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SERVICE MANUAL

MODEL DS325-322

The Robbins Company


29100 Hall Street
Solon, Ohio 44139
The Robbins Company
5866 South 194th Street
Kent, Washington 98032

All rights reserved. This book, or any part thereof, may not be reproduced or transmitted
in any form or by any means, electronic or mechanical, including photocopying,
recording, or information storage and retrieval systems, for any purpose without the
express written permission of The Robbins Company.
2008 by The Robbins Company All rights reserved.
Published 2008
Printed in the United States of America

322Copyright Page

October, 2008

GENERAL INDEX

Model DS325-322

Title

Section

Revision Record

Safety Considerations

General Information

General Description

Operation

Maintenance

General Assembly
Includes General Assembly, Weights & Dimensions,
and Site Layout/Site Assembly Sequence

Cutterhead Assembly
Includes 17& 19 Cutter Assemblies

Main Bearing and Seal Assembly


Includes Stud Tensioning Unit

Forward Shield Assembly


Includes Cutterhead Support Plumbing
& Dust Shield Assembly

Main Drive Assembly


Includes Gear Reducer Assemblies & Torque Coupling Assembly

Telescopic Shield Assembly


Includes Articulation Cylinders

Gripper Shield Assembly


Includes Cylinder Position Indicating, Propel Cylinders
& Gripper Cylinders

10

Conveyor Assembly
Includes Drive Pulley Assembly
Tail Pulley Assembly & Snubber Pulley Assembly

11

Ground Support Equipment


Includes Segment Erector Assembly, & Probe Drill assembly

12

322Index

November, 2008

GENERAL INDEX

Model DS325-322

Title

Section

Operator Station Assembly


Includes Operators Console Assembly & QuickPanel Control

13

Lube System Assembly


14
Includes Lube Schematic & Cutterhead Support Pressurization Assembly
Hydraulic System Assembly
Includes Hydraulic Schematic

15

Electrical System Assembly


Includes PLC Installation, Methane Monitor Assembly,
& Electrical Schematic

16

Water System Assembly


Includes Water Schematic

17

Position Monitoring Equipment


Includes Guidance System Assembly & PPS Guidance System

18

Miscellaneous Equipment
Includes Service Beam Assembly, Cutter Handling Assembly
& Fire Alarm System Assembly

19

Backup Equipment
Includes Transfer Conveyor and Gantry Assemblies

20

322Index

November, 2008

REVISION RECORD
Original Release

MODEL DS325-322
October, 2008

This form is a sample of the revision records that may be sent in the future to update
the service manual when required. When a revision is received, the revised pages of
text, drawings, and/or tables of contents should be inserted into the manual, and the
existing material may be discarded. All copies of this form should be kept in the
REVISION RECORD section of the manual to serve as record of all changes made.

322RevRec

October, 2008

TUNNEL BORING MACHINE SAFETY PROCEDURES

ALL TBMs

DO NOT ALLOW ANYONE TO OPERATE THIS


TUNNEL BORING MACHINE UNLESS THEY ARE
QUALIFIED BY TRAINING AND EXPERIENCE IN THE
SAFE OPERATION OF THIS EQUIPMENT.
TRAINING INCLUDES COMPLETE KNOWLEDGE OF THE EMPLOYER'S WORK
RULES; ALL GOVERNMENTAL REGULATIONS; THE MANUFACTURER'S
OPERATION, MAINTENANCE, AND SAFETY INSTRUCTIONS.

AN UNTRAINED OPERATOR SUBJECTS HIMSELF


AND OTHERS TO RISK OF DEATH OR SERIOUS
INJURY.
All persons that will be working on this Tunnel Boring Machine, whether operating,
maintaining, or repairing it, should be thoroughly familiar with the operating systems and
characteristics. All cautions and warnings throughout this manual should be strictly
observed.

NOTE:
This guide is not intended to be all-inclusive. Refer to cautions and warnings
throughout this manual.
Refer to the appropriate section of the manual for more details. Common sense and good
judgment should always be exercised. This manual assumes that only qualified personnel
will operate or maintain the Tunnel Boring Machine. Refer to all applicable safety standards
and regulations, that is, OSHA, MSHA, ANSI, NEC, and others.
Be constantly alert for hazards. Make immediate corrections if possible; otherwise alert all
other personnel and notify the responsible person of any unsafe condition.
Always observe Management Safety Policy and Decisions that apply to the particular job.

317 & 318safe

October, 2008

TUNNEL BORING MACHINE SAFETY PROCEDURES

Unsafe Acts
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Unsafe Conditions

Operating equipment at improper speeds.


Operating equipment without authority.
Using equipment improperly.
Using defective equipment.
Making safety devices inoperable.
Failure to warn co-workers or to secure equipment.
Failure to use personal protective equipment (e.g. safety
harness, hearing protection, steel-toed boots, etc.).
Improper loading or placement of equipment or supplies.
Taking an improper working position.
Improper lifting.
Servicing equipment in motion.
Horseplay.
Use of alcoholic beverages.
Use of drugs.
Standing under suspended loads (e.g., unsecured segments
and ring beams).

317 & 318safe

ALL TBMs

1.
2.
3.
4.
5.
6.
7.

Inadequate supports or guards.


Defective tools, equipment or supplies.
Congestion of work place.
Inadequate warning systems.
Fire and explosion hazards.
Poor housekeeping.
Hazardous atmospheric conditions (Gases, dust, fumes
and vapors.)
8. Excessive noise.
9. Poor illumination.
10. Poor ventilation.
11. Radiation exposure.

October, 2008

TUNNEL BORING MACHINE SAFETY PROCEDURES

ALL TBMs

WARNING!
THE OPERATION OF THIS MACHINE CAN CREATE CRYSTALLINE SILICA DUST
IMPROPER HANDLING OR EXPOSURE TO THE DUST MAY CAUSE SILICOSIS
(A SERIOUS LUNG DISEASE), CANCER AND DEATH.

RESPIRATOR REQUIRED
MINIMIZE DUST AND USE PROPER DUST CONTROL EQUIPMENT
WEAR, MAINTAIN, AND CORRECTLY USE APPROVED PARTICULATE
RESPIRATORS. FOLLOW DIRECTIONS AND GUIDELINES THAT ARE
BASED ON OSHA OR MSHA REGULATIONS.

317 & 318safe

October, 2008

TUNNEL BORING MACHINE SAFETY PROCEDURES

ALL TBMs

General Safety

1.1

The following safety equipment is recommended as a minimum for all personnel


working on or near the machine: hard hat, steel-toed safety shoes or boots, safety
harness, gloves, eye protection, and hearing protection (earmuffs, earplugs or both).
Also, follow job site management's safety rules and local safety laws and regulations.

1.2

Always observe all job site safety policies and procedures, and local laws and
regulations. Obtain any required training or certifications before going underground.

1.3

ALL persons entering the tunnel must recognize machine start-up audible signals,
and any other visual or audible warning signals.

1.4

Never use a moving conveyor belt as carrier for equipment or personnel.

1.5

Avoid looking directly into the laser beam. Eye injury may result, despite its low
wattage.

1.6

Never position yourself where you may be injured from a falling load or a moving
machine part. This is especially important when operating ground support equipment
such as segment or ring beam erectors, service hoists, or cutter handling equipment.

1.7

Carefully check for potentially hazardous rock-fall conditions on the exposed tunnel
face and the crown in front of cutterhead support. Bar down loose material and
provide support if needed. When possible, continue boring until reaching more
competent rock before performing maintenance. Be constantly alert for possibility of
loose material dropping from conveyors, tunnel crown, or top of machine surfaces
where material may have settled.

1.8

To avoid slipping, use caution when climbing and moving around the machine.
Handrails, walkways and ladders must be kept clear, clean, and in good working
order. Wipe up any oil spills immediately. Note that the tunnel invert is a curved
surface and can be very slippery - use caution when moving under the machine.

1.9

Do not step on or pull on hydraulic hoses while they are under pressure. Do not use
hydraulic hoses or electrical cables as ladder rungs, working platforms, or storage
areas.

1.10

Route all hoses and cables in such a method to reduce tripping hazards and to prevent
damage to other equipment. Keep areas around the machine clear, clean and free of
other tripping hazards.

1.11

To avoid back strain and other injuries, use care when handling cutter assemblies or
other heavy items. Most cutter assemblies weigh more than 136 kg (300 lbs.), and
the center (twin disc) cutter assemblies are approximately twice as heavy.

317 & 318safe

October, 2008

TUNNEL BORING MACHINE SAFETY PROCEDURES

ALL TBMs

1.12

Check all slings, hoists and other lifting equipment at the start of each shift for good
condition. Do not use lifting devices for purposes for which they were not intended,
and do not exceed the specific load rating of these devices.

1.13

Do not allow unauthorized personnel to operate equipment or make adjustments.

Operator Responsibilities

2.1

The key for the TBM control power switch must always remain in possession of the
TBM operator. NEVER allow a duplicate key in the tunnel.

2.2

The operator is responsible for the machine. Therefore, he must always be aware of
the location of all personnel. Anyone finding himself or herself in an area outside the
visibility of the operator must inform him of this fact. Ensure that all personnel are
clear of the machine before operating.

2.3

At the start of each shift, ensure that all warning-lights and signals are functional.

2.4

Ensure that all interlocks associated with failure protection of equipment are
operating correctly. Never operate the machine with interlocks bypassed. This is
particularly important in the lubrication system and the gripper high-pressure circuit.

2.5

Ensure that all hydraulic hoses and electrical cables that must move with the machine
are free to do so.

2.6

For main beam TBMs (gripper-type TBMs), ensure that the rear support legs are in
contact with the tunnel invert before retracting the gripper. Also, during boring, raise
the rear support legs only far enough to clear the invert - one or two inches are
usually sufficient. Maintain this spacing throughout curves.

2.7

The operator should avoid excessive steering movements that cause equipment
damage. Physical limitations of movement must always be considered.

317 & 318safe

October, 2008

TUNNEL BORING MACHINE SAFETY PROCEDURES

ALL TBMs

Maintenance Considerations
NOTE:

Refer to the Mechanical Maintenance Section, the Electrical Maintenance


Section, and related drawings for additional information.
3.1

During inspection or maintenance of the cutterhead, or other machine areas where


movement could cause personal injury, the drive and propel systems must be locked
out. This is accomplished by removing the control power key.

3.2

Only the jogging (inching) drive should be used to rotate the cutterhead during cutter
inspection or other maintenance. All personnel must be clear of the cutterhead during
this operation. As the control power key also operates the jogging (inching) drive, all
other machine functions will be locked out.

3.3

Each person to go through the cutterhead support to the front of the cutterhead must
have his personal JOG ENABLE lockout padlock key with him. This also applies
whenever personnel will be working in areas where machine start-up could cause
injury.

3.4

Ensure that all fasteners are tightened to the appropriate torque value and remain so.

3.5

Before performing repairs to the machine, ensure that all potentially hazardous stored
energy is locked out or released. This applies to electrical power, pneumatic (air)
pressure, hydraulic pressure, or mechanical energy of springs or hanging loads.

3.6

Do not attempt to use bare hands to find leakage in hydraulic circuitry. Highpressure injection of hydraulic fluid through the skin may result, and can cause
serious injury.

3.7

Check all slings, hoists and other lifting equipment at the start of each shift for good
condition. Do not use lifting devices for purposes they were not intended, and do not
exceed the specific load rating of these devices.

317 & 318safe

October, 2008

TUNNEL BORING MACHINE SAFETY PROCEDURES

ALL TBMs

Electrical Safety Considerations


NOTE:

Electrical systems are inherently dangerous. Refer to the Electrical


Maintenance Section and related drawings for additional information.
4.1

Electrical power and control cabinets should remain locked when not under the direct
control of a qualified electrician.

4.2

Do not use electrical cabinets as a toolbox or as a spare part(s) storage area. The
inherent vibration and magnetism associated with transformers and motor starters can
cause inadvertent contact of foreign objects with live circuitry.

4.3

Troubleshooting, maintenance, service and repairs must be performed by qualified


and trained electricians. Remove all watches or rings that could contact live electric
circuits. Power should be locked out and the switch tagged "OUT OF SERVICE"
when doing maintenance on associated electrical circuitry.

4.4

Some electrical components may have multiple power sources - verify that they are
all disconnected before servicing. Also, solid-state devices may contain hazardous
voltages when they are switched off. These devices should be isolated from the
power source before being serviced.

4.5

Do not tamper with safety interlock circuits, safety guards, or other safety devices,
except as required during normal maintenance and troubleshooting. Severe electrical
shock and/or death to personnel and/or mechanical, hydraulic or electrical damage to
the TBM may result from defeating any safety interlocks. Confirm that all safety
devices and circuits are replaced and functioning before operation is resumed.

4.6

De-energize electrical power while making or breaking electrical cable connections.

4.7

Installing any electrical components that are contrary to the national electrical code is
forbidden. Changes in the electrical system may void warranties.

4.8

Safety of the operational personnel is an absolute requirement.

317 & 318safe

October, 2008

MODEL DS325-322
SECTION 0 General Information
Table of Contents
Page
1. INTRODUCTION

2. DESCRIPTION OF MANUAL CONTENTS

3. HOW TO USE THE MANUAL

4. REVISION RECORD

5. WARRANTY AND LIABILITY LIMITATION

6. INSTRUCTIONS FOR ORDERING SPARE PARTS

7. SPECIFICATIONS

322tc0

November, 2008

SECTION 0 GENERAL INFORMATION

MODEL DS325-322

Introduction

The Robbins Model DS325-322 tunnel boring machine has been specifically designed
for use in mixed rock formations and therefore is equipped with features suitable for this
application. These features will be covered in detail in the Description section of this
manual.
This machine is completely shielded and is equipped with a segment erector system to
allow placement of concrete lining segments as the machine advances. A rotary
cutterhead assembly is utilized on the machine and is constructed to allow the use of
Robbins 483 mm (19 inch) face and gage disc cutters, and 432 mm (17 inch) center disc
cutters, which are normally mounted from the rear side of the cutterhead. Center cutters
are numbered 1 through 8, face cutters are numbered 9 through 56, and gage cutters are
numbered 57 through 67. Positions 68 through 70 are used for over-cutting, increasing
the tunnel size from 10.0 m (32.8 ft) to 10.20 m (33.5 ft).
Rotary power is supplied by 14 variable frequency drive 422 HP (315 kW), water-cooled,
three-phase, electric motors that drive the cutterhead through associated gear reducer
assemblies from 0 to 8.05 RPM. These main drive assemblies are equipped with 12
torque coupling assemblies without brake on positions 2 through 13 and torque coupling
assemblies with brake assembly on positions 1 and 14.
Cutterhead thrust is furnished in one of two ways, either by 12 main thrust cylinders or
by nineteen auxiliary thrust cylinders. In competent ground, cutterhead thrust is
transferred to the tunnel walls through hydraulically-extended gripper shoes. The main
thrust cylinders are connected between the forward shield and the gripper shield. In
unstable ground, the gripper shoes are left retracted, and the auxiliary thrust cylinders,
mounted to the aft end of the gripper shield, are fitted with shoes to allow them to push
off the tunnel segments. Both of these sets of cylinders have independent control to allow
for steering movements.
The maximum recommended cutterhead thrust force is 20,904 kN (4,699,406 lbf.), based
on a recommended maximum loading of 312 kN (70,000 lb) per cutter.
This machine is equipped with a Politenger Precision System (PPS) Tunnel Guidance
System for position monitoring.
A troughed belt conveyor is used to transport rock cuttings from the cutterhead area to
the rear of the machine for transfer to other conveyors that move this material into
transport cars for removal from the tunnel.

Description of Manual Contents

The intent of this manual is to provide sufficient information to attain a good working
knowledge of the machine from both operational and general maintenance standpoints.

322s00

0.1

October, 2008

SECTION 0 GENERAL INFORMATION

MODEL DS325-322

Coverage included: (1) A description of the physical and functional characteristics of the
equipment; (2) operating procedures; (3) disassembly, service or repair, and assembly
procedures and (4) illustrated parts lists.
It is beyond the scope of this manual, however, to detail all conditions or problems which
may occur. In the event of problems arising, which are not specifically covered in the text
sections of this manual, reference should be made to the appropriate Robbins drawing
and/or supplier information contained in Sections 4 through Section 20. It may also be
necessary to contact the Robbins Company Field Service Department and/or Engineering
Department, in some cases.
The operational systems of the machine are described in detail, with an attempt made to
provide sufficient information to allow proper operation of the equipment and efficiently
troubleshoot and correct any malfunctions that may occur. Characteristics and functional
relationships between the electrical, hydraulic, and mechanical systems must be
understood to ensure proper operation and maintenance.
Procedures in this manual assume that only qualified mechanics and electricians will
work on the machine. Hydraulic components need special attention to ensure cleanliness
and to prevent damage to seals and fittings during assembly. Maintenance of electrical
devices demands qualified electricians who know how to service systems with similar
voltages and characteristics without endangering personnel or damaging equipment.
General precautions and procedures, and information such as the handling of bearings
and the tightening of standard size capscrews to proper torque values, are included as
guides. Detailed maintenance instructions describe special procedures and safety
precautions.

How to Use the Manual

Sections 0 through 3 of this manual cover the general and specific descriptions, the
operating procedures, and maintenance instructions.
Additional sections of the manual are used for engineering drawings, covering the major
assemblies and systems that together make up the complete machine.
3-1
Page Numbering
Sections 4 through 20, containing primarily engineering drawings, are pages-numbered
with the section number followed by a period and the page sequence. Any subassembly
or detail drawing which is part of this main assembly, and which are included in the
manual, are page-numbered with the same basic page number as the top drawing and
followed by a hyphen plus an additional digit.
This digit corresponds to the item or piece number as listed on the top drawing.
Supplemental material, such as parts and service information, vendor literature, etc., will
have the same page number as the relevant drawing, plus a letter (A, B, C, etc.).

322s00

0.2

October, 2008

SECTION 0 GENERAL INFORMATION

MODEL DS325-322

For example, in Section 11, Conveyor Assembly, a subassembly called Drive Pulley
Assembly, (item 12 on the Conveyor Assembly, drawing D107974) is numbered Page
11.1-12. Figure 0.1, shown below, is a portion of Section 11 Table of Contents.
1

D101473-1

CONVEYOR ASSEMBLY

11.1

5750011369

TAIL PULLEY ASSEMBLY

11.1-10

5750011372

SNUBBER PULLEY ASSEMBLY

11.1-11

D100898-1

DRIVE PULLEY ASSEMBLY

11.1-12

HYDRAULIC MOTOR

11.1-12-4

3 A92266-1

Figure 0.1 Table of Contents - Section 11


3-2
Topic Numbering
The topics for each section of the manual are topic-numbered using the sequence number
as a prefix, followed by a hyphen (-) and the sub-topic sequence number. For example,
this sub-topic is numbered 3-2 because it is the second sub-topic under topic 3, How to
Use the Manual.
A general index for this manual is included in the front of each of the binders. This index
lists the various sections of the manual and the applicability of a particular section to this
machine. A table of contents is included at the beginning of each section.
3-3
Format Conventions
Two format conventions are used throughout the manual to identify notable topics and
hazards. These are examples of the conventions:

NOTE:
Topics of special interest are written in this font and preceded by a Note
Arrow above the text.

Rules, directives, remarks, and warnings that concern safety are written in
this format and preceded by a "Warning Bar" above the text. Refer to the
SAFETY CONSIDERATIONS section in this manual for additional safety
information relating to these machines.

322s00

0.3

October, 2008

SECTION 0 GENERAL INFORMATION

MODEL DS325-322

Revision Record

The Revision Record is intended to provide a complete record of revisions that may be
made to the manual following the original release. These revisions will be numbered
sequentially, 1, 2, 3, etc., and will show all changes to the manual. Any changes made to
written material in Section 0 through 3, and to any Tables of Contents pages, will be
identified by the addition of a revision number to the file name, (Example: 322s00Rev.1)
with month and year, at the lower right-hand corner of the affected page.
Sufficient copies of all changes and additions will be forwarded to the manual owners to
permit incorporation into each copy of the manual in their possession. Each revision
should be added to the Revision Record section as it is received.

Warranty and Liability Limitation

Use only authorized parts. Warranty or Product Liability does not cover any damage or
malfunction caused by the use of unauthorized parts.
Any warranty for work performed only covers original Robbins Company parts and
components.

Instructions for Ordering Spare Parts

To speed up the ordering and shipment of spare parts for the machine, the following
procedure should be followed whether the order is made by fax, telephone
communication, normal correspondence or electronically.
6-1

Always indicate the following items:


1.

The machine model number.

2.

The assembly nomenclature and the assembly drawing number which


show the desired item and the description of that assembly.
The part number, the description of the desired item, and the desired
quantity.

3.

EXAMPLE:
Tunnel Boring Machine Model DS325-322
Conveyor Assembly, Drawing D107974
Part No. 5750011438, Belt Splice Kit, 54 Belt, 1 each

322s00

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October, 2008

SECTION 0 GENERAL INFORMATION


6-2

MODEL DS325-322

If the desired item does not have a Robbins Company drawing part number,
specify by using the item number, the Robbins Company stock number (if given),
and a brief description of the part as shown on the assembly or installation
drawing.

NOTE:
The stock number is shown in the part number column on the drawings as
a multiple-digit, hyphenated number that is sometimes preceded by a letter
prefix.
6-3

Include all necessary instructions for routing:


1.
2.
3.
4.

6-4

Shipping address
Special marking instructions, if any.
Mode of shipment.
Special shipping and/or importation instructions.

Direct all inquires and orders to:


The Robbins Company
29100 Hall Street
Solon, OH 44139
USA

Telephone:

(440) 248-3303

Fax:

(440) 248-1702

The Robbins Company


5866 South 194th Avenue
Kent, WA 98032
USA

Telephone:

(253) 872-0500

Fax:

(253) 872-0199

For more information visit our website: www.Therobbinscompany.com

322s00

0.5

October, 2008

SECTION 0 GENERAL INFORMATION

MODEL DS325-322

General Specifications

Year of Manufacture

2008

Machine Diameter
Nominal
Overbore 3 Cutters

10.0 Meters (32.8 ft)


10.20 Meters (33.46 ft)

Cutters
Face/Gage
Center
Number of Disc Cutters
Loading
Maximum Recommended Individual Cutter Load
Cutterhead
Cutterhead Thrust at 228 bar (3,307 psi)
Maximum Operating Cutterhead Thrust
Cutterhead Drive

Series 19 (483 mm)


Series 17 (432 mm)
67
Front/Back
312 kN (70,000 lb.)

34,392 kN (7,731,629 lbf.)


20,904 kN (4,699,406 lbf.)
VFD Electric Motors
Safe Sets, Gear Reducers

Cutterhead Power

4,410 kW (14 X 315 kW)


5,914 HP

Cutterhead Speed

0 3.66 rpm
3.40 8.05 rpm
11,508 kNm (8,487,852 lbf. ft.)
5,231 kNm (3,858,182 lbf. ft.)

(Constant torque range)


(Constant power range)
Cutterhead Torque (At 3.66 rpm)
(At 8.05 rpm)
Thrust Cylinder Stroke (Effective)

1700 mm (67)

Hydraulic System
Electric Motors (11)
System Maximum Operating Pressure
Emergency Auxiliary Thrust Pressure
Auxiliary Thrust at 244 bar (3,539 PSI)

745 kW (999 HP)


350 bar (5,076 psi)
450 bar (6,527 psi)
58,190kN (13,081,112 lbf.)

Electrical System
Cutterhead Drive
Primary Voltage
Secondary Voltage
Transformer Size

VFD System
33,000V, 50 Hz
690V, 3 phase, 50 Hz
2 X 3,000 kVA (690V)

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October, 2008

SECTION 0 GENERAL INFORMATION

MODEL DS325-322

Electrical System Auxiliaries


Primary Voltage
Secondary Voltage
Transformer Size
Control System & Lighting

33,000V, 50 Hz
400V 3 phase, 50 Hz
1 X 2,000 kVA (400V)
24VDC, 220VAC,110VAC

Machine Conveyor
Belt
Length
Capacity
Belt Speed

1,372 mm (54)
30 m (98)
1,500 tons/hour
0 to 2.3 m/second

TBM Weight (approx.)


Front Shield, Cutterhead, and Drive Unit
Gripper Shield, Rear Shield, and Erector

1400 tons
750 tons
650 tons

General Assembly Drawing


Back-up General Assembly Drawing

D107803
D109000

322s00

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October, 2008

MODEL DS325-322
SECTION 01 Description
Table of Contents
Page
1. INTRODUCTION

2. GENERAL ASSEMBLY

3. CUTTERHEAD ASSEMBLY

4. MAIN BEARING & SEAL ASSEMBLY

5. FORWARD SHIELD ASSEMBLY

6. MAIN DRIVE ASSEMBLY

GEAR REDUCERS

DRIVE MOTORS

7. TELESCOPIC SHIELD ASSEMBLY

8. GRIPPER SHIELD ASSEMBLY

9. CONVEYOR ASSEMBLY

10. SEGMENT ERECTOR ASSEMBLY

11. PROBE DRILL ASSEMBLY

12. VENTILATION ASSEMBLY

13. OPERATORS STATION ASSEMBLY

14. LUBRICATION SYSTEM

15. HYDRAULIC SYSTEM

13

16. ELECTRICAL SYSTEM

32

17. WATER SYSTEM ASSEMBLY

37

18. POSITION MONITORING EQUIPMENT

41

322tc01

November, 2008

MODEL DS325-322
SECTION 01 Description
Table of Contents
Page
19. MISCELLANEOUS EQUIPMENT

43

20. BACK-UP SYSTEM

44

5750 9900 17 TIGHTENING TORQUE THREADED FASTENERS

SECTION 3

322tc01

November, 2008

SECTION 1 DESCRIPTION

MODEL DS325-322

Introduction

This section of the manual provides a description of major structural components and
assemblies, operating systems, and auxiliary equipment of the tunnel boring machine.
Sections 4 through 20 contain all assembly, subassembly, component, and installation
drawings that make up the machines. In addition, service and parts information is also
contained in these sections. While reading the following descriptions, refer to the
referenced sections and drawings to provide a more complete understanding of the
machine and its operating systems.

General Assembly

The TBM general assembly drawing D107803 is located in Section 4. The drawing
indicates all major assemblies and operational systems with references to applicable The
Robbins Company Engineering detail drawings. Section 4 also includes a weights and
dimensions drawing D103330 and other drawings.

Cutterhead Assembly

The cutterhead assembly Section 5 shown on drawing D102102 is the assembly that
accomplishes the actual rock boring operation. The cutterhead assembly is mounted to
the main bearing assembly. Fourteen 3 phase, 690 volts, water-cooled VFD electric
motors, provide drive torque for the cutterhead assembly each delivering 315 kW. These
motors, driving through gear reducer assemblies into a main ring gear (bull gear), which
is attached to the cutterhead, rotate the cutterhead from 0 to 8.05 rpm in a clockwise
direction as viewed looking forward.
Structurally, the cutterhead assembly is made of heavy steel plates, internally reinforced,
with integral buckets to remove the rock cuttings. The pickup devices, or buckets, scoop
up the material at the tunnel invert and deliver it by gravity into the conveyor system
within the cutterhead support as each bucket rotates to the crown of the tunnel. These
buckets are equipped with bolt-on replaceable lips for longer wear and ease of
replacement.
The cutterhead assembly is the mounting structure for the 63 cutter housing assemblies,
having a total of 67 replaceable cutter rings, used on this machine. The cutterhead has an
additional three cutter housings, which are used for over bore increasing the tunnel
diameter from 10 m (32.8 ft) to 10.20 m (33.46 ft). The eight cutter rings located at the
center of the cutterhead are 432 mm (17) in diameter and are twin-disc assemblies. The
remaining cutter rings are single disc assemblies with 483 mm (19) in diameter. All
cutter assemblies and housings are designed so the cutters may be changed from the front
and back of the cutterhead.

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The individual cutter rings are numbered radially from the center outward from number 1
through number 70. Cutter numbers 1 through 8 are commonly referred to as center
cutters; positions 9 through 56 face cutters and 57 through 67 gage cutters, and position
68 through 70 overbore cutters.
Each cutter ring describes an individual radial pattern as the cutterhead rotates through a
complete revolution. The cutterhead assembly also provides a mounting base for water
spray nozzles and associated plumbing used with the water spray system, which is
described as a separate topic.
3-1
Cutter Assemblies
There are two types of cutters used on this machine, namely, center and face cutter
assemblies, or hub and shaft assemblies, as they are called on their assembly drawings.
Center cutters use replaceable 432 mm (17) and face and gage cutters use 483 mm (19)
cutter rings. The center cutter assemblies are twin-disc type, in order to keep ring spacing
to a minimum at the center of the cutterhead.
Procedures for determining cutter loading, as well as recommended limit, are included in
Section 2, Operation. Procedures for checking cutter ring wear, limits of wear, and cutter
assembly installation procedures are included in Section 3, Maintenance.

Main Bearing and Seal Assembly

The main bearing and seal assembly Section 6 shown on drawing D101462 consists of
the main thrust bearing, main drive ring gear, and inner and outer seal assemblies (the
inner and outer seal assemblies are used to seal the bearing and gear cavities against loss
of lubricating oil, and to prevent contamination created during operation).
The main bearing assembly is a tri-axis, bearing that accepts both radical and thrust
loading of the cutterhead assembly. The bearing consists of tri-cylindrical roller bearings
that are mounted on the main bearing and held in place by the cutterhead adapter.
The ring gear is an external-toothed gear that is mounted to the cutterhead adapter. The
ring gear is secured in place by studs, hex nuts, and washers.
The seal assembly consists of an inner and outer seal. The outer seal group is mounted to
non-rotating structural components with the lips of the seals providing sealing action
against rotating components. The inner seal group is the opposite of the outer seal group.
Both the inner and outer seal assemblies are installed in a specific order (refer to
drawings). This order of installation is done to avoid damaging the seal assemblies.
The seals are oriented so the lips prevent entrance of contaminants into the cavities. A
spacer is installed between the seals and serves to port lubricating fluid to the seals.
Lubrication for the main bearing and ring gear is provided by the lubrication system, and
is pumped to the components through porting in the structure.

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Forward Shield Assembly

The Forward Shield Assembly Section 7 shown on drawing D107804 is the primary
support structure of the machine.
5-1
Forward Shield
The forward shield supports the weight of the cutterhead assembly, and also provides
mechanisms for stabilizing it against movement within the bore section of the tunnel. The
forward shield provides the primary structure for mounting the cutterhead assembly and
the mounting base for the main drive assemblies, and a machined and drilled structure for
mounting of the main bearing assembly. This component also includes provisions for
mounting of the conveyor, muck chute, and stabilizer cylinders and shoes.
5-2
Stabilizer Shoes
Two stabilizer shoes that are attached to the cutterhead support in the upper left and
right-hand quadrants and extend through holes in the forward shield provide stabilization
of the front shield. A stabilizer cylinder is connected to raise or lower each stabilizer
shoe.
5-3
Lift Cylinders
Two lift cylinders that are attached to the bottom quadrant are utilized for the TBM over
cutting capabilities.
5-4
Cutterhead Support Pressurization Assembly
Please refer to Lubrication System description Section 14 for more information

Main Drive Assembly

The main drive assembly Section 8 shown on drawing D107805 is mounted into the
forward shield assembly and secured in place using hex head cap screws. The machine is
equipped with fourteen main drive assemblies, each powered by a 315 kW, 690-volt, 3phase, 50Hz, water-cooled, VFD electric motor. For reference purposes, with respect to
the electrical system schematic, drive position 1 is installed in the lower left-hand
position and numbering is clockwise around the cutterhead support. The assembly having
the torque coupling assembly with brake assembly is installed at the number 1 and
number 14 positions.
6-1
Gear Reducers
The gear reducers are planetary-type; two stage reduction that provides an overall ratio of
20.44:1. The output pinions of the gear reducer drive into the common main ring gear.
6-2
Drive Motors
Each of the cutterhead drive motors, as previously mentioned, is 315 kW, and is watercooled.

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A minimum of 20 lpm (5.2 gpm) of water must be supplied to each motor for proper
cooling. Maximum water temperature should not exceed 25C (77F). Maximum water
pressure is 8 bar (116 psi).
Each motor is equipped with grease fittings and grease relief ports to allow periodic relubrication of shaft support bearings. Recommendations for the lubricants, as well as
intervals of service are in the manufacturer's literature, included in Section 8.

Telescopic Shield Assembly

The telescopic shield assembly Section 9 shown on drawing D103600 provides the
intermediate stage between the forward shield and the gripper shield. The telescopic
shield comprises an inner shield and an outer shield.
The outer shield is connected to the forward shield assembly by hex-head capscrews, and
provides coverage of the bored tunnel during thrust cylinder extension.
The inner shield is connected to the gripper shield assembly by the action of sixteen
articulation cylinders. Nine doors are provided on the inner shield; they are used for
inspection of ground conditions and when cleaning the area between the two shields
7-1
Shield Articulation Cylinders
A total of sixteen articulation cylinders are mounted around the periphery between the
telescoping shield and the gripper shield. These double-acting hydraulic cylinders allow
the articulation between these shield assemblies.
It is very important to the control of the shield that the axial elements of the shield
periphery be straight. The articulation of the shield allows the assembly to be trimmed to
compensate for any discrepancies, allowing the shield to negotiate a tighter turn than
would otherwise be possible, and aids in controlling the roll of the machine.

Gripper Shield Assembly

The gripper shield assembly Section 10 shown on drawing D102100 includes the tail
shield assembly, articulation cylinders, positioning indicating cylinder, gripper cylinders
and shoes, auxiliary thrust cylinders and shoes, torque arm cylinders, and the main thrust
cylinders.
The tail shield assembly is connected to the aft end section of the gripper shield assembly
by hex head capscrews and provides final coverage of the bored tunnel for segment
erection.

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8-1
Gripper Cylinders
The two gripper cylinders are double-acting cylinders. The cylinders develop the
hydraulic force needed to hold the gripper shoe assemblies tightly against the sides of the
tunnel to react to the torque and propel forces needed for boring.
8-2
Gripper Shoes
The two gripper shoes provide the structure to transfer the hydraulic force generated by
the extending gripper cylinder rods to the sidewalls of the tunnel. One gripper cylinder is
mounted to the upper ends of each shoe and one more gripper cylinder is mounted to the
lower ends of each shoe. They force the gripper shoes apart, thereby exerting force
against the tunnel walls.
8-3
Auxiliary Thrust Cylinders
Nineteen thrust cylinders are provided. Each cylinder has a thrust shoe attached to the rod
end of the cylinder, which reacts against the tunnel lining segments. The cylinders are
mounted through holes in the gripper shield, held in place at the aft end by a pin, which
holds the auxiliary thrust shoe and at the forward end by a retainer. The piston rods
extend aft and have three functions:
1.

They assist in moving the gripper shield assembly forward during the gripper
repositioning cycle, by pushing on the tunnel segments.

2.

They serve as a fixed-length strut between the gripper assembly and tunnel lining
segments. In this mode they assist the gripper system in providing a reaction force
for the thrust system.

3.

They serve to force the associated segments into proper position and hold them in
place as the complete ring of segments is installed.

8-4
Main Thrust Cylinders
Twelve thrust cylinders are provided to generate the hydraulic thrust forces necessary for
propelling and steering the machine. Refer to the specifications in Section 0 for more
information.
The cylinders are installed between the gripper shield and the forward shield. The rod
ends extend aft to propel the forward shield assembly.
8-5
Torque Cylinders
Two cylinders are installed between the forward shield and the gripper shield providing
roll control, the arrangement of the cylinders, along with the hydraulic circuit functions,
permits the cylinders to provide vertical steering of the forward shield and cutterhead.
8-6
Position Indicating Cylinder
Four position indicating cylinders are provided; each having a stroke of 1750 mm (69)
each of these cylinders sends an electric signal to the PLC.

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These signals are proportional to the extension of each of the cylinders. The average
value of these cylinder extensions is representative of the present distance the forward
shield and cutterhead have advanced with respect to the gripper shield (boring stroke).
The extension values from these cylinders are additionally used to limit extensions
between the shield to avoid damaging the propel cylinders.

Conveyor Assembly

The primary structure of the TBM conveyor Section 11 shown on drawing D107974
consists of a multi-section conveyor frame, that provides a mounting base for the return
and troughing idlers, the tail pulley assembly, the conveyor drive assembly, belt tension
cylinders, mounts for the flashing and scraper assemblies and a mounting base for the
impact pan. Provisions are included to allow adjustment of the positions of all rollers and
pulleys to properly train the belt.
9-1
Conveyor Drive System
A drive pulley assembly drives the conveyor. Two single speed hydraulic motors are
used, each having a displacement of 800 cubic centimeters per revolution (48.8 in /rev).
The case of this motor drives directly into the head pulley drum. Hydraulic fluid is routed
through the shaft of the motors.
9-2
Tail Pulley Assembly
The primary tail pulley assembly is located at the forward end of the conveyor.
Adjustments are provided to allow proper alignment.
The tail pulley assembly is sealed and lubricated in the same manner as the cutter
assemblies. Proper lubricant level is approximately one-half full with approximately 19
liters (5 US gallons) of lubricant.
9-3
Snubber Pulley Assembly
This unit is located at the aft of the conveyor acts as a snubber for the conveyor
assembly.
9-4
Conveyor Belt
The conveyor belt is 1,372 mm (54) wide. Vulcanizing is the preferred method of
joining belt ends. Splicing of the belt is permitted only if skived flush with the top and
bottom of the belt to prevent belt scraper damage. Both belt scrapers must not be in
contact with the conveyor belt during reverse operation or damage to the scrapers will
occur.
Belt splicing is accomplished by using the splice kit that contains the entire necessary
fastener strips, rivets, and hinge pins.

