMPORTANT! Ensure when storing that any new supplies are stored separately from existing stocks in such a way that on removal, old stocks are always taken first. * “HYDROCOR CV 50” is a trade name of Theunissen Chemische Fabrik GmbH, Wuppertal / GERMANY

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3.3


Storage Used equipment If there is any need to store hydraulic equipment, that has been in use before, you have to apply the measures mentioned above in the section ”Storage of new Equipment” also except of the paragraph ”corrosion protection”. Regarding corrosion protection apply the following: Corrosion protection

In case the hydraulic system will be put out of operation temporarily or used hydraulic components will be stored, special measures regarding corrosion protection are to be taken: – Flush the hydraulic components / system carefully. – The emulsion must be replaced completely by an anti corrosive fluid e.g. HYDROCOR CV50.

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CAUTION! There is a highly danger of hardly damaging or destroying the hydraulic components, if you do not replace the emulsion by an suitable anti-corrosive fluid. The emulsion possibly will change its properties within short time - caused e.g. by microbial attack - to an aggressive acting fluid. Flush the hydraulic components respectively system carefully and replace the emulsion completely by an suitable anti-corrosive agent.

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DBT - Control valve block, 10 functions


Transport Transport Transport Crates Several control blocks are packed together in transport crates. They should remain in these crates until they reach their final place of installation in order to protect them from damage. Ensure that the crates are not damaged during transport. Pay attention in particular that they do not: J fall or J burst open

during transport. Protect the transport crates from rain by covering with tarpaulins, etc. Temperatures below freezing

Before transporting the control block at temperatures below freezing, the block must be completely emptied and then filled with a preservative fluid (e.g. HYDROCOR CV 50).

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Transport of equipment at temperatures between -21°C and -40° C is only permissible when certain measures were taken to meet these conditions at the design and manufacturing stages. DBT GmbH, Lünen 2002

For transport, also ensure that the control block is not subjected to sudden impact loads and is only loaded statically.

Dimensions and Weight of the Control Block J Depth:

340 mm

J Width:

297 mm

J Height:

148 mm

J Weight:

62.5 kg

Plugs The connections of the individual control blocks are sealed with plastic plugs to protect these from damp, dirt and damage. NOTICE! Dirt in the hydraulic system can result in failure of the whole system and necessitate costly repairs. Remove the plugs only immediately before installation and connection of the control block.

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4

Installation



Installation of the Control Block

Installation This chapter contains important and useful information intended to help you with your work. Please read this chapter through carefully and observe the instructions given. WARNING! Improper or incorrect installation endangers you and others. Carry out the installation only when you have the necessary special knowledge to do so and can evidence this knowledge!

Installation of the Control Block Removal of the Control Block Before starting the installation or replacement of control blocks, you must take safety precautions: Safety

. Cordon off your working area for other persons. . Have mining stopped in this area. . Inform your colleagues about the type and duration of the repair work and about your exact location.

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. Actuate the support lock-out switch . Secure the shield to prevent it lowering under its own weight; e.g. with wedges in the control arms (lemniscates) or by supporting the canopy bar. Shutoff hydraulic pressure

. Depressurise the hydraulic system of the shield in question. . Check that the hydraulic lines are really depressurised. When everything is OK, you can proceed to the next steps.

Removing the control block

. Mark the connecting cables and hydraulic hoses to prevent any confusion later.

. Pull the connecting cables from the covers of the pilot control valves. DANGER! If the couplers cannot be removed or are very difficult to remove, the hydraulic line may still be pressurised. Jumping hydraulic hoses can cause serious injury or even death! Be sure to depressurise the hydraulic hose.

. Loosen all hydraulic connections on the rear of the control block and ensure that the connections are not damaged or soiled.

. Secure the control block with hoists and transport belts. NOTICE! Do not secure the control block with chains or steel ropes in order to avoid any danger of injury. Use only transport belts as they fit closely to the control block and prevent slipping.

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4.3


Installation of the Control Block . Loosen the bolts of the control block mounting. . Pull the control block out of the mounting. Installation of the Control Block

. Place the control block into the holder and tighten the bolts (M10) properly. CAUTION! Prior to assembly, sockets and nipples of the plug-in O-couplers must be treated with a type B3 lubricating paste according to EWN 7068, which is free of molybdenum disulfide. See chapter 6, section “Recommended Lubricating Greases and Pastes”.

. Connect the hydraulic hoses, ensuring that the connections are

Safety

. Check the hose connections again. The hose nipples must fit tightly in the sockets and be secured with coupler clamps. The clamps must engage in the sockets with both sides. Ensure that the connections are leak-tight.

. After connecting the hoses and checking the connections, plug the connecting cable of the electrohydraulic controller into the connecting sockets of the pilot valves. Observe the circuit diagram and the markings on the cables.

. Check all the connections once more against the hose connection diagram.

. Test all the functions of the shield and remove the shield blocking elements inserted at the start of work. WARNING! Release the shield for operation again only when you have checked the function and observed no malfunctions.

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DBT - Control valve block, 10 functions

DBT GmbH, Lünen 2002

DANGER! Jumping hydraulic hoses can cause serious injury or even death. Secure the couplers only with coupler clamps. Hook into the clamps completely with both sides of the clamp. Never use nails, wire or similar items.

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not confused. Observe the hose connection plan and the markings on the hoses.


Installation of the Control Block Fig. 7: 7

4

Mounting arrengement, example

8

1

6

1 Holder 3 Pin 4 Stud bolt

DBT GmbH, Lünen 2002

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6,7 Hex. head bolt and nut, M10 8 Locking clip 10 Spring clip 10

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DBT GmbH, Lünen 2002

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DBT - Control valve block, 10 functions


5

Operation



Operation and Function of the Pilot Valves

Operation This chapter contains information on the operation of the control block and on its functions. Be sure to also observe the operating manuals for the support and the controller. DANGER! Do not operate the controller of the shields unless you have a good knowledge of the operating elements and their fundtions. You must have been instructed on the controller installed.

Operation and Function of the Pilot Valves Control of the shields is particularly dangerous during repairs, as you can directly control the shield under which you are working. It is therefore extremely important that you know and understand the different sequences of movements of the shields. If you are controlling the shield with the repair control unit, no other persons may be allowed to remain in the movement area of the shield.

Operation DBT GmbH, Lünen 2002

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There are two push-buttons on the covers of each of the individual pilot valves. When you press a button, the working valves are directly controlled. The function is terminated as soon as you release the button. DANGER! Blocking the push-buttons can result in uncontrolled movements of the shields. These could lead to serious injury or even death! Therefore never block the push-buttons. Fig. 8:

Push buttons

Function The function of the individual pilot valves is variable and depends on the external connections. The assignment Function/Push-button is shown on a symbol strip located underneath the pilot valves.

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Filter Cartridge Filter Cartridge The filter cartridge in the Manifold Block must be replaced at regular intervals. NOTICE! The recommended maintenance intervals must be understood as a guideline and must be adapted to the individual operating conditions . Depending on the actual operating conditions the maintenance intervals possibly must be shortened or can be prolonged. Replace the filter cartridge: J After the 1st week

– When installing a new system and – After extensive repairs on the hydraulic system.

Replacing the Filter Cartridge Preparation

. Secure the shield mechanically to prevent it from lowering under its own weight WARNING! Hydraulic fluids escaping under high pressure can cause serious injury or death. Be sure to depressurise the hydraulic system before starting work. The pressure must be relieved at ports P or Pw.

. Lock the shut-off tap in the pressure line P (hydraulics). . Check the system for any residual pressure. This pressure can build up in the hydraulic system as a result of the loads on the props and cylinders. Depressurise the system. Observe also the hose connection diagram and hydraulic circuit diagram. When the system has been depressurised, you can continue with the next working steps.

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DBT - Control valve block, 10 functions

DBT GmbH, Lünen 2002

CAUTION! Use each filter cartridge only once and do not try to clean them. Soiling in the hydraulic system is a frequent cause of costly repairs. Always use only new filter cartridges and seals.

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J Every 3 months (guideline)


Filter Cartridge Unscrew the filter cartridge

. Remove any dust and dirt from the control block. CAUTION! Soiling in the hydraulic system can result in serious damage to the whole hydraulic system! Always ensure that your working area is clean.

. Unscrew the filter cartridge using a screwdriver. Unscrew the filter cartridge

DBT GmbH, Lünen 2002

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Fig. 9:

IMPORTANT! The filter cartridge is soiled with emulsion residues and deposits. Dispose of the filter cartridge in accordance with the environment protection regulations!

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Filter Cartridge Screw in the new filter cartridge

. Screw in the new filter cartridge.