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9-5
Speed Switch
This unit is included to detect conveyor belt low speed during operation. The mechanism
includes a wheel assembly and a speed switch.
The conveyors rotation drives the wheel. A warning message is displayed at the
operators console when the conveyor speed drops to approximately 80% of full speed.
9-6
Belt Tension Cylinders
Two hydraulic cylinders are mounted between the rear conveyor frame and the take-up
frame to allow adjustment of belt tension. This is accomplished by pumping grease into
the appropriate ends of the cylinders while venting the other ends.
9-7
Conveyor Lift
The conveyor is equipped with two conveyor lift cylinders attached to the front section,
one on each side of the conveyor. These cylinders have a stroke of 381 mm (15) and
work together to raise the conveyor away from the pickup point. This provides access to
the muck chute for cleaning.

10

Segment Erector Assembly

The segment erector Section 12 shown on drawing D103855 furnished with this machine
consists of the erector frame; an erector drive system for radial positioning; a braking
system; hydraulic cylinders for lateral positioning, for lifting and lowering the segments,
and for slight adjustment of the segments. The erector is connected to the machine by a
ring gear that is supported by roller assemblies.
10-1 Erector Drive Assemblies
The two erector drive assemblies are powered by two bent-axis hydraulic motors that are
coupled through hydraulic brakes to gear reducers and finally to pinions which drive the
erector ring gear. The brakes are designed to require hydraulic pressure to release;
therefore, they are locked whenever the erector is not being rotated.
10-2 Radial Extension Cylinders
There are two hydraulic cylinders one on each side of the erector, used for lifting the
segments and placing them against the tunnel wall. These cylinders are guided by radial
guide tubes, to keep the cylinders on each side parallel to each other. These cylinders are
equipped with counterbalance valves in both the rod end and the cap end.
10-3 Axial Positioning Cylinders
These two cylinders are connected between the erector rotating frame and the axial frame
brackets, and they are used for moving the erector fore and aft. These cylinders are
guided by guide tube carriages also feature counterbalance valves.

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10-4 Yaw Cylinder


This cylinder is also connected between the radial frame and the pickup pan, but is
positioned laterally so the segment may be rotated on its center axis; single
counterbalance valves are connected to the cap end and rod of the cylinder.
10-5 Tilt Positioning Cylinders
Four tilt cylinders are used for orienting the segments up, down, left and right position;
counterbalance valves are connected to the cap end of each cylinder.

11 Probe Drill Assembly


The probe drill assembly Section 12 showing on drawing D103859 is intended for
exploration holes in the crown to determine rock conditions in front of the cutterhead.
The probe drill assembly is mounted just behind the gripper shield on a ring gear, which
is mounted on a four piece drive ring and four carriage position cylinders that are
attached to the gripper carrier to control its position. Drill feed cylinder is also provided
as well as radial cylinder which allow the drills to be tilted out from their vertical
position by approximately 7.0
Drawings of these assemblies are included in Section 12.

12

Ventilation System

The ventilation system Section 20 for this machine consists of ducting that is mounted
along the right side of the conveyor assembly. Curved plating that is mounted to each
main structural beam of the conveyor frame forms the ducting. Transition ducting is
included to allow mating with ventilation ducting that is part of the backup system. The
duct on the right-hand side of the conveyor frame (as viewed looking forward) carries
dust-laden air back to a scrubber unit mounted on the backup equipment.
The conveyor assembly also provides mounting at the forward end for a dust shield
assembly that will provide sealing to prevent escape of dust-laden air except through the
ventilation line leading to the scrubber unit.

13

Operator's Station Assembly

The operators cab assembly Section 13 shown on drawing D110297 consists of all
controls and indicators necessary to operate and monitor the various hydraulic and
electrical functions of the machine during normal boring. This includes all the controls
for the various hydraulic actuators and electric motors; controls for setting propel speed
and pressure, and pressure gauges, ammeters, indicator lights for monitoring the systems,
and the QuickPanel.

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14

MODEL DS325-322

Lubrication System

The lubrication system of the machine Section 14 shown on drawing D107811 provides
the means for lubricating the main bearing, main gear (bull gear), inner and outer seal
assemblies, and the gearbox.
The system also provides the equipment for extracting the oil that accumulates in the
bearing and gear cavities, and routing it back to the lube oil reservoir, thus allowing
constant re-circulation of the gear oil.
The reservoir for the system is on the back-up assembly. This reservoir has a capacity of
1,136 liters (300 gallons) and is vented by a breather assembly.
The breather (BR40-1) uses a replaceable element (BR39-1) that should be changed
periodically, the frequency of replacement being dictated by the operating environment.
Refer to Section 3 for more maintenance information.
A level gauge (SG47-1) provides a visual indication of lube oil level, while one level
float switch (LS44-1) is incorporated to detect a low fluid level. This switch is
interlocked electrically to shut off the lubrication system pump motor. The switch also
will illuminate a warning light at the operator's control console. A second float switch
(LS44-2) will detect rising fluid level in the reservoir and will stop the lube system return
pump drive motor until the fluid level in the reservoir has lowered to a normal level. This
switch also displays a warning for the operator.
The reservoir is equipped with a thermometer (TG41-1) to provide a visual indication of
temperature. Ball valve (BV38-1) allows the reservoir to be drained, and a sampling
valve (NV42-1) is provided. There are two heaters (HTR 43-1 & HTR 43-2) installed on
this reservoir that switch on automatically when the oil temperature falls below 38 C
(100 F), a temperature transducer (TT45-1) is used to monitor oil temperature with
readout at the QuickPanel, temperature switch (TS46-1) displays a warning message at
the operators console when lube oil temperature is above 60 C (140 F). Access for
cleaning the reservoirs interior is provided.
One 55 kW (40 HP) 380-volt, 3-phase motor (M35) drives four pumps common to the
lube supply system. This motor and pump assembly supplies gear oil for pinions, main
bearing, and front and rear pinion bearing lubrication.
14-1 Seal Lubrication Circuit
The hydraulic system provides lubrication of the inner and outer seals in the cutterhead.
The 0 to 135 LPM (0 to 36 GPM) pump (PMP16-1) driven by electric motor (M29)
provides hydraulic oil flow for the seals. Flow from this pump continues through an
isolation check valve (CV86-4) with pressure reduced to 100 bar (1,450 psi) by pressure
reducing valve (PCV135-2).

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Flow is directed to a 5 micron filter (PF55-1) that is equipped with an electronic dirt
alarm. This device displays a warning message at the console indicating that the filter
elements need to be replaced. The flow then advances to directional control valve
(DCV56-1); oil volume into the system is controlled by a variable pressure compensator
flow control valve (FCV54-1).
Back pressure surges is protected by check valve (CV57-1); a normally closed needle
valve (NV58-1) is used to by pass the directional control valve (DCV56-1) these valves
are mounted on manifold (MFD53-1).
The oil is directed to flow divider valve (FB24-1) that automatically cycles to distribute
the oil flow in measured quantities to two outer seal assembly ports and one inner seal
assembly port.
A proximity switch (PXS25-1) is included to initiate a signal through the electrical
system that will indicate to the operator that flow is correct. In normal operation, the
proximity switch operates a flashing indicator at the operators console, indicating rate of
oil cycle. Pressure in the system is monitored by pressure gauge (PG59-1).
14-2 Pinion Lube Circuit
The 53 LPM (14 GPM) portion of double internal-gear pump (PMP5-1) provides lube oil
flow for the drive pinion. Input to the pumps is by gravity flow from the lube oil
reservoir. Ball valve (BV11-1) allows the flow to be shut off for reservoir maintenance
purposes.
Flow from this pump continues through an isolation check valve (CV12-1) that protects
the pumps from back pressure surges, pressure in this circuit is limited to 100 bar (1,450
psi) by a pilot-operated relief valve (PRV15-1), oil that travels through this valve
(PRV15-1) is routed back to the reservoir.
Flow from the pump passes through a 10-micron filter (PF13-1) that is equipped with an
electronic dirt alarm. This device displays a warning message at the console indicating
that the filter elements need to be replaced.
One pressure gauge (PG16-1) provides an indication of the operating pressure. The oil
continues through an oil flow meter (FM19-1) that provides a visual indication of flow
being delivered to the system. The flow indication should be checked at least once each
shift. Flow of less than 34 LPM (9 GPM) may be indicative of pump wear, depending on
oil operating temperature.
The oil is then directed to a feeder block (FB26-1) for distribution to the gear reducer
pinions through flow meter switch (FS20-1), this switch is set at 28 LPM (7 GPM),
decreasing flow rate will stop the cutterhead and a warning message will be displayed at
the operators console . Two outlets from feeder block (FB26-1) are directed to the front
and rear pinion bearings feeder blocks (FB26-2 & FB26-3) and one outlet is directed to
pump (PMP29-1) for internal lubrication.

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14-3 Main Bearing Lube Circuit


The 68 LPM (18 GPM) portion of double internal-gear pump (PMP5-1) provides lube oil
flow for the six main bearing ports. Ball valve (BV11-2) allows the flow to be shut off
for reservoir maintenance purposes.
Flow from this pump continues through an isolation check valve (CV12-2) that protects
the pump from back pressure surges, pressure in this circuit is limited to 41 bar (595 psi)
by a pilot-operated relief valve (PRV15-2), oil that travels through this valve (PRV15-2)
is routed back to the reservoir.
Flow from the pump passes through a 10-micron filter (PF13-2) that is equipped with an
electronic dirt alarm. This device displays a warning message at the console indicating
that the filter elements need to be replaced.
One pressure gauge (PG16-2) provides an indication of the operating pressure. The oil
continues through an oil flow meter (FM19-2) that provides a visual indication of flow
being delivered to the system. The flow indication should be checked at least once each
shift. Flow of less than 43 LPM (11 GPM) may be indicative of pump wear, depending
on oil operating temperature.
The oil is then directed to manifold (MFD22-1) for distribution to the six main bearing
lube ports. Proximity switches (FS21-1) through (FS21-6) provide a signal to an
undespeed relay module (USM), monitoring the rate of oil flow. When cycling rate
indicates flow below 4.5 LPM (1.1 GPM) through the feeder, the cutterhead will stop
after 10 seconds of low flow displaying an alarm message at operators console.
14-4 Front Pinion Bearing & Rear Pinion Bearing Lube
Two identical 53 LPM (14 GPM) internal-gear pumps (PMP6-1) independently provide
lube oil flow to the front and rear pinion bearings. Input to the pumps is by gravity flow
from the lube oil reservoir. Ball valves (BV11-3 and BV11-4) allow the flow to be shut
off for reservoir maintenance purposes.
Flow from this pump continues through isolation check valves (CV12-3 and CV12-4)
that protects the pump from back pressure surges, pressure in this circuit is limited to 100
bar (1,450 psi) by pressure relief valves (PRV15-3 and PRV15-4), oil that travels through
this relief valves (PRV15-3 and PRV15-4) is routed back to the reservoir.
The oil flows through a filters (PF13-3 and PF13-4) that are equipped with an electronic
dirt alarm. This device displays a warning message at the console indicating that the filter
elements need to be replaced.
Pressure in each circuit is displayed on pressure gauges (PG16-3 and PG16-4). The oil
then passes through flow meters (FM19-3 and FM19-4) that provide a visual indication
of oil flow being delivered to the pinion bearings.

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The flow indication should be checked at least once per shift. Flow less than 34 LPM (9
GPM) may be indicative of pump wear, depending on the oils operating temperature.
The oil is then directed to feeder blocks (FB26-2 and FB26-3) for distribution to the each
of the pinion bearings lube ports through flow switches (FS20-2 and FS20-3) that provide
a signal to an undespeed relay module (USM), monitoring the rate of oil flow.
When cycling rate indicates flow below 28 LPM (7 GPM) through the feeder, the
cutterhead will stop after 10 seconds of low flow displaying an alarm message at
operators console.
14-5 Lube Return Circuit
The lubricant to the pinions and the main bearing drains by gravity to the lower portion
of the cutterhead support cavity. The oil is then scavenged by means of a screw-type
pump (PMP29-1). A hydraulic gear motor (MTR28-1) that is powered by the machine
hydraulic system drives this pump. Input to the pump is through a ball valve (BV27-1).
The flow from the pump is directed through a magnetic strainer (ST34-1), check valve
(CV35-1), return filter (RF36-1), and through return line filters (RF37-1 & RF37-2).
Pressure transducer (PT18-1) is used in the return line to sense pressure in the circuit.
When pressure reaches above 2.8 bar (40 psi), a message is displayed at the operators
console indicating return filters are by passing stopping the lube motor M35 (MTR4-1)
after 10 minutes.
14-6 Filling the Reservoir
A quick-disconnect coupler (QD49-1 through QD52-1) in the lube return circuit serves as
a connection point into the system to allow the lube reservoir to be filled. An air-operated
transfer pump (PMP48-1) allows the fluid to be pumped from a barrel and through the
two return line filters into the reservoir. The check valve (CV35-1) in the return circuit
prevents the lube oil from flowing back into that circuit while the reservoir is being filled.
14-7 Cutterhead Support Pressurization Assembly
The cutterhead support pressurization system is shown on drawing B62272, Section 14,
and provides for a small amount of air pressure to enter the main bearing cavity. This
slight pressurization is meant to assist the main bearing seals, while boring in very wet
ground conditions, to keep water out of the lube oil.
Supply pressure to this system should not be allowed to exceed a maximum of 10 bar
(145 PSI). If not needed this system may be shut down with ball valve (2). Air passes
through an in-line filter (12). The pressure is reduced, and monitored, to .69 bar (10 psi)
by the regulator (3).
The pressure is further reduced to 0.21 bar (3 psi) maximum with the precision regulator
(4). The adjusted pressure can be monitored by the pressure gauge (6).

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If the pressure rises above 0.29 bar (4 psi), pressure switch (7) will open and display a
message on the QuickPanel at the operators console.
Cavity pressure is controlled by a pop-off type relief valve (5). Cavity air exhaust is
provided through a breather filter (11).

15 Hydraulic System
15-1 Introduction
A complete understanding of the hydraulic system of the machine Section 15 shown on
drawing D107812, including the inter-relationship of the various hydraulic functions, is
essential for proper utilization of these functions.
This understanding is even more essential for proper and efficient maintenance, whether
preventive or corrective. The complete hydraulic system consists of many circuits, the
hydraulic reservoir and interconnections, and the controls and indicators used by the
operator to control and monitor these hydraulic functions. Each is treated as a separate
topic.
Most of the directional control valves, check valves, pressure-reducing valves, relief
valves and flow control valves are manifold-mounted, and in many instances share
common manifold blocks. The primary method of interconnection is by high pressure
hoses.
All relief valves, pressure-reducing valves, pressure switches, holding valves, and most
flow control valves have manual adjustments along with locking devices to maintain the
setting.
This reservoir has a capacity of 9,500 liters (2,500 US gallons) and is vented by four
breather assemblies. The breathers (BR210-1 through BR210-4) use a replaceable
element that should be changed periodically, the frequency of replacement being dictated
by the operating environment. Refer to Section 3 for more maintenance information.
A level gauge (SG204-1) provides a visual indication of lube oil level, while one level
float switch (LS189-1) is incorporated to detect a low fluid level. This switch is
interlocked electrically to shut off motor groups M21 through M31 if low level condition
exists. The switch also will display a warning message at the operator's control console.
The reservoir is equipped with two thermometers (TG207-1 and TG207-2) to provide a
visual indication of temperature. Ball valve (BV35-2) allows the reservoir to be drained,
and a sampling valve (NV130-1) is provided. A temperature transducer (TT187-1) is
used to monitor oil temperature with readout at the QuickPanel, temperature switch
(TS188-1) displays a warning message at the operators console when hydraulic oil
temperature is above 60 C (140 F). Access for cleaning the reservoirs interior is
provided.

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All the hydraulic pumps utilized in the system are gravity-fed with fluid first passing
through ball valves (BV36-1, through BV36-11, BV35-1, BV37-1 through BV37-5).
These valves must be open except for maintenance. Various motors drive the system
pumps common to the hydraulic system. These motors, identified as (M21 through M31),
drive the following pumps to supply flow for the many hydraulic circuits:

PMP 13-1 through PMP 13-5


PMP 14-1
PMP 15-1 through PMP 15-4
PMP 16-1

Flow from all main return lines passed through four 10 micron return filters (RF183-1
through RF183-4) that are equipped with a gauge type dirt alarm.
15-2 Filling the Reservoir
A quick-disconnect coupler (QD200-1 through QD203-1) in the hydraulic return circuit
serves as a connection point into the system to allow the lube reservoir to be filled. An
air-operated transfer pump (PMP208-1) allows the fluid to be pumped from a barrel and
through the four return line filters into the reservoir.
15-3 Motor M25 Propel System
This 75 kW, 100 HP, 1450 RPM motor drives a double variable-volume pump and a
fixed volume pump (PMP14-1), the two variable pumps supplies flow to the main thrust
cylinders while the fixed pump supplies flow to the auxiliary thrust exceptional high
pressure system. The outlet volume on the fixed volume pump is 38 LPM (10 US GPM)
with maximum pressure set at 450 bar (6,500 psi) by unloading relief valve (URV143-1),
pressure in this circuit is displayed on pressure gauge (PG194-1).
Ball valves (33-1 through 33-19) on the auxiliary thrust circuit should be closed when the
exceptional high pressure system is utilized. The pumps flow is returned to reservoir via
a directional control valve when this exceptional high pressure system is not utilized.
The outlet volume on the variable pumps is from 0 to 135 LPM (0 to 36 US GPM) with
maximum pressure set at 325 bar (4,714 psi) by pressure relief valve (PCV152-1). These
pumps have a dual pressure compensator set at 100 bar (1,450 psi) and 275 bar (3,989
psi) with a 37 kW limit. The output sides of these pumps are protected from back
pressure surges by check valve (CV86-1).
Pressure in this circuit is displayed on pressure gauge (PG196-1). Flow then advances to
a 10 micron pressure filter (PF184-1), equipped with a visual indicator dirt alarm to show
element condition. The flow then advances to proportional directional control valves
(PDV99-1 through PDV99-4). The output sides of these proportional valves are protected
from back pressure surges by check valves (CV80-1 through CV80-4). A directional
control valve (DCV108-1) provides the pilot pressure needed to activate directional
control valves (DVC111-1 through DCV111-4) that are part of the main thrust circuit.

322s01

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MODEL DS325-322

Each extend and retract line circuits of the main thrust cylinder are connected via shuttle
valves (SV157-1 through SV157-4). These valves route fluid to the cap end or rod end of
these cylinders. Pressure in this circuit is displayed on pressure gauges (PG196-2 through
PG196-5).
Twelve main thrust cylinders operate in groups depending on the position they occupied.
The top position utilizes cylinders numbered 12 and 1; right position uses 2, 3, and 4;
bottom position uses 5, 6, 7, and 8; and left position uses 9, 10, and 11. Top main thrust
cylinder positions 1 and 12 have a counter balance valves (CBV 93-1 through CBV93-4)
incorporated in their circuit, their purpose is to keep the circuit pressurized.
Three directional control valves (DCV114-1, DCV114-3 and DCV 114-4) mounted on
the gripper shield are utilized to reset the twelve main thrust cylinders, the flow is
provided by pumps (13-2 through 13-5, 14-1 and 15-1) with a combined volume of 2,060
LPM (544 US GPM). Pressure in this circuit is reduced to 200 bar (2,901 psi) by pressure
reducing valve (PCV140-1) flow to the cylinders is directed through check valves
(CV85-1 through CV85-4).
15-4 Motor 30 Oil Cooling
This motor drives a double vane pump (PMP13-1), which is utilized for hydraulic oil
cooling purposes, the volume at the outlet of these pumps is 378 LPM (100 GPM) with
maximum pressure set at 35 bar (500 psi) by pressure relief valve (PRV149-1). There is a
10 micron pressure filter (PF184-2), equipped with a visual indicator dirt alarm to show
element condition in the system. Flow is returned to the hydraulic reservoir through a
heat exchanger (HX199-1).
15-5 Motor M28 TBM Conveyor System
The machine conveyor is driven by hydraulic fluid provided by a 55 kW, 74 HP, 1,450
RPM double variable volume pump (PMP15-1) similar to the propel system pump that is
driven by motor (M28). The outlet volume on each of these variable pumps is from 0 to
135 LPM (0 to 36 US GPM) with maximum pressure set at 250 bar (3,626 psi) by
pressure relief valve (PCV152-2).
These pumps are equipped with a dual pressure compensator set at 100 bar (1,450 psi)
and 200 bar (2,901 psi) with a 27 kW limit. The output sides of these pumps are protected
from back pressure surges by check valve (CV86-2). Flow from these pumps passes
through a 10-micron filter (PF184-3) equipped with a visual indicator dirt alarm to show
element condition.
Pressure gauge (PG196-6) provides a visual indication of this circuits pressure.
Directional control of the hydraulic fluid for the conveyor drive is provided by a
solenoid-controlled, pilot-operated, three-position directional control valve (DCV117-1).
Oil flow to the hydraulic motors is controlled by a flow control valve (FCV123-20) set at
141 LPM (37 GPM).

322s01

1.15

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SECTION 1 DESCRIPTION

MODEL DS325-322

The pressure and return lines to the hydraulic motors are connected via a shuttle valve
(SV156-1), this valve routes hydraulic fluid to the forward and reverse rotation of these
two hydraulic motors.
15-6 Lube Return Pump Drive Circuit
A hydraulic gear motor is used to drive the lubrication system return pump. Hydraulic
flow to this motor is derived from motor (M28) and pump (PMP15-1).
Flow to the motor is limited by a pressure-compensated flow control valve (FCV123-21)
set at 19 LPM (5 GPM). A solenoid-operated, spring-offset, two-position directional
control valve (DCV114-2) is used to control flow to the hydraulic motor.
15-7 Segment Feeder
Flow for the segment feeder cylinders is provided by a 55 kW, 74 HP, 1,450 RPM double
variable volume pump (PMP15-2) driven by motor (M31), similar to the propel system
pump that is driven by motor (M25). The outlet volume on each of these variable pumps
is from 0 to 125 LPM (0 to 33 US GPM) with maximum pressure set at 200 bar (3,901
psi) by pressure relief valve (PCV152-3). These pumps are equipped with a dual pressure
compensator set at 150 bar (2,175 psi). The output sides of these pumps are protected
from back pressure surges by check valve (CV86-3).
Flow from these pumps passes through a 10-micron filter (PF184-4) equipped with a
visual indicator dirt alarm to show element condition. Pressure gauge (PG196-7) provides
a visual indication of this circuits pressure.
15-7-1 Segment Lifter Cylinders
Flow control valves (FCV121-10 through FCV121-13) provide speed control on each
circuit. Directional control is provided to each circuit by a 3-position, 4-way manual
directional control valve (DCV119-1 through DCV119-4). Return center position on each
directional control valve is open to tank to remove any trapped oil in the circuit. One
counterbalance valve per cylinder (CBV92-7 through CBV92-14) set at 160 bar (2,321
psi) is provided to control the load, metering the flow equally to the cap end of each
cylinder is provided by flow dividers (FD126-1 through FD126-4).
15-7-2 Segment Advance Cylinder
Directional control is provided by two, 3-position, 4-way directional control valve
(DCV108-7 & DCV107-3). Return center position on directional control valve
(DCV108-7) is open to tank to remove any trapped oil in the circuit. Speed control is
provided by flow control valves (FCV121-14 & FCV121-15).
15-7-3 Outer Frame Lift Cylinders
Directional control is provided by a 3-position, 4-way directional control valve
(DCV108-8). Return center position is open to tank to remove any trapped oil in the
circuit. Flow control valve (FCV121-16) provides speed control.

322s01

1.16

October, 2008

SECTION 1 DESCRIPTION

MODEL DS325-322

Flow to the cap end of each cylinder is through a regular flow divider (FD127-1) and two
sets of rotary gear flow dividers (FD128-1 & FD128-2) each with relief valves set at 120
bar (1,740 psi). Counter balance valves (CBV92-15 & CBV92-16) set at 160 bar (2,321
psi) are also provided on this circuit.
15-8 Transfer Conveyor Circuit
Fluid for this circuit is supplied by pump (PMP15-2) that supplies flow to the segment
feeder system circuit. Speed control is provided by pressure compensated flow control
valve (FCV123-22). Solenoids A or B of directional valve (DCV117-2) control the
operation of the hydraulic motor. Each direction of the hydraulic motor lines is connected
via shuttle valve (SV156-3). This valve directs the flow to either side of the hydraulic
motors while blocking the flow from the return side, pressure transducer (PT191-17)
monitors the system pressure.
15-9 Working Window
Directional control is provided to each cylinder by a 3-position, 4-way manual directional
control valve. Return center position on each directional control valve is open to tank to
remove any trapped oil in the circuit. Pressure in this circuit is limited to 200 bar (2,901
psi).
15-10 Advancing Tail Piece
This circuit is similar to the working window circuit. Directional control is provided to
each cylinder by a 3-position, 4-way manual directional control valve. Return center
position on each directional control valve is open to tank to remove any trapped oil in the
circuit. Pressure in this circuit is limited to 200 bar (2,901 psi).
15-11 Gripper High Pressure Circuit (Slow)
This circuit provides the high pressure necessary to maintain the gripper shoes in their
securely locked position against the bore of the tunnel.
The gripper cylinders and auxiliary functions is driven by hydraulic fluid provided by a
55 kW, 74 HP, 1,450 RPM variable volume pump (PMP16-1) driven by motor (M20),
this pump is similar to the propel system pump that is driven by motor (M25).
The outlet volume on this variable pump is from 0 to 135 LPM (0 to 36 US GPM) with
maximum pressure set at 350 bar (5,076 psi) by pressure relief valve (PCV152-4).
This pump is equipped with a dual pressure compensator set at 100 bar (1,450 psi) and
310 bar (4,496 psi) with a 55 kW limit. The output side of this pump is protected from
back pressure surges by check valve (CV86-4). Output flow from this pump passes
through a 10-micron filter (PF184-5) equipped with a visual indicator dirt alarm to show
element condition. Pressure gauge (PG196-8) provides a visual indication of this circuits
pressure.

322s01

1.17

October, 2008

SECTION 1 DESCRIPTION

MODEL DS325-322

Flow is directed to the gripper circuit through pressure reducing valve (PCV139-1) that is
set at 325 bar (4,714 psi), check valve (CV83-1) protects the system from back pressure
surges and a 9.4 liter (2.5 gallon) accumulator (ACC209-1) that acts as a shock absorber
as well as an instant fluid source for the circuit should the need arise. Normally closed
needle valve (NV132-1) is provided for isolating and draining the accumulator for
maintenance, this valve is to be opened only to service the circuit when the TBM in not
in operation, opening this valve will allow discharge of the hydraulic side of the
accumulator. Gas side will not be discharged.
CAUTION:
This accumulator should be pre-charged to 140 bar (2,031 psi) using only
dry nitrogen (N2).
Flow to the two gripper cylinders is controlled by a solenoid-operated, three-position,
directional control valve (DCV113-1). This valve is controlled by selector switch at the
operator's console that is labeled (S5).
When switch (S5) is set to the extent position, solenoid "B" of directional control valve
(DCV113-1) is energized.
The valve will shift to direct high pressure fluid to the cap ends of the two gripper
cylinders, passing in the free-flow direction through pilot-operated check valves (CV89-1
and CV89-2). Flow from the rod end of the cylinders returns through the directional
control valve passing first in the free-flow direction through a check valve (CV83-2).
The cylinders will extend to force the gripper shoes into contact with the bore of the
tunnel. Since the cylinder piston rods are restricted from extending further by physical
contact of the gripper shoes with the bore of the tunnel, pressure will increase to the
compensator setting of 310 bar (4,496 psi) and hold steady at that pressure.
Two pressure transducers (PT191-7 and PT191-8) are included in the cap end circuits to
provide an electrical interlock with the cutterhead drive system through the programmed
electrical circuits to stop cutterhead rotation if the gripper pressure drops below 138 bar
(2,000 psi). This action will open the programmed circuits that must be completed for
main drive actuation. The drives will stop and cannot be started until gripper pressure
rises again. An alarm message at the operator's console will display when the pressure is
low.

The gripper pressure interlock circuits are very important for safe
operation of the machine. Do not attempt to bypass or alter the
recommended setting except as approved by The Robbins Company
engineering department.

322s01

1.18

October, 2008

SECTION 1 DESCRIPTION

MODEL DS325-322

When the switch is set to the retract position, the check valve (CV83-2) in the rod end
circuit prevents flow of high pressure fluid to the rod ends of the gripper cylinders. The
primary purpose of this feature is to allow gripper cylinder cap end high pressure to bleed
off through the high pressure directional control valve to the reservoir before attempting
to use the fast reset system to retract the gripper shoes. This also acts as a safety device to
prevent rapid loss of gripper high pressure should the control switch inadvertently is
moved to the retract position while boring is in progress.
A path for the cap end fluid is provided from each gripper cylinder through pilot-operated
check valves (CV89-1 and CV89-2) when pilot pressure is applied from the rod side of
the circuit. A .5 mm orifice provides a bleed path to prevent entrapment of this pilot
pressure when the directional valve is shifted to neutral.
The operator should allow the cap end pressure to bleed down to at least 103 bar (1500
psi) before using the fast reset function to avoid unnecessary hydraulic shock into a
circuit operating at a lower pressure.
15-12 Gripper Reset Circuit
This circuit permits rapid re-cycling of the gripper cylinders at the completion of a propel
stroke. The circuit must be used for retracting the gripper cylinder because the gripper
high-pressure circuit cannot perform this function.
Hydraulic fluid for this circuit is available at a combined flow rate of 1,790 lpm (473
gpm) from dual assembly fixed displacement vane pumps (PMP13-2 through PMP13-5)
driven by motors (M21 through M24) and by variable displacement pump (PMP15-1)
driven by motor (M28) previously described, flow from this pump is through directional
control valve (DCV114-3) and check valve (CV86-5).
Flow from these pumps passes through 10-micron pressure filters (PF184-6 through
PF184-9). Each filter assembly is equipped with a visual indicator to show element
condition.
Pressure on these systems is limited to 100 bar (1,450 psi) by pressure relief valves
(PCV151-1 through PCV151-4) these valves are vented to tank through directional
control valves (DCV102-1 through DCV102-4).
Pressure gauges (PG195-1 through PG195-4) provide a visual indication of this circuits
pressure. The hydraulic pumps are protected from backpressure surges by isolation check
valves (CV87-1 through CV87-4).
The control switch for the gripper fast reset function is located at the operator's control
station and is labeled (S5 and S7). When fast (L) and retract are selected, the directional
control valve (DCV116-1) B side solenoid of is energized, flow is directed to the rod end
of each cylinder.

322s01

1.19

October, 2008

SECTION 1 DESCRIPTION

MODEL DS325-322

Return flow from the gripper cylinder cap end is blocked until pressure from the gripper
cylinder rod ends is enough to open pilot-operated check valves (CV88-20 and CV8821). Fluid from the gripper cylinder cap end then flows back to the reservoir.
When switch S5 is the in the extend position, the directional valve (DCV116-1) A side
solenoid is energized.
The combined flow is directed in the free-flow direction through check valves (CV88-20
and CV88-21) to the cap ends of the two gripper cylinders. Fluid from the rod ends then
flows back to the reservoir.
15-13 Gripper Shield Reset Circuit
This system is used to set up the next propel stroke after the main thrust cylinders have
finished a propel stroke.
The main thrust cylinders are retracted, thus moving the gripper shield forward. The
double shield reset system uses a total flow of 1,790 LPM (473 GPM) that is provided by
pumps (PMP14-1, PMP13-2 through PMP13-5).
The shield reset can be accomplished in any of the following two modes:

Double Shield

12 Main Thrust Cylinder Mode

Single Shield

19 Auxiliary Thrust Cylinder High Pressure Mode

NOTE:
Before retraction of the main thrust cylinders is permitted, the installation
of a ring of segments (if used) must be completed and the power removed
from the segment operator's control. Additionally, the gripper shoes in the
gripper shield must be retracted fully; the Stabilizer switch (S9) must be in
the Extend position; and the Stabilizer Pressure switch (S13) must be in the
High position.
15-14 Double Shield Reset
The oil supply pumps are brought on-line by energizing reset enable solenoid-operated
directional control valves (DCV114-1 and DCV114-4).
A combined flow rate of 1,790 LPM (472.8 GPM) is directed to the rod end of the twelve
main thrust cylinders to retract these cylinders.
NOTE:
DCV108-1 must be energized during reset operation.

322s01

1.20

October, 2008

SECTION 1 DESCRIPTION

MODEL DS325-322

Solenoid-operated directional control valve (DCV108-1) is energized to direct pilot


pressure to the four pilot-operated directional control valves (DCV111-1 through
DCV111-4).
This action allows the main thrust cylinder rod end oil to flow back to the reservoir. This
action is accomplished by shifting the Thrust switch (S4) to retract and shifting the
Regrip switch (S6) to the On position at the operators console.
15-15 Single Shield Reset - High Pressure
If unstable ground conditions are encountered and it becomes necessary to reposition the
gripper shield with high pressure, this is accomplished by utilizing only the nineteen
auxiliary thrust cylinders. The main thrust cylinders must be in the fully retracted
position and a complete set of segments must be installed.
The flow for the high-pressure single shield reset mode is from the high-pressure pumps
(PMP14-1 and PMP16-1). Flow from pump (PMP16-1) is directed through flow control
valve (FCV121-1) and pressure control valve (PCV135-1) this valve is set at 160 bar
(2,321 PSI). The solenoid-operated directional control valve (DCV105-1) is energized to
join the flow from the 38 LPM (10 GPM) pump (PMP14-1).
The exceptional high pressure is obtained by energizing the solenoid controlled
directional control valve on this system; the operator's control this function by activating
switch (S3).
Maximum system pressure of 450 bar (6,500 PSI) is limited by unloading relief valve
(URV143-1). Flow then is routed to the cap end of each auxiliary thrust cylinders that
extend the cylinders against the ring of segments.
NOTE:
Ball Valves (BV33-1 through BV33-19) must be locked during single shield
reset operation.
15-16 Stabilizer Circuit
Two stabilizer shoes are located in the upper left and right-hand quadrants of the forward
shield. These devices aid in stabilization during boring, react against rolling, and assist in
holding the forward shield stationary during gripper shield reset operation.
When retracting the gripper shield, the stabilizer cylinders are extended at high pressure.
Each stabilizer shoe is extended or retracted by a single double-acting cylinder.
Fluid for this circuit is supplied by the same pump (PMP16-1) that supplies high pressure
flow for the gripper circuits. The operator's control for this function is switch labeled
(S9). An associated control allows the operator to select operation at low pressure or high
pressure using control is switch labeled (S13). Flow in this circuit is limited to 16 GPM
(60 LPM) by needle valve NV133-1)

322s01

1.21

October, 2008

SECTION 1 DESCRIPTION

MODEL DS325-322

The following activities will occur when the operator sets switch (S9) to the extend
position and sets switch (S13) to the L position:

Solenoid "B" of a solenoid operated pilot-assisted, three-position, springcentered, directional control valve (DCV112-1) will energize. The valve will shift
to direct pump flow through a pressure reducing/relieving valve (PCV141-1) to
the cap ends of the two stabilizer cylinders.

The extend circuit and retract lines of each cylinder are connected by a shuttle
valve (SV156-2). This shuttle valve permits cap end or rod end pressure readings
from the cylinders through pressure transducer (PT191-9). Return flow from the
rod ends is routed back through (DCV112-1) to the reservoir.

When the stabilizer shoes are in contact with the bored tunnel, the pressure will
reach a maximum of 70 bar (1,015 PSI). This is the normal operating pressure for
extending the cylinders during machine operation.