DBT GmbH, Lünen 2002

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Fig. 10: Fitting the new filter cartridge

. Tighten the cartridge finger-tight. . Check that the cartridge is fitted leak-tight. When you have checked the system and found no faults, the control unit can be pressurised again. Remove the shield supports only when you are sure that the hydraulic components are correctly pressurised.

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DBT - Control valve block, 10 functions


6

Technical data



Description

Technical Data This chapter contains important and useful information on the design and materials used, etc. A list of media approved by DBT (hydraulic fluids and process water) can be found at the end of the chapter. IMPORTANT! Please use the spare parts folder supplied when ordering spare parts.

Description Functions The control block is able to control 10 functions independently of one another. The working valves of the supports are controlled by electromagnetic pilot control valves. An electronic controller, e.g. PM 4, is required to control the pilot control valves. Front view of the control block

DBT GmbH, Lünen 2002

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Fig. 11:

1

2

5

1 Hydraulic connections 2 Manifold block 5 Pilot control valves

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Description Design The main components of the control block are: J Manifold block with

– Working valves, Check Valve, Filter cartridge, Accumulator – and Connecting sockets J Channel plate J Pilot control valves

Dimensions and Weight Depth/Width/Height

340 mm / 297 mm / 148 mm

Weight:

62.5 kg

Pressure Permissible working pressure

320 bar

Hazard test pressure:

350 bar

DBT GmbH, Lünen 2002

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Fig. 12: Front view of the control block

1

5

2 1 Connecting sockets 2 Manifold block 5 Pilot control valves

6.4

6

7 6 Push button 7 Connectors for the controller

DBT - Control valve block, 10 functions


Description Materials Employed The control block is made of corrosion-resistant materials such as steel, brass, bronze, etc. The connection between manifold block and channel plate is sealed with O-rings. The seal materials are designed for operation with HFA hydraulic fluids (oil-in-water emulsions).

Mountings There are 4 threaded bores (M 10) on the top of the control block and 2 bores (M 10) on each side. Fig. 13: Threaded bores

M10

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M10

DBT GmbH, Lünen 2002

M10

Valves Working valves: J 5 x 3/2-way directional control valves (NG 16) J 6 x 3/2-way directional control valves (NG 10)

They are controlled by pilot control valves. Pilot control valves: J 5 x double 3/2-way directional control valves (NG 0.5)

They are controlled by a controller (e.g.: PM 4). The pilot control valves can be actuated directly during removal operation. For this, the valve covers each have 2 push-buttons. WARNING! The support may be controlled directly via the control block only during removal operation, i.e. during repairs. The control block must not be employed without a suitable controller.

Filter The filter cartridge protects the pilot control circuit against impurities. Use only new filter cartridges, never ”cleaned” cartridges. Only new filter cartridges have the necessary filtration properties (mesh size = 25 mm). See also chapter: Operation: Replacing filter cartridge

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Power Supply to the Pilot Control Valves Power Supply to the Pilot Control Valves The power supply comes via a 4-pin plug contact. Each pilot control valve is connected to the controller via a cable to the corresponding output of a valve control strip.

Connection Data Double 3/2-way pilot solenoid valve NG 0.5 Approval No.

96.D7019x

Approval office: INERIS Rated voltage:

12 V, AC

Perm. deviation: -2 V Switching current:160 mA Current drop:

max. down to 30 mA

WARNING! As soon as the current drops to a level below 30 mA, the switching positions become unstable. This results in malfunctions or even failure of the controller.

Hirschmann

Solenoid design: Thomas Magnete, Type: 81-9133-040/002

Hydraulic flow diagram Fig. 14: Control valve block, 10 functions

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DBT - Control valve block, 10 functions

DBT GmbH, Lünen 2002

Plug design:

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Protection type: EExib l


Connections Connections The connection ports for the hydraulics and for the water supply are located on the rear of the control block. Fig. 15: Rear view of the control block

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Hydraulic Connections DBT GmbH, Lünen 2002

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large-volume consumers

medium-volume consumers

low-volume consumers

Pressure supply / tank line

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Connections:

5 x DN 20 socket, round

Marking:

3, 3, 7, 8, SP

Flow rate:

max 340 l/min

Application:

large-volume consumers

Connections:

1 x DN 12 socket, round

Marking:

5

Flow rate:

max 180 l/min

Application:

medium-volume consumers

Connections:

6 x DN 10 socket, round

Marking:

1, 2, 4, 6, 9, 10

Flow rate:

max 80 l/min

Application:

low-volume consumers

Connections:

2 x DN 25 socket, round

Marking:

P (Pressure supply) T (Tank line)

Application:

Pressure supply to the system or return line to the tank

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Connections Hydraulic fluids of group HFA NOTICE! Use only hydraulic fluids approved by DBT! These fluids have been tested at DBT and guarantee a reliable operation of the hydraulic system. Hydraulic fluid concentrates List of approved water-miscible hydraulic fluid concentrates for the production of fire-resistant hydraulic fluids of Group HFA. Tab. 4: Approval list (Part 1)

type X test water

type Y test water

type Z test water

P 87 AF

not tested

1.5 %

3%

Carl Bechem

Fimitol P 87 AF

not tested

1.5 %

3%

Castrol

Anvol C 18

not tested

5%

not tested

Anvol C 19

not tested

5%

not tested

Anvol SF 2000

not tested

2.5 %

not tested

Solcenic 2

not tested

5%

not tested

Solcenic 2BW Code 44 32 50 AA

not tested

5%

not tested

Solcenic 2000 M

not tested

not tested

2%

Solcenic 2011

not tested

5%

not tested

Solcenic 2012

not tested

5%

5%

Solcenic 2020

4%

not tested

not tested

Solcenic 3002

not tested

2%

3%

Solcenic Ecosyn 3050

not tested

1.5 %

not tested

Solcenic Ecosyn 3060

not tested

not tested

2%

Renolin Ecubsol BOA ||

not tested

1.5 %

2%

Mobil Oil

Mobilmet S-122

not tested

5%

not tested

Quaker LTD

Quintolubric 812-01

not tested

3%

not tested

Quintolubric 814-01

not tested

5%

not tested

Quintolubric N 807 Al

not tested

3%

not tested

Shell Tellina Q

not tested

5%

not tested

DBT - Control valve block, 10 functions

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Recommended concentration for use with process water according to the chemical composition

ARAL Lubricants

Fuchs/Century

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Product designation

DBT GmbH, Lünen 2002

Manufacturer


Connections Tab. 5: Approval list (Part 2) Manufacturer

Product designation

Recommended concentration for use with process water according to the chemical composition type X test water

type Y test water

type Z test water

GS 460 N

not tested

1.5 %

2%

Isosynth VX 110 BF 5

not tested

not tested

1.5 %

Hydrocor TS 100 N

not tested

2%

not tested

Isosynth VX 110 BF 1) 2)

not tested

1.5 %

1.5 %

Texaco USA

Concentrate 18

not tested

5%

not tested

Total France

Lactuca LT 2

not tested

5%

not tested

D. A. StuartTh Theunissen i

1) Will be distributed as “Anvol JD 2000” by Castrol. 2) Only permissible is the variant manufactured in Germany. The variant of Isosynth VX 110 BF, manufactured and distributed in USA, is not permissible because of different ingredients.

DBT GmbH, Lünen 2002

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IMPORTANT! We expressly point out that the approval of the listed products relates only to the pure technical use in our hydraulic systems. The responsibility for the constituents used in the hydraulic concentrates lies solely with the respective manufacturer. Storage of the hydraulic fluid concentrate Do not store the hydraulic fluid at temperatures below 5° C. Avoid excessive heating of the fluids. Protect the concentrate against direct exposure to sunlight. IMPORTANT! Be sure to observe the manufacturer’s instructions for use. Preconditions for use underground The approval of the responsible Mines Inspectorate is required for use underground. The approval presupposes an examination by the RW TÜV/Essen and of the Hygiene Institute of the Ruhr/Gelsenkirchen (Germany). For use in international mining, the relevant national regulations must be observed. Approval by the responsible authorities may be necessary. Responsibility for the approvals procedure lies with the equipment operator. Suitability of the hydraulic fluid The suitability of the hydraulic fluid for use in mining equipment must be demonstrated by positive experience in practice. Should a product exhibit any negative characteristics during operation, we reserve the right to delete the product from our approval list. Working concentration of the hydraulic fluid The recommended working concentration of the products essentially corresponds to the concentration at which the product passed the crevice corrosion test in accordance with the DBT Works Standard or RAG Standard.