During gripper shield repositioning, the operator must increase the stabilizer pressure to
310 bar (4,496 PSI) by setting the switch (S13), stabilizer pressure low/high to the high
position. The solenoid of a solenoid-operated, spring-offset, two-position directional
control valve (DCV105-2) will energize.
The valve will shift to insert a pilot-operated pressure relief valve (PRV147-1) into the
drain circuit from the pressure reducing/relieving valve (PCV141-1). This relief valve is
set to attain a pressure in the stabilizer circuit of 345 bar (5,004 PSI) and may be verified
at test port (TP13). When the switch (S9) is set to the retract position, solenoid "A" of
(DCV112-1) is energized.
The valve will shift to direct fluid flow to the rod ends of the two stabilizer cylinders.
Maximum pressure on the rod ends is limited to 50 bar (725 psi) by pressure relief valve
(PRV148-1) Cap end flow passes through check valve (CV84-1) and through (DCV1121) to the reservoir.
Pressure settings are additive, maximum cylinder working pressure is 345 bar (5,004 PSI)
NOTE:
If it is necessary to make a roll correction of the forward shield, the
stabilizer shoes should be retracted slightly for the duration of the roll
correction movement, and then restored to normal operating position.
15-17 Conveyor Lift Circuit
Two double-acting hydraulic cylinders are mounted in on the side of the conveyor
forward frame and the muck chute assembly. Oil flow is supplied to these cylinders by
pump (PMP16-1) that has been described previously in this section.

322s01

1.22

October, 2008

SECTION 1 DESCRIPTION

MODEL DS325-322

The oil passes through a solenoid directional control valve (DCV109-1). Port B is
activated for retraction; line A is activated for extension. Pressure in the circuit is
limited by pressure-relief valves (PRV146-1 and PRV146-2). These valves are set at 34
bar (500 psi) above the pressure required to lift the load under normal operating
conditions.
Flow control valve (FCV121-3) set at 40 LPM (11 GPM) provides speed control on this
circuit. A normally closed needle valve (NV132-2) controls the flow from the rod end
side of the cylinders. The two cylinders have integral counterbalance valves each set 150
bar (2,176 psi) the cross-port connected between the rod and cap end of the cylinders
hold the muck chute in position.
15-18 Telescopic Shield Articulation Cylinders Circuit
A total of sixteen articulation cylinders are mounted around the periphery between the
telescoping shield and the gripper shield. These double-acting hydraulic cylinders allow
the articulation between these shield assemblies.
It is very important to the control of the shield that the axial elements of the shield
periphery be straight. The articulation of the shield allows the assembly to be trimmed to
compensate for any discrepancies, allowing the shield to negotiate a tighter turn than
would otherwise be possible, and aids in controlling the roll of the machine.
Flow for these cylinders is supplied by pump (PMP16-1) that has been described
previously in this section. Pressure in the circuit is reduced to 245 bar (3,553 PSI) by
pressure reducing valve (PCV138-1).
Control for these cylinders is provided by directional control valve (DCV118-1) and by
flow control valves (FCV122-1 and FCV122-2). There are two check valves (CV89-3
and CV89-4), flow from either side of the cylinders is restricted until pressure is
sufficient to open them. Pressure relief valves (PRV147-2 and PRV147-3) limits system
pressure in this circuit to 200 bars (2,900.7 PSI) on cylinders rod ends and 225 bars
(3,263 PSI) on the cylinders cap end.
A pressure transducer (PT191-11) is furnished to monitor the retract pressure side of the
circuit and is set at 172 bar (2,500 PSI) pressure, rising above this setting will display an
alarm message at the QuickPanel.
Pressure transducer (PT191-10) is furnished to monitor the extend side of the circuit and
is set at 137.8 bar (2,000 PSI) pressure, rising above this setting will display an alarm
message at the QuickPanel. There are sixteen normally open ball valves (BV34) on the
cap end of each cylinder.
15-19 Cutterhead Support Lift Cylinders Circuit
Two double-acting hydraulic cylinders are mounted on the cutterhead support bottom;
this circuit is similar in components to the Telescopic Shield Articulation Cylinders.

322s01

1.23

October, 2008

SECTION 1 DESCRIPTION

MODEL DS325-322

Flow for these cylinders is supplied by pump (PMP16-1) that has been described
previously in this section. Pressure in the circuit is reduced to 345 bar (5,003.8 PSI) by
pressure reducing valve (PCV138-2).
Control for these cylinders is provided by directional control valve (DCV118-2) while
flow control valves (FCV122-3 and FCV122-4) controls the speed of the cylinders
displacement. Dual Pilot-Operated Check Valves (CV89-5 and CV89-6) provide holding
action for the cap ends and rod ends of these two cylinders.
Pressure relief valves (PRV147-4 and PRV147-5) limits system pressure in this circuit to
345 bars (5,003.8 PSI) and 250 bars (3,625.9 PSI) respectively. Pressure transducers
(PT191-12 and PT191-13) are furnished to monitor pressure in the system.
There are two normally closed ball valves (BV34-16 and BV34-17) on the cap end of
each cylinder, these valves should remain locked closed during non over boring
operation.
15-20 Roll Control Circuit Torque Cylinders
The same pump (PMP16-1) that supplies high pressure flow for the gripper circuits
supplies fluid for this circuit. The operator's control switch for this function is labeled
(S14).
Oil passes through pressure reducing valve (NV138-3) set at 345 bar (5,300.8 PSI) and
into solenoid operated, three-position, directional control valve (DCV118-3). This valve
is controlled by switch (S14). The valves solenoid is energized as long as the switch is
held in either direction.
By turning switch (S14) to the right position, solenoid A of (DCV118-3) is energized.
The oil is routed through flow control valve (FCV122-6) set at 100 LPM (26 GPM) with
pilot pressure supplied to check valve (CV89-7) with free flow through check valve
CV89-8 and through pressure transducer (PT191-14) that monitors pressure in this
circuit, flow then is directed to extend (upward movement) the left hand cylinder while
retracting (downward movement) of the right hand side of the double acting equal area
cylinders, resulting in rolling the forward shield to the right (clockwise).
To rotate the shield to the left, turn (S14) to the left position. Solenoid B of (DCV1183) is energized. The oil travels through flow control valve (FCV122-5) set at 100 LPM
(26 GPM) with pilot pressure supplied to check valve (CV89-8) with free flow through
check valve (CV89-7) and through pressure transducer (PT191-15) that monitors
pressure in this circuit, flow is then directed to retract (downward movement) the left
hand cylinder while extending (upward movement) of the right hand side of the double
acting equal area cylinders, resulting in rolling the forward shield to the left
(counterclockwise).

322s01

1.24

October, 2008

SECTION 1 DESCRIPTION

MODEL DS325-322

Maximum system pressure for this circuit is 345 bar (5,300.8 PSI) at pilot operated relief
valves (PRV147-6 and PRV147-7), the cross plumbing on the check valves provides
holding action in each side of the roll control circuit.
15-21 Cutterhead Parking Brake Circuit
The brake is only to be used to prevent unintended movement of the cutterhead during
cutter changes and maintenance of the head. The brake is not designed to stop normal
head rotation and will wear out very fast if it is used in that manner.
Fluid for this circuit is supplied by pump (PMP16-1) that has been described previously
in this section.
Pressure in the circuit is reduced to 100 bar (1,450 PSI) by pressure reducing valve
(PCV135-2). Flow is then directed to check valve (CV83-3), directional control valve
(DCV106-1) provides directional control for this circuit. When solenoid valve A is
energized, flow is directed to the brake calipers to release the brake.
Pressure is monitored through pressure gauge (PG195-5); this gauge must read zero (0)
pressure before personnel entering the cutterhead area, pressure indicates cutterhead
brake released. Pressure transducer (PT190-8) set at 82.7 bar (1,200 PSI) monitors
pressure in the circuit, pressure falling below this setting shuts down the cutterhead and
displays a warning message at the operators console.

NOTE:
Hydraulic pressure is used to release the motor brake and return springs
are used to apply the brake.
Flow passing through the pressure reducing valve is also directed to the inner and outer
seals on the cutterhead this circuit is listed on the lube schematic drawing D107811.

Cutterhead parking brake release pressure displayed on the system


pressure gauge MUST read ZERO (0) pressure prior to personnel entering
the cutterhead area. Pressure indicates cutterhead brake released.
15-22 Probe Ring Positioning Circuit
Fluid for this circuit is supplied by pump (PMP16-1) that has been described previously
in this section.
Four double acting hydraulic cylinders are connected between the gripper shield
assembly and the probe drill ring. Speed control is provided by pressure compensated
flow control valve (FCV121-9). Solenoids A or B of directional valve (DCV118-4)
control the operation of these cylinders, this directional control valve is to be activated
when the segment erector forward/aft travel directional valve is active.

322s01

1.25

October, 2008

SECTION 1 DESCRIPTION

MODEL DS325-322

Pressure setting on pressure reducing valves (PCV138-4 and PCV138-5) to be 15 bar


(217.5 PSI) above normal operation pressure. The cap end and rod end port of the
cylinders is provided with a counterbalance valve (CVB94-1 and (CBV94-2) to hold the
cylinder position in place. Two additional directional control valves (SV98-1 and SV982) one in each circuit provide a flow path back to tank, these valves to be energized
simultaneously with the segment erector fwd/aft operation.
15-23 Towing Cylinder Circuit
Two double acting hydraulic cylinders are connected between the machine conveyor
frame and the front support that is part of the backup equipment structure. During the
boring cycle, the two cylinders are allowed to extend as the machine moves forward.
At the completion of the boring stroke, these cylinders are retracted to pull the backup
equipment forward in preparation for another boring stroke. The fluid power source for
this circuit is from pump (PMP16-1).
Flow is delivered through flow control valve (FCV122-7) this valve is set at site
assembly in such a way that the retraction rate of the thrust cylinders is equal the
retraction rate of the towing cylinders.
The solenoid-operated, three-position, directional control valve (DCV110-1) provides
directional control for this circuit. This valve is not actuated during the boring cycle. As
the machine advances, the cylinder rods are extended automatically. Flow from the rod
end is routed through (DCV110-1) back to tank through pressure relief valve (PRV145-1)
adjusted to 10 bar (145 PSI). This provides enough resistance to keep the towing cables
tight. At the same time, oil is suctioned from the return line through the check valve
(CV85-1) into the cap end of the cylinders.
The control for the towing circuit selector switch that is labeled (S10) is located on the
operators control console. With the selector switch set to the extend position, solenoid
B of (DCV110-1) is energized. The valve then shifts to direct pump flow to the cap
ends of the two cylinders. As the cylinders retract, the backup equipment is moved
forward.
If the switch is set to the retract position, solenoid A is energized. The valve then shifts
to direct pump flow to the rod ends of the two cylinders to retract the cylinders.
When the pressure transducer (PT191-16) senses resistance pressure above 110.3 bar
(1600 PSI), the main thrust is disabled; an alarm message will be displayed at the
operators control console indicating higher than normal towing pressure.
This message usually signifies an interference with the advancement of the backup. TBM
operator must not restart the thrust systems until the cause of the interference is resolved.

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If the pressure transducer senses resistance pressure below 34 bar (500 PSI) an alarm
message will be displayed at the operators control console indicating lower than normal
towing pressure.
Both the rod end and cap end circuit pressures are limited by the pressure relief valves
(PRV147-8 and PRV147-9) set at 240 bar (3,480.9 PSI) and 150 bar (2,175.5 PSI)
respectively.
15-24 Conveyor Belt Tensioning Cylinders
Two double-acting cylinders are used to tension the conveyor belt. Grease is used for this
purpose. Needle valves (NV131-1 through NV131-4) are used at each cylinder port to
control flow to/from the cylinders.
15-25 Auxiliary Thrust Cylinders Circuit
The auxiliary thrust system is used primarily as an aid in installation of tunnel lining
segments. In special cases, such as a partially stuck shield, it may be necessary to use
these cylinders in the high-pressure extend mode and apply extra moving force forward
by extending the cylinders against the installed segment lining.
Nineteen cylinders are used and are spaced around the aft end of the gripper shield.
Whether used during segment installation or operated to assist in resetting the shield, the
cylinders are operated individually.
Flow for the auxiliary thrust cylinders is provided by 55 kW, 74 HP, 1,450 RPM double
variable volume pump (PMP15-2) driven by motor (M31), previously described.
The solenoid-operated, three-position, directional control valve (DCV150-1 through
DCV150-19) provides directional control for this circuit. Free flow to the cap end of each
cylinder through pilot operated check valves (CV88-1 through CV88-19), flow to the
reservoir from the cap ends is restricted until there is enough pressure to open the check
valves.
Oil volume into the rod end of each cylinder is controlled by a variable pressure
compensator flow control valves (FCV123-1 through FCV123-19). Pressure in this
system is controlled by pressure relief valves (PRV150-1 through PRV150-19). There are
six pressure switches (PS190-1 through PS190-7) mounted on the cap end side of
cylinders 4, 7, 10, 13, 16 and 18.
NOTE:
Ball Valves (BV33-1 through BV33-19) must be locked during single shield
reset operation.
15-26 Segment Erector Circuits
All electrical controls for the segment erector circuits are described in the electrical
system description.

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15-26.1 Erector Rotate Circuit


Fluid for this circuit is derived from two double variable-volume pumps (PMP15-3 and
PMP15-4) that are driven by motors (M26 and M27).
The outlet pumps volume is from 0 to 540 LPM (0 to 142.6 US GPM) with maximum
pressure set at 275 bar (3,989 psi) by each pressure relief valves (PCV152-5 and
PCV152-6). These pumps have a dual pressure compensator set at 100 bar (1,450 psi)
and 250 bar (3,626 psi) with a 45 kW limit. The output sides of these pumps are protected
from back pressure surges by check valves (CV86-6 and CV86-7).
Flow from these pumps passes through 10-micron pressure filters (PF184-10 and PF18411). Each filter assembly is equipped with a visual indicator to show element condition.
Two pressure gauges (PG196-9 and PG196-10) mounted on the hydraulic power unit
indicate pressure in these two circuits.
Fluid is directed to manifold (MFD68-1) with distribution ports to the erector rotate and
the segment erector circuits.
Flow to the erector rotate is through a pilot operated proportional directional control
valve (PDV100-1), pilot pressure to this valve is supplied from directional control valve
(DCV103-1) within the same circuit that enables erector rotation.
Erector rotation is selected by energizing solenoid A or B of pilot operated directional
control valve (PDV100-1). A hydraulic parking brake is mounted on each drive unit to
control rotation positioning.
The brakes are spring set and hydraulic pressure released. Whenever either solenoid of
(PDV100-1) is energized, shuttle valve (SV157-5) will direct oil to pressure reducing
valve (PCV136-1) set at 20 bar (290 psi).
The oil shifts the spool allowing fluid to disengage the brakes. Counterbalance valves
(CBV95-1, CBV96-1, CBV96-2 and CBV95-2) provide dynamic braking for this system.
15-26.2 Segment Erector Rotation Ring Circuit
Fluid from manifold (MFD68-1) is directed through pressure control valve (PCV140-2)
set at 200 bar (2,901 psi) that provides flow to a hose reel that provides storage for the
hydraulic lines that must rotate with the erector and also provides flow to the segment
erector axial cylinders, radial settings cylinders, yaw cylinder, pitch and roll cylinders
and vacuum assembly.
15-26.3 Erector Axial Positioning Circuit
The erector axial positioning circuit is controlled by solenoids A or B of directional
valve (DCV108-2). Speed control is provided by flow control valve (FCV121-4).

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Maximum pressure setting in the forward mode is set at 65 bar (943 psi) by pressure
relief valve (PRV146-3), setting on the aft mode is set at 85 bar (1,233 psi) by pressure
relief valve (PRV146-4). Each cylinder port is provided with a counterbalance valve
(CVB93-5 through (CBV93-8) set at 40 bar (580 psi) to hold the load in place.

NOTE:
Probe ring positioning directional control valve (DCV118-4) to be activated
when the segment erector forward/aft travel directional control valve
(DCV108-2) is active.
15-26.4 Erector In/Out Circuit
Speed control is provided by pressure compensated flow control valve (FCV121-6).
Solenoids A or B of directional valve (DCV108-3) control the erector radial circuit
(in/out). Maximum pressure setting in the out mode is set at 220 bar (3,191 psi) by
pressure relief valve (PRV146-5), setting on the in mode is set at 85 bar (1,233 psi) by
pressure relief valve (PRV146-6). Each cylinder port is provided with a counterbalance
valve (CVB93-9 through (CBV93-12) set at 180 bar (2,611 psi) on the rod end port of
each cylinder and at 120 bar (1,741 psi) on the cap end port of each cylinder to hold the
load in place.
A directional control valve (DCV104-1) connected to the cap end of the cylinders
permits flow to return to tank when energized with flow passing through pressure relief
valve (PRV144-1) set at 25 bar (363 psi).
15-26.5 Segment Rotate (Yaw) Cylinder Circuit
This circuit rotates the segment slightly Clockwise (CW) or counterclockwise (CCW) to
help accurately position the segment. The motion is controlled by directional control
valve (DCV108-4) solenoid B of this directional control valve directs flow to the cap
end of the cylinder, solenoid A directs the flow to the rod end.
The rotation speed is controlled by flow control valve (FCV121-8). Counterbalance
valves (CBV92-1 and CBV92-2) set at 100 bar (1,450 psi) hold the load in place.
15-26.6 Vacuum Grip
This circuit has a total of six cylinders, two cylinders for the middle pad in/out positions
and four cylinders for the side pad in/out positions. Flow to these two circuits is through
two directional control valves, four flow control valves connected to each port of the
cylinders, four counterbalance valves set at 140 bar (2,031 psi) each are provided to hold
the load in place. Pressure to this circuit is reduced by pressure reducing valve (PCV1371) set at 150 bar (2,176 psi).
15-26.7 Segment Tilt Circuit (Right/Left and Up/Down)
Directional valve (DCV108-5) controls the right and left movements of the segments,
while (DCV108-6) controls the up and down movements.

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Counterbalance valves (CBV92-3 through CBV92-6) each set 160 bar (2,321 psi) are
cross-port connected between the rod and cap end of the cylinders; they hold the segment
in position. Flow control valve (FCV130-2 through FCV130-5) provides speed control
for this circuit.
15-27 Main Thrust Circuit
This circuit propels the cutterhead and forward shield forward during the boring cycle.
The twelve main thrust cylinders are controlled as four groups of cylinders. The TBM
operator controls the flow rate to each of these four groups individually. When all four
groups receive the same flow rate, the cutterhead advances straight ahead.
By directing more or less flow rate to certain groups of cylinders, the cutterhead will
reposition at a new angle and steering will be affected.
Flow for this circuit is provided by the variable-volume piston pump (PMP14-1) driven
by motor M25 (MTR9-1).
The main thrust cylinders can be extended or retracted by use of solenoid-operated
directional control valve (DCV108-1). Energizing solenoid A provides pilot oil to the
A side of the pilot-operated directional control valves (DCV111-1 through DCV111-4)
resulting in retracting the main thrust cylinders.
Conversely, energizing solenoid B will cause the main thrust cylinder to extend (boring
cycle). The speed of the main thrust cylinders is controlled by four proportional
directional control valves (PDV99-1 through PDV99-4). Control of these valves is by
means of a potentiometer at the operator station labeled (R1).
NOTE:
For reference purposes, the main thrust cylinders are numbered from 1
through 12 in a clockwise direction as viewed looking forward to the
connection points at the back of the forward shield. Using top center as a
starting point, cylinder number 1 is located immediately clockwise of
center while number 12 is immediately counterclockwise of center.
Pressure transducers (PT191-1 through PT191-5) are furnished so cutterhead thrust
forces can be determined by the PLC.
15-28 Steering Corrections
During normal boring of the Double Shield TBM, steering corrections are made by
adding oil to one of four quadrants. The addition of this oil must be made in such a
manner as to prevent the buildup of pressure in the thrust circuit beyond the pressure
being used to advance forward. When steering oil is added the pressure in that quadrant
tends to rise. As the pressure in the quadrant rises it is necessary to lower the
flow/pressure of oil to all quadrants in order to avoid an overall increase in thrust force.
Following are procedures to be used for steering corrections.

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The machine is to be operated at thrust pressures not to exceed the net average thrust
cylinder pressure. (Thrust pressure of 12 cylinders less drag, towing loads, cutterhead
stabilization, and factoring the compound angle of the thrust cylinder in the fully
extended position.)
Steering corrections are to be made in the following manner:
Steering flow controls set to minimum flow position.
Steering control valve to be shifted to desired position.
Reading on PPS guidance system literature to be noted.
Steering flow control to be opened slowly.
Thrust pressure to be noted.
Thrust pressure/flow to be lowered as needed to ensure that the net pressure does
not rise.

NOTE:
It is important to ensure that pressures and flows in the thrust circuit are
diminished as the steering flow controls are increased in order to prevent
overload of the thrust circuit / cutterhead. All steering motions must be
conducted while boring, and not when the cutterhead is stationary.
The following list associates main thrust cylinders with their steering quadrant:
Steering Direction

Main Thrust Cylinder Numbers

Down

1, 12

Up

5, 6, 7 and 8

Left

2, 3 and 4

Right

9, 10 and 11

The groups of main thrust cylinders listed above provide the maximum steering effort.
The operator can decrease the steering effort of a given quadrant by blocking the steering
oil from reaching one or more of the cylinders in that quadrant.
Blocking the flow of oil is accomplished by de-energizing the appropriate proportional
directional control valves that are identified as (PDV99-1 through PDV99-4). For full
steering effort these valves are energized to allow oil to advance. Oil is prevented from
advancing to a cylinder when a valve is not energized. Each steering valve has a manual
switch control for the TBM operators use (R1 through R5).
Steering UP is accomplished energizing proportional control valve (PDV99-3) side so
that main thrust cylinders 5, 6, 7 and 8 extend faster than the other cylinders. Thus, the
cutterhead and forward shield will aim Up.

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Steering DOWN is accomplished by energizing proportional control valve (PDV99-1)


so that main thrust cylinders 1 and 2 extend faster than the other cylinders. Thus, the
cutterhead and forward shield will aim Down.
Steering RIGHT is accomplished by energizing proportional directional control valve
(PDV99-4) so that main thrust cylinders 9, 10 and 11 extend faster than the other
cylinders. Thus, the cutterhead and forward shield will aim Right.
Steering LEFT accomplished by energizing proportional directional control valve
(PDV99-2) so that main thrust cylinders 2, 3 and 4 extend faster than the other cylinders.
Thus, the cutterhead and forward shield will aim Left.

16 Electrical System
The electrical system Section 16 primary controls and indicators are located at the
operator console assembly. Extensive use of a PLC (Programmable Logic Controller) is
made on this machine for controlling electrical functions.
Incoming power to the machine is 33 kV, 3-phase, 50 Hz. It is supplied by trailing cable
from the customer furnished switching equipment.
Two 3100kVA transformers (OT01 and OT2) and one 2000kVA (OT3) are furnished.
The transformers are air ventilated. Operation and maintenance instructions for the
transformers are included in Section 16.
The primary side of transformer (OT1) primary side is delta connected and the secondary
side is wye-connected with neutral, transformer (OT2) primary and secondary side is wye
connected with neutral.
Phase to phase voltage at secondary connection is 690V, 50Hz. Primary side of
transformer (OT3) primary side is delta and secondary side is wye connected with neutral
brought out. Phase to phase secondary connection is 400V, 50Hz. Taps are provided on
the primary side to allow adjustment for voltages above or below the nominal 33kV input
level (+5% and +2.5%, nominal, -2.5% and -5%).

NOTE:
The secondary circuit of transformers T1, T2, and T3 is identical. Therefore,
only the secondary of transformer T1 is described.
The secondary output of transformer T1 (0T01) is routed to VFD cabinet #1 which
provides power to cutterhead motors 1 through 7; transformer T2 (0T02) and VFD
cabinet #2 provides power to cutterhead motors 8 through 14; transformer T3 (0T03)
provides power to the TBM switchgear cabinet.

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This TBM has the capability of driving the cutterhead in two different speed ranges in the
forward (clockwise) direction and one speed in the reverse (counter clockwise) direction,
viewed from the back of the cutterhead.
TBM Switchgear Cabinet
The secondary output of transformer T3 is routed to the TBM switchgear cabinet where
the power is connected to ground fault relay (1K91) and Phase fault (1K92).
Additionally, power is routed to a 3000 amp circuit breaker (1Q91) this circuit breaker is
equipped with an under voltage trip unit (1Q91:1).
This under voltage trip unit (1Q91:1) is the means for tripping the ground fault relay
(1K91). Power continues to the motors (M21 through M31, M35 and M41 through M46).
Power to motors (M21 through M25, M28, M29 M31 and M35) is through a set of 200
amps, 3-pole, manually reset circuit breakers and motor starters (1Q21/1K21 through
1Q25/1K25, 1Q28/1K28, 1Q29/1K29, 1Q31/1K31 and 1Q35/1K35) one set per circuit.
Current sensing on these circuits is performed by current transformers (1T21 through
1T25, 1T28, 1T29, 1T31 and 1T35).
Power to motor (M26 and M27) is through a set of 300 amps, 3 pole, manually reset
circuit breaker and motor starter (1Q26/1K26 and 1Q27/1K27) Current sensing on the
hydraulic motors is performed by current transformers (1T26 and 1T27).
Power to motor (M30) is through a set of 100 amps, 3 pole, manually reset circuit breaker
and motor starter (1Q30/1K30) Current sensing on the hydraulic motors is performed by
current transformers (1T30).
Power to motor (M41) is through a set of 30 amps, 3 pole, manually reset circuit breakers
and motor starters (1Q41/1K41).
Power to motors (M42 through M45) is through a set of 50 amps, 3 pole, manually reset
circuit breakers and motor starters (1Q42/1K42 through 1Q45/1K45).
Power to the erector vacuum pump motor (M46) is through a set of 15 amps, 3 pole,
manually reset circuit breakers and motor starters (1Q46/1K46).
Power to the two air compressors is through a set of 400 amps, 3 pole, manually reset
circuit breakers (1Q50 and 1Q51).
Power to the two dust scrubber fans and probe drill power unit and two booster fans is
through a set of 200 amps, 3 pole, manually reset circuit breakers (1Q52 through 1Q54)
and (1Q78 and 1Q79).

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Power to the grout pump, continuous mixer, davits on gantry #0 and gantry #5, grout
crane, cassette hoist, cranes on gantry 7, dust scrubber and pea gravel shotcrete 2 is
through a set of 30 amps, 3 pole, manually reset circuit breakers (1Q55, 1Q58, 1Q61
through Q63, 1Q74 through 1Q76, 1Q80 and 1Q81)
Power to the screw conveyor, agitators on gantry #3 and gantry #4 is through a set of 15
amps, 3 pole, manually reset circuit breaker (1Q59, 1Q72 and 1Q73).
Power to the mixer, pump 1 and pump 2 on gantry 4 is through a set of 40 amps, 3 pole,
manually reset circuit breaker (1Q56, 1Q57 and 1Q60).
Power to the main segment hoist is through a set of 60 amps, 3 pole, manually reset
circuit breaker (1Q64).
Power to the hoist on gantry #4 is through a set of 50 amps, 3 pole, manually reset circuit
breaker (1Q65).
Power to the two welding outlets is through a set of 50 amps, 3 pole, manually reset
circuit breaker (1Q70 and 1Q71).
Power to the transfer relay that feeds the genset transfer cabinet is through a set of 400
amps, 3 pole, manually reset circuit breaker (1Q77).
Power to the genset transfer cabinet is through a set of 400 amps, 3 pole, manually reset
circuit breaker (2Q100).
The methane monitor circuit is connected to the genset estop circuit, if contact 1K81:2 is
open the genset cannot start.
Power to the three hose reels, two invert water pumps and HV cable reel is through a set
of 15 amps, 3 pole, manually reset circuit breaker (2Q101 through 2Q105 and 2Q109).
Power to the distribution panel is through a set of 50 amps, 3 pole, manually reset circuit
breaker (2Q107).
Power to the dewater tank pump motor (M106) is through a set of 100 amps, 3 pole,
manually reset circuit breaker and motor starter (2Q106 and 2K106).
Power to the emergency dewater pump motor is through a set of 200 amps, 3 pole,
manually reset circuit breaker and motor starter (2Q108 and OS108).

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16-1

MODEL DS325-322

Electrical Controls and Interlocks

NOTE:
Refer to Section 2 for images and description of the QuickPanel Pages.
The TBM is controlled via a Programmable Logic Controller (PLC). With the exception
of a few hard-wired safety items, all electrical devices on the TBM are routed through the
PLC. The operator may, for example, push a button to start a hydraulic pump motor, but
the button is not directly connected to the motor. Instead, the button signals the PLC that
the operator wishes the pump motor to start.
The PLC then examines the current state of the machine and makes a decision as to
whether it is proper to allow the starting of this motor. If all is correct per the PLCs
programmed logic, the motor is commanded to start by the PLC.
This is commonly known as the machine interlock logic. The PLC resides primarily in
the PLC Cabinet, located in the operators cabin. It consists of a computer module (CPU),
a number of input and output modules, and a number of communication modules.
Additionally, there are a number of remote I/O modules located in the TBM and on the
backup gantries, which collect and distribute electrical signals to various devices. These
remote I/O modules communicate with the PLC via two serial networks known as
Mininets.
The most visible electronic device that the operator sees is the graphical display unit,
known by its trade name as the QuickPanel.
This is not part of the PLC; rather it is a relatively dumb device that makes no
decisions as to how the TBM is to operate. It is simply an interface device allowing the
operator to communicate with the PLC.
It displays a great deal of information about the status of the TBM and it allows the
operator to make a number of commands via soft buttons, or graphical representation
of control buttons that the operator can push.
The QuickPanel displays its information on a number of pages, which the operator can
select. The pages are:

DIRECTORY

BORING

CUTTERHEAD MOTORS

WATER SYSTEMS

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LUBE SYSTEM

SUPPORT MOTORS

SUPPORT MOTORS 2

CONVEYORS

LUBE INTERLOCKS

MOTORS AMPS KW TORQUE PER MOTOR

INTERLOCKS ELECTRICAL CONTROLS CUTTERHEAD JOG


SUPPORT MOTORS

INTERLOCKS DOUBLE/SINGLE SHIELD MODE

INTERLOCKS MAIN THRUST AND GRIPPER CIRCUITS

16-1.1 Methane Monitors OE11, OE12 & OE13


Three methane monitors are provided, each with one remote sensing head.
The sensing heads are located at the top of the cutterhead support, operators station and
at the exhaust. Each monitor has a digital amplifier readout unit in the operators cabin;
refer to manufacturers literature found in Section 16 of this service manual for more
information.
16-1.2 Carbon Monoxide Monitor OE14
One monitor is provided with a sensing head located at the operators station; refer to
manufacturers literature found in Section 16 of this service manual for more
information.
16-1.3 Oxygen Monitor OE15
One monitor is provided with a sensing head located at the operators station; refer to
manufacturers literature found in Section 16 of this service manual for more
information.
16-1.4 Carbon Dioxide Monitor OE16
One monitor is provided with a sensing head located at the operators station; refer to
manufacturers literature found in Section 16 of this service manual for more
information.
16-1.5 Emergency Stop Push Buttons
There are 13 emergency stop circuits located throughout the TBM. All E-stops on the
TBM have the same effect. When an E-stop is pushed in, the TBM control power is
de-energized. Power is turned off to all PLC outputs. PLC inputs still function.

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16-1.6 Main Thrust Stroke Position Transducers


Four position indicating cylinders are provided and are located at the gripper shield
assembly. These are Temposonic brand magnetostrictive position transducers.
Each sends an RS422 signal to its AOM (Analog Output Module), which in turn sends a
4-20 mA signal to the PLC. Each cylinder's stroke is displayed on the QuickPanel. Refer
to manufacturers literature found in Section 10 of this service manual for more
information.
16-1.7 Speed Switch
The conveyor has a speed switch (N/O) that is operated by a wheel in contact with the
belt.
The switch closes when the conveyor is up to speed. If the conveyor speed slows down
and the switch opens, the PLC turns off the conveyor, and stops the cutterhead motors
after two seconds. The delay avoids nuisance shutdowns. During starting of the
conveyor, also allows two seconds for the conveyor to reach full speed, before enabling
the speed switch. Refer to manufacturers literature found in Section 11 of this service
manual for more information.
16-1.8 Cutterhead Motors Warning and Shutdown Temperature Switches
Each motor (M1 through M14) is provided with two sets of temperature switches,
each set comprise of three normally closed switches, one per phase and wired in
series. First set opens at 140C (284F) and provides a warning message on the
QuickPanel. The second set opens at 160C (320F) and disables the cutterhead
motors.

17

Water System Assembly

The machine is equipped with a water spray system to provide a means for cooling the
main drive assemblies, VFD drive system, probe drill, seal flushing and other structures
and equipments where dust suppression or cooling is needed. Refer to Water Schematic
drawing number D107810, in Section 17 of this service manual.
Water should be delivered into the system at a minimum of 1,200 LPM (317 US GPM) 3
bar (43.5 PSI) at a maximum temperature of 20C (68F).
Incoming water is routed through two butterfly valves. One valve (BFV34-1) allows the
water to be shut off at this point. The other valve (BFV34-2) is installed right after the
water filter (WF12-1) that provides filtration for the incoming water.
This filter has a screen element that can be removed and cleaned when required. The
cleanliness of the incoming water will dictate the frequency for filter maintenance.

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Water flow is then routed through a Water Temperature Gauge (WTG13-4) and a Water
Pressure Gauge (WPG39-4) and into the TBM/Back-up Water reservoir. A float valve
(WFV24-1) controls the water level in the reservoir and one gate valve (WGV38-2) is
provided for draining the reservoir or for use as cleaning or dust control outlets.
TBM/Backup Water Reservoir 10000 Liter
A sight gauge (SG21-2) provides a visual indication of fluid level within the reservoir. In
addition, a low water level switch (LS20-3) interlocked electrically to stop/motor
(PMP/MTR44 and PMP/MTR45) if the water level drops below a safe operating levels.
A high level switch (LS20-6) monitors the high water level in the reservoir. Both
switches display an alarm message at the operators console if the water level is low or
high.
A temperature switch (TS14-1) is set to detect high temperature, the switch is set below
35C (95F), if temperature reaches this setting an alarm message is displayed at the
operators console. A water temperature gauge (WTG13-5) is available to monitor the
water temperature in the reservoir.
Two 750 LPM (198 GPM) 7 bar (101.5 PSI) pumps driven by two 15kW, 400V, 50Hz, 3
phase electric pump motors (PMP8-1 and PMP8-2) are utilized in this system. With
reference to the electrical system assembly these motors are identified as (M44 and
M45). Flow to these pumps is routed through butterfly valves (BFV33-3 and BFV33-4);
these valves should remain open when operating these circuits.
Each pump is protected from back pressure surges by isolation check valves (CV23-3 and
CV23-4). System pressure is limited to 7 bar (101.5 PSI) by pressure relief valves
(WRV19-3 and WRV19-4).
Pressure in this system is monitored by water pressure gauge (WPG39-6) while a
temperature transducer (TT15-1) senses pressure in the system.
Water flow continues through two butterfly valves (BFV34-3 and BFV34-4) installed on
both sides of water filter (WF12-2). This filter has a screen element that can be removed
and cleaned when required. The cleanliness of the water will dictate the frequency for
filter maintenance.
The water is then distributed to the main drive assemblies and to two heat exchangers
used on the hydraulic system and the variable frequency drive system.
Water flowing to the main drive assemblies is directed through a water solenoid valve
(WDV17-2) that activates automatically when main drive motors are energized, this
valve stays on 5 minutes after the main drive motors are shut down.

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Pressure is reduced to a maximum of 5 bar (72.5 PSI) by pressure reducing valve


(PCV18-1), the system pressure is indicated on water pressure gauge (WPG39-3) and
system temperature is monitored by water temperature gauge (WTG13-3).
There are fourteen water gate valves (WGV35-1 through WGV35-14) that regulates the
water flow coming from the gear reducers and main drive motors, flow continues through
fourteen water flow meters (WFM26-1 through WFM26-14) average a flow through
these flow meters is 30 LPM (7.9 GPM) each.
Decreasing flow of 150 LPM (39.6GPM) during operation will cause actuation of Flow
Meter/Switch (WFS27-1) timer within 10 seconds; cutterhead motors will drop out of
service after a 15 second timer delay and will display and alarm message at the operators
console. Water return flow is routed back to the TBM/Back-up water return reservoir.
Flow from these pumps is also used for the seal flush system and cutterhead water spray.
Seal Flush and Water Spray Console
Water to these two systems is through pressure gauge (WPG39-1) that monitors pressure
is this system, hydraulic oil heat exchanger and water temperature gauge (WTG13-2) that
monitors system temperature. Flow to the seal flush system is through a water solenoid
valve (WSV16-1) that has a duty cycle of 5 seconds on and 55 seconds off, the operator
can adjust the seal flush timer by pressing the corresponding QuickPanel screen button,
every press of the button will add or subtract the timer amount by one second. This valve
comes on automatically when the cutterhead is rotating.
Water to the four seal flush ports is through two water gate valves (WGV35-29 and
WGV35-30) and two water flow meters (WFM26-15 and WFM26-16). A minimum flow
of 19 LPM (5 GPM) each, is required for this system. This flow also is made available to
other spray points common to the cutterhead support and around the gripper shield.
Water to the cutterhead water spray nozzles is through water solenoid valve (WSV16-2)
that comes on automatically whenever the cutterhead is rotating, water gate valve
(WGV36-9) located near the operator control cabinet controls water flow to the
cutterhead nozzles, flow continues to water rotary union and cutterhead nozzles.
Water solenoid valve (WSV17-1) is energized when the hydraulic power unit is running
and cutterhead seal flush and cutterhead water spray solenoid valves are de-energized,
returning water flow to the TBM/Back-up water return reservoir. A water gate valve
(WGV37-1) and water pressure gauge (WPG39-2) are incorporated into this circuit.
Discharge Water Reservoirs 5000 Liter
Water from the main drive assemblies and from TBM/Back-up water supply through
solenoid valves (WSV17-1 and WFS27-4) is returned to the 5000 liters TBM/Back-up
water return reservoir or discharge water reservoir. This reservoir is similar in operation
and components to the TBM/Back-up water reservoir.

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A sight gauge (SG21-1) provides a visual indication of fluid level within the reservoir. In
addition, a low water level switch (LS20-1) interlocked electrically to stop/motor
(PMP/MTR42 and PMP/MTR43) if the water level drops below a safe operating levels.
A high level switch (LS20-5) monitors the high water level in the reservoir, starting
PMP/MTR42 if level is high. An additional level switch (LS20-2) starts pump/motors
(PMP/MTR42 and PMP/MTR43) when the water system in on. These switches display
an alarm message at the operators console if the water level is low or high.
A water temperature gauge (WTG13-6) is available to monitor the water temperature in
the reservoir, a gate valve (WGV38-1) is provided for draining the reservoir or for use as
cleaning or dust control outlets.
Two 600 LPM (159 GPM) 10 bar (145 PSI) pumps driven by two 15kW, 400V, 50Hz, 3
phase electric pump motors (PMP9-1 and PMP9-2) are utilized in this system. With
reference to the electrical system assembly these motors are identified as (M42 and
M43). Flow to these pumps is routed through butterfly valves (BFV33-1 and BFV33-2);
these valves should remain open when operating these circuits.
Each pump is protected from back pressure surges by isolation check valves (CV23-1 and
CV23-2). System pressure is limited to 10 bar (145 PSI) by pressure relief valves
(WRV19-1 and WRV19-2). Pressure in this system is monitored by water pressure gauge
(WPG39-5).
Water flow from these two pumps is directed to the TBM discharge hose reel.
Variable Frequency Cooling 1,500 Liter Reservoir
The closed loop variable frequency drive or VFD cooling water/glycol reservoir with a
mixing ratio of 5:3 is located on the back-up assembly, the system is described as
follows; a breather assembly (BR40-1) provides venting for this system.
This assembly utilizes a replaceable element that should be changed periodically. The
operating environment dictates the frequency of change.
A sight gauge (SG21-3) provides a visual indication of fluid level within the reservoir. In
addition, a level switch (LVS20-4) interlocked electrically to stop/motor (PMP/MTR101) if the water level drops below a safe operating level, displaying an alarm message at
the operators console simultaneously.
A double temperature switch (TS14-2) with a high setting of 60C (140F) and low
setting of 30C (86F) activates a normally closed water solenoid valve (WSV16-3); this
valve is energized when the temperature is below 30C and closes when the temperature
is above 60C, flow from this valve is directed to the TBM/Back-up water return
reservoir.

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A water gate valve (WGV37-3) allows the reservoir to be drained, water temperature
gauge (WTG13-7) monitors water temperature in the reservoir.
The 420 LPM (110.9GPM), 7 bar (101.5 PSI Pump is driven by a 3kW, 400V, Electric
Motor (PMP/MTR10-1), with reference to the electrical system this motor is identified as
(M41). Flow is routed through a butterfly valve (BFV32-1), back pressure surges is
protected by a water check valve (CV22-1).
Water pressure gauge (WPG39-7) is provided to monitor pressure in the system. Two
butterfly valves (BFV32-2 and BFV32-3) are located before and after the water filter
(WF11-1). Flow continues through heat exchanger (HX31-1) and onto fourteen VFD
inverter assemblies. Each assembly is provided with a water gate valve (WGV35-15
through WGV35-28) to adjust the water flow, average flow passing through the water
flow meters (WFM25-1 through WFM25-14) is 30 LPM (7.9 GPM).
Decreasing flow of 150 LPM (39.6GPM) during operation will cause actuation of Flow
Meter/Switch (WFS27-2 and WFS27-3) timer within 10 seconds; cutterhead motors will
drop out of service after a 15 second timer delay and will display an alarm message at the
operators console.
Water supply flow to heat exchanger (HX31-1) passes through water gate valve
(WGV37-2) and is monitored by water flow switch (WFS27-4) that is set at 80 LPM (21
GPM) decreasing flow will display an alarm message at the operators console.

18 Position Monitoring Equipment


The position monitoring equipment provided as a part of this machine consists of the
Guidance System and PPS Guidance System. These drawings are included in Section 18
of this manual.
18-1 PPS System
The TBM Guidance System
The Guidance System is designed to provide maximum TBM positional information to
the operator of the Tunnel Boring Machine (TBM) while requiring a minimum of
attention.
The system will automatically determine the exact position and driving direction of a
TBM in three-dimensional space. It also gives the operator complete information about
the deviation of the TBM from the designed centerline.
A projected path display is optionally provided to show the operator the optimal course
along which to guide a deviated TBM back to the design centerline. For tunnels with
segmented liners, ring calculation software is also available.

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To measure the location and driving direction of a TBM, at least two defined points on
the TBM, together with pitch and roll, must be measured in three-dimensional space.
These two points are the two EDM prisms installed in the forward section of the TBM.
Their placement positions on the machine are arbitrary as long as a line of sight to the
theodolite is available.
After final positioning, the exact location relative to the TBM axis and local TBM coordinate system is then measured, with these values becoming part of the one-time TBM
setup parameters.
Because the TBM will roll and pitch during boring, the TBM co-ordinate system is
usually not parallel to the global co-ordinate system. Therefore, roll and pitch of the
TBM must be measured accurately, which is accomplished electronically by the robust
two-axis inclinometer mounted on the TBM.
The two prisms on the TBM are automatically measured by a motorized theodolite whose
standpoint and orientation have been previously defined. New coordinates for the
theodolite standpoint are easily determined by using a standard function of the guidance
system. Orientation of the horizontal angle system of the theodolite is easily
accomplished by aiming the theodolite at the reference prism, whose coordinates are
known. The Look-Ahead Theodolite Station Setup function of the system then inserts the
new station and orientation information into the system computer.
Subsequently, the global co-ordinates of the two primary points on the TBM may now be
established by measuring the slope distance and horizontal and vertical angles from the
oriented theodolite.
Since the location of the prisms in the TBM co-ordinate system was established at TBM
set-up, and the roll and pitch of the TBM are known at all times, any point of the TBM
(e.g. the center of the cutter head) can be calculated in global three dimensional space.
The tunnel design centerline is also known in the global co-ordinate system and has been
entered into the system computer at the project start. Therefore, horizontal and vertical
deviation of the TBM from the design centerline, together with TBM orientation, is
calculated and presented graphically to the TBM pilot in real time.
If desired, a projected path can also be calculated and displayed to show the optimum
path back to the design centerline, considering parameters such as minimum turning
radius, or, related to the geometry of pre-cast liner elements.
The remote prism plays a critical part in the assurance of system accuracy. In addition to
providing a reference during the orientation of the theodolite, it also allows automatic online detection of potential errors caused by any movement of the theodolite standpoint.
Because the theodolite is usually mounted on the wall of the just-bored tunnel, about 25
to 300m behind the TBM, it has a high potential for movement.

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Additionally, the platform may be hit and moved by unknown events. Such movement, if
undetected, can have an adverse effect on the accuracy of boring.
Consequently, the TBM Guidance System theodolite periodically measures the remote
prism to check the stability of the theodolite standpoint and notifies the TBM operator if
movement has occurred.
The interval of these reference measurements is fully dictated by the user with password
protected parameter menus.
18-2 TV System Assembly
The TV System (part of the electrical system, Section 16) consists of four cameras, a
monitor and a video processor. The monitor and the video processor are located in the
TBM operator cabin. The four cameras are mounted by the erector area, rail installation
area, muck transfer area and end of back-up area. Literature for the video processor is
included in Section 16.

19

Miscellaneous Equipment

This section includes all items and systems not covered under the standard manual
sections. Equipment included for this machine, Service Beam Installation, Cutter
Handling Assembly, walkways and ladders assembly, and fire alarm system assembly.
19-1 Service Beam Installation
The service beam installation consist of four electric chain hoist and four manual chain
hoist used to transport main drive motor assemblies to and from the front of the machine.
This assembly utilizes the cutter handling beam assembly.
19-2 Cutter Handling Assembly
The cutter handling assembly consists of the handling tools and cutter track used to move
cutter assemblies to and from the front of the machine during cutterhead maintenance.
19-3 Walkways & Ladders
The walkways and ladders are used by operation and maintenance personnel to gain
access to different areas in and around the machine.
19-4 Fire Alarm System Assembly
The fire alarm system assembly consists of fire detectors installed throughout the TBM.
These detectors are connected to a 10 zone fire alarm control panel.
There are six smoke detectors that are mounted at the following locations: cutterhead
support, erector, bridge gantry #0, gantry #2, gantry #6 and gantry #7.

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Backup System

20-1 Introduction
The back-up assembly consists of seven gantries assemblies that carry the different
components need it for the operation of the TBM, most gantries are equipped with
structural members to support vent lines, water lines, air lines, cable and hose trays, and
more, depending on the location in the string. The backup system provides mounting for
the operators cab, hydraulic, lube and electrical components such as transformers, and
electrical cabinets also included are, hose reel, generator, water tank, compressor, grease
system and the ventilation duct cassette.
Details of each deck could be found in Section 20 of this service manual under drawing
D109000. A description of each of the structural assemblies is included; the structural
equipment is covered in order from the front (TBM and backup interface) to the rear.
20-2 Gantry Assemblies
A brief description follows for each of these structural elements that make up the backup
equipment. The descriptions also provide identifications of the components mounted on
each gantry.
20-2.1 Bridge Gantry Assembly
The bridge gantry assembly includes the bridge gantry structure, transfer conveyor
assembly; lube oil reservoir, probe drill power unit, operators cab assembly, hydraulic
reservoir, three hydraulic power units, hoists, two advance cylinders and a tow arm
assembly . This structure also provides a mechanical link between the machine and
gantry #1.
A wheeled trolley that travels on rails mounted on the upper section of the forward
transfer conveyor assembly supports the machine conveyor. During normal boring
operations the machine and this trolley advance and the towing cylinders are extended for
the distance of a thrust stroke. The towing cylinders are retracted to advance the entire
Backup equipment.
20-2.2 Gantry 1
The upper section of this gantry provides support structures for the left and right VFD
cabinet assemblies and two 3100 kVA transformers, these components are equally
mounted on each side of the gantry.
The segment lifter assembly is mounted on the lower section of this gantry. A walkway is
provided on each lower section of this gantry.
20-2.3 Gantry 2
The upper section of this gantry provides support structures for the TBM switchgear
cabinet assembly, 2000 kVA transformer, lunch room, office, and work bench.

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The segment lifter assembly is mounted on the lower section of this gantry. A walkway is
provided on each lower section of this gantry.
20-2.4 Gantry 3
The upper section of this gantry provides support structures for the upper crane bridge
with hoists assembly, invert grout system which includes continuous mixer, primary
grout agitator, primary grout pump, , grout mixer, and screw conveyor.
The davit arm assemblies with hoist assemblies are mounted on the lower section of this
gantry.
20-2.5 Gantry 4
The upper section of this gantry provides support structures for the pea gravel system and
hoist assembly.
A walkway is provided on each lower section of this gantry.
20-2.6 Gantry 5
The upper section of this gantry provides support structures for the refugee chamber,
dirty water reservoir, clean water reservoir and hot water return reservoir.
A walkway is provided on each lower section of this gantry.
20-2.7 Gantry 6
The upper section of this gantry provides support structures for the air system assembly
that includes two air compressors, air dryer, and air receiver; ventilation booster fan, a
generator and generator control panel.
The 33kVA high voltage cable reel and chain hoist assembly are mounted on the lower
section of this gantry.
20-2.8 Gantry 7
The upper section of this gantry provides support structures for the vent line to the
scrubber, scrubber fan, duck storage cassette assembly and hoist assembly. The water
curtain with 49 nozzles is mounted throughout the gantry frame.
Two hose reels are mounted on the lower section of this gantry.
20-3 Ventilation System
Incoming fresh air is brought in through flexible ducting from outside the tunnel. This
ducting is connected through a duct section that is folded into a cassette located on gantry
#7; the ducting in the cassette has an appearance similar to an accordion. As the machine
advances, this ducting will gradually be pulled from the cassette and hung from the
tunnel crown.

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Once this section has been extended to full length, the empty cassette is removed and a
full cassette is brought in to continue the ducting. The empty cassette is taken out of the
tunnel to be reloaded.
Ducting is provided along the length of the upper section of the backup equipment to
circulate fresh air to and from the front of the backup.
Additional ducting is mounted on the upper section of the backup to extract the dustladen air and transport it to the scrubber.
20-4 Walkway Installation
Each gantry is equipped with a walkway on the left and right hand side. This allows the
tunneling personnel to gain access to the components on each gantry and to move around
the backup independent of the trains position.

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SECTION 2 Operation
Table of Contents
Page
1. INTRODUCTION

2.1

2. MACHINE ASSEMBLY, TRANSPORT & CHECKOUT

2.1

3. CONTROLS & INDICATORS

2.1

4. OPERATOR CONTROL PANEL (QUICKPANEL)

2.2

5. QUICKPANEL CONTROL PAGES

2.3

6. QUICKPANEL CONTROL BORING PAGE

2.3

7. QUICKPANEL CONTROL CUTTERHEAD MOTORS PAGE

2.6

8. QUICKPANEL CONTROL CUTTERHEAD MOTORS 2 PAGE

2.7

9. QUICKPANEL CONTROL SUPPORT MOTORS PAGE

2.8

10. QUICKPANEL CONTROL SUPPORT MOTORS 2 PAGE

2.10

11. QUICKPANEL CONTROL CONVEYORS PAGE

2.11

12. QUICKPANEL CONTROL LUBE PAGE

2.12

13. QUICKPANEL CONTROL WATER PAGE

2.13

14. QUICKPANEL CONTROL HYDRAULICS PAGE

2.14

15. QUICKPANEL CONTROL TBM BORING CONFIGURATION PAGE

2.15

16. QUICKPANEL CONTROL LUBE INTERLOCKS PAGE

2.16

17. QUICKPANEL CONTROL MANUAL OPERATION SYSTEM PAGE


INTERLOCKS PAGE

2.17

18. QUICKPANEL CONTROL DOUBLE SHIELD MODE


INTERLOCKS PAGE

2.18

19. QUICKPANEL CONTROL ELECTRICAL INTERLOCKS PAGE

2.19

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SECTION 2 Operation
Table of Contents
Page
20. QUICKPANEL CONTROL ALARM PAGE

2.20

21. OPERATING INSTRUCTIONS

2.21

22. PRELIMINARY CHECKS & ADJUSTMENTS

2.21

23. STARTING PROCEDURE

2.22

24. BORING MODE

2.24

25. ADVANCE RATE

2.26

26. REGRIPPING CYCLE

2.26

27. STOPPING PROCEDURES

2.29

28. MACHINE ALIGNMENT & STEERING

2.30

29. CUTTERHEAD THRUST LOADING

2.33

30. JOG DRIVE STATION

2.33

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Introduction

Before attempting to operate this machine, the operator should be thoroughly familiar with the
machine systems, the functions of the various actuators, the controls and monitoring devices, and
the safety instructions. All warnings in the Safety Considerations Section at the beginning of
the manual as well as in this section should be adhered to strictly. Section 1, Description,
contains detailed information on the various assemblies and systems that make up the complete
machine. The operator should refer to this section for additional information on any topics that
are not familiar, as well as to the relevant schematics and drawings that are included in Sections
4 through 20.

Machine Assembly, Transport, and Checkout

The methods used for assembling the machine, moving it to the starting point of the tunnel, and
preparing a starting chamber will depend on the configuration of the site and the equipment
available. Drawing D103330 shows the weights and dimensions of the major assemblies and
drawing D103854 site layout/site assembly sequence are included in Section 4 as a guide for
assembling the machine and moving it into the starting chamber. Before beginning to bore the
tunnel, the machine should be inspected and all systems tested, as advised by Robbins field
service personnel.

Controls and Indicators

Most TBM functions, and some backup decks functions, are monitored and controlled at the
Operator Console located in the Operator Cabin. The electrical control system for this TBM uses
a Programmable Logic Controller (PLC). A PLC is an industrial computer well suited to
service a large number of inputs and outputs.
Inputs consist of operator-activated switches, pressure switches, limit switches, level switches,
temperature switches, pressure transducers, and position transducers. Outputs consist of
solenoid valves, indicator lamps, relays, motor starters, meters, and alarm horns.
The PLC is located in the Operator Cabin in an enclosure called the PLC Cabinet. The PLC
consists of a number of electronic modules plugged into racks. These modules include power
supplies, the CPU, input and output cards, and communication cards. In order to greatly reduce
the amount of wiring to input and outputs located in dispersed areas of the TBM and backup
decks, there are a number of remote I/O modules.
These modules locally service inputs and outputs, and communicate with the PLC via a high
speed cable network.

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Thus, two twisted pairs of wires of the cable network replace hundreds of wires that would
normally be needed to bring signals from input and output devices to the PLC. Remote I/O
modules are located in the Hydraulic Power Unit Cabinet, the Main Electrical Cabinet, and the
two VFD cabinets.
The PLC runs a program written specifically for this TBM. The program is written in a
language known as Ladder Logic. This program is designed to examine the inputs and then
make a decision as to which outputs are to be activated. For instance, the operator may press
the button to start a pump. The PLC will see that this button has been pressed.
However, before the PLC commands the pump motor starter to energize, it will first examine
some other inputs to see if it is ok to start the pump. These checks are known as interlocks
and may consist of examining that the circuit breaker is not tripped, that the motor overload relay
is not tripped, and that there is sufficient hydraulic oil in the reservoir. Only if all of these
interlocks are satisfied will the PLC energize the pump motor starter.
3-1
Operator Control Panel (QuickPanel)
Located in the Operator Console is a video display unit known by its brand name as the
QuickPanel. The QuickPanel is often mistakenly thought of as the primary controller of the
TBM. In reality, the QuickPanel is simply another I/O device as far as the PLC is concerned. The
QuickPanel displays a number of buttons on a number of screens. The operator can touch a
button to request that a given machine operation take place.
The buttons change color and display operational status as various machine operations take
place. The QuickPanel also displays useful information concerning the machine operation.
These displays include ammeters, stroke position, advance rate, and status indications. Due to
the large number of operations and displays required and the limited amount of area on the video
display, the QuickPanel is structured in a number of different pages.
The operator can easily jump from page to page with the press of a button. The pages are
logically arranged to each show a different area of machine control. The following sections of
this document consider each page of the QuickPanel.

NOTE:
There is one very important safety interlock system that must be cleared before any
machine operations can be performed. This is the E-stop interlock system. Any E-stop
button that is activated on the TBM will both electronically disable the PLC and will
mechanically drop out all of the relays that supply power to the outputs.
To clear the E-stop interlock system, first confirm that all of the E-stop buttons on the machine
are in the normal run position. Then press the Reset button.
Most operator controls and indicators are located in the operator's control station, inside the
operator's cab. For specialized functions, the controls are located at the relevant area of the
machine.

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3-2
QuickPanel Control Pages
Each of the operational screen pages is shown and described below. The interlock and status
pages provide information only and are not designed to accommodate operator input.

Figure 2.1 QuickPanel Control Boring Page


3-2.1
QuickPanel Boring Templates
The operator usually selects this page when the TBM is boring. It displays useful information
related to the boring operation.
Reset Template
This template will display Ready to Reset provided the E-stop interlocks are clear and there
are no PLC faults, the Operator Console key is inserted and turned to the right. When Reset is
pressed, the button will turn green and indicate OP Console Enabled.
Siren Template
The operator sounds the siren from this template.

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CH Run Template
Normal cutterhead can be started from this template when button turns white and indicates
Ready, after the start button is pressed the template will turn green and will display
Running. If there is a fault or the stop button is pressed the template turns red and displays
Fault
Conveyors Group Start Template
This template displays the TBM and transfer conveyor status. Operator can start, and stop both
conveyors using this template. Siren automatically sounds for 10 seconds before conveyor starts.
This template will turn green and will display Running when the conveyors are operating, after
the reset button is pressed the template turns white and displays Ready to Run. If there is a
fault or the stop button is pressed the template turns red and displays Fault, after the start
button is pressed the template will turn yellow and display Starting.
Interlocks: Tunnel conveyor must be running before TBM and transfer conveyor can be run.
Support Motors Group Start Template
This template button will conveniently start and stop motors M21 through M31, in a timed
sequence. This template will turn green and will display Starting when pressing the start
button, the template displays Running when the motors are operating. If there is a fault the
template turns red and displays Fault
Interlocks: all individual interlocks for M21 through M31 must be clear. See QuickPanel
hydraulics and lube for interlock status.
Hydraulic Pumps Amps Display Template
Eleven bar ammeters indicate the M21 through M31 hydraulic pump motor amps. Motor M21
have a full load amp rating of 147A. Values displayed below 147A are shown as green. Values
above 147A are shown as red.
Motor M22 through M25 have a full load amp rating of 122A. Values displayed below 122A are
shown as green. Values above 122A are shown as red.
Motor M26 and M27 have a full load amp rating of 147A. Values displayed below 147A are
shown as green. Values above 147A are shown as red.
Motor M28, M29 and M31 have a full load amp rating of 90A. Values displayed below 90A are
shown as green. Values above 90A are shown as red.
Motor M30 have a full load amp rating of 41A. Values displayed below 41A are shown as green.
Values above 41A are shown as red.
Cutterhead Speed Set/Actual RPM Display Template
The actual cutterhead running speed, expressed in terms of percentage, is shown in the CH
Speed, Set and Actual bar displaying a numeric display.

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Set values displayed below 10000 are shown as green and values displayed above 10000 are
shown as red; actual values displayed below 11.57 are shown as green and values displayed
above 11.57 are shown as yellow. By pressing the plus or minus button the RPM is increased or
decreased.
Average Motor CHD Amps Display Template
A bar ammeter and numeric display indicate the average per-motor amps for the cutterhead
motors. Each motor have a full load amp rating of 314A. Values displayed below 314A are
shown as green, values displayed above 314A are shown as red.
TBM Status Displays Template
Status of critical systems are displayed: Tunnel Conveyor speed, Transfer Conveyor speed,
TBM Conveyor speed, CH Air Pressure, Seal Flush, CH Spray, Motor Cooling, VFD1 and
VFD2 Cooling, Hydraulic High Temp, Bearing Lube, Pinion Lube, Seal Lube, Lube Level Low
and Gripper Extent/Retract. In addition there is a lube return override button.

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Figure 2.2 QuickPanel Control Cutterhead Motors Page


3-2.2

QuickPanel CHD Drive Motors Templates

VFD/M1 through M14 Bypass Templates


These buttons indicate when a VFD is on line or in a faulted state. Additionally, the operator can
chose to Bypass one or more VFD/Cutterhead motor. If a Cutterhead motor or VFD is faulted the
cutterhead cannot be run unless the corresponding VFD/Cutterhead motor is bypassed. When
bypassed, the status is ignored by the interlock logic. Pressing the reset button can reset VFD
errors.
Template color and message displayed will change accordingly, if a motor is bypassed the
template turns yellow and displays Bypassed, when the motor is operating, the template turns
green and displays Online. If there is a fault or the motor stop button is pressed the template
turns red and displays Fault
Interlocks: See QuickPanel Cutterhead Drive Interlocks Page status.

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Figure 2.3 QuickPanel Control Cutterhead Motors 2 Page


3-2.3
QuickPanel CHD Drive Motors Bar Graphs Templates
The actual cutterhead motor amperage, load in kW and torque are displayed in bar graphs
format.
Amps per Motor
Drive Motors M1 through M14 have a full load amp rating of 310A. Values displayed below
310A are shown as green. Values above 310A are shown as red.
Kilowatts per Motor
Drive Motors M1 through M14 have a full load kW rating of 100kW. Values displayed below
100kW are shown as green. Values above 100kW are shown as red.
Torque Percentage per Motor
Drive Motors M1 through M14 have a torque percentage load rating of 100. Values displayed
below 100 are shown as green. Values above 100 are shown as red.
Cutterhead Speed
These two bar templates have been described previously, see boring page description.

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Figure 2.4 QuickPanel Control Support Motors Page


3-2.4
Support Motors Page Template
Hydraulic pump motors M21 through M31 can be start or stop individually or as a group using
the correspondent assigned template.
Template color and message displayed will change accordingly, if a motor is operating the
template turns green and displays Running, the template turns gray and displays Ready
when the reset button is pressed. If there is a fault or the motor stop button is pressed the
template turns red and displays Fault
Bar Graphs Amps per Motor
Pump motors M21 through M25 have a full load amp rating of 122A. Values displayed below
122A are shown as green. Values above 122A are shown as red.
Pump motors M26 and M27 have a full load amp rating of 147A. Values displayed below 147A
are shown as green. Values above 147A are shown as red.
Pump motors M28, M29 and M31 have a full load amp rating of 90A. Values displayed below
90A are shown as green. Values above 90A are shown as red.
Pump motor M30 have a full load amp rating of 41A. Values displayed below 41A are shown as
green. Values above 41A are shown as red.
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Lube System Template


Lube pump motor M35 can be start or stop individually or as a group using the correspondent
assigned template, this motor has a full load amp rating of 90A. Values below 90A are shown as
green. Values above 90A are shown as red.
Template color and message displayed will change accordingly.
Motor M35 template turns green when the motor is operating and displays Running, the
template turns gray and displays Ready when the reset button is pressed. If there is a fault or
the motor stop button is pressed the template turns red and displays Fault
Main Bearing Template
There are four display messages and colors on this template. Red indicates Fault in the system,
yellow indicates Warning, green indicates system running Ok, dark grey indicates system is
Off.
Pinions Template
Same as the main bearing template description.
Front Pinion & Rear Pinion Template
Same as the main bearing template description.
Seal Lube
Red indicates Fault in the system, yellow indicates Warning, green indicates system running
On, dark grey indicates system is Off.
Seal Lube Indicator
This indicator flashes on and off every time the seal lube feeder cycles, the flasher changes from
green to blue and vice versa.
Seal Lube Valve
The seal lube directional control valve DCV56-1 operates automatically when the cutterhead is
running, the operator can override the activation of this valve by pressing buttons Manually
closed or Manually open
Lube Return Template
Red indicates Fault in the system, yellow indicates Warning, green indicates system
Running, light grey indicates system is Ready and dark grey indicates system is Off.

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Figure 2.5 QuickPanel Control Support Motors 2 Page


3-2.5
Support Motors Page 2 Template
Hydraulic pump motors M41 through M45 and M106 can be start or stop individually or as a
group using the correspondent assigned template.
Template color and message displayed will change accordingly, if a motor is operating the
template turns green and displays Running, the template turns gray and displays Ready
when the reset button is pressed. If there is a fault or the motor stop button is pressed the
template turns red and displays Fault

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MODEL DS325-322

Figure 2.6 QuickPanel Control Conveyors Page


3-2.6

QuickPanel Conveyors Template

Conveyor System Templates


TBM Conveyor template displays status of TBM conveyor. Operator can start, stop and jog the
TBM conveyor by pressing the corresponding control button. This conveyor can be jog forward
or in reverse mode. Siren automatically sounds for 10 seconds before conveyor starts.
This template will turn green and will display Running when the conveyor is operating, will
turn green and displays Starting when the starting button is pressed. This template turns blue
when is jogging in reverse and yellow when jogging in forward direction.
If there is a fault the template turns red and displays Fault, if the conveyor is active the
template turns grey and displays Off.
Interlocks: Back-up conveyor and transfer conveyor must be running before TBM conveyor
can be run. See QuickPanel Conveyor Interlocks status on this page.
The Transfer Conveyor template is operated identical to the TBM conveyor.
Interlocks: See QuickPanel Conveyor Interlocks status on this page.
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MODEL DS325-322

The Tunnel Conveyor template does not have any operator input; the template turns green when
is Running or grey when is Off.
Interlocks: See QuickPanel Conveyor Interlocks status on this page.

Figure 2.7 QuickPanel Control Lube Page


3-2.7
Lube System Templates
The Seal Lube template, Lube Return template and the Lube Sys M35 template were previously
described on QuickPanel Support Motors page.
Interlocks: See QuickPanel Lube 2 Interlocks page status.
Lube Status Display Templates
Status of critical systems is displayed: temperature, reservoir level, pumps operation, filter
condition, and system pressures, green indicate system is working, color indicators varied from
system to system, with templates on the pressure filters using the color green to indicate system
Off condition and color red to show system On, pump used color dark green so indicate
system Off and color light green to indicate system is On.

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MODEL DS325-322

Figure 2.8 QuickPanel Control Water Page


3-2.8
Water System Templates
The Pump/Motor templates (M42 through M45 and M106), were previously described on
QuickPanel Support Motors 2 page.
TBM Discharge Water
This circuit can be automatic operated or manually operated, pressing the Auto/Man template
button activates pumps M42 and M43, template messages changes to Auto On Auto Off,
Man On Man Off depending on the operators input.
Water Status Graphic Display Templates
Status of critical systems is displayed: temperature, reservoir level and filter condition, green
indicate system is working, blue indicates system is off, on some components red indicates
system is off.

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MODEL DS325-322

Figure 2.9 QuickPanel Control Hydraulics Page


3-2.9
Hydraulics Page
The operator can extend or retract the Telescopic Shield and Lift the Cutterhead Support by
pressing the template buttons Ret for retract and Ext for extend from this page. Pressure
setting for the telescopic shield articulation in the extend mode is 138 bar (2002 PSI). Values
displayed below 138 are shown as green. Values above 138 bars are shown as red. In the retract
mode the setting is 172 bars (2495 PSI). Values displayed below 172 are shown as green. Values
above 172 are shown as red.
Pressure setting for the Cutterhead Support Lift is 350 bars (5076 PSI). Values displayed below
350 are shown as green. Values above 350 are shown as red.

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MODEL DS325-322

Figure 2.10 QuickPanel Controls TBM Boring Configuration Interlocks Page


3-2.10 Hydraulic Interlocks Page
This page displays the interlocks status for the double shield mode and single shield mode
hydraulic system.

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MODEL DS325-322

Figure 2.11 QuickPanel Controls Lube Interlocks Page


3-2.11 Lube Interlocks Page
This page displays the interlocks status for the lube system.

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MODEL DS325-322

Figure 2.12 QuickPanel Controls Manual Operation System Interlocks Page


3-2.12 Manual Operation System Interlocks Page
This page displays the interlocks status for the gripper and thrust cylinders manual operations
system.

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MODEL DS325-322

Figure 2.13 QuickPanel Controls Double Shield Mode Interlocks Page


3-2.13 Controls Interlocks Page
This page displays the interlocks status for the double shield mode hydraulic system.

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MODEL DS325-322

Figure 2.14 QuickPanel Controls Electrical Interlocks Page


3-2.14 Conveyors Interlocks Page
This page displays the Electrical Interlocks.

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2.19

November, 2008

SECTION 2 OPERATION

MODEL DS325-322

Figure 2.15 QuickPanel Controls Alarm Page


3-2.15 Alarm Page
This page displays the alarms message history which can be cleared by selecting the Clear
Alarms button.

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MODEL DS325-322

Operating Instructions

The following topics describe the operating procedures for this tunnel boring machine. Follow
all safety instructions in the text as well as those in the Safety Considerations section at the front
of this manual.

Preliminary Checks and Adjustments

NOTE:
Observe all safety instructions located in this text as well as those in the Safety
Considerations section at the beginning of the manual.

The following checks and adjustments assume that the machine has been assembled, tested, and
has bored enough tunnel to be beyond the collaring-in phase. Each step should be followed at
the start of each shift or after each time the machine is shut down for any length of time.
Make sure all personnel are clear of the cutterhead, conveyor, and all other moving parts of the
machine. Check with maintenance personnel to ensure no components or systems are under
repair before proceeding.
5-1

Make sure the level of fluid in the lube and hydraulic reservoirs is satisfactory as
indicated on the respective level indicators. Add fluid as necessary before starting.

5-2

Make sure the inlet valves to all pumps are open.

5-3

Verify all circuit breakers in the electrical cabinets and lighting panel are closed.

5-4

Make sure all hydraulic control switches are in the center or neutral position. Rotate the
Thrust Cylinders Speed switch R1 fully counterclockwise.

5-5

Verify the incoming water supply is connected and the valves are open.

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MODEL DS325-322

Starting Procedure

To start cutterhead rotation, perform the following steps in the sequence described.
6-1

Initial Sequence

6-1.1 Insert the control key into the Console Power Off/On key switch S16 and rotate to the On
position.
6-1.2 Turn on control power by highlighting the Reset template and pressing the control button.
6-1.3 Verify gauges are operating properly: hydraulic and lube function gauges show no
pressure; electrical system meters show zero; water pressure gauge indicates pressure in
the water system.
NOTE:
If ammeter(s) do not indicate zero, adjust by turning front panel adjustment
screw(s) until meter needle(s) indicate zero.
6-1.4 Highlight the Lube System template (QuickPanel Support Motors page) and press control
button Start. This will start lube pump drive motor M35. The flow switch indicators
(Bearing, Pinions, Front Pinion Bearing and Rear Pinion Bearing) should turn green and
the Seal Lube Cycle indicators should blink on/off about once every 1-2 seconds.
6-1.5 Highlight the Sup Motors Group Start template (QuickPanel Boring page). Press control
button START. Motors M21 through M31, M35, M41 through M46 and M106 will start.
6-1.6 Highlight the Conveyors Group Start template (QuickPanel Boring page). Press control
button START. If the Continuous Conveyor speed switch signal is received, the following
sequence will occur:
TBM siren will sound for ten seconds before conveyor startup
Transfer Conveyor will start followed by the TBM conveyor
CCA

Verify that the conveyor areas are clear of all personnel before starting.
6-1.7 To start cutterhead water spray automatically, verify that the CH Spray template is
enabled. Highlight the template (QuickPanel Water page) and press control button, Auto/Man,
until the template displays Auto On.
NOTE:
The operator may manually control the cutterhead water spray using the same
control button. This template has four different messages/settings these are:
Auto On, Auto, Manual On and Manual Off.
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6-1.8 Highlight the CH Run template (QuickPanel Boring page). Press control button Start.
The fourteen cutterhead motors should start simultaneously. The motors will accelerate up to a
preset speed following a fixed ramp. When all fourteen running signals are received, the
cutterhead motors template turns green and displays Running.
NOTE:
Use the CH Speed Set template to set a new speed for the cutterhead motors.
Refer to the QuickPanel Boring Page description described earlier in this section.

NOTE:

Proceed to Topic 6-2 for Double Shield Mode operation.


Proceed to Topic 6-3 for Single Shield Mode operation.

6-2

Double Shield Mode Starting Procedure

6-2.1 Set the Grippers pressure control switch S7 to L (fast). Set the Grippers switch S5 to
extend. When the gripper shoes contact the tunnel wall, return switch S5 to the center
position.
6-2.2 Set the Grippers pressure control switch S7 to H (slow). Set the Grippers switch S22 to
extend. The Gripper High Pressure indicator on Boring Configuration page will turn
green when the gripper pressure reaches approximately 138 bar (2,000 PSI). Verify that
the Gripper pressure gauge rises to approximately 310 bar (4496 PSI) and stabilizes.
NOTE:
Switch S5 must remain in the Extend position during the boring cycle.
NOTE:
Two gripper pressures are available: Slow (high pressure) and Fast (low
pressure). Fast is a low pressure selection used to recycle the gripper shoes at
the end of the propel stroke. The Fast selection is not used for gripping the
machine for boring. The Slow selection is used for gripping the tunnel wall
during the boring cycle.
6-2.3 Set the Stabilizer Pressure switch S13 to the L (low pressure).
6-2.4 Set the Stabilizer switch S9 to the Extend position.
NOTE:
The purpose of these two cylinders is to stabilize the forward shield assembly
during the boring cycle. The amount of pressure applied to these cylinders
should be sufficient to maintain cutterhead stability, but not so great as to cause
excessive drag loads for the thrust system.

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MODEL DS325-322

As the gage cutterhead rings wear, minor adjustments should be made to the
stabilizers to compensate for the decrease in the tunnel diameter.
6-2.5 Ensure that the ventilation equipment is operating.
6-2.6 Check the roll and position of the machine by viewing the guidance system targets.
NOTE:
Refer to the PPS manufacturers instructions in Section 18 of this manual.
6-2.7 If necessary, correct the position of the machine as Topic 11, Machine Alignment and
Steering.
6-3

Single Shield Mode Starting Procedure

6-3.1 Set the Grippers switch S5 to Retract until the gripper pressure drops to near zero, then
center the control (this assumes the grippers are extended against the tunnel wall). An
alarm message will display on the QuickPanel.
6-3.2 Set the Grippers pressure control switch S7 to L (fast). Set the Grippers switch S5 to
Retract. Allow the gripper shoes to retract fully and return switch S5 to the center
position.
6-3.3 Extend the stabilizers enough to sufficiently maintain cutterhead stability.
6-3.4 As the Single Shield Mode of operation is conducted with the gripper in the fully
retracted position, the user may proceed directly to Topic 7-2 Single Shield Boring Mode
operation.