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6.9


Connections Quality of the process water The quality of the process water is a critical factor for the functional reliability of the emulsion. The water must not contain any solid or liquid impurities and must satisfy the bacteriological requirements for drinking water (DIN 2000). The figures quoted for the concentration of the hydraulic fluids were obtained from trials with test water samples. The chemical composition of the test water samples used are shown in the table below for your orientation.

type Y test water (DIN 24320 resp. Luxembourg Report)

type Z test water (NCB 19 to Luxembourg Report)

pH value

6.5 - 8.5

6.5 - 8.5

6.5 - 8.5

hardness mmol/l

2.5 (=14°d)**

3.58 (= 20°d)**

7.5 (= 42°d)**

chloride

200 mg/l

200 mg/l

200 mg/l

sulfate

240 mg/l

150 mg/l

720 mg/l

nitrate

0 mg/l

20 mg/l

0 mg/l

magnesium

30 mg/l

50 mg/l

90 mg/l

sodium

130 mg/l

115 mg/l

130 mg/l

calcium

50 mg/l

61 mg/l

150 mg/l

iron, max.

0.3 mg/l*

0.3 mg/l*

0.3 mg/l*

* These values deviate from the quoted standard or from the Luxembourg Report. ** °d = degree German hardness (is no longer permissible in accordance with the applicable legal regulations. The information given is intended only for orientation.)

If the process water available does not have the demanded quality, the special approval of DBT must be obtained before use. Emulsion values pH value: 7.5 - 9.5 Permissible bacteria in the emulsion: ≤ 105 Kol/ml The maximum permissible temperature is 55° C; normally 45° C, should not be exceeded. A higher working temperature will reduce the consistency of the emulsion and shorten the service life of the seal material. Checking of the emulsion values At least once per week, check: J the pH value J the concentration

test method: by agreement with the concentrate manufacturer J the microbial load

test method: dip slides IMPORTANT! Further information is contained in DIN 24320.

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DBT GmbH, Lünen 2002

type X test water (NCB 18 to Luxembourg Report)

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Tab. 6: Chemical composition of the test water samples used


Hydraulic Fluids of Group HFA Storage of the Hydraulic Fluid Concentrate Do not store the hydraulic fluid at temperatures below 5° C. Avoid excessive heating of the fluids. Protect the concentrate against direct exposure to sunlight. IMPORTANT! Be sure to observe the manufacturer’s instructions for use. Preconditions for Use Underground The approval of the responsible Mines Inspectorate is required for use underground. The approval presupposes an examination by the RW TÜV/Essen and of the Hygiene Institute of the Ruhr/Gelsenkirchen or of the Pharmacological Institute of the University of Hamburg. Suitability of the Hydraulic Fluid The suitability of the hydraulic fluid for use in mining equipment must be demonstrated by positive experience in practice. Should a product exhibit any negative characteristics during operation, we reserve the right to delete the product from our approval list. Working Concentration of the Hydraulic Fluid

DBT GmbH, Lünen 2002

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The recommended working concentration of the products essentially corresponds to the concentration at which the product passed the crevice corrosion test in accordance with the DBT Works Standard or RAG Standard.

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DBT GmbH, Lünen 2002

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DBT - Control valve block, 10 functions


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For your information



Our Service

For Your Information Our Service If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us directly.

Service address Germany

DBT GmbH Service Industriestraße 1 D-44534 Lünen

DBT GmbH, Lünen 2002

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Phone: + 49 (0) 23 06 / 70 9 - 0 Fax: + 49 (0) 23 06 / 70 9 - 421 E-mail: infodbt@dbt.de Internet: http://www.dbt.de

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7.3


Our Service Referenced Standards and Guidelines

7.4

Title

DIN EN 292/1

Safety of Machinery

DIN EN 292/2

Safety of Machinery

DIN EN 982

Safety of machinerySafety requirements for fluid power systems and their components

DIN EN 60445

Identification of Connections

DIN 2000

Central drinking water supply Guidelines regarding requirements for drinking water, planing, construction operation and maintenance of plants

DIN 6789

Documentation System

DIN 8418

Information for Users

DIN 20043

Plug Connectors for Hydraulics

DIN 21555

Graphic Symbols for Self-Advancing Supports

DIN 24320

Fire Resistant Hydraulic Fluids

DIN 24343

Hydraulic fluid power systems and components; list for attendance inspection of hydraulic equipments

DIN 24346

Hydraulic Systems; Design Principles

EWN 6003

Pretensioning forces and tightening torques

EWN 7068

Lubricants

EWN 7069

Nonmetallic surface protection

DBT - Control valve block, 10 functions

DBT GmbH, Lünen 2002

Designation

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The following table shows only a selection of the standards and guidelines employed by us during the development and manufacture of the control block.


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