Boring Mode

During the boring cycle, the operator must continuously adjust and monitor all functions,
controls, and indicators at the operator's control station. Additionally, the operator must
determine the proper propel pressure to be applied to the cutterhead, as detailed below.
CCA

Do not ignore abnormal indications. If an indicator shows a malfunction that


does not result in machine shutdown through normal interlocks, stop the
machine to investigate. Disregarding a malfunction indicator may result in
damage to the machine and/or injury to personnel.

NOTE:
Proceed to Topic 7-1 for Double Shield Boring Mode operation.

Proceed to Topic 7-2 for Single Shield Boring Mode operation.

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7-1

MODEL DS325-322

Double Shield Boring Mode

7-1.1 Ensure that the Speed control switch R1 is at the minimum setting (fully
counterclockwise).
7-1.2 Ensure that the Thrust control switch S4 is centered.
7-1.3 Ensure that the Roll Correction control switch S14 is centered.
7-1.4 To apply initial thrust, turn the Thrust control switch S4 to the Extend position. Rotate
the Speed control switch R1, until the forward shield and cutterhead begin to advance.
The cutterhead advance rate is determined by the output of the propel pump.
Displacement percentage of this pump is determined by the position of the Speed control.
The pressures of thrust cylinder groups are displayed on the pressure gauges that are part
of manifold MFD 58-1mounted on the gripper shield.
NOTE:
During the boring cycle, the operator must continuously monitor the indicators
and adjust the controls at the control console.
NOTE:
The TBM line and grade must be continuously monitored by the operator during
the boring cycle. A PPS system is used for monitoring the TBM line and grade.
Steering corrections must be continuously made by the operator throughout the
boring cycle. For more information, refer to machine alignment and steering
information that is toward the end of this section.
7-2

Single Shield Boring Mode

NOTE:
Retraction of the auxiliary thrust cylinders is controlled only by the erector
pendant operator. This is to ensure that the erector operator can safely control
the auxiliary cylinders that are holding segments in place.
7-2.1 Retract the gripper shield according to Topic 9, Re-gripping Cycle.
7-2.2 Rotate Thrust control switch S4 to Retract until the thrust (propel) cylinders are fully
retracted. Center the selector switch.
7-2.3 Rotate the two position Single Shield Mode control switch S11 to the On (clockwise)
position.
7-2.4 Ensure that the Roll Correction control switch S14 is centered.
7-2.5 Extend the auxiliary cylinders by using the auxiliary cylinder control station pendant
switch to the Extend position. The auxiliary thrust cylinders will extend in this mode,
advancing the TBM by pushing against the pre-cast concrete tunnel lining segments.
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MODEL DS325-322

NOTE:
In extreme conditions when even more auxiliary thrust pressure is needed, the
Exceptional Auxiliary Thrust Pressure mode may be used. For more information,
refer to Topic 9, Re-gripping Cycle.

Advance Rate

Cutterhead advance rate is determined by propel pressure and propel pump output. The limiting
factor in most ground conditions is main drive motor current load. Motor loading is directly
related to the torque required to turn the cutterhead.
8-1

Advance Rate Control Procedures

8-1.1 Set the Speed selector switch R1 to approximately 50 percent (indicated on the Main
Thrust meter).
8-1.2 Gradually increase thrust (propel) pressure by rotating the Speed selector switch R1
clockwise while monitoring the Cutterhead Amperes meter. The thrust pressure can be
set at the point where motor loading is approaching but not exceeding the maximum
level, assuming that machine vibration is not excessive.
NOTE:
Consideration must be given to cutter loading as described later in this section.
8-1.3 Continue to observe propel pressure during the propel stroke. If the propel pressure
increases with no change in pump output, an increase in rock hardness is indicated.
Propel pressure should then be increased (if possible), or pump flow should be decreased.
8-1.4 If the propel pressure decreases with no change in pump output, softer material has been
encountered. The pump output should then be increased or propel pressure decreased.
Always strive for optimum performance while not exceeding the limitation of the main
drive motors and cutter assemblies.

Re-gripping Cycle

NOTE:
The erector must be disabled before re-grip can be performed.
Once the thrust (propel) cylinders have been extended to the limit of their stroke, the machine
must be stopped to allow the gripper shield to be repositioned as described below.

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MODEL DS325-322

CAUTION
If the cutter rings require inspection, back the machine up before re-gripping.
The cutterhead must be rotating, the stabilizers must be relaxed, the erector
pendant must be disabled before backing the cutterhead away from the rock face.
Use only the propel high pressure system in the retract mode. Failure to do so
will result in serious damage to the cutter assemblies.
9-1

Initial Sequence

9-1.1 Make sure the machine is level and note position of PPS guidance system.
9-1.2 Rotate Thrust selector switch (S12) to Retract until the thrust (propel) pressure drops to
near zero. Center the selector switch to the center position.
9-1.3 Allow cutterhead to continue rotation for several revolutions to clear cuttings from the
cutterhead and muck chute areas.
9-1.4 Highlight the CH Run indicator template (QuickPanel Boring page) and momentarily
press Stop control button.
9-1.5 Make sure the machine and transfer conveyors are clear, and then highlight the
Conveyors Group Start indicator template (QuickPanel Boring page). Stop the
conveyors by pressing Stop control button.
9-1.6 Enable high pressure extension of the forward stabilizers by turning the Stabilizer control
switch S13 to H (high).
9-1.7 Extend the forward stabilizers by turning the Stabilizer control switch S9 to Extend.
9-1.8 Set the Grippers control switch S5 to Retract until the gripper pressure drops below 138
bar (2000 PSI). Center the switch to the center position.
9-1.9 Set the Grippers pressure control switch S7 to L (fast). Turn control switch S5 to
Retract. Allow the gripper shoes to retract fully.
9-1.10 Ensure that the auxiliary thrust cylinders are fully extended against the segments.

322s02

NOTE:
Proceed to Topic 9-2 for Double Shield Re-grip Mode operation.
Proceed to Topic 9-3 for Single Shield Re-grip Mode operation.
Proceed to Topic 9-4 for Exceptional High Pressure System.

2.27

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SECTION 2 OPERATION
9-2

MODEL DS325-322

Double Shield Mode Re-gripping Cycle

9-2.1 Verify that the auxiliary thrust cylinders shoes are contacting the segments. If they are
not, extend each group of cylinders, as required, by using the auxiliary cylinder control
station pendant switch to the Extend position.
9-2.2 Ensure that the Re-grip pressure control switch S7 is set to the L (fast) position.
9-2.3 Set the Re-grip control switch S6 to the On position. By selecting the On position, all
nineteen auxiliary thrust cylinders will extend. Simultaneously, the main thrust
cylinders will retract.
9-2.4 Allow the main thrust cylinders to retract fully, and then return the Re-grip control switch
S6 to center position.
9-2.5 Set the Grippers pressure switch S7 to L (fast). Turn control switch S5 to Extend.
Allow the gripper shoes to extend until they contact the tunnel wall, then center switch
S5.
9-2.6 Set the Grippers pressure control switch S7 to H (slow). Turn control switch S5 to
Extend and leave it in this position. The gripper pressure will rise to 310 bar (4496 PSI).
9-2.7 Continue with the previously described starting procedure, beginning with the conveyors
startup.
9-3

Single Shield Mode Re-gripping Cycle

9-3.1 Verify that the auxiliary thrust cylinders shoes are contacting the segments. If they are
not, extend each group of cylinders, as required, by using the auxiliary cylinder control
station pendant switch to the Extend position.
9-3.2 Set the Thrust control switch S4 to the Retract position until thrust cylinders are fully
retracted. Return Thrust control switch S4 to the center position.
9-3.3 Set the Re-grip Pressure control switch (S7) to the H position (slow).
9-3.4 Set the Regrip switch S6 to the On position. By selecting the On position all nineteen
auxiliary thrust cylinders will extend, advancing the gripper shield by pushing against the
segments.

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SECTION 2 OPERATION
9-4

MODEL DS325-322

Exceptional High Pressure (Single Shield Mode Re-gripping Cycle)

CCA

Use this mode under extreme caution and only with authorized supervision.
9-4.1 Verify that the auxiliary thrust shoes are contacting the segments. If they are not, extend
each group of cylinders, as required, by using the auxiliary cylinder control station
pendant switch to the Extend position.

CAUTION
Using the Exceptional High Pressure system requires manual preparations of the
hydraulic system.
9-4.2 Close all auxiliary thrust cylinders ball valves (BV33-1 through BV33-19) connected to
the cap end of the cylinders that provide normal high pressure flow to the auxiliary
thrust cylinders. The ball valves are mounted in the gripper shield
9-4.3 Extend the auxiliary thrust cylinders by turning the Exceptional High Pressure control
switch S3 to the H (high pressure) position.

10

Stopping Procedure

The following describes routine and emergency stopping procedures.


10-1

Routine Stopping

10-1.1 Set the Thrust switch S4 to Retract for a sufficient period to allow the thrust (propel)
pressure to drop to near zero. Center the switch.
10-1.2 Allow the cutterhead to rotate for several revolutions to clear cuttings from the cutterhead
face.
10-1.3 Highlight the CH Motors indicator template (QuickPanel Boring page) and momentarily
press CH Stop control button. Power to all fourteen cutterhead motors should be
de-energized immediately.
10-1.4 Make sure the machine conveyor and the transfer conveyor is clear of cuttings, and then
highlight the Conveyors indicator template (QuickPanel Boring page). Stop the
conveyors by pressing control button Stop.
10-1.5 Highlight the SUP Motors Group Start indicator template (QuickPanel Boring page) and
momentarily press Stop control button.
10-1.6 Highlight the CH Spray template (QuickPanel Water page) and press control button Stop.
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MODEL DS325-322

10-1.7 Where applicable, set the selector switches to their center/neutral position.
10-1.8 Verify that the main drive motors have stopped coasting. Turn the Console Power key
switch (S16) to the Off position.

CAUTION
The control key is to remain in the operators possession until he gives it to the
next operator.
10-2

Emergency Stopping

All emergency stop buttons are in series. Therefore, press any emergency stop button to stop all
machine functions immediately.

CAUTION
Use emergency stop buttons only for emergency situations.

11

Machine Alignment and Steering

Proper steering is probably the most critical factor in the operation of the machine. A properly
steered machine will have very few cutter assembly failures due to bearing damage or ring
displacement. Also, heavy loading and damage to the cutterhead, cutterhead support and shield
assemblies are often caused by excessive steering movements.
Steering of the machine is accomplished by changing the attitude of the forward shield and hence
the cutterhead in relation to the bored tunnel centerline.
The cutterhead is supported by the forward shield and main bearing and seal assembly. The rod
ends of the main thrust cylinders are attached to the gripper shield assembly. The cap ends of
these cylinders are attached to the cutterhead support structure, within the forward shield. The
gripper shield is held within the bored tunnel by the action of the gripper cylinders. All steering
movements are accomplished by increasing the rate of extension of selected main thrust
cylinders. This change in the rate of extension of these selected propel cylinders causes a
change in the attitude of the forward shield in relation to the bored centerline of the tunnel.
The Roll Correction control switch S14 is utilized to correct any roll in the forward shield
attitude. Adjustment of this control will provide the required reaction force for the shield.
11-1 Proper Steering
Proper steering can be defined as maintaining line and grade without any noticeable variation in
the tunnel walls due to steering corrections. Proper steering depends on correct use of the
steering controls. Incorrect use of these devices can also contribute to excessive cutter ring
wear, premature cutter failure, bucket lip wear and unacceptable errors in line and grade.

322s02

2.30

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SECTION 2 OPERATION

MODEL DS325-322

11-2 Steering Methods


Correction of the forward shield and cutterhead attitude with relation to the tunnel centerline is
accomplished by increasing the flow to selected main thrust cylinders, thereby causing more
rapid extension of these cylinders and consequent skewing of the shield due to this extension.
The amount of flow increase is controlled by manipulation of the Thrust Cylinders control
switches R2 through R5 for the 12 main thrust cylinders and the two Steering selector switches,
S8 for Up and Down and S2 for Left and Right.
The two selector switches S2 & S8 are used to steer the machine by controlling the oil flow to
the main thrust cylinders.
By selecting a direction switch, the flow to the corresponding cylinders will increase and then go
back to the previous flow. This means a certain volume of oil has been added compared to the
normal flow.
During the same period the flow to the opposite cylinders will decrease by the same amount
which means the volume is less than normal. This is to remain the overall average. If the
switch is selected again, another increase/decrease of oil flow will make the volume difference
between opposite cylinders bigger and therefore generate more steering.
The amount of steering is displayed on the boring page of the QuickPanel. Two steering
movements can be proportionally controlled simultaneously by selecting two adjacent steering
switches.
The result of steering correction will not be seen on the guidance equipment until the invert skid
plate of the forward shield has advanced far enough through the bore to be affected by the
change. For this reason it is highly recommended that gross steering corrections be avoided
until the operator is fully aware of the response characteristics of the machine.
To Steer Up
Increase the flow to main thrust cylinders 5, 6, 7, and 8 by turning on Thrust Cylinder switch R2,
turning off all other cylinder switches and selecting the Up direction on selector switch S8.
To Steer Down
Increase the flow to main thrust cylinders 1 and 12 by turning on Thrust Cylinder switch R3,
turning off all other cylinder switches and selecting the Down direction on selector switch S8.
To Steer Left
Increase the flow to main thrust cylinders 2, 3 and 4 by turning on Thrust Cylinder switch R4,
turning off all other cylinder switches and selecting the Left direction on selector switch S2.
To Steer Right
Increase the flow to main thrust cylinders 9, 10 and 11 by turning on Thrust Cylinder switch R5,
turning off all other cylinder switches and selecting the Right direction on selector switch S2.

322s02

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SECTION 2 OPERATION

MODEL DS325-322

NOTE:
Do not allow the main thrust cylinders to completely "Bottom Out" at the end of
the thrust stroke or steering corrections will be partially lost.
11-3 Limitations on Steering Movements
All steering movements of the machine must be accomplished with the cutterhead turning.
Steering of a double shield is not confined to a single movement. It is an operation in that
induced forward movement occurs constantly throughout the propel stroke.
During normal boring operations, steering corrections are made by adding oil to one of four
quadrants. The Thrust selector switch S4 should not be centered when performing a steering
correction. Instead, the addition of the oil to a quadrant must be performed in such a manner as
to prevent the buildup of pressure in the thrust circuit beyond the pressure being used to advance
forward. The operator must very slowly and carefully reduce the propel pump displacement and
increase the amount of steering very carefully so as to prevent abrupt changes in direction.
The following limitations should govern steering movements:
11-3.1 No steering correction, either vertically or horizontally, should be made that will result in
displacement of the gage cutter more than 3mm (0.125-inch) at any one movement.
11-3.2 At least 25 mm (1 inch) should be bored before making any additional correction. This
allows the gage cutter the time and distance required to cut a new path before adding
additional loading.
11-3.3 Total gage cutter displacement should not exceed 13mm (0.5-inch) in a bored distance of
254mm (10 inches). The primary reason for this limitation is to allow sufficient
clearance for gage cutter housings and hubs, which could otherwise be damaged by
contact with the tunnel walls.
11-3.4 Total gage cutter displacement should not exceed 25 mm (1 inch) in a bored distance of
914mm (36 inches). This limitation ensures adequate clearance between the bucket lips
and the tunnel walls.

CAUTION
The operator should also be constantly aware of the limitations of the structural
configuration of the machine. The articulation cylinders, which act to allow
pivoting between the telescopic shield and the gripper shield, are especially
critical.
During the boring cycle the articulation cylinders must not be
overloaded, or allowed to become fully extended.
11-4 Forward Shield Roll Correction
The roll correction of the forward shield is performed by use of the Roll Correction switch (S14)
on the control console. Roll control is accomplished by positioning the control in the Left
(counter-clockwise) or Right (clockwise) positions. The roll of the forward shield will
determine the roll position of the gripper shield after the reset cycle.
322s02

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SECTION 2 OPERATION

12

MODEL DS325-322

Cutterhead Thrust Loading

It is recommended that thrust loading of the 483 mm (19) cutter assemblies not exceed 20,904
kN (4,699,406 lbf.). Recommended maximum load for individual 19 cutter rings is 70,000 lbs
(311.3 kN).
In actual operation, the total thrust can be determined by multiplying thrust pressure by the total
area of the cap ends of the main thrust cylinders. Once this figure is determined, the force per
cutter is obtained by dividing the total thrust by the total number of cutter rings on the
cutterhead.
To roughly calculate the force required to overcome the drag, or friction of the machine, leave
the cutterhead rotating, back the machine away from the tunnel face, adjust the thrust pressure
just enough to move the TBM, advance the machine back towards the face and note the amount
of propel pressure needed. The formula for determining net average cutter loading then
becomes:
(Thrust Pressure - Drag Pressure) X Cylinder Area) / Number of Cutters
NOTE:
These are not exact calculations, and the total thrust is not evenly distributed
between each cutter.

13 Jog Drive Station


When boring, the Console Power key switch S16 is on, and the Jog Enabled and Jog Key
Switch are both off. To jog the cutterhead, the operator must carry out the following
sequence of operations, in the correct order:

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MODEL DS325-322

Figure 2.12 Jog Station


13-1

Enabling the Jogging System

13-1.1 The operator turns off the Console Power key switch S16 and removes the key.
Removing the console key disables all controls on the operator's console (QuickPanel
included). The QuickPanel display/messages and PLC inputs still function.
CCA

The Console Power key switch S16 and the Jog Key Switch use the same key.
Only one key for these switches is allowed in the tunnel at any one time.
13-1.2 The operator inserts the key in the Jog Key Switch at the jog station and turns it on.
This results in the following:

322s02

The amber Jog Station light on the operator console lights up.
The green Jog Station Enabled light on the jog station starts blinking.
Hydraulic pump motor M29 starts. (This supplies oil to the cutterhead parking brake
and conveyor lift circuit).
2.34

November, 2008

SECTION 2 OPERATION

MODEL DS325-322

The Variable Frequency Drives are enabled (in jog mode only).

13-1.3 The operator turns on the Jog Enable switch. This is provided with space for one or two
padlocks, to allow this switch to be locked in the On position.
CCA

Each person entering the cutterhead must lock the Jog Enable switch On,
using his own padlock, to which only he carries a key. The key must remain
on this person while he is in the cutterhead.
This switch has space for only two padlocks. Therefore, if more than two persons enter the
cutterhead at the same time, a lockout extender must be used to provide space for each person's
padlock.
NOTE:
Lockout extender to be supplied by customer.
13-1.4 If both the Jog Key Switch and the Jog Enabled switch are on, all valves and motors on
the TBM are disabled, excluding the following:

Hydraulic pump motor M29 starter 1K29

Cutterhead parking brake valve DCV106-1

Conveyor lift valve DCV109-1

Sirens 0H01 and 0H02

Variable Frequency Drive Jog Enable for units 1 through 14.


13-1.5 The Conveyor Lift switch is enabled only when the Jog Key Switch and the Jog Enabled
switch are on. This makes is possible to lift the conveyor to allow access to the
cutterhead. The green Jog Station Enabled light on the jog station comes on solid,
indicating that it is safe to enter the cutterhead.

NOTE:
The green Jog Station Enabled light comes on solid if all the following conditions
are true:

Jog Key Switch is On.


All master control relays are closed
Jog Enabled switch is on

13-1.6 To rotate the cutterhead, the operator turns on the Jog Enable switch, selects Speed
switch to Low or High speed and selects cutterhead rotation using Direction control
switch to rotate the cutterhead clockwise (CW) or counter clockwidse (CCW).

322s02

2.35

November, 2008

SECTION 2 OPERATION

MODEL DS325-322

To start cutterhead rotation the operator pushes and holds the Jog switch. If all
conditions are satisfied, the jog sirens will begin to sound. After 10 seconds, the
cutterhead brake is automatically released and the Variable Frequency Drive starts the
jog rotation. The jog siren remains on continuously while the cutterhead is being
jogged. If the Jog Rotate switch is released and activated again within 5 seconds, the
10-second start delay is neglected and the brake remains released. If the switch is
released for more than 5 seconds the brake is automatically applied.
13-2

Disabling the Jogging System

To resume normal boring mode after jogging, the operator must carry out the following sequence
of operations, in correct order:
13-2.1 All persons must exit the cutterhead, and remove their padlocks from the Jog Enable
switch.
13-2.2 The operator lowers the conveyor to its fully down position.
13-2.3 The operator turns the Jog Enable switch to the Off position.
13-2.4 The operator turns off and removes the key from the Jog Key Switch.
The Jog Enabled switch and the Jog Key Switch are provided with a normally open (N/O) plus a
normally closed (N/C) contact each for the signals to the PLC. This allows the PLC to check
that the switches are functioning correctly and that no wires are broken or shorted. Also, this
ensures that the switches cannot be forced in the PLC.

322s02

2.36

November, 2008

MODEL DS325-322
SECTION 3 Maintenance
Table of Contents
Page
1. INTRODUCTION

2. MAINTENANCE RECORDS

3. SAFETY PRECAUTIONS

4. PREVENTIVE MAINTENANCE

5. ROUTINE MAINTENANCE CHECKLIST EACH SHIFT

6. PERIODIC MAINTENANCE SCHEDULE MECHANICAL

7. PERIODIC MAINTENANCE SCHEDULE ELECTRICAL

11

8. CORRECTIVE MAINTENANCE

14

9. CUTTER INSPECTION GUIDE

23

10. CUTTERHEAD INSPECTION GUIDE

24

11. LUBRICATION SCHEDULE

25

12. TYPICAL FLUID SPECIFICATIONS

26

13. TYPICAL GREASE SPECIFICATIONS

27

14. LUBRICANT APPROVAL CHART

28

TIGHTENING TORQUE THREADED FASTENERS


5750 9900 17

29

322tc03

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SECTION 3 - MAINTENANCE

MODEL DS325-322

Introduction

Maintenance of this machine consists of preventive maintenance and corrective repairs to


ensure that the equipment remains in peak operating condition. This section deals with
both types of maintenance. As with most mechanical equipment, conscientious
application of preventive maintenance practices will greatly reduce the need for
corrective maintenance and the loss of machine availability during repairs.
Both types of maintenance are treated separately. Before performing any maintenance
operation, refer to the appropriate schematic, assembly drawing, and vendor information
contained in the remaining sections of this manual, as well as the information supplied in
this section. Also, all safety instructions in the beginning of the manual, as well as any
that appear in this section should be strictly followed.

Maintenance Records

Accurate and complete records must be maintained for all maintenance activity, whether
preventive or corrective. The records should include the date, operating hours, parts
replacements, or other action taken to correct machine problems.

Safety Precautions

A thorough understanding of the system is essential before attempting any servicing.


Unknowledgeable tampering may result in serious damage to equipment, subsequent
delays, and injury to personnel. Some common sense safety precautions should always be
exercised.

Always turn off control power and remove the key when performing
maintenance in areas where machine operation could cause injury.
Never attempt to repair a hydraulic hose or fitting while it is under
pressure! Do not attempt to locate a leak with bare hands! High-pressure
injection of oil through skin may result, causing severe injury.
Only qualified electricians must do servicing of electrical equipment. Power
must be locked out before repair or servicing the equipment to avoid
electrical shock or unintentional actuation of the machine or accessories.

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MODEL DS325-322

Hazardous voltages are present within the electrical cabinet when the
incoming power cable is connected and energized. Trained and qualified
electricians must adjust system parameters within electrical cabinets and
enclosures.
For additional safety precautions, see Safety Considerations in the front of
this manual.

Never:

Open a hydraulic component or line that is still pressurized.


Step on or pull a hose loop.
Install new hydraulic fluid without sampling the bottom of the drum for
water.
Let the reservoir level drop to the point where the pumps cavitate.
Continue running an abnormally noisy system.
Make system alterations without factory approval.
Attempt repair or adjustments to electrical system without first shutting
off the power. Qualified electrical personnel should do electrical system
repairs.

Always:

Replace hose assemblies before they fail completely.


Use only approved fluids and lubricants. Refer to the figures at the end
of this section.
Understand all aspects of the system - one section may affect another.

Preventive Maintenance

Routine preventive maintenance is recommended as a very effective means for spotting


or preventing potential machine problems before they result in the failure of a component
or system and the resulting downtime for repairs.
The items requiring maintenance are listed in the following paragraphs, along with the
details and recommended frequency of application. Maintenance schedules are included
at the end of this section, which list these maintenance recommendations and their
frequency, such as daily, weekly, monthly or other recommended intervals.
4-1
Lubrication
The Lubrication Schedule (Topic 11) and Lubricant Approval Chart (Topic 14) provide a
list of items requiring lubrication.

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MODEL DS325-322

The charts contain information relative to applicable types and grades of lubricants,
approved brands, and designations, frequency of service and recommended quantities.
Typical Fluid Specifications (Topic 12) and Typical Grease Specifications (Topic 13)
provide specifications for each type of lubricant.
The frequency and the specifications for lubrication of the hydraulic pump drive motors
and other electric motors on the machine are covered in literature supplied by the motor
manufacturer. The frequency for application is dependent on the severity of the operating
conditions. Generally, operation of these motors in a tunnel boring application is
considered as severe operating conditions.

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3.3

November, 2008

SECTION 3 - MAINTENANCE

MODEL DS325-322

Routine Maintenance Checklist - Each Shift

MAINTENANCE ITEM
NOTES
Refer to Topics 11 and 14 for lubricant
1.
Hydraulic & Lube Reservoir:
Check for proper fluid levels and quantities & specifications. Temperature
fluid temperatures.
must not exceed 120 (49C) for the Lube
System and 150 (65.6C) for the Hydraulic
System.
If fluid is below acceptable levels,
pump motors will be disabled and a
warning message will be displayed on
the Operators Control Console.

If the hydraulic oil temperature is too


high, a warning message will be
displayed on the Operators Control
Console.

2.
3.

4.

322s03

The level should be near the upper mark on


the sight gauge, but may fluctuate during
initial startup. The level should stabilize
during machine operation when the supply
and return systems equalize.
The oil temperature will normally increase as
the cutterhead operating torque increases. An
abnormally low temperature during operation
may indicate poor circulation in the system
and the machine should be stopped to
investigate the problem.

Pumps, Motors, and Valves: Check


for unusual noises.
Hydraulic System: Check for
leakage in the system at normal
operating temperatures and pressures.

Hydraulic & Lube Oil Filter


Assemblies: Check that these
components mechanical indicators
should be operating with red pop-up
NOT showing. If filters become
clogged, a message will be displayed
on the Operators Control Console.

3.4

Never attempt to repair a hydraulic


hose or fitting while it is under
pressure! Do not attempt to locate a
leak with bare hands! High-pressure
injection of oil through skin may
result, causing severe injury!
During the initial break-in period, the filter
element changes will be more frequent due to
the initial wear on the different components.
Element condition should be closely
monitored for the first 500 hours of
operation. Inspect the filters while the fluid is
at normal operating temperature. If the
indicator is showing red (at normal operating
temperature), replace the filter element. The
condition of the Main Bearing, Main Gear,
and Drive Pinions can be monitored by
inspection of the elements in the return filter
assemblies.

November, 2008

SECTION 3 - MAINTENANCE

MODEL DS325-322

MAINTENANCE ITEM
5.
Gauges and Meters: Inspect these
components for proper functioning
and abnormal indications.
6.
Indicator Lights: Ensure that all are
functioning properly (press to test).
7.
Breather Elements: Check the
breathers on the hydraulic, the lube
oil reservoir, and the bearing/gear
cavity.
8.
All Systems: Ensure that all systems
are functioning properly.
9.
Cutter Assemblies: Check condition
of every assembly, observing ring
wear and damage. See Cutter
Inspection
Guide
for
typical
checklist. Spot check, torque of cutter
mounting bolts and visually inspect
saddles, retainers, and other parts for
damage. If cutter assemblies are
removed, check that helicoil inserts
are in good condition, and that the
locking feature is functional.
10.
Lube Oil: Monitor the flow and
pressure
during
the
machine
operation.

11.

12.

13.

322s03

NOTES

Change the elements as required or at 500hour intervals whichever comes first.

Note and rectify any abnormal conditions.


Refer to the Cutter Inspection Guide for
more information.

Significant changes in flow or pressure


indicate problems with the lube system - stop
the machine and investigate! The lube oil
pressure will vary inversely with the oil
temperature; therefore, pressure will be
greater during cold start-ups of the system.
Seal deterioration will be accompanied by
accelerated loss of lube oil.

Gear Reducers: Check the flow


indicators and the oil level window
on each reducer.
Seal Lube System: Check for proper Ensure that the system is supplying enough
oil to the inner and outer seals. Adjust the
operation.
flow control valve as necessary to alter the
output.
Ring Beam Erector Assembly:
Inspect the assembly for worn,
deformed,
or
malfunctioning
components.

3.5

November, 2008

SECTION 3 - MAINTENANCE

MODEL DS325-322

Periodic Maintenance Schedule - Mechanical

NOTE:

The procedures in this guide are divided into daily, weekly, monthly, semiannual, and annual operations. However, this is dependent upon the
severity of the operation conditions during the given time period. Meters
bored and hours of operation (per the hour meter) should be considered.
As a rule, for maintenance purposes, 1 month is equal to 500 meters bored,
or 250 hours of operation. Similarly, 1 week is roughly equal to 100 meters
bored, or 50 hours.
6-1

Daily Maintenance

MAINTENANCE ITEM
NOTES
1.
Hydraulic Fittings and Hoses:
Visually inspect all accessible
components for damage and/or Never attempt to repair a hydraulic
hose or fitting while it is under
leakage.
pressure! Do not attempt to locate a
leak with bare hands! High-pressure
injection of oil through skin may
result, causing severe injury!
2.
Cylinder Rods: Visually check for Remove sharp edges before rod is retracted.
nicks or gouges.
3.
Cylinders: Check for leakage at rod Refer to the cylinder assembly drawing for
seals and packing instructions.
packing glands.
Clean as necessary. Check conveyor flashing
4.
Conveyor Belt, Belt Splice, and
for damage and proper position. The
Rollers: Ensure that the belt is
aligned properly and check for build- cleaning can usually be accomplished using
high pressure water flushing. If this method
up of debris under the belt,
is not effective, cleaning should be
particularly in the tail pulley area.
accompanied by using hand tools.
5.
Fasteners in General: Visually Refer to drawing 5750 9900 17 for fastener
check them for tightness. Spot check torque values in this section.
with wrenches if looseness is
suspected.
6.
Pressure Gauges: Check for damage
and proper operation.
Refer to Cutter Inspection Guide in this
7.
Cutters: Perform inspection.
section.

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3.6

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SECTION 3 - MAINTENANCE

MODEL DS325-322

MAINTENANCE ITEM
8.
Walkways, Guard Rails, and
Ladders: Check condition and
proper installation.
9.
Service Beams/Lifting Equipment:
Check condition of these
components.
10.
Lube Return Pump: Check packing
for excessive leakage.
11.
Water System: Check the filter and
clean as required. Check main drive
assembly water flow and adjust as
required. Check for leaks, faulty
components, or other damage.
12.
Conveyor Tension Cylinders:
Ensure that the needle valves remain
closed when not in use.
13.
Ring
Beam
Erector
lifting
mechanism: Inspect for worn,
deformed,
or
malfunctioning
mechanism. The mechanism must be
suitable for use before attachment to
the ring beam sections.
14.

15.

322s03

NOTES

Refer to Water System Schematic.

A worn, deformed or malfunctioning


mechanism could potentially lead to a
loose or dropped beam!
This mechanism is critical to securely attach
the ring beam sections to the erector.
Ring Beam Erector Roller Guides: Failures can be caused by loss of reel spring
The Winch Cable can become tension, kinks in the cable or misalignment in
feeding.
damaged due to improper reeling.
Ring Beam Erector Drive: Inspect
for muck build-up on the drive ring.
Any dirt accumulation must be
brushed out.

3.7

November, 2008

SECTION 3 - MAINTENANCE
6-2

MODEL DS325-322

Weekly Maintenance

MAINTENANCE ITEM
NOTES
1.
Daily Check List: Perform checks as
noted on list.
2.

Cutterhead: Visually inspect welded Clean bucket openings as required. Inspect


system for damage.
areas for cracks.

3.

Buckets: Visually inspect for


excessive wear or damage to hard
facing.
Hydraulic Oil and Gear Oil: Take a Oil should be analyzed every 100 hours for
small sample from each reservoir for the first 500 hours of operation and every
500 hours thereafter. Lube oil analysis is the
primary indicator of the condition of the
main bearing, main gear, and seal
assemblies. High metal content may indicate
gear or bearing damage and an influx of sand
or water usually indicates seal leakage.
Grease: Apply grease at all grease Refer to Topic 13 & 14 for lubricant
specifications.
fittings. (Except electric motors.)

4.

5.

6-3

Monthly Maintenance

MAINTENANCE ITEM
NOTES
1.
Daily and Weekly Schedules:
Perform checks as noted in the
schedules.
2.
Pressure Gauges: Check their
calibration.
3.
Hydraulic System: Verify proper
adjustment of all valves and pressure
switches.
4.
Lube System: Verify proper
adjustment of all pressure and flow
switches.
5.
Fixed-volume Pumps: Ensure proper
output.
6.
Variable-volume Propel Pumps:
Ensure that the output of the pumps
can be adjusted from zero to
maximum.

322s03

3.8

November, 2008

SECTION 3 - MAINTENANCE

MODEL DS325-322

MAINTENANCE ITEM
7.
Conveyor System: Check for wear or
damage; clean enclosed conveyor
areas, and check troughing and return
rollers. Replace components as
necessary.
8.
Structural Fasteners: Check all
fasteners on the machines major
assemblies.
9.
Filter Elements: Check and replace
(if necessary), all elements in the lube
and hydraulic systems. Replace the
breather elements on the hydraulic
reservoir and the lube reservoir.
10.
Connecting Pins and Keepers:
Check all connecting pins and
keepers on the cylinders and hinged
devices.
6-4

NOTES

Refer to drawing 5750 9900 17 for fastener


torque values.
The condition of the Main Bearing, Main
Gear, and the Drive Pinions can be
monitored by inspection of the elements in
the return filter assemblies.

Semi-annual Maintenance

MAINTENANCE ITEM
NOTES
1.
Hydraulic Fluid: Replace if the test
results warrant.
2.
Replacing Hydraulic Fluid: If the
fluid is being replaced, flush and
clean the reservoir and magnetic
suction strainers and check operation
of float switch.
3.
Lube Oil Reservoir and magnetic
Suction Strainer(s): Drain, clean and
check the float switch for proper
operation.
4.
Main Bearing & Main Ring Gear
Teeth: Check the condition of each
by removing one Main Drive
Assembly.
5.
Hydraulic Cylinders: Check the
condition of the rod wipers.

322s03

3.9

November, 2008

SECTION 3 - MAINTENANCE

MODEL DS325-322

MAINTENANCE ITEM
NOTES
6.
Pivot
Points,
Swivels,
and
Bushings:
Check for looseness or wear.
7.

Fasteners: Check for proper torque.

8.
9.

Accumulators: Check the nitrogen


charge in every unit.
Pump Couplings: Lubricate.

6-5

Refer to drawing 5750 9900 17 for proper


torque values.
Refer to the Hydraulic Schematic for proper
charge pressures.

Annual Maintenance

MAINTENANCE ITEM
1.
Remove & disassemble gear
reducers.

NOTES

2.

Check for possible wear and


movement of the main bearing.

If practical, remove cutterhead and check


rolling torque, per main bearing procedure

3.

Lube Oil Return Pump:

Perform
manufacturers
maintenance.

322s03

3.10

recommended

November, 2008

SECTION 3 - MAINTENANCE

MODEL DS325-322

Periodic Maintenance Schedule - Electrical

NOTE:
The procedures in this guide are divided into daily, weekly, monthly, semiannual, and annual operations. However, this is dependent upon the
severity of operation conditions during the given time period. Meters bored
and hours of operation (per hour meter) should be considered. As a rule,
for maintenance purposes, 1 month is equal to 500 meters bored, or 250
hours of operation. Similarly, 1 week is roughly equal to 100 meters, or 50
hours.

Only qualified electricians must do servicing of electrical equipment. Power


must be locked out before repair or servicing the equipment to avoid
electrical shock or unintentional actuation of the machine or accessories.
Hazardous voltages are present within the electrical cabinet when the
incoming power cable is connected and energized. Trained and qualified
electricians must make adjustments to systems parameters within
electrical cabinets and enclosures.
For additional safety precautions, see Safety Considerations in the front of
this manual.
7-1

Daily Maintenance

MAINTENANCE ITEM
NOTES
1.
Meters: Check for damage and for
proper functioning.
2.
Lighting Fixtures: Check the
condition of all lighting units.
3.
Electrical Cables: Visually inspect
all accessible cables for damage. Pay
particular attention to cables that
must move with the machine, are
routed through cable reels, or
otherwise are subjected to wear or
damage.

322s03

3.11

November, 2008

SECTION 3 - MAINTENANCE

MODEL DS325-322

MAINTENANCE ITEM
4.
Secondary Voltage: Verify that the
voltage is at the proper level.
5.
Electrical Cabinets: Visually inspect
each cabinet interior for loose
terminals.
6.
Starters and Circuit Breakers:
Visually inspect for signs of
deterioration or corrosion.
7.

8.
9.
10.

11.

12.

7-2

NOTES

Ensure that the doors are kept closed.

Determine and eliminate the cause of dirt


entering the sealed enclosures(s). Dirty, wet,
or corroded parts must be replaced if they
cannot be cleaned effectively.

Main Drive Motors: Visually


inspect condensation drain ports for
restriction.
Quick-disconnect Couplers:
Visually inspect that all are tight.
Auxiliary Boxes: Visually check that
all boxes are closed.
Mechanical Linkages: Visually Check for free operation of all moving parts.
check that mechanical linkages for Replace any badly worn or damaged parts.
Do not lubricate electrical control equipment
the oil fuse cutouts are satisfactory.
unless specifically instructed to do so by the
manufacturers instructions.
Emergency Stop Circuits: Verify
that the emergency stop (E-Stop)
Never bypass any emergency stop
switches are functional.
switches.
Electrical Controls: Verify that all
controls are functioning properly.
Weekly Maintenance

MAINTENANCE ITEM
NOTES
1.
Daily Schedule: Perform checks as
listed on daily schedule.
2.
Electrical Cabinets: Clean their
interiors.
3.
Door Seals: Ensure that all cabinet
and enclosure door seals are in good
condition.
4.
Electric Motors: Clean their Use dry compressed air.
exteriors.

322s03

3.12

November, 2008

SECTION 3 - MAINTENANCE

MODEL DS325-322

MAINTENANCE ITEM
NOTES
5.
Conveyor Under-speed Switch
Assemblies: Check for loose
mounting, muck accumulation and
exposed wiring.
6.
Terminals: Ensure that all bolted Replace any parts damaged by overheating
electrical terminals are tight and free due to loose connections.
of corrosion.
7.
Miscellaneous:
Verify
proper
functioning of ground fault systems,
insulation monitors, and other parts.
7-3

Monthly Maintenance

MAINTENANCE ITEM
NOTES
1.
Electrical Meters: Check their
calibration.
2.
Connections: Check all switches
and interior of electrical control
panels for loose connections.
3.
Contacts:
Check all contacts for Do not file contacts discoloration and
extensive wear and dirt accumulation. slight pitting is not harmful to silver oxide
contacts used in most industrial equipment.
Replace contacts in complete sets to avoid
uneven contact pressure.
4.
Verify condition of contacts in all
switch gears.
7-4

3 Month Maintenance

MAINTENANCE ITEM
NOTES
1.
Motors: Re-lubricate all electrical Refer to manufacturers
lubrication instructions.
motors.
7-5

literature

Semi-annual Maintenance

MAINTENANCE ITEM
NOTES
1.
Jackets: Check all cable terminations
and cables for damaged jackets.

322s03

3.13

November, 2008

for

SECTION 3 - MAINTENANCE

MODEL DS325-322

MAINTENANCE ITEM
NOTES
2.
Electrical Devices: Thoroughly
inspect and clean circuit breakers,
starters, auxiliary contacts, relays,
and others.
3.
Motor Junction Box Covers: Ensure
good condition of bolted connections.
7-6

Annual Maintenance

MAINTENANCE ITEM
NOTES
1.
Main Drive Motors: Remove and
send to qualified electrical shop for
thorough testing and reconditioning.
Bearings should be replaced.
2.
Auxiliary contacts: Replace, in
circuit breakers and starters.

Corrective Maintenance

Corrective maintenance is isolating a malfunctioning component and then repairing or


replacing the item. The troubleshooting and correction of malfunctions can be a timeconsuming process. The following is offered as a guide to speed up the process.
8-1
General Troubleshooting Guide
The troubleshooting of any problem should be approached in an analytical, open-minded
manner.
The troubleshooting suggestions described below are intended primarily for hydraulic
malfunctions; however, these suggestions could apply to other malfunctions, too. These
suggestions are intended to help the troubleshooter save time and avoid unnecessary
replacement of parts.
8-1.1 Define the Problem
A clear definition of the problem is essential to make effective and efficient corrections.
As an aid in making this definition, the following questions should be considered:
1.

What abnormal actions are occurring, or have occurred?

2.

What abnormal indications are present?

3.

Did the malfunctions occur gradually or suddenly?

322s03

3.14

November, 2008

SECTION 3 - MAINTENANCE
4.

MODEL DS325-322

Is there any physical evidence of a component or assembly failure?

8-1.2 Isolate the Malfunctioning Item


Determine, by logical process of elimination, which component would most likely cause
the defined problem. Formulate a plan of action before disassembly of the equipment is
started. The following are suggestions for formulating this logical plan of action:
1.

Refer to the schematics, other drawings, or technical literature to determine which


components is involved in the malfunction.

2.

Based on the clear definition of the problem, determine which component or


components would be most likely to cause the noted problem.

3.

If possible, isolate or bypass the most likely component and recheck the function
of the machine. If the operation is satisfactory with the suspected component
isolated, the malfunctioning component has been identified. If the problem still
exists, proceed to the next most likely component on the list.

4.

Do not overlook a simple solution just because it appears too simple.

8-1.3 Correct the Malfunction


1.

If possible, determine what caused the component to fail. There may be another
system fault that caused the failure. Merely repairing an item may affect a
temporary cure while leaving the basic ailment to cause future failures.

2.

Correct any contributing malfunctions.

3.

If practical, repair the defective component; otherwise replace it.

4.

Retest the system to confirm proper operation.

8-2

Troubleshooting the Hydraulic System

Hydraulic systems are precision units and their smooth operation depends on proper care.
Therefore, DO NOT NEGLECT THEM. Keep them clean and change oil and filters
elements at established intervals.
In spite of precautions taken, improper operation does occur. Cause can generally be
traced to one of the following:

Use of wrong viscosity type of oil.


Insufficient fluid in the system.
Presence of air in the system.
Mechanical damage or structural failure.
Internal or external damage.

322s03

3.15

November, 2008

SECTION 3 - MAINTENANCE

MODEL DS325-322

Dirt, decomposed packing, water, sludge or rust in the system.


Improper adjustments.
Oil cooler plugged, dirty or leaking.
Improper pressure setting.

8-3
Troubleshooting Guide - Mechanical Malfunctions
A troubleshooting guide is included in this section of the manual to assist in locating
malfunctions. The malfunctions are listed in the left-hand column, the most probable
causes listed in the center column, and the corrective action to be taken listed in the right
column. An accurate record should be maintained of all adjustments, parts replacements,
or non-corrected erratic/abnormal operations.

NOTE:
In cases where more than one possibility exists for a particular
malfunction, an attempt has been made to list the possibilities in order of
most to least likely.
MALFUNCTION
1.
Pump does not
produce flow.

CORRECTIVE ACTION
Open immediately.

Low fluid level in the


reservoir. This condition will
be accompanied by noisy
pump operation due to
cavitation.
DO NOT ALLOW
OPERATION TO
CONTINUE!

Stop the pump immediately.


Check fluid level and fill to
the proper level.

Pump/motor coupling is
loose or broken.

Check and repair or replace


as needed.

Incorrect rotation of the


pump.
DO NOT ALLOW
OPERATION TO
CONTINUE!

322s03

POSSIBLE CAUSE
Pump suction line shut-off
valve is closed.

Have an electrician reverse


two phases to the pump drive
motor.

3.16

November, 2008

SECTION 3 - MAINTENANCE
MALFUNCTION
Pump does not produce
flow. (Ctd.)

MODEL DS325-322

Remove the pump inlet line


connection and check for
flow. If low, drain the
reservoir, clean the reservoir
and suction strainers, and
refill with new fluid.

On variable-volume pumps,
stroke or stroke limits are not
set properly.

Pump
will
develop pressure.

CORRECTIVE ACTION
Normally, this condition
would exist only in low
ambient temperature
conditions. Grade of oil may
have to be changed, or preheating of the oil may be
required before starting the
pump motors.

Suction strainer or inlet line


is plugged.

2.

POSSIBLE CAUSE
Fluid viscosity is too high to
permit the pump to prime
itself.

Check for proper adjustment


of pump.

Pump is damaged internally-broken shaft or stroke limits


are not set properly.
not Pump is not producing flow.

Remove the pump and


inspect its interior. (See
manufacturers information.)
Check according to
preceding malfunction.

Disconnected or broken hose


on the pumps output side.
One or more directional
valves in the system allowing
free return flow to the
reservoir.

Determine which valves are


in the particular system and
check that each is in the
proper position and
functioning correctly.

Relief valve(s) is (are) set


too low or it is stuck open.

322s03

Verify that all hoses are


intact.

Determine which relief


valves affect the system.
Check for proper setting;
disassemble if necessary to
check internally.

3.17

November, 2008

SECTION 3 - MAINTENANCE

MODEL DS325-322

MALFUNCTION
POSSIBLE CAUSE
Pump will not develop Pump is damaged internally:
it will produce flow at low
pressure. (Ctd.)
pressures, but not under load.
3.

Noisy pump
operation.

Pump is cavitating due to


low fluid level in the
reservoir.

CORRECTIVE ACTION
Remove pump and
disassemble to inspect
interior. Repair or replace
damaged parts as required.
Stop immediately, check the
fluid level, and fill to proper
level.

Pump is cavitating due to


leakage in the inlet
connection.
Inlet to the pump is blocked.

Correct the rotation of the


drive motor. If still noisy, the
pump has suffered damage.

Pump is damaged internally.

Propel pump pressure


compensator is set too high,
causing excessive flow over
the propel pressure relief
valve.

Remove the pump and


inspect its interior. Repair or
replace as required.
Adjust pump compensator
until flow is correct. Direct
cooling water through the
heat exchanger to lower the
temperature.

Excessive slippage in the


high pressure pump.

Check the pumps output


using a test unit if possible.

Pressure compensator is not


adjusted properly or is
malfunctioning (gripper
high-pressure system).

322s03

Check and replace the


element.

Pump rotation is incorrect.

Excessive hydraulic
fluid temperature.

Check to make sure that the


inlet shut-off valve is open.
Check to make sure that it is
not blocked - may be due to
plugged suction strainer.

Reservoirs air breather is


blocked.

4.

Stop immediately, check, and


tighten the inlet fittings.

Check that the gripper


pressure is correct; the
pressure should be slightly
less than the relief valve
setting.

3.18

November, 2008

SECTION 3 - MAINTENANCE

MODEL DS325-322

MALFUNCTION
POSSIBLE CAUSE
5.
Machine conveyor is Under-speed switch is not set
properly or is
too slow.
malfunctioning.

CORRECTIVE ACTION
Determine if the conveyor is
traveling at correct speed. If
speed is OK, then check the
under-speed switch for
proper operation.

Conveyor is partially
jammed due to excessive
loading or blockage.

Belt is too tight.

Cutterhead drive
motors will not
start.

Check the operating pressure


at the tensioning cylinder
pressure. Correct as
necessary.

Full fluid flow is not being


delivered to the conveyors
hydraulic drive.

6.

Check the operating


pressure. If the pressure is at
the relief valve setting, fluid
is bypassing over the relief.
Stop the cutterhead and the
conveyor and determine if
block-age exists. Correct the
condition. Allow the belt to
clear before re-starting
cutterhead.

Verify that the valve is


operating properly. Check
the pumps output.

Hydraulic motor is bypassing Remove and inspect the


interior. Repair or replace as
internally.
needed.
Turn on the circuit breakers.
Circuit breakers are off.
Check for proper flow and
pressure.

Lube oil flow switch is set


incorrectly or
malfunctioning.

Have a qualified electrician


inspect the switch and its
connections.

Gripper pressure is less than


the pressure switch setting.

322s03

Low lube oil flow or


pressure.

Extend the grippers using the


gripper high pressure system.

3.19

November, 2008

SECTION 3 - MAINTENANCE

MODEL DS325-322

MALFUNCTION
Cutterhead drive
motors will not
start. (Ctd.)

POSSIBLE CAUSE
Gripper pressure switch is set
incorrectly or
malfunctioning.
Jogging (inching) system is
engaged

CORRECTIVE ACTION
Check the pressure setting. If
it is satisfactory, have a
qualified electrician inspect
the circuitry.

7.

Circuit breakers are turned


off.

Turn on the circuit breakers.

Low fluid level in the


reservoir.

Fill the reservoir to the


proper level.

Hydraulic drive
motors, or lube oil
drive motor will not
start.

Float switch is set incorrectly Check for proper operation


and have a qualified
or not functioning properly.
electrician inspect the circuit.
Overloads on motor starter
are tripped.

Seal lube
indicator/light is not
cycling on and off.

CAUTION:
Do not continue
operation if this
condition exists.
9.
No water at
cutterhead when
operating, or low
water volume.

Seal lube pump hydraulic


circuit is not cycling.

Have a qualified electrician


check the circuit.

Feeder block is
malfunctioning.

Check the unit for proper


operation.

Switch in feeder block is not


operating.
Water is not turned on.

Have a qualified electrician


check switch and circuitry.
Open the gate valve for the
water spray system.

Water filter is blocked.

Remove, clean, and reinstall


the element.

Solenoid-operated control
valve is malfunctioning.
Spray nozzles are plugged.

8.

Have a qualified electrician


reset. If they are not tripped,
check the circuitry.

Have a qualified electrician


check valve and circuitry.
Clean the nozzles.

8-4
Cutterhead Seal Wear Band Replacement
Notes on the Main Bearing and Seal Assembly drawing cover primary instructions for
wear band replacement, which is included in Section 6 of this manual. If a replacement is
required, it will probably have to be done in the tunnel. Additional recommended steps
are covered in the following paragraphs.

322s03

3.20

November, 2008

SECTION 3 - MAINTENANCE

MODEL DS325-322

8-4.1 If the wear band change involves the outer seal assembly, every effort should be
made to accomplish the change in competent, self-supporting ground. This is
because the cutterhead assembly must be removed from the machine to permit
access to the outer seal cavity.
8-4.2 The cutterhead assembly must be blocked up securely to prevent any downward
shifting once the machine is backed away. It must also be supported by means of
rock bolts to prevent any movement once it is freestanding.
8-4.3 The worn wear band must be split to allow removal - use caution to avoid
damaging the mounting structure.
8-4.4 The structural mounting surface must be thoroughly cleaned and checked for any
damage, particularly burns or upset areas. The inside of the seal ring must be
cleaned thoroughly as well.
8-4.5 Once the structure and wear band are cleaned, the band should be checked against
the mounting structure to ensure that it is not oversized. The wear band must be a
shrink-fit onto the structure. Therefore, it must be heated to allow sufficient
expansion. This can be done using acetylene, butane, or propane torches. The
heating must be done uniformly.
Therefore, stand-offs should be welded or bolted (if possible) to the mounting
structure to allow the band to be supported in approximately the correct position
while still allowing it to be rotated past the heating torch. The band should be
heated to a maximum of 392F (200C). A temperature crayon should be used to
check for proper temperature.
8-4.6 Sufficient personnel should be available to allow quick and positive placement of
the wear band once heating is complete. The maneuver of placing the band onto
the mounting structure must be a well-coordinated effort so that the band goes on
evenly and quickly. In the event that some tapping in place is needed, it should be
done using wood blocks rather than by direct hammer blows. Since the band will
shrink quickly, timing is very critical.
8-5
Cutterhead Seal Replacement
Refer to notes on the main bearing and seal assembly drawing in Section 6 covering the
instructions for replacement of the seals.
8-6
Main Thrust Bearing or Ring Gear Replacement
The possibility for having to replace either of these items in the tunnel is quite remote;
however, consideration must be given to the method for accomplishing this.
As with outer seal or seal ring replacement, the cutterhead assembly must be removed
and secured against movement to permit access to these items.

322s03

3.21

November, 2008

SECTION 3 - MAINTENANCE

MODEL DS325-322

A cavity or niche must be made in the wall of the tunnel to allow enough space to pass
the defective item to the rear as well as to allow the replacement parts to be moved to the
forward side of the cutterhead support. Additionally, the machine must be able to move a
sufficient distance forward and aft to permit the passage of the components.
Sufficient hoisting mechanisms must be provided to allow disassembly of the defective
units and re-positioning of the replacement parts. It may be necessary to remove rock
from the crown of the tunnel to create space for positioning and operation of the hoisting
mechanisms.
Corrective action in this circumstance is a major operation, hampered by the confines of
the tunnel. Therefore, plans for accomplishing the task should be well formulated to
avoid as much delay as possible. One of the prime considerations is maintaining the
cleanliness of the new parts and the exposed structural surfaces to which they mount. The
main bearing installation procedure is provided in Section 6.
8-7
Conveyor Belt Alignment
To attain the maximum conveyor belt life, ensure that the belt is constantly centralized on
all conveyor rollers. If the belt is allowed to move to one side or the other where the edge
is in contact with the conveyor structure, fraying of the edges will occur quickly.
Moreover, this contact causes additional belt friction that must be overcome by the drive
pulley. The following items describe some of the typical belt misalignment conditions
along with the probable cause and the suggested corrections.
8-7.1 If the entire length of the belt runs off through a particular section of the conveyor
assembly, the likely cause is misalignment of the idlers or pulleys in that area. To
correct this condition, the end of the idler or pulley where the belt is shifting
should be moved longitudinally in the same direction the belt is traveling.
8-7.2 If one or more points of the belt run off for the entire length of the conveyor, the
cause is most likely to be the belt itself or the splicing of the belt. Verify that the
splice was installed properly. Another cause can be uneven or off-center loading
of the belt. This condition will cause the belt to move to one side as the load tries
to center itself in relation to the troughing rollers. Off-center loading is not
normally a problem due to the muck chutes configuration.
8-7.3 All pulleys and idlers should have their axis 90 degrees to the intended path of the
belt. Only minimum shifting at one end of a particular roller should be necessary.
8-7.4 Normally, the belt can be trained properly to the tail pulley by proper adjustment
of the return idlers. However, adjusting devices are provided at the tail pulley if
some alignment is necessary. Once centralized on the tail pulley, the troughing
rollers, assuming they are aligned correctly, will normally train the belt properly.
No adjustment of the head pulley should be required if the belt has been trained
properly.

322s03

3.22

November, 2008

SECTION 3 - MAINTENANCE

MODEL DS325-322

8-7.5 Periodic cleaning of the area below the conveyor is necessary to prevent build-up
of dirt or other debris. Debris can affect the action of the return idlers, or
otherwise upset the free movement of the conveyor belt.

Cutter Inspection Guide

The cutter assemblies are the key units to successful operation of the machine. A proper
inspection program is mandatory to achieve the maximum service life from these
expendable items. It is suggested that the following inspection program be implemented:
9-1

Perform visual inspection of the cutters every four hours of operation for the
initial 150 meters (500 feet) of boring.

9-2

If the inspections accomplished during the initial 150 meters (500 feet) warrant,
the inspection may be extended to a daily basis. However, normal practice is to
make a cutter check once each shift.

9-3

If the sudden loss of a cutter is indicated during actual boring (for example,
reduced penetration, and increased amperage), boring should be stopped
immediately and a cutter inspection should be performed.

9-4

Replace cutters if any of the following conditions are noted:

Excessive Ring Wear


Average maximum recommended wear for gage cutters is 13 mm (1/2 inch) from the
radius. However, this can vary as much as 6.35 mm (1/4 inch), depending on the
machine's structure and tunnel requirements. The proper allowable wear should be
determined in the initial stages of the boring process. Gage cutters reaching the maximum
wear limit may be moved to face positions to attain maximum ring life. Maximum wear
for face positions can be described as that amount of wear that does not cause damage to
the cutter hub, saddles, and other parts and does not seriously affect the penetration rate.
Uneven Ring Wear, Flat Spots, Will Not Rotate, Rough Rotation
Any of these conditions are indicative of failed seals or badly worn bearings. Muck
build-up under the cutter assembly may be another cause for the condition(s).
Loss of Split Ring
Remove cutter and replace split ring.
Oil Leakage
Remove the cutter and send it to the cutter repair shop for determination of cause of
leakage. Do not attempt to refill cutter while on the cutterhead.

322s03

3.23

November, 2008

SECTION 3 - MAINTENANCE

10

MODEL DS325-322

Cutterhead Inspection Guide

The cutterhead assembly should be checked at each cutter inspection as follows:


10-1

Check fasteners common to the cutter assemblies, and check all accessible
fasteners common to the cutterhead assembly for proper torque.

10-2

Check welds common to bucket scoops and cutter housings. Check bucket lips for
evidence of wear and for loosening of the fasteners.

10-3

Inspect gage cutter housings for damage on the outboard ends.

10-4

Check water spray nozzles for damage or plugging, and check that all protective
angle irons for water spray system hoses are in place.

322s03

3.24

November, 2008

SECTION 3 - MAINTENANCE

MODEL DS325-322

11 Lubrication Schedule
NOTE:
1.

Hours shown in the following chart are actual machine operating


hours (per the hour meter).

2.

Lube oil viscosity is dependent on operating temperature see


temperature vs. viscosity chart on Typical Fluid Specifications in
Topic 12.

3.

Volumes are approximate values.

ITEM
Lube Oil System
(See Note 2)
Tail Pulley Assembly
Cutter Assemblies
Face/Gauge
Cutter Assemblies
Center
Hydraulic System

SERVICE
INTERVAL
Check every 8 hours
Check during belt
removal
At every assembly
At every assembly
Check every 8 hours

Grease Fittings

Grease every 40 hours

Exposed Steel and


Adjusting Screws
Electric Motors

As needed to prevent
rusting
See motor literature

Flushing Hydraulic
System
Conveyor Drive
Assembly
Cutterhead Seal
Assembly

As necessary

322s03

Check every 8 hours


Check every 8 hours

3.25

QUANTITY
PER UNIT
1135 liters
(300 gallons)
17 liters
(4.5 gallons)
1.8 liter
(60 Oz)
2.8 Liters
(96 Oz)
9500 liters
(2500 gallons)
As required

LUBRICANT

As required

A or B

See motor
literature
As required

See motor
literature
E

See grease
fittings above
See Hydraulic
System above

A
A
G
G
B

November, 2008

SECTION 3 - MAINTENANCE

MODEL DS325-322

12 Typical Fluid Specifications


NOTE:
Texaco furnishes the following specifications. They can be used as a
guideline for determining the suitability of alternate brands of lubricants
not shown in the Lubrication Schedule (Topic 11) and in the Lubricant
Approval Chart (Topic 14).
TEXACO
DESIGNATION
TYPE OF FLUID
APPEARANCE
GRAVITY, API
FLASH COC,
F/C
POUR POINT,
F/C
VISCOSITY
CENTISTOKES
At 40C
At 100C
VISCOSITY,
SUS
At 100F
At 210F
VISCOSITY
INDEX
PERCENT
SULFUR
PERCENT
PHOSPHOROUS
TIMKEN OK
LOAD, LBS
AGMA EP
NUMBER

322s03

MEROPA 220 RANDO HD-46

RANDO HD-32

GENERAL
OIL
VERY DARK
RED
26.2
450/232

HYDRAULIC
OIL
PALE
30.3
415/213

HYDRAULIC
GENERAL
OIL
OIL
LIGHT BROWN VERY DARK
BROWN
31
25.3
450/232

0/-18

-30/-34

-30/-3

0/-18

209
17.5

43.3
6.6

29.7
5.2

308
23.9

1080
90

223
49

153
44

1636
118

92

102

107

98

.92

--

--

.93

.05

--

--

.05

60

--

--

60

--

--

3.26

MEROPA 320

November, 2008

SECTION 3 - MAINTENANCE

MODEL DS325-322

13 Typical Grease Specifications


NOTE:
Texaco furnishes the following specifications. They can be used as a
guideline for determining the suitability of alternate brands of lubricants
not shown in the Lubrication Schedule (Topic 11).
CHARACTERISTICS

APPEARANCE
LITHIUM SOAP, %
MOLYBDENUM
DISULFITE, %
LEAD, % (ASPbO)
PENETRATION,
ASTM at 77F (25C)
UNWORKED
WORKED
DROPPING POINT,
F/C
OIL VISCOSITY,
CENTISTOKES
at 40C
at 100C
OIL VISCOSITY, SUS
at 100F
at 210F
GUIDE TO USEABLE
TEMPERATURE
MAXIMUM, F/C
MINIMUM, F/C
CONT. TEMP, F

322s03

TEXACO PRODUCT DESIGNATION


MARFAK ALLMOLYTEX
PURPOSE
EP2
VERY DARK GREEN
GRAYISH
BLACK
6.0
7.8
-3.0

MULTIFAK
EP0
DARK GREEN
4.0
--

.3

.36

.3

295
281
390/199

290
281
392/199

398
378
367/186

195
15.6

175
15.1

195
15.6

1043
82

918
80

1043
82

350/177
-30/-34
250

250/121
-23/-30.5
250

350/117
-30/-34
250

3.27

November, 2008

14 Lubricant Approval Chart


NOTE:
1.
2.

Not all brands of lubricants are listed. Contact The Robbins Company for approval of brands not listed. Specifications pertinent to the lubricant for which approval is sought should be furnished.
Mixing different brands of lubricants is not recommended.

OIL CO.

A.

GEAR OIL AGMA


5EP

AGIP

Blasia 220

Oso 46

Blasia 32
Oso 32

Blasia 320

Blasia 68
Oso 68

ARAL

Degol BG 220
Degol BAB 220
Degol PAS 220

Degol BG 46
Vitam EHF 46

Degol BG 32
Degol BAB 32

Degol BG 320
Degol BAB 320
Degol PAS 320

Degol 68
Degol BAB 68

BP

Energol GR-XP 220


Enersyn HTX 220

Energol GR-XP 46
Energol HLP-HM 46
Bartran HV 46
Biohyd SE 46

Energol HLP-HM 32
Energol HL-XP 32
Bartran HV 32

Energol GR-XP 320

Energol GR-XP 68
Energol HLP-HM 68
Bartran HV 68
Biohyd SE 68

CASTROL

Alphasyn T 220
Alphasyn EP 220
Alpha SP 220
Alpha ZN 220
Alpha MW 220

Hyspin AWS 46
Hyspin AWH-M 46
Hyspin Sp 46
Alphasyn T 46

Spheerol EP 2

Hyspin AWS 32
Hyspin SP 32
Alphasyn T 32

N/A

Alpha syn T 320


Alphasyn EP 320
Alpha SP 320
Alpha ZN 320
Alpha MW 320

Hyspin AWS 68
Hyspin AWH-M 68
Alphasyn T 68
Alpha SP 68
Alpha ZN 68

CHEVRON

Gear Compound 220


Synthetic Gear Lub. Tegra
220

Mechanism LPS 46

Duralith EP2

Mechanism LPS 32

Polyurea EP0

Gear Compound EP 320

Gear Compound EP 68
Mechanism LPS 68

Molebgras EP 2

CONDAT

B. AW HYD. OIL ISO VG


46

C.

GREASE EP 2

D.

FLUSHING OIL

E.

GREASE EP0

F.

GEAR OIL AGMA 6EP

G.

AW HYD. OIL ISO VG 68

Condat 46

REPSOL

Tauro 220

Telex E 46

Grassa Litica Type 0

Tauro 320

ELF

Reductelf SP 220
Elf Epona Z 220
Reductelf Synthes 220

Elfolna DS 46
Elfolna HMD 46
Hyddrelf BIO 46

Elfolna DS 32
Elfolna HMD 32

Reductelf SP 320
Elf Epona Z 320

Elfolna DS 68
Elfolna HMD 68
Reductelf SP 68
Elf Epona H 68

ESSO

Spartan EP 220
Spartan Synth. EP 220

Hydraulikoel HLP 46
Hydraulikoel HLP 46 AF
Hydraulikoel HE 46

Febis 32

Spartan EP 320

Spartan EP 68
Univis N 68
Nuto H 68

FUCHS

Renolin AWD 220


Renolin CLP 220
Renolin UNISYN CLP 220
Plantogear 220 S

Renolin B 46 HVI
Renolin B15 VG 46
Renolin MR 46 MC
Renolin MWB 46
Plantogear 46 S

Renolin B 32 HVI
Renolin B 10 VG 32
Renolin MR 32 MC
Renolin MWB 32
Plantohyd 32 S

Renolin AWD 320


Renolin CLP 320
Renolin Unisyn CLP Plantogear 320 S

Renolin CLP 68
Renolin Unisyn CLP 68
Renolin MR 68 MC
Renolin MWB 68
Plantogear 68 S

KLBER

Lamora 220
Klberoil GEM 1-220
Klbersynth GEM 4-220

Q8 Schumann 46
Q8 Goya 46
Q8 Hydraulic S 46
Q8 Holbein 46

Klbersynth GEM 4

Lamora 320
Klberoil GEM 1-320
Klbersynth GEM 4-320

Lamora 68
Klberoil GEM 1-68
Klbersynth GEM 4-68

MOBIL

Mobilgear 630
Mobilgear SHC 220

Hydraulikoel HLPD 46
EAL Syndraulic 46

Mobilplex 47 or Mobilplex EP2


Mobilith SHC 460

Hydraulikoel HLPD 32
Mobil SHC 624

Vactra Light or Mobilsol

Mobilgear 632
Mobilgear SHC 320

Hydraulikoel HLPD 68
Mobil SHC 626
Mobilgear 626

SHELL

Omala 220

Tellus 46
Tellus T 46
Naturelle HF-E 46

Alvania EP 2

Tellus 32
Tellus T 32

Alvania EP0

Omala 320

Tellus 68
Tellus T 68
Omala 68
Naturelle HF-E 68

TEXACO

Meropa 220
Syngear 220

Rando HD 46
Rando HDZ 46

Multifak EP-2

Rando HD 32
Rando HDZ 32

Multifak EP0

Meropa 320

Rando HD 68
Rando HDZ 68
Meropa 68

TRIBOL

Tribol 1100/220
Tribol 1510/220
Tribol 1115
Tribol 1810/220

Tribol 1550/46

Tribol 1100/320
Tribol 1510/320

Tribol 1100/68
Tribol 1550/68

Tribol 1550/32
Tribol 1840/32

Esso Unirex 3C

3.28

3.29

MODEL DS325-322
SECTION 4 General Assembly
Table of Contents
Level

Drawing

Description

Rev.

Page

D107803-1

GENERAL ASSEMBLY

4.1

D103330-1

WEIGHTS & DIMENSIONS

4.1-23

D103854-1

SITE LAYOUT/SITE ASSEMBLY


SEQUENCE

4.1-28

D103853-1

PROBE DRILL PATTERN

4.1-29

D103852-1

DISASSEMBLY CHAMBER

4.1-30

D103869-1

DISASSEMBLY SEQUENCE

4.1-31

D105363-1

SAFETY LABELS & DECALS

4.1-32

D104544-1

SITE ASSEMBLY
COMPONENT STAGING AREA

4.2

D102102-1

CUTTERHEAD ASSEMBLY

SECTION 5

D101462-1

MAIN BEARING & SEAL ASSEMBLY

SECTION 6

D107804-1

FORWARD SHIELD ASSEMBLY

SECTION 7

D107805-1

MAIN DRIVE ASSEMBLY

SECTION 8

D103600-1

TELESCOPIC SHIELD ASSEMBLY

SECTION 9

D102100-1

GRIPPER SHIELD ASSEMBLY

SECTION 10

D107974-1

CONVEYOR ASSEMBLY

SECTION 11

D103855-1

ERECTOR ASSEMBLY

SECTION 12

D103859-1

PROBE DRILL ASSEMBLY

SECTION 12

D110297-1

OPERATORS CAB ASSEMBLY

SECTION 13

D107811-1

LUBE ASSEMBLY

SECTION 14

322tc04

August 2008

MODEL DS325-322
SECTION 4 General Assembly
Table of Contents
Level

Drawing

Description

Rev.

D107812-1

HYDRAULIC ASSEMBLY

SECTION 15

D107809-1

ELECTRICAL ASSEMBLY

SECTION 16

D107810-1

WATER ASSEMBLY

SECTION 17

D103861-1

GUIDANCE SYSTEM ASSEMBLY

SECTION 18

D104341-1

SERVICE BEAM ASSEMBLY

SECTION 19

D103863-1

CUTTER HANDLING ASSEMBLY

SECTION 19

D103851-1

WALKWAYS & LADDERS ASSEMBLY

SECTION 19

D104486-1

FIRE ALARM SYSTEM ASSEMBLY

SECTION 19

D109000-1

TBM & BACK-UP


GENERAL ARRANGEMENT

SECTION 20

322tc04

Page

August 2008

MODEL DS325-322
SECTION 5 Cutterhead Assembly
Table of Contents
Level

Drawing

Description

Rev.

Page

D102102-1

CUTTERHEAD ASSEMBLY

5.1

D103688-1

CUTTERHEAD PLUMBING
NOTE: SHEET 4 NOT INCLUDED

5.1-9

D94790-1

19 CUTTER HOUSING
B. L. W. L. ASSEMBLY

5.1-10

D38630-1

HUB & SHAFT ASSEMBLY


19 FACE CUTTER
NOTE: SHEET 2 NOT INCLUDED

5.1-10A

A39380-1

19 FACE & GAGE CUTTER


MAINTENANCE MANUAL

5.1-10B

A48648-1

TOOL LIST CUTTER HANDLING


& MAINTENANCE 19

5.1-10C

D95084-1

HARDWARE WEDGE LOCK


CENTER CUTTER

5.1-11

D103823-1

HUB & SHAFT ASSEMBLY


17 W. L. CENTER CUTTER

5.1-11A

A94924-1

17 CENTER CUTTER B. L. W. L.
MAINTENANCE MANUAL

5.1-11B

D98113-1

HARDWARE ASSEMBLY
OVER CUTTER HOUSING

5.1-12

D98017-2

HUB & SHAFT ASSEMBLY


17 B. L. W. L. OVER CUTTER

5.1-12A

A66258-1

MAINTENANCE MANUAL

5.1-12B

A66975-1

TOOL LIST MAINTENANCE


17 CENTER CUTTER

5.1-12C

322tc05

August, 2008

MODEL DS325-322
SECTION 5 Cutterhead Assembly
Table of Contents
Level
2

Drawing

Description

Rev.

Page

D103222-1

SCRAPER INSTALLATION
NOTE: SHEET 4 NOT INCLUDED

5.1-14

5750990017 TIGHTENING TORQUE FASTENERS

322tc05

SECTION 3

August, 2008

MAINTENANCE MANUAL
For
19 DIAMETER CUTTERS
D38630-1 FACE CUTTER ASSEMBLY
&
D38757-1 GAGE CUTTER ASSEMBLY

NOTES:
1. These maintenance procedures are to be accomplished using tools listed
on TOOL LIST A48648.
2. Recommended oil : Texaco Meropa 320
Recommended grease : Mobile Mobilith SHC 460 (Synthetic)

A39380 REV.2

1 of 26

14 May 2007

I. CLEAN COMLETELY
1. Clean cutter assembly. Wire brush and/or steam clean.

II. INITIAL INSPECTION


2. Put D48286-1 Torque Ring on Hub.

3. Check torque in Press or with B49310-1 Shaft Wrench.

A39380 REV.2

2 of 26

14 May 2007

4. Check for flat spots on Ring and oil leaks.

5. Remove Split Ring with Cutoff Saw D46326-1 or Torch.


6. Remove Disc Ring with Cutoff Saw D46326-1.

A39380 REV.2

3 of 26

14 May 2007

7. Remove Pipe Plugs.

8. Drain oil.

9. Air test with C6570-AE Seal Test Tool.

A39380 REV.2

4 of 26

14 May 2007

III. PARTIAL REBUILD/RE-RING


10. Clean and inspect Hub ring area.
10.1

File:

10.2

Measure:

11. Heat Disc Ring.

A39380 REV.2

5 of 26

14 May 2007

12. Install Disc Ring.

13. Check if the Disc Ring is seated against the Hub.

14. Install Split Ring with Split Ring Installation Tool C78867-1.

A39380 REV.2

6 of 26

14 May 2007

15. Put D48286-1 Torque Ring on Hub (same as Step 2.).


16. Check torque in Press or with B49310-1 Shaft Wrench (same as Step 3.).
17. Refill with oil using Funnel B61478-1 or fill with grease.

18. Install Pipe Plugs (reverse of Step 7.).


19. Weld Split Ring.

A39380 REV.2

7 of 26

14 May 2007

20. Plug the wrench holes, pipe plugs and Nut gap area with silicone.

IV. COMPLETE REBUILD DIS-ASSEMBLY


21. Clean cutter assembly. Wire Brush and/or steam clean (same as Step 1.).
22. Remove Split Ring (same as Step 5.).
23. Remove Disc Ring with D46326 Cutoff Saw (same as Step 6.).
24. Remove Pipe Plugs (same as Step 7.).
25. Drain oil (same as Step 8.).
26. Put cutter in Press and heat the Nut with Torch.

A39380 REV.2

8 of 26

14 May 2007

27. Install C47801-1 Nut Removal Wrench.

28. Install C47848-1 Bridge.

29. Press C47848-1 Bridge with 100 tons.


30. Remove Nut by hammer or by A48648-68 Pipe.
30.1

A39380 REV.2

By hammer:

9 of 26

14 May 2007

30.2

By pipe:

31. Remove top Retainer with B48073-1 Lift Eye Tool.

32. Remove Seal Sets.

A39380 REV.2

10 of 26

14 May 2007

33. Remove top O-Ring.

34. Put cutter on C48065 Tube, C48027 Plate, and D48008 Platform

35. Press out Shaft and bottom Retainer.

A39380 REV.2

11 of 26

14 May 2007

36. Move Spacer to one side and install Small Cutter Spacer.

37. Put in C48009-1 Tube and press out bottom Seal Retainer.

38. Turn Hub over and press out top Seal Retainer.

A39380 REV.2

12 of 26

14 May 2007

39. Inspect Bearings and keep in sets. If Bearings are damaged go to Steps 40 & 41.
40. Install B47756-1 Cup Removal Tool and B47764-1 Spacer Plate.

41. Press out Bearing Cups

A39380 REV.2

13 of 26

14 May 2007

42. Put Shaft and bottom Retainer on Plate Adapter C48027.

43. Press Shaft out through bottom Retainer.

V. COMPLETE REBUILD ASSEMBLY


44.

Clean all parts. Wire brush and/or sandblast.

A39380 REV.2

14 of 26

14 May 2007

45.

Discard all Seals and O-Rings

46.

Install bottom O-ring on Shaft

47.

Heat bottom Retainer. Do not exceed 250 F (120 C).

48.

Install bottom Retainer on Shaft.

A39380 REV.2

15 of 26

14 May 2007

49.

Heat Disc Ring (same as Step 11.).

50.

Install Disc Ring.

51.

Check if Disc Ring is seated against Hub (same as Step 13.).

52.

Install Split Ring with Split Ring Installation Tool C78867-1.

53.

Apply Anti-Seize to Bearing Cup bores.

A39380 REV.2

16 of 26

14 May 2007

54.

Press in Bearing Cups with B47783-1 Seating Tool.

55.

Heat Bearing Cone. Do not exceed 250 F (120 C).

56.

Install bottom Bearing Cone in Hub.

A39380 REV.2

17 of 26

14 May 2007

57.

Install O-Ring in bottom Seal Retainer.

58.

Apply Anti-Seize to bottom Seal Retainer and retainer area in Hub.

59.

Press bottom Seal Retainer in Hub and over Bearing Cone using Tool C47794-1.

A39380 REV.2

18 of 26

14 May 2007

60.

Install half of Seal Set in bottom Seal in Hub.

61.

Install other half of Seal Set in bottom Retainer on Shaft.

62.

Apply Anti-Seize to Shaft.

A39380 REV.2

19 of 26

14 May 2007

63.

Clean and oil Seal Sets.

64.

Turn Hub by hand or with D48250-1 Turning Tool.

65.

Place Hub (with Seal Set and Bearing Cone) over Shaft and onto Retainer.

66.

Place C47865 Tube and B47866 Extension on Bearing Cone.

A39380 REV.2

20 of 26

14 May 2007

67.

Press Hub and Bearing Cone or install them hot.

68.

Install Crushable Spacer.

69.

Heat top Bearing Cone (same as Step 55.).

70.

Install top Bearing Cone.

71.

Install O-Rings in top Seal Retainer (same as Step 57.).

A39380 REV.2

21 of 26

14 May 2007

72.

Apply Anti-Seize to Seal Retainer and retainer area in Hub (same as Step 58.).

73.

Press top Seal Retainer in Hub over Shaft with C47794-1 Tool.

74.

Install O-Ring on Shaft.

75.

Install Relief Valve and Vent Plug.

A39380 REV.2

22 of 26

14 May 2007

76.

Apply Anti-Seize to top Retainer.

77.

Apply Anti-Seize to Shaft O-Ring groove and threads.

78.

Install half of Seal Set in top Seal Retainer in cutter.

79.

Install other half of Seal Set in top Retainer.

80.

Clean and oil Seal Sets (same as Step 63.).

81.

Install top Retainer with Seal into cutter.

A39380 REV.2

23 of 26

14 May 2007

82.

Install O-Ring onto Nut.

83.

Apply Anti-Seize to Nut and Nut area in top Retainer.

84.

Thread Nut onto Shaft.

85.

Put D48286-1 Torque Ring on Hub (same as Step 2.).

A39380 REV.2

24 of 26

14 May 2007

86.

Put cutter in Press (same as Step 26.).

87.

Install C47801-1 Nut Removal Tool/Wrench (same as Step 27.).

88.

Install C47848-1 Bridge (same as Step 28.).

89.

Crush the Crushable Spacer with C47848-1 Bridge per the following procedure:
89.1

After cutter assembly cools, press with Bridge on top Retainer gradually
increasing the load while turning Hub assembly until rolling torque of the
assembly starts to increase. Spacer should crush with a load between 6065 tons.

89.2

While increasing the load, continue gradually to crush the Spacer while
checking rolling torque as often as possible.

89.3

Rotate Hub while pressing and measure the rolling torque until it is
between 35-40 ft-lb (47-54 Nm).

89.4

Tighten Nut with hammer or long pipe while assembly is under 60-65 ton
press load.

A39380 REV.2

25 of 26

14 May 2007

89.5

Release the press load.

89.6

Remove Bridge and Wrench.

89.7

Check the rolling torque with a 12 Torque Wrench at 10 off center


(same as Step 3.). The desired rolling torque range is 25-30 ft-lb (34-41
Nm).

90.

Air test with C6570-AE Seal Test Tool (same as Step 9.).

91.

Refill with oil using Funnel B61478-1 or fill with grease (same as Step 17.).

92.

Install Pipe Plugs (same as Step 18.).

93.

Weld Spilt Ring (same as Step 19.).

94.

Fill Wrench holes, Pipe Plugs, and Nut gap area with silicone (same as Step 20.).

A39380 REV.2

26 of 26

14 May 2007

11 October, 2004

Page 2/8
A94924 Rev. 0

MAINTENANCE PROCEDURES
17 WEDGE LOCK BACKLOADING CENTER CUTTER
D95082-1
D95082-2

The radial wear allowance for standard cutter rings is as follows:


Center Positions:

25mm

These maintenance procedures are to be carried out in conjunction with tools called out on the
following lists:
A66975
A66742
A66165
I.

Special Robbins designed tools


General shop tools
Electrical tools and accessories

PREPARATION
1.

Pressure wash cutter assembly completely, removing all muck buildup. Clear
thread and seal gland areas as best as possible.

2.

Remove cutter disc and split ring.


a.
Place cutter assembly on carriage rollers of cutoff saw D46326-1, disc ring
perpendicular to saw wheel.
b.
Saw through disc and split ring, making (2) cuts, approximately 180
apart. Maximum penetration into hub surface shall not exceed .20 in
(5mm) at any one location. If sawcuts already exist in hub, cut at these
locations only. It is not necessary to cut through 100% of the disc ring
section since it cracks very easily due to fit.
c.
Using a cold chisel and a large hammer, drive disc and split ring halves
apart until separated from hub.
d.
Place cutter assembly on workbench. Discard disc and split ring halves.
WARNING: Hammer blows to disc ring can cause hard slivers of steel to fly off
in all directions. Wear face and hand protection at all times.

3.

Clean all parts.

11 October, 2004

Page 3/8
A94924 Rev. 0

a.
b.

4.

Clean, deburr, and smooth all mating surfaces. Use a powered wire wheel
to remove hard muck buildup as needed.
Use a hand stone with solvent to smooth disc ring seat of hub O.D. Avoid
power tool grinding on this surface if at all possible.

Drain oil.
a.
Remove and clean threaded end oil plugs (2). If an oil plug is tight, heat
oil plug to 300F (150C) maximum, apply oil to thread area, then
remove. Alternately, weld a length of small diameter pipe, on the I.D., to
the plug and remove with pipe wrench.
b.
Drain oil completely, placing threaded end of cutter assembly down and
over work bench grill.
c.
Apply sealant 654-022 to threads of (1) oil plug, then install in right seal
carrier SNUG tight.
d.
Loosely hand thread remaining oil plug into right seal carrier to prevent
contaminants from entering assembly.
WARNING: Overtightening oil plug will make it difficult to remove later. Welder
grounding and arc strikes are permitted on local shaft retainer, seal carrier, and
pipe surfaces only.

II. INSPECTION
1.

If cutter does not roll, cutter leaks oil at seal gland areas, or magnetic oil plug(s)
have large metal particles attached, rebuild IS required. Skip remaining steps and
proceed to section IV for complete cutter rebuild.

2.

Measure cutter roll torque.


a.
Place cutter assembly vertical, split ring up.
b.
Place torque ring D90194-1, hex stud(s) up, on split ring end of hub O.D.
Place torque wrench on a torque ring stud, handle extending radially
outward.
c.
To keep cutter shaft and supports from rotating. Place cutter under press
with approximately 2 ton load.

3.

If roll torque falls between 20-25 ft-lb (27-34 Nm) without disc ring, rebuild is
NOT required. Skip remaining steps and proceed to section III for disc ring and
oil replacement only.

4.

If roll torque is incorrect or if it varies by more than 6 ft-lb (8 Nm), rebuild IS


required. Skip remaining steps and proceed to section IV for complete cutter
rebuild.

III. DISC RING AND OIL REPLACEMENT ONLY

11 October, 2004

Page 4/8
A94924 Rev. 0

A. INSPECTION
1.

Pressure test cutter assembly.


a.
Replace loosely threaded oil plug on nut end with seal test tool C5670AE, snug tight.
b.
Pressurize assembly to 3-5 psi (21-34 kpa).
c.
If cutter assembly fails to hold the same pressure for (5) minutes
minimum, cutter assembly will leak oil. Cause of air leak must be found
and corrected. Proceed to section IV for complete cutter rebuild if
necessary.
d.
Replace seal test tool with oil plug, loosely fitted.

2.

Replace any excessively worn or damaged parts.

B. ASSEMBLY
1.

Install new disc ring.


a.
Place cutter assembly vertical, split ring up.
b.
Remove all oil residue from disc ring bore and seat surface of hub O.D.
with a strong solvent.
c.
Heat disc ring to 350F (175C) maximum with induction heater.
d.
Slip disc ring onto hub O.D. against shoulder.
e.
If disc ring sticks, use disc ring tool D7251-T7 in press to seat against hub
shoulder.
WARNING: Do not allow disc ring to remain at 300-250F (150-175C) for
longer than 5 minutes. Disc ring hardness will be otherwise lost, thus reducing
cutter life.

2.

Install split ring B60262/A12069.


a.
Slip split ring over hub into split ring groove, slot area facing up.
b.
Compress split ring with split ring clamp D63138/DM1726, aligning a
relieved area of clamp with split ring slot.
c.
Attach welder ground to split ring clamp or hub surface.
d.
Bevel weld split ring at slot area. Do not weld split ring to hub or disc
ring surface.
WARNING: Arc strikes are permitted on hub or split ring clamp surfaces only.
DO NOT STRIKE ANY ARC ON DISC RING.

3.

Allow cutter assembly to cool to ambient temperature.

4.

Check cutter roll torque.

11 October, 2004

Page 5/8
A94924 Rev. 0

a.

Measure cutter roll torque with torque ring D90194-1 and torque wrench,
as described in section II.

b.

If roll torque falls between 20-25 ft-lb (27-34 Nm) with new disc ring
installed, proceed to step 5.
If roll torque is incorrect or if it varies by more than 6 ft.-lb (8 Nm),
rebuild IS required. Skip remaining steps and proceed to section IV for
complete cutter rebuild.

c.

5.

If removed, install tab B61260-1.


a.
Place tab in right shaft retainer slot, long edge against nut O.D.
b.
Attach welder ground to right shaft retainer.
c.
Back weld nut tab to nut, .25 - .35 in (6 9mm) X .65 - .75 (16 19mm)
long, avoiding nut spanner holes.
WARNING: Do not weld nut tab to any part of shaft retainer. Arc strikes are
permitted on nut and right shaft retainer surfaces only.

6.

Fill cutter assembly with new oil.


a.
Place cutter assembly on end, threaded side up, then remove loose oil
plug.
b.
Fill cutter with Meropa 320 oil or equivalent, using funnel assembly
B61478-1, until oil just covers top bearing cage (about 95% of total
capacity).
c.
Apply sealant 654-022 to threads of remaining oil plug and install SNUG
tight.
WARNING: Do not overfill. A leaking cutter will result. Overtightening oil plug
will make it difficult to remove later.

7.

Cutter ready for use.

IV. COMPLETE CUTTER REBUILD


A. DISASSEMBLY
1.

Clean cutter assembly completely.

2.

Remove cutter ring with cutter ring saw or gas torch.

3.

Remove oil plugs from both ends of cutter and drain oil completely.

4.

Remove tab weld with grinder. Remove tab and discard.

5.

Use spanner wrench C66977-1 to remove nut.

11 October, 2004

Page 6/8
A94924 Rev. 0

6.

Place cutter assembly in press on press platform and shaft adapter D17238-T5.
Push shaft out of assembly with press. Cushion fall of shaft with a piece of wood.

7.

Remove cups from hubs by using tool D17238-T8 and T2.

8.

Clean and inspect all parts. Repair or replace any damaged parts.

B. INSPECTION
1.

Replace bearing sets if any one of the following conditions exist:


a.
Cup/cone raceway indenting is evident.
b.
Cup/cone raceway spalling or pitting is evident.
c.
Cup/cone raceway surface cracks can be detected.

2.

Replace face seal pairs if .20 in (5mm) or more of wear is evident down to sealing
band of face. (i.e., area of face between O.D. and narrow shiny band).

3.

Replace shaft if any one of the following conditions exist:


a.
Surface cracks in thread root areas are evident.
b.
Surface cracks along shaft length are evident.
c.
Severe galling from bearing cones is evident. If shaft threads are dented in
any way, carefully file or die grind to original profile until seal carrier
threads on freely.

4.

Replace any other excessively worn or damaged parts.

5.

Clean all parts.


a.
Clean, deburr, and smooth all mating surfaces. Use an air powered wire
wheel to remove hard muck buildup as needed.
b.
Use sand paper to smooth gall marks in hub bearing bores if cups were
removed.
c.
Use a hand stone with solvent to smooth stepped areas on shaft O.D. if any
exist.

C. ASSEMBLY
1.

Place o-ring, piece 14 on shaft. Heat bottom retainer, piece 5 to 150 degrees
centigrade. Place the hot part over shaft and slide to bottom against shoulder.
Allow retainer to cool. Do not use anti-seize lubricant on shaft.

2.

After retainer is cool, seat retainer on shaft with 30 tons by use of tool D17238T4.

3.

Heat cutter rings to 175 degrees centigrade and place on hubs. Place split rings in
grooves on hubs. Clamp split rings with clamp tool D63138/DM1726 and weld
split rings.

11 October, 2004

Page 7/8
A94924 Rev. 0

4.

Press bearing outer rings into hubs with D17238-T3. Seat with 20 tons of force.

5.

Install Seal into bottom retainer.

6.

Heat bearing inner ring to 100 degrees centigrade and slide over shaft against
bottom retainer. After assembly has cooled, seat bearing with 20 tons.

7.

Install seal in bottom hub assembly.

8.

Without scratching seal, lower hub assembly with hub shoulder down over
bearing on shaft.

9.

Heat bearing inner ring to 100 degrees centigrade and slide over shaft against
bearing outer ring in hub.

10.

Install seal in top of bottom hub assembly on shaft.

11.

Install seals in center shaft retainer piece 6.

12.

Orient center retainer as shown in assembly drawing D95082 and slide over shaft
against bearing and seals.

13.

Heat bearing inner ring to 100 degrees centigrade and slide over shaft against
center retainer. Allow assembly to cool.

14.

Using tool D17238-T4, carefully press on uppermost bearing until rolling torque
of bottom hub assembly is 22 to 33 foot pounds.

15.

Install seal in bottom of top hub assembly.

16.

Without scratching seal, lower hub assembly with hub shoulder down over
bearing on shaft.

17.

Install seal in top of hub assembly.

18.

Apply anti-seize to shaft with a brush. (Note: Anti-seize is not applied in any of
the previous steps).

19.

Heat bearing inner ring to 100 degrees centigrade and slide over shaft against
outer ring in hub. Allow assembly to cool.

20.

Install seal in top shaft retainer piece 7. Install o-ring piece 15.

21.

Slide top shaft retainer over shaft against bearing.

11 October, 2004

Page 8/8
A94924 Rev. 0

22.

Use spanner wrench C66977-1 to tighten nut until the rolling torque is 22 to 33
foot pounds.

23.

Align shaft retainers by striking with a rubber hammer to attain co-planar


mounting surfaces between all three retainers.

24.

Place tab in slot in retainer and weld to nut.

25.

Use seal test tool C5670-AE to air test both ends of assembly with 3 to 5 psi air
pressure. Correct any leaks that occur.

26.

Fill cutter with oil until oil just covers the cage of the top bearing (by
approximately 3mm).

27.

Replace oil plugs.

28.

Cutter assembly ready for use.

5 June, 2007

Page 2/7
A66258 Rev. 5

MAINTENANCE PROCEDURES
17 WEDGE LOCK BACKLOADING CENTER CUTTER
D66250

These maintenance procedures are to be carried out in conjunction with tools called out on the
following lists:
A66975
A66742
A66165

Special Robbins designed tools


General shop tools
Electrical tools and accessories

I - PREPARATION
1.

Pressure wash cutter assembly completely, removing all muck buildup. Clear thread
and seal gland areas as best as possible.

2.

If cutter does not roll, leaks oil at seal gland areas, or has metal particles in the
lubricant, bearing change is required.

3.

Measure cutter roll torque.


a. Place cutter assembly vertical, threaded end up.
b. Install and tighten torque ring D90194-1, hex stud up, on disc ring O.D.
c. Place torque wrench A10930-101 on a torque ring stud, with handle extending
radially outward.
d. To keep cutter shaft and supports from rotating. Place cutter under press with
approximately 2 ton load.

4.

If roll torque falls between 5-20 ft-lb (7-27 Nm) without disc ring, bearing change may
not be required. See disassembly procedure for visual bearing inspection.

5.

If roll torque is incorrect or if it varies by more than 6 ft-lb (8 Nm), bearing change is
required.

6.

Remove cutter disc and split rings.


a. Place cutter assembly on carriage rollers of cutoff saw D46326-1, disc rings
perpendicular to saw wheel.
b. Saw through disc and split ring, making (2) cuts, approximately 180 apart.
Maximum penetration into hub surface shall not exceed .20 in (5mm) at any
one location. If sawcuts already exist in hub, cut at these locations only. It is

5 June, 2007

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A66258 Rev. 5
not necessary to cut through 100% of the disc ring section since it cracks very
easily due to fit.
c. Using a cold chisel and a large hammer, drive disc and split ring halves apart
until separated from hub.
d. Place cutter assembly on workbench. Discard disc and split ring halves.

WARNING: Hammer blows to disc ring can cause hard slivers of steel to fly off in all
directions. Wear face and hand protection at all times.
7.

Drain oil (unless grease filled).


a. Remove and clean all plugs. If a plug is tight, heat plug to 300F (150C)
maximum, apply oil to thread area, then remove. Alternately, weld a length of
small diameter pipe, on the I.D., to the plug and remove with pipe wrench.
b. Drain oil completely, placing threaded end of cutter assembly down and over
work bench grill.

II - DISASSEMBLY
1.

Remove tab weld with grinder. Remove tab (piece 9) and discard.

2.

Use spanner wrench C66977-1 to remove nut.

3.

Place cutter assembly in press on press platform and shaft adapter D17238-T5. Push
shaft out of assembly with press. Cushion fall of shaft with a piece of wood.

4.

Clean and inspect all parts. Repair or replace any damaged parts. See Inspection
below.

5.

If bearings are being replaced and the hub is not, remove cups from hubs by using tool
D17238-T8 and D17238-T2.

III - INSPECTION
1.

Replace bearing sets if any one of the following conditions exist:


a. Cup/cone raceway indenting is evident.
b. Cup/cone raceway spalling or pitting is evident.
c. Cup/cone raceway surface cracks can be detected.
d. Cutter did not turn or failed torque criteria in items 4 and 6 of Preparation
section above.

2.

Replace face seal pairs if 0.20 in (5mm) or more of wear is evident on sealing band of
face. (i.e., area of face between O.D. and narrow shiny band).

3.

Replace shaft if any one of the following conditions exist:


a. Surface cracks in thread root areas are evident.
b. Surface cracks along shaft length are evident.

5 June, 2007

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A66258 Rev. 5
c. Severe galling from bearing cones is evident. If shaft threads are dented in
any way, carefully file or die grind to original profile until seal carrier threads
on freely.

4.

Replace any other excessively worn or damaged parts.

5.

Clean all parts.


a. Clean, deburr, and smooth all mating surfaces. Use an air powered wire
wheel to remove hard muck buildup as needed.
b. Use sand paper to smooth gall marks in hub bearing bores if cups were
removed.
c. Use a hand stone with solvent to smooth stepped areas on shaft O.D. if any
exist.
d. Use a hand stone with solvent to smooth disc ring seat of hub O.D. Avoid
power tool grinding on the surface if at all possible.

IV - ASSEMBLY
1.

Place o-ring (piece 14) on shaft (piece 4).

2.

Apply sealant 654-022 to threads of plugs, then install in left retainer SNUG tight.
WARNING: Over tightening plug will make it difficult to remove later.

3.

Place left retainer (piece 5) over shaft and slide to bottom against shoulder. Do not use
anti-seize lubricant on shaft.

4.

Install a disc ring onto each hub per the following.


a. Heat disc ring to 350F (175C) maximum with induction heater
A66165-509/609 or oven A95802-1.
b. Slip disc ring onto hub O.D. against shoulder.
c. If disc ring sticks, use disc ring tool D7251-T7 in press to seat against hub
shoulder.
WARNING: Do not allow disc ring to remain at 300-350F (150-175C) for longer
than 5 minutes. Disc ring hardness will be otherwise lost, thus reducing cutter life.

5.

Install split ring B60262/A12069.


a. Slip split ring over hub into split ring groove, slot area facing up.
b. Compress split ring with split ring clamp D63138/DM1726, aligning a
relieved area of clamp with split ring slot.
c. Attach welder ground to split ring clamp or hub surface.
d. Bevel weld split ring at slot area. Do not weld split ring to hub or disc ring
surface.
WARNING: Arc strikes are permitted on hub or split ring clamp surfaces only. DO
NOT STRIKE ANY ARC ON DISC RING.

5 June, 2007

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A66258 Rev. 5

6.

Allow cutter assembly to cool to ambient temperature.

7.

If installing new bearings, press bearing cups (piece 10) into hubs.
a. Lightly coat hub bearing bores and O.D. of bearing cups with anti-seize
654-025.
b. Press bearing cups into hub with insertion tool D17328-T3, seating to twenty
(20) tons maximum.
WARNING: Be sure bearing cups are pressed in squarely. If cup enters bore severely
misaligned, the cup MUST be removed and hub bore examined for damage.

8.

Install seal B47037-1 in left retainer.


a. Remove all oil residue from retainer seal gland and used seals (if seal reused).
b. If installing used seals, clean and install new torics on seal.
c. Expand installation tool C14835-1 around one seal half, such that it captures
seal with the face inward and the toric outward against tool end. Be sure that
the toric seam line is positioned the same way around the seal circumference.
d. Install one seal half in seal gland, pushing down evenly on opposite end of
seal tool, until it pops in. Seal face will extend .30-.40 in (8-10mm) beyond
seal gland lip surface upon correct installation.
e. Clean seal face with solvent.
f. Apply 4-6 spaced drops of oil to seal face.
WARNING: Be sure all surfaces in contact with seal torics remain oil free until cutter
assembly is complete.

9.

Install bearing cone (piece 11) on shaft.


a. Heat bearing cone to 250F (120C) maximum with induction heater
A66165-509/609 or oven A95802-1.
b. Slip cone onto shaft until fully seated against left retainer.
c. Allow assembly to cool to ambient temperature.
d. Place a few drops of oil between rollers and raceways.
e. Place shaft assembly, threaded end up, on cover plate B63185-1 in press.
f. Using seating tool D17238`-T4, press bearing cone with twenty (20) tons until
bearing cone is fully seated against left retainer, no gaps remaining.

10.

Install seal half in hub assembly using substeps a thru e of step 8. Seal half must
be in correct end of hub such that it mates with seal half in left retainer when hub is
installed. See assembly drawing for hub orientation.

11.

Without scratching seal, lower hub/disc assembly over bearing on shaft.

12.

Install bearing cone (piece 11) on shaft.


a. Heat bearing cone to 250F (120C) maximum with induction heater
A66165-509/609 or oven A95802-1.

5 June, 2007

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A66258 Rev. 5
b. Slip cone onto shaft until fully seated against bearing cup in hub. Allow
assembly to cool.
c. Place a few drops of oil between rollers and raceways.

13.

Install seal in hub assembly on shaft using substeps a thru f of step 8.

14.

Install seal in one side of center retainer (piece 6) using substeps a thru e of step 8.

15.

Orient center retainer as shown in assembly drawing D66250, aligned with left retainer,
and slide over shaft against bearing and seals.

16.

Install seal in other side of center retainer (piece 6) using substeps a thru f of step
8.

17.

Install bearing cone (piece 11) on shaft.


a. Heat bearing cone to 250F (120C) maximum with induction heater
A66165-509/609 or oven A95802-1..
b. Slip cone onto shaft until fully seated against center retainer.
c. Allow assembly to cool to ambient temperature.
d. Place a few drops of oil between rollers and raceways.

18.

Install and tighten torque ring D90194-1, hex stud up, on disc ring O.D.

19.

Place torque wrench A10930-101 on torque ring stud, with handle extending radially
outward.

20.

Using tool D17238-T4, carefully press on uppermost bearing until rolling torque of
bottom hub assembly is 13 to 20 foot pounds (17 to 27 Nm).

21.

Install seal in bottom of top hub assembly using substeps a thru e of step 8. . Seal
half must be in correct end of hub such that it mates with seal half in center retainer
when hub is installed. See assembly drawing for hub orientation.

22.

Without scratching seal, lower hub/disc assembly over bearing on shaft.

23.

Apply anti-seize to shaft with a brush. (Note: Anti-seize is not applied in any of the
previous steps).

24.

Install bearing cone (piece 11) on shaft.


a. Heat bearing cone to 250F (120C) maximum with induction heater
A66165-509/609 or oven A95802-1.
b. Slip cone onto shaft until fully seated against bearing cup in hub. Allow
assembly to cool.
c. Place a few drops of oil between rollers and raceways.

25.

Install o-ring (piece 15) and o-ring (piec17) on shaft and apply anti-seize to o-rings.

26.

Install seal in top of hub assembly using substeps a thru f of step 8.

27.

Install seal in right retainer (piece 7) using substeps a thru e of step 8.

28.

Slide right retainer with seal over shaft against bearing.

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A66258 Rev. 5

29.

Apply anti-sieze to nut (piece 8) threads and install nut.

30.

Remove torque ring D90194-1 from lower disc and install and tighten on upper disc.

31.

Place torque wrench A10930-101 on torque ring stud, with handle extending radially
outward.

32.

Use spanner wrench C66977-1 to tighten nut until the rolling torque is 13 to 20 foot
pounds (17 to 27 Nm).

33. Align retainers by striking with a rubber hammer to attain co-planar mounting surfaces
between all three retainers.
34. Pressure test cutter assembly.
a. Install seal test tool C5670-AE, snug tight in one plug hole in right retainer
b. Apply sealant 654-022 to threads of plugs, then install in right retainer SNUG
tight. Do not over tighten.
c. Pressurize assembly to 3-5 psi (21-34 kpa).
d. If cutter assembly fails to hold the same pressure for five (5) minutes
minimum, cutter assembly will leak oil. Cause of air leak must be found and
corrected.
e. Remove seal test tool and one plug.
35.

Fill cutter assembly with new oil.


a. With cutter assembly on end, threaded side up, fill cutter with Meropa 320 oil
or equivalent, using funnel assembly B61478-1, until oil just covers top
bearing cage by approximately 3mm (1/8 inch). If grease filled see document
A98192.
b. Apply sealant 654-022 to threads of plugs, then install in right retainer SNUG
tight.
WARNING: Over tightening plugs will make it difficult to remove later.

36.

Install tab (piece9).


a. Place tab in right retainer slot, long edge against nut O.D.
b. Attach welder ground to right retainer.
c. Weld tab to nut, .25 - .35 in (6 9mm) X .65 - .75 (16 19mm) long,
avoiding nut spanner holes.
WARNING: Do not attach welder ground to any other part other than specified. Do
not weld tab to any part of retainer. Arc strikes are permitted on nut and right retainer
surfaces only.

37.

Apply silicone sealant 654-020 to gap between nut (piece 8) and right retainer (piece 7),
nut spanner holes, and plug sockets to prevent muck buildup.

38.

Cutter assembly is ready for use.

MODEL DS325-322
SECTION 6 Main Bearing & Seal Assembly
Table of Contents
Level

Drawing

Description

Rev.

Page

D101462-1

MAIN BEARING & SEAL ASSEMBLY

6.1

6.1-34

5750008337 STUD TENSIONING UNIT


MANUFACTURERS LITERATURE
5750990017 TIGHTENING TORQUE FASTENERS

322tc06

6.1-34A
SECTION 3

August, 2008

MODEL DS325-322
SECTION 7 Forward Shield Assembly
Table of Contents
Level

Drawing

Description

Rev.

Page

D107804-1

FORWARD SHIELD ASSEMBLY

7.1

D101841-1

STABILIZER ASSEMBLY
NOTE: SHEET 2 NOT INCLUDED

7.1-8

D101464-1

CYLINDER STABILIZER

7.1-8-8

D91755-1

CYLINDER LIFT

7.1-9

D101770-1

DUST SHIELD ASSEMBLY


NOTE: SHEET 3 NOT INCLUDED

7.1-25

D103209-1

CUTTERHEAD SUPPORT PLUMBING

7.1-27

5750990017 TIGHTENING TORQUE FASTENERS

322tc07

SECTION 3

August, 2008

MODEL DS325-322
SECTION 8 Main Drive Assembly
Table of Contents
Level

Drawing

Description

Rev.

Page

D107805-1

MAIN DRIVE ASSEMBLY

8.1

D104117-1

OUTPUT SHAFT ASSEMBLY

8.1-3

D103203-1

GEARBOX

8.1-5

D107840-1

ELECTRIC MOTOR ASSEMBLY

8.1-6

MANUFACTURERS LITERATURE

8.1-6A

5750013784 TORQUE COUPLING ASSEMBLY

8.1-14

D110056-1

8.1-14-3

SAFESET COUPLING ASSEMBLY


MANUFACTURERS LITERATURE

5750013783
3

TORQUE COUPLING W/BRAKE

3035032874 YOKE SET FOR BRAKE ASSEMBLY


MANUFACTURERS LITERATURE
5750990017 TIGHTENING TORQUE FASTENERS

322tc08

8.1-14-3A
1

8.1-15

8.1-15-3
8.1-15-3A

SECTION 3

August, 2008

OPERATINGINSTRUCTIONS
Three-phase-asynchronous motor
with
squirrel-cage rotor
TBM Velingonda India
Mat. no. D107840-1

Type:
Serial no.:
Customer:
Customers order no.:
Our order / project:

MKH735U06
505750 08001
The Robbins Company
0098045
127648 / K.S31-08144

Issue no.:
Date:

01
01.10.2008

This Operating instruction is a translated version of the Betriebshandbuch of ELIN EBG Motoren GmbH. It is understood that in all
cases of mistranslation and/or misinterpretation the German version shall be valid.
This Document must neither be copied nor used in any other way without our written consent. Neither is it to be handed over; nor in other
way communicated to a third party. Infringement will lead to prosecution.
ELIN EBG Motoren GmbH

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World in Motion

ELIN EBG Motoren GmbH


Elingasse 3
8160 Weiz, Austria

Gesellschaftssitz Weiz,
registriert beim Handelsgericht Graz unter
FN 58429a; UID: ATU1477 3404; DVR 0748897

Tel.: (+43/3172) 90 606-0


Fax: (+43/3172) 90 606-784

www.elinebgmotoren.at

1. Safety instructions
This operating instruction contains important warning instructions and safety instructions. The user
has to pay attention to this.
This motor is assigned only for a certain use which is described in the instructions. Besides you
find the most important assumptions and safety measures for use and running the machine to
guarantee a running without complaining.
We dont take the guarantee and responsibility for use outside the described purpose and without
attention to the necessary assumptions and safety measures.
Only specialists are allowed to transport, set up, connect, put into operation, service and operate
motors and generators. The specialist has to know the valid safety regulations and erection
standards.
All work has to be controlled by responsible specialists.
The specialists have to be authorized for their work.
Specialists are people who

are well skilled and have the experience

know the valid standards, instructions, regulations and accident prevention


instructions

know the functioning and operating conditions of the electrical machines

know and may avoid dangers

Non-qualified people and wrong use can lead to dangers for

body and life

the machine and further property of the user

the efficient function of the machine

Its only allowed to operate a machine with the delivered accessories and material from ELIN EBG
Motoren GmbH

The danger warnings characterized in this manual have to be especially


considered.

Warning of dangerous electrical voltage.

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BTHB_505750_E_01

Protection equipment
Insulated tools, isolating protective clothing, protection device, seat belts,
devices and other aids must be received in perfect condition. The isolating
protective clothing must be examined before each use by the user for obvious
damage.
Damage to isolating protective clothing may be eliminated only by technically suitable workshops.
Gloves may not be repaired however. Isolating gloves and shoes must be examined in certain
time intervals also electrically for their protective effect.
Carrying of wrist-watches, rings and bracelets with the work is forbidden.

First aid measures by accidents with electrical current

By accidents with electrical current you should take the following measures:

Interruption of circuit by switching off, by pulling the plug, by taking the safety device out.
If these measures are not immediately possible, casualty must be pulled away from the
electric circuit by using non conductive articles.
Call a doctor!
Emergency call:
Rescue guidance centre ........................................... Phone: ..........................................
Accomplish first aid measures up to the arrival of the doctor.
- immediate placing in rest position
- control of respiration and pulse
- when respiratory arrest then breath donation
- when cycle stop then heart-lung-revival
- when unconsciousness and existing respiration then side storage
- germ-free coverage of the fire wounds

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BTHB_505750_E_01

Table of contents
1. Safety instructions ........................................................................................................ 2
Table of contents............................................................................................................... 4
2. Technical Data ............................................................................................................... 6
3. Operating and maintenance instructions .................................................................... 8
3.1 Transport and storage ..................................................................................................... 8
3.1.1 Storage .................................................................................................................. 8
3.1.2 Long time storage (more than 3 months)............................................................... 8
3.1.3 Measures to be taken after prolonged storage ...................................................... 9
3.1.4 Storage of used motors ......................................................................................... 9
3.2 Coolant mixture................................................................................................................ 9
3.3 Safety measures .............................................................................................................. 9
3.4 Coupling and installation .............................................................................................. 10
3.4.1. Condensation drain holes (only valid for IP56, IP66, IP67!) ............................... 10
3.4.2 Installation of the overload clutch (only for drilling head motor)........................... 10
3.5 Cooling water ................................................................................................................. 11
3.5.1 Water specification for stator cooled electrical machines .................................... 11
3.5.2 Connections......................................................................................................... 11
3.5.3 Cleaning instructions for electrical machines with water cooling ......................... 12
3.5.4 Recommended cleaning process with boiler cleansing compounds ................... 13
3.6 Electrical connection ..................................................................................................... 14
3.7 Drying of moist windings .............................................................................................. 15
3.8 Bearing lubrication ........................................................................................................ 16
3.9 Bearing replacement...................................................................................................... 18
3.10 Cleaning ........................................................................................................................ 18

4. Check list for first start up .......................................................................................... 19


5. Warranty / Malfunctions / Repairs .............................................................................. 21
CAUTION: The following instructions apply only to drilling head motors with
integrated overload clutch .................................................................................................. 22
5.1 Measures to be taken in the event of failure of individual drive components ......... 22
5.2 Failure ............................................................................................................................. 23

6. Emergency data........................................................................................................... 24
Fire fighting .......................................................................................................................... 24
First aid measures by accidents with electrical current .................................................. 25

7. Spare Parts................................................................................................................... 26
7.1 Spare parts inventory .................................................................................................... 26
7.2 Order procedure............................................................................................................. 26
7.3 Spare part list ................................................................................................................. 27
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BTHB_505750_E_01

List of revisions ............................................................................................................... 28


Use confirmation ............................................................................................................. 29
Appendix .......................................................................................................................... 30
Drawings............................................................................................................................... 30
EC-Declaration of Conformity............................................................................................. 30
Failure report ........................................................................................................................ 30
Actuation for the relubrication............................................................................................ 30

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BTHB_505750_E_01

2. Technical Data
Three-phase asynchronous motor MKH735U06
Welded housing / water-cooled stator
330 kW S1, 690 V D, 50 Hz, 989 1/min
IM3001 (B5), IP67, RAL5012
Technical description:
Execution: DIN-EN 60034, IEC 60034, ELIN-motor-lists
Welded housing / water-cooled stator
Type of construction
: IM3001 (B5)
Type of protection
: IP67
Weight (kg)
: appr. 1610
Colour
: RAL5012 - K2
IEC-frame size
: 355
Terminal box
: radial on the housing near NDE
Line entrance
: in DE direction
2x 2 1/2 inch NPT (plugged)
2x 3/4 inch NPT (plugged)
Shaft end
: 1x special glad
Bearings
: NDE (clutch side) -> ball bearing
DE (gear side) -> roller bearing (isol.)
Lubrication
: grease, relubrication device
Insulation class
: H
Water inlet temp. (degr.C)
: max. 25
Water flow (l/min)
: min. 25
Water pressure (bar)
: max. 5
Technical data:
Output [kW]
Duty type
Voltage [V]
Connection
Frequency [Hz]
Speed [1/min]
Current [A]
Torque [Nm]
Efficency [%]
Power factor

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Sinus-Data
: 330
: S1
: 690
: D
: 50
: 990
: 348
: 3183
: 95.7
: 0.83

Issue no:
Date:

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VFD-Data
330
S1
690
D
50
989
360
3187

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BTHB_505750_E_01

Additional equipment, -execution:


* Motor protection: 2x 3 bimetallic switches normally closed contact
(3x warning, 3x shutdown)
* Space heater (130 W, 230 V, 50 Hz)
* Shake proofed design (resistant against vibrations up to 5g)
* Seals against entrance of water and oil
* 6 Condensation drain holes on DE and NDE
* Suitable for 6 fitting positions
* second name plate for VFD-operation
* special copper rotor
Comments:
Converter
0- 50 Hz
50- 85 Hz
85-100 Hz

operation:
(989 1/min) -> constant torque 3187 Nm
(1679 1/min) -> constant power 330 kW
(1980 1/min) -> reduced power 270 kW at 100 Hz

Winding isolation for:


Rise time
Voltage rise
0.1 mysec
10.4 kV/mysec
0.8 mysec
1.8 kV/mysec

Peak voltage
1300 V
1800 V

Dimension drawing -> 6184164

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BTHB_505750_E_01

3. Operating and maintenance instructions


3.1 Transport and storage
On delivery the machines are packed on woods. These woods are intended for loading by means
of stacker.
Lift machines only on lifting eyes provided. The lifting eyes are designed for
machine mass only. Do not add any load to machine. (Weight see 2. Technical
Data).
Machines with cylindrical roller bearings, ball bearings of the type 6328 and
higher and special bearings are protected against bearing damage during
transport by means of a locking device which has to be removed before
putting the machine into operation.
The locking device must also be used for any further transport of the machine!

3.1.1 Storage
All blank parts are protected against corrosion by using special agents (e.g. Tectyl 506).
If the machine has to be stored, because it cant be fitted and started running on arrival at point of
destination, take notice of the storage area. Machines and equipment have to be stored in rooms
which are well-ventilated, dry, dust-free, temperate and vibration proof.

3.1.2 Long time storage (more than 3 months)


For long time storage without operational readiness the machine must be protected against
damages. All blank parts have to be protected against corrosion using special agents (e.g. Tectyl
506). Additionally to the above mentioned arrangements the machine must be packaged in a
plastic cover and Silicagel must be added (desiccant). The transport safeguard must be installed. If
a space heater is available it must be switched on. The ambient temperature should be approx.
20C and the relative air humidity approx. 55 %.
Machines have to be stored in rooms which are vibration proof. The storage at cold walls, stone
floors, heater pipes as well as in surrounding atmosphere with aggressive media is not permissible.
The cooling ducts of water-cooled machines must be filled completely with
coolant (with inhibitor). The cooling ducts of oil-cooled machines must be filled completely with oil.
In order to prevent damage of the bearings caused by non operation, the
machines should be switched on resp. the rotor should be turned for a short
time at least every three months. The transport safeguard must be loosened
before and installed afterwards.
If turning of the rotor is not possible every 3 months, then the bearings must
be renewed before start-up.

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BTHB_505750_E_01

3.1.3 Measures to be taken after prolonged storage


Lubricants tend to age, which is associated with the loss of specific properties. Ensure that the
bearing lubricant is of sufficient quality for its purpose. This reduces the relubricating period until
the next maintenance job! After a storage period of more than 3 years, the bearing lubricant
must be replaced. The bearing grease must be replaced in the course of the replacement of
the bearings. Use only grease of the prescribed grade (see Lubrication shield/2. Technical
Data). Unless the rotor has been rotated ever 3 months, the bearings must be replaced. In
machines that are to be restarted after a prolonged period of storage, check the insulation
resistance (see Control of the isolation resistance/3.7 drying of moist windings). Install the
equipment according to the instructions in the operating manual.

3.1.4 Storage of used motors


Prior to putting the motor into storage, we recommend sending it to an authorised ELIN service
agent for proper dismantling, cleaning and conservation. The motor should subsequently be stored
indoors in a facility with a stable climate. Ensure that the motor is stored in such a way that the
condensation drain holes are opened and facing down (drainage).
There is no guarantee for bearing and grease after a long stop time!

3.2 Coolant mixture


We commend following antifreeze with rust inhibitor:

GlycoShell
Glysantin G-03
Havoline XLC
Mobil antifreeze H

For a temperature range up to - 30 C use 60% water and 40% antifreeze (e.g. GlycoShell).
Antifreeze has always to be thin with water. The frost proof depends of the mixing ratio. Please note
the chapter 3.5 Cooling water!

3.3 Safety measures


The safety instructions must be adhered strictly (see chapter 1)!
Only qualified and authorized personnel are allowed to carry out works on
machines. Refer also to DIN VDE 0105 or IEC 364.
Before carrying out any work on the machines, disconnect and secure it
against restarting.

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BTHB_505750_E_01

3.4 Coupling and installation


Remove corrosion protection at plank parts. Loosen transport locking screw. The fixing bolts have
to be tightened and secured against loosening. The machine is dynamically balanced.
Lift machines only on lifting eyes provided. The lifting eyes are designed for
machine mass only. Do not add any load to machine. (Weight see 2. Technical
data).

Machines with cylindrical roller bearings, ball bearings of the type 6328 and
higher and special bearings are protected against bearing damage during
transport by means of a locking device which has to be removed before
putting the machine into operation.
The locking device must also be used for any further transport of the machine!

Care for a plane mounting place to avoid bracing of the housing. Re-check
alignment with the machine at operating temperature.

3.4.1. Condensation drain holes (only valid for IP56, IP66, IP67!)
The machine is equipped with a number of condensation drain holes with screw plugs. Depending
on the position of installation at DE and NDE, the bottom screw plug must be replaced with the
sintered bronze filters (supplied as loose parts in the terminal box!). The screw plugs with the
sintered bronze filters must be regularly opened to drain off the condensation from the
motor chamber. This should be done at the lubricating intervals laid down in the schedule,
see Appendix.
These connections must be sealed with Loctite 577.
Tightening torque: 15.6 Nm

3.4.2 Installation of the overload clutch (only for drilling head motor)
1. Connect the motor to the gear system.
2. Insert the torsion shaft into the hollow motor shaft (apply a little grease, e.g. gleitmo WSP 5040
Fuchs Lubritech GmbH or equivalent product, onto the gearing) and engage the internal toothing of
the transmission system.
3. Insert the 30x2.65 O-ring into the torsion shaft (after visual inspection).
(O-ring, item 130 in sectional drawing, included with torsion shaft.)
4. Mount and press Safeset according to the instructions in the separate installation manual
onto the hollow and the torsion shaft.
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3.5 Cooling water


3.5.1 Water specification for stator cooled electrical machines
Nominal data
pH value
Water hardness (dH)
Suspended solids (ppm)
Filter aperture width (m)

Recommended quality
7.5 up to 8.5
4 up to 6
< 10
30

Accepted quality
6.5 up to 9.0
< 10
< 30
<100

Remaining specification according to DIN 50930.


Have special attention to the observance of pH-value, water hardness and quantity of suspended
solids.
In the relation quantity of suspended solids to water hardness the following has to be considered:
The higher the water hardness the lower must be the quantity of suspended solids.
Past experience has shown that as long as continuous cooling water through-flow is ensured also
a substantially higher quantity of suspended solids will not cause impermissible soiling of the
cooling channels in the machine.
The Cleaning Instructions for Electrical Machines with Water Cooling should be noted in case of
frequent time of standstill and deviations to the above mentioned approximate values.
In existence of a closed cooling water circuit we recommend the antifreeze GlycoShell or a similar
inhibited antifreeze satisfying grade 1 according to ASTM D 1384-87 in dependence on the
material of the cooling circuit.
For a temperature range up to - 30 C use 60% water and 40% antifreeze. It should be verified
every 5 years that the inhibitor of the coolant is not consumed otherwise the coolant has to be
changed to prevent stopping up because of excessive corrosion. For refilling use the same coolant
system because of the possibility of incompatibility of inhibitors.

3.5.2 Connections
The water in- and outlets are evident on machine dimension drawing.
Before putting into operation the machine must be deaerated and filled with coolant.
Cooling water through-flow must be absolutely ensured.
During operation the permissible inlet temperature of the coolant, the
minimum water through-flow and the allowable water pressure in the cooling
water circulation must be observed (see 2. Technical data).

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3.5.3 Cleaning instructions for electrical machines with water cooling


To guarantee optimal cooling effect of the water the cleaning of the cooling channels of the
machines in corresponding periods is recommended
Machines with open cooling circuit:
Machines with closed cooling circuit:
*

< 1 year*
< 5 years*

The indicated intervals referring to the permissible boundary values for water hardness and
suspended solids of the cooling water depend on the factual soiling of the cooling channels
of the machine.
Signs for impermissible soiling of the cooling channels are e.g.: increasing drop in pressure
and/or increasing heating during constant operation of the machine.

The higher the water hardness (lime content) the sooner a soiling of the cooling channels may be
expected.
An essential difference for the highness of the quantity of suspended solids is also the type of duty:
- continuous duty (WITHOUT time of standstill)
- intermittent duty (WITH time of standstill)
In practice a continuous duty will be hardly realized. In case of continuous duty the quantity of
suspended solids of the cooling water can be substantial higher if the cooling channels of the
machine are entirely drained and flushed at standstill (e.g. maintenance).
In case of intermittent duty with time of standstill of the machine and thus also of the cooling water
flow the quantity of suspended solids has to be kept very low optimum: max. 10 ppm. This is
necessary because in case of standstill the suspended solids have an effect as an absorptionmedium to ions and fine distributed particles (e.g. calcium carbonate) comprised in the water. They
fix themselves on the suspended solids, grow and can thus block off smaller sections in the inside
of the cooling system. Moreover we recommend admixing an inhibitor to the cooling water (for
example Ferrophos 8579 from Henkel).
For rotor cooled machines water hardness and quantity of suspended solids have also an influence
to function and lifetime of the mechanical seal. A clogging of the cooling channels can stop the
cooling and the flushing of the mechanical seal and consequently lead to a break-down.
The higher the quantity of suspended solids of cooling water, the higher is also the rate of wear of
the mechanical seal, which depends also from many factors of the suspended solids (hardness,
grain size, surface form, grain size distribution).
In case of impermissible soiling of the cooling channels of the machines the following cleaning
process is recommended.

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3.5.4 Recommended cleaning process with boiler cleansing compounds

Only qualified personnel are allowed to carry out chemical cleaning!


All cautions and warnings on the products and safety instructions should be
noted!

1.
2.

What type of cleansing compound to be used depends on the composition of the


incrustation and on what materials in the cooling circuit come into contact with the solvent.
Complete drainage and cooling down of the machines to 40 C min.

3.

Connection of the water in- and outlets of the machines for a circuit to a suitable tank
provided with a pump (e.g. decalcification pump EKP 30 / Thermochema). Regarding the size
of the tank the volume of the cooling channel has to be considered.

4.

Cleaning of the cooling channels


Diluting of cleansing compound proportionately with water (e.g. 1 part of boiler cleansing
compound DC 314/1 / Thermochema with 2 parts of water). The diluted solution shall circulate
through the pump for approx. 2 to 3 minutes every hour.
The reaction time depends on quantity and composition of the incrustation. However, the
incrustation should be removed after 12 to14 hours at least.
Great quantity of carbon dioxide may develop make sure that an outlet for the gas escape is
provided on the highest place of the system (exhaustion).
Disposal of waste cleansing compound as described in point 7.

5.
6.

7.

After cleaning, the cooling channels are to be flushed with water for approx. 1 hour.
Preserving of the cooling channels
Installation of a circuit as described in point 3, diluting of the passivator (after treatment main
against rust film) e.g. rust preventing means and passivator DC 500 / Thermochema
proportionately with water and circulation of the diluted solution through the pump for approx. 2
to 3 minutes every 15 minutes. The reaction time is 1 to 2 hours.
The indicated passivator may be let into the public sewer by addition of a more than
proportional quantity of water.
Waste disposal of cleansing compound
Dissolve the neutralizer (e.g. DC 315/3 / Thermochema) proportionately in water (approx.
1:10) and add it to the waste solution until it is pH-neutral. After that the solution may be let
into the public sewer by addition of a more than proportional quantity of water.

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3.6 Electrical connection


Electrical connection must be carried out according connection diagram in the terminal box
(enclosed). Connection of the protective conductor inside the terminal box and/or on the housing
has to be established.
Connections of the additional equipment (e.g. anti-condensation-heater, thermistor for winding and
resistance thermometers for bearings) are established on connection diagrams (enclosed).
After drawing-in of the wires, the inlets must be tightened (dense!).
Work on the electrical connections of machines must be carried out by
qualified and authorized personnel only.
Refer also to DIN VDE 0105 or IEC 364 !
Connection of the supply cables must be done with special care to ensure
a permanent and reliable contact
Supply cables must be stress relieved so that no cantilever loads are exerted
on the terminals.

For shielded cables, ensure that the shielding is connected across a large
cross-section to the ground bolt in the terminal box by means of an EMC cable
screw adapter or a flexible earthing tape (HF potential equalization conductor)
and shielded clip.
Correct cabling and 360-connection of the cable shielding at both ends
significantly improve the EMC behaviour of the installation.
After connection of the machine, make sure that no foreign matter is left in the
terminal box, and that it is clean and dry.
In order to maintain the degree of protection, always make sure to use the
original gaskets when closing the terminal box.
Only valid for IP56, IP66, IP67:
All bolts which are opened in the terminal box area must be protected with
Loctite 577 (243).
Cable entries which are not used have to be sealed up dust and water-tight.
Lay the motor connecting cables so that they are at the base of the unit.
Regularly inspect them for damage, whereby the inspection intervals should
be determined on the basis of the actual load (vibration, moving cable, etc.).

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Connection through screw thread or bars


Permissible constant
current intensity

screw thread
d

Material of
bolts

Tightening torque
Nm

A
16
25
63
100
160
250
315
400
200
315
400
630
800
1000
1250
1600

M4
M5
M6
M8
M10
M12
M16
M20
M10
M12
M16
M20
M24x2
M30x2
M33x2
M36x3

CuZn37 F35

1.2
2
3
6
10
15.5
30
52
10
15.5
30
52
80
150
197
252

CuZn37 F38
E-Cu F25

Winding
180 C switch off temperature independent from used type of sensing device.

3.7 Drying of moist windings


The insulation of the winding has to be checked after long term storage or long periods of standstill
(if anti-condensation heater has not been in operation) and after flooding.
The insulation resistance of the cold winding should be at least 6000 M. In our experience the
insulation resistance is lower after putting into operation. We therefore recommend repeating the
measurement in warm condition. The winding has to be dried in case the insulation resistance
drops below 1 M at a winding temperature of 60 C to 80 C.
For measurement disconnect the machine from all external connections. The drying is effected at
open machine by:
a.

Drying by current, whereas the heating current should be adjusted to approx. 50 % of nominal
current with all phases symmetrically loaded. The stator winding temperature must not exceed
100 C

b.

Drying in an oven, whereas the stator only is dried 100 C for approx. 12 hours.

Space heater* (*Only for machines which are equipped with space heaters)
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By activating the space heater during standstill, the air temperature inside the machine will be kept
some degrees higher then outside the machine. Thus dew formation, also at strong variations in
temperature as well as moist surroundings, will be prevented. Consequently, the machines are
ready for operation at any time.
During operation of the machine the space heater must be switched off.
Activating of the space heater is recommended after a standstill time of
10-12 hours.

The space heater should be activated until the restart of the machine except
the period of standstill is long enough that the drying of the moist winding
(drying by current or in an oven) before putting into operation is more
advantageous.

Work on the electrical connections of machines must be carried out by


qualified and authorized personnel only.

3.8 Bearing lubrication


The machines are ready to operate.

Observance of regreasing intervals is vital for the operational reliability of the


machine
Relubrication plate indicates relubrication quantity and relubrication interval, optimized for an
ambient temperature of -30 C till +50 C

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For lubricants, relubrication quantities, lubrication and replacement intervals


(for drilling head motors only), see Appendix. After the number of specified
relubrication procedures is reached, i.e. 12 relubrications or 10.400 operating
hours, the bearings must be dismantled, the old grease must be removed and
about half as much new grease must be filled in before the bearings are
mounted again. We recommend exchanging the bearings in this process.
Relubrication must be documented; for a form, see Appendix.

The calculated service life of the bearings is 20.000 operating hours.


If heat-stabilised bearings are used, please adhere to the following:
bearing temperature max. 130 C
The bearings must be relubricated irrespective of the motor type or
application and while the machine is running. If possible lubricate the unit
when it is at operating temperature and run at 50% its rated speed.
Always strictly adhere to the prescribed intervals and lubricant quantities.
After the grease has been applied, let the machine run for a short period of
time (approx. 5 minutes).

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3.9 Bearing replacement


Bearing replacement in accordance with enclosed drawings
All work on the machines must be carried out by duly qualified staff and
authorized bodies only. Observe the regulations of DIN VDE 0105 and IEC 364
(see chapter 5. Warranty/Malfunctions/Repair).
Prior to carrying out any work at the machines, they must be shut down and
protected against restarting.

In order not to void the warranty, during the warranty period, do not replace
the bearings without the prior consent of the motor manufacturer.

3.10 Cleaning
Deposits on the surface have to be removed regularly; especially the deaeriation screws and drain
plugs for condense water.
The seals are not suitable for steam-jet cleaning (high pressure cleaning).

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4. Check list for first start up

The machine is surely installed:


Screw firmly attraction?
After longer storage or stop:
Insulation resistances of the windings are ok?
Examine the electrical connections:
Correct connection?
Perfect condition of the terminals?
Terminal distances ok?
Mechanical firmness given?
Electrical conductivity?
Protection device:
Everything ok?
None manipulates?
Function control?
Transport safeguard devices:
Are all devices from the machine shaft removed?
Examine the free movement:
Correct adjustment?
Lock the covers and cover plates:
Are all again properly locked?
Examine the direction of rotation:
The machine turns into the correct direction?
Lock the terminal box cover (only valid for IP56, IP66,
IP67):
Are the screws protected with Loctite 577?

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Condensation drain holes (only valid for IP56, IP66,


IP67):
Are the changed screw connections protected with
Loctite 577?

Abnormal behaviour:
Vibrations?
Noise?
Cooling:
Sufficient cooling ensure?
Bearings:
Function control during operation?
Machine is ready for use!

Confirmation to manufacturer

The first start up was accomplished by:

Name:

Date: .

Company:

Signature:

.........................
.....................

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5. Warranty / Malfunctions / Repairs


In case of any warranty claims, the General Terms of Delivery of the Austrian Electric and
Electronic Industry shall apply for goods supplied within Austria.
For supplies to foreign countries, our General Terms of Delivery shall apply. They are essentially
based on the recommendations of the United Nations Economic Commission for Europe.
We want to emphasize that we will not assume any liability in case of nonobservance of this Installation, Operating and Maintenance Instruction.
We also can not take on the liability resp. guarantee for damages on the
machine which has been caused by independent works resp. not under the
supervision of experts of our company.
Not to loose the right to guarantee, please inform in any way our department Services

ELIN EBG Motoren GmbH


Dep. Services
Elingasse 3
8160 Weiz
Austria
Phone: (+43/3172) 90 606 2463 - 0
Fax: (+43/3172) 90 5850
E-mail : serviceemg@elinebgmotoren.at

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CAUTION: The following instructions apply only to drilling head motors with
integrated overload clutch
5.1 Measures to be taken in the event of failure of individual drive
components
In the event of failure of a drive component (frequency converter, motor, Safeset, gear system) and
resulting standstill of the motor, there is a risk of damage to the motor bearings caused by vibration
from continued propulsion.
The drive stroke can be completed after the following events:
1. Motor standing still and mounted, and
2. Safeset dismantled, and
3. torsion rod (inner shaft) dismantled
Subsequently, the following mandatory measures must be taken:

Failure of a frequency converter:

Deselect the defective frequency converter at the visualisation panel. If required, change
the master selection.
Ensure that the associated Safeset remains activated (motor rotates with gear)
Replace or repair the defective frequency converter without delay.

Failure of a motor:
Deselect the frequency converter of the defective motor at the visualisation panel. If
required, change the master selection.
Deactivate the respective Safeset.
Dismantle Safeset and torsion rod.
Replace or repair the defective motor without delay.
If the motor cannot be repaired while mounted, it must be dismantled!
Safeset triggered:
Reactivate the Safeset without delay.
Turn the drilling head only, if all mounted Safesets are activated!
Replace the defective Safeset without delay.
Failure of a gear system:
Deselect the respective defective frequency converter at the visualisation panel. If required,
change the master selection.
Dismantle the associated motor.
Replace the defective gear system without delay.

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For more detailed instructions regarding repairs and the replacement of parts,
please refer to the relevant supplier documentation, which must at all times be
adhered to!

5.2 Failure
If there occurs any failures you must switch off the machine and please contact
our service-department (address see above). In the appendix there are some failure
reports which you can send us by fax. So we can treat your failure diagnosis faster.

Electronic failure report

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6. Emergency data
Fire fighting

1)
2)
3)
4)

Switch off the machine immediately


Secure against restarting
Contact the fire department and refer to electrical fire
Fight fire with suitable extinction agent (e.g. CO2 - Fire extinguisher)

False

Correct
Attack the fire
in wind
direction!

Put out from


the front to the
rear and from
down upwards!

But: drop- and


flow fires must
be put out from
above
downwards.

Use several fire


extinguishers at
the same time
not one after
another.

Attention to
reflammation
put out glow
nests always
with water!

Used fire
extinguishers
must be filled
don't hang them
up again!

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First aid measures by accidents with electrical current

By accidents with electrical current you should take the following measures:

Interruption of circuit by switching off, by pulling the plug, by taking the safety device out.
If these measures are not immediately possible, casualty must be pulled away from the
electric circuit by using non conductive articles.
Call a doctor!
Emergency call:
Rescue guidance centre ........................................... Phone: ..........................................
Accomplish first aid measures up to the arrival of the doctor.
- immediate placing in rest position
- control of respiration and pulse
- when respiratory arrest then breath donation
- when cycle stop then heart-lung-revival
- when unconsciousness and existing respiration then side storage
- germ-free coverage of the fire wounds

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7. Spare Parts
7.1 Spare parts inventory
A list of the parts subjected to wear is attached to the specification. This list shows those parts
which are usually required. There is a precise distinction between parts subjected to normal wear
and tear, which can therefore be regarded as "required" spare parts, and parts that might become
faulty and are therefore merely "recommended" spare parts.

7.2 Order procedure


Ordering address:

ELIN EBG Motoren GmbH


Dep. Services
Elingasse 3
8160 Weiz
Austria
Phone: (+43/3172) 90 606 2463 - 0
Fax: (+43/3172) 90 5850
E-mail : serviceemg@elinebgmotoren.at

Necessary data for a perfect order processing:

Machine data:
Type:
Serial no..:

MKH735U06
505750 08001

Data of spare parts: (e.g.: Bearing DE)


Stock no. :
Spare part :
Quantity :

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1 piece

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7.3 Spare part list

Spare part which are recommended by manufacturer:


Spare parts inventory necessary
Spare parts inventory recommended

Spare part

Pcs.

Type-Drawing No.

Stock-No.

Bearing DE

Cylinder roller bearing (insul.)

Bearing NDE

Grooved ball bearing

Sealing ring

Shaft sealing ring

10950

KLUEBERPLEX BEM 41-132

11196

Grease

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List of revisions
Date of
issue
01.10.2008

Issue
01

Modified
page
-

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First edition

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gh

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Use confirmation
I confirm that I read the operating manual attentively and I will keep the aforementioned
regulations and references.

I have read the operating manual and fully understand its content:

............................................................

..............................

Signature

Date

............................................................

..............................

Signature

Date

............................................................

..............................

Signature

Date

............................................................

..............................

Signature

Date

............................................................

..............................

Signature

Date

ELIN EBG Motoren GmbH


Elingasse 3
8160 Weiz
Austria
Phone: (+43/3172) 90 606 0
Fax:
(+43/3172) 90 606 499
E-mail: dokucenteremg@elinebgmotoren.at
Internet: http://www.elinebgmotoren.at/en/home

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Appendix

Drawings
Outline drawing

1 page

Sectional drawing + Legend

2 pages

Connection diagram + Lubrication plate

1 page

EC-Declaration of Conformity
Form

2 pages

Failure report
Form

1 page

Actuation for the relubrication


Form

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Legend

10
11
12
13
14
15
16

Stator frame
Stator core
Stator winding
Earthing connection
Air exhaust
Discharge
Condensation drain hole

20
21
22
23
24
25
26

Shaft
Rotor core
Rotor winding
Pushing
Cover for pushing
Connection tube
O-ring for pushing

17
18
19

Fan DE
Cooling hose DE
Labyrinth ring DE

27
28
29

Fan NDE
Cooling hose NDE
Labyrinth ring NDE

30
31
32
33
34
35
36
37
37a

Bearing DE
End shield DE
Bearing cover outside DE
Bearing cover inside DE
Grease sling washer
Lubrication nipple
Star spring
Sealing ring
Sealing ring only if there are 2 diff. sealing elements

40
41
42
43
44
45
46
47
47a

Bearing NDE
End shield NDE
Bearing cover outside NDE
Bearing cover inside NDE
Grease sling washer
Lubrication nipple
Star spring
Sealing ring
Sealing ring only if there are ..

38
39

Pressure plate
Cir clip

48
49

Pressure plate
Cir clip

50

Terminal box (-cover)

60

Terminals

70

Speed acquisition

80

Vibration acquisition

90

Auxiliary terminal box

100

Bearing - PT100, DE, NDE

110 Bearing fan DE


111 Fan cowling DE
112 Used grease reservoir DE

120
121
122
123
125
130

Bearing fan NDE


Fan cowling NDE
Used grease reservoir NDE
Console for slip ring
Protection disk
O-ring for torsion shaft

137 Felt ring

147 Felt ring

140 Safeset coupling


141 Prodection cover for Safeset coupling

150 Lock washer


151 Inductive - sensor

Failure report for industry machines


1. Supplier
Company:
ELIN EBG Motoren GmbH
Elingasse 3
8160 Weiz
Austria

Fax:

(++43/3172) 90 5850

Phone: (++43/3172) 90 606-2463


E-mail: serviceemg@elinebgmotoren.at

Contact persons department services:

Mr. Gnther Pttler, Mr. Josef Nistelberger


Mr. Manfred Schlagbauer

2. Customer
Company:

Fax:
Phone:
E-mail:

Contact person:
Address of the plant:

Description of way

3. Machine data
Serial number:
Project name:

First starting up:


Running hours:

4. Failure description
Date of breakdown:
Failure description:

Initiated by:

Attach possibly existing recordings please!


Plant in operation:

YES

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NO

Date:

Page:
Document:

1 from 1
QC4-EMG02-002E

Actuation for the relubrication

No.

Date

Agent

Operating hours Lubr. quantityt

Commonnes
achieved
Yes / No

1
2
3
4
5
6
7
8
9
10
11
12

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ELIN EBG Motoren GmbH


Elingasse 3
8160 Weiz, Austria

Place of business Weiz,


registered at Handelsgericht Graz under
FN 58429a; UID: ATU1477 3404; DVR 0748897

Tel.: (+43/3172) 90 606- 0


Fax: (+43/3172) 90 606-784

www.elinebgmotoren.at

Page 1 / 1

OPERATINGINSTRUCTIONS
Three-phase-asynchronous motor
with
squirrel-cage rotor
TBM Velingonda India
Mat. no. D107840-1

Type:
Serial no.:
Customer:
Customers order no.:
Our order / project:

MKH735U06
505750A 08001-08012
The Robbins Company
0098045
127648 / K.S31-08144

Issue no.:
Date:

01
01.10.2008

This Operating instruction is a translated version of the Betriebshandbuch of ELIN EBG Motoren GmbH. It is understood that in all
cases of mistranslation and/or misinterpretation the German version shall be valid.
This Document must neither be copied nor used in any other way without our written consent. Neither is it to be handed over; nor in other
way communicated to a third party. Infringement will lead to prosecution.
ELIN EBG Motoren GmbH

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ELIN EBG Motoren GmbH


Elingasse 3
8160 Weiz, Austria

Gesellschaftssitz Weiz,
registriert beim Handelsgericht Graz unter
FN 58429a; UID: ATU1477 3404; DVR 0748897

Tel.: (+43/3172) 90 606-0


Fax: (+43/3172) 90 606-784

www.elinebgmotoren.at

1. Safety instructions
This operating instruction contains important warning instructions and safety instructions. The user
has to pay attention to this.
This motor is assigned only for a certain use which is described in the instructions. Besides you
find the most important assumptions and safety measures for use and running the machine to
guarantee a running without complaining.
We dont take the guarantee and responsibility for use outside the described purpose and without
attention to the necessary assumptions and safety measures.
Only specialists are allowed to transport, set up, connect, put into operation, service and operate
motors and generators. The specialist has to know the valid safety regulations and erection
standards.
All work has to be controlled by responsible specialists.
The specialists have to be authorized for their work.
Specialists are people who

are well skilled and have the experience

know the valid standards, instructions, regulations and accident prevention


instructions

know the functioning and operating conditions of the electrical machines

know and may avoid dangers

Non-qualified people and wrong use can lead to dangers for

body and life

the machine and further property of the user

the efficient function of the machine

Its only allowed to operate a machine with the delivered accessories and material from ELIN EBG
Motoren GmbH

The danger warnings characterized in this manual have to be especially


considered.

Warning of dangerous electrical voltage.

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Protection equipment
Insulated tools, isolating protective clothing, protection device, seat belts,
devices and other aids must be received in perfect condition. The isolating
protective clothing must be examined before each use by the user for obvious
damage.
Damage to isolating protective clothing may be eliminated only by technically suitable workshops.
Gloves may not be repaired however. Isolating gloves and shoes must be examined in certain
time intervals also electrically for their protective effect.
Carrying of wrist-watches, rings and bracelets with the work is forbidden.

First aid measures by accidents with electrical current

By accidents with electrical current you should take the following measures:

Interruption of circuit by switching off, by pulling the plug, by taking the safety device out.
If these measures are not immediately possible, casualty must be pulled away from the
electric circuit by using non conductive articles.
Call a doctor!
Emergency call:
Rescue guidance centre ........................................... Phone: ..........................................
Accomplish first aid measures up to the arrival of the doctor.
- immediate placing in rest position
- control of respiration and pulse
- when respiratory arrest then breath donation
- when cycle stop then heart-lung-revival
- when unconsciousness and existing respiration then side storage
- germ-free coverage of the fire wounds

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Table of contents
1. Safety instructions ........................................................................................................ 2
Table of contents............................................................................................................... 4
2. Technical Data ............................................................................................................... 6
3. Operating and maintenance instructions .................................................................... 8
3.1 Transport and storage ..................................................................................................... 8
3.1.1 Storage .................................................................................................................. 8
3.1.2 Long time storage (more than 3 months)............................................................... 8
3.1.3 Measures to be taken after prolonged storage ...................................................... 9
3.1.4 Storage of used motors ......................................................................................... 9
3.2 Coolant mixture................................................................................................................ 9
3.3 Safety measures .............................................................................................................. 9
3.4 Coupling and installation .............................................................................................. 10
3.4.1. Condensation drain holes (only valid for IP56, IP66, IP67!) ............................... 10
3.4.2 Installation of the overload clutch (only for drilling head motor)........................... 10
3.5 Cooling water ................................................................................................................. 11
3.5.1 Water specification for stator cooled electrical machines .................................... 11
3.5.2 Connections......................................................................................................... 11
3.5.3 Cleaning instructions for electrical machines with water cooling ......................... 12
3.5.4 Recommended cleaning process with boiler cleansing compounds ................... 13
3.6 Electrical connection ..................................................................................................... 14
3.7 Drying of moist windings .............................................................................................. 15
3.8 Bearing lubrication ........................................................................................................ 16
3.9 Bearing replacement...................................................................................................... 18
3.10 Cleaning ........................................................................................................................ 18

4. Check list for first start up .......................................................................................... 19


5. Warranty / Malfunctions / Repairs .............................................................................. 21
CAUTION: The following instructions apply only to drilling head motors with
integrated overload clutch .................................................................................................. 22
5.1 Measures to be taken in the event of failure of individual drive components ......... 22
5.2 Failure ............................................................................................................................. 23

6. Emergency data........................................................................................................... 24
Fire fighting .......................................................................................................................... 24
First aid measures by accidents with electrical current .................................................. 25

7. Spare Parts................................................................................................................... 26
7.1 Spare parts inventory .................................................................................................... 26
7.2 Order procedure............................................................................................................. 26
7.3 Spare part list ................................................................................................................. 27
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List of revisions ............................................................................................................... 28


Use confirmation ............................................................................................................. 29
Appendix .......................................................................................................................... 30
Drawings............................................................................................................................... 30
EC-Declaration of Conformity............................................................................................. 30
Failure report ........................................................................................................................ 30
Actuation for the relubrication............................................................................................ 30

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2. Technical Data
Three-phase asynchronous motor MKH735U06
Welded housing / water-cooled stator
330 kW S1, 690 V D, 50 Hz, 989 1/min
IM3001 (B5), IP67, RAL5012
Technical description:
Execution: DIN-EN 60034, IEC 60034, ELIN-motor-lists
Welded housing / water-cooled stator
Type of construction
: IM3001 (B5)
Type of protection
: IP67
Weight (kg)
: appr. 1610
Colour
: RAL5012 - K2
IEC-frame size
: 355
Terminal box
: radial on the housing near NDE
Line entrance
: in DE direction
2x 2 1/2 inch NPT (plugged)
2x 3/4 inch NPT (plugged)
Shaft end
: 1x special glad
Bearings
: NDE (clutch side) -> ball bearing
DE (gear side) -> roller bearing (isol.)
Lubrication
: grease, relubrication device
Insulation class
: H
Water inlet temp. (degr.C)
: max. 25
Water flow (l/min)
: min. 25
Water pressure (bar)
: max. 5
Technical data:
Output [kW]
Duty type
Voltage [V]
Connection
Frequency [Hz]
Speed [1/min]
Current [A]
Torque [Nm]
Efficency [%]
Power factor

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Sinus-Data
: 330
: S1
: 690
: D
: 50
: 990
: 348
: 3183
: 95.7
: 0.83

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VFD-Data
330
S1
690
D
50
989
360
3187

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Additional equipment, -execution:


* Motor protection: 2x 3 bimetallic switches normally closed contact
(3x warning, 3x shutdown)
* Space heater (130 W, 230 V, 50 Hz)
* Shake proofed design (resistant against vibrations up to 5g)
* Seals against entrance of water and oil
* 6 Condensation drain holes on DE and NDE
* Suitable for 6 fitting positions * protection cover for shaft
* second name plate for VFD-operation
* special copper rotor * torsion shaft separate delivered
Comments:
Converter
0- 50 Hz
50- 85 Hz
85-100 Hz

operation:
(989 1/min) -> constant torque 3187 Nm
(1679 1/min) -> constant power 330 kW
(1980 1/min) -> reduced power 270 kW at 100 Hz

Winding isolation for:


Rise time
Voltage rise
0.1 mysec
10.4 kV/mysec
0.8 mysec
1.8 kV/mysec

Peak voltage
1300 V
1800 V

Dimension drawing -> 6184161

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3. Operating and maintenance instructions


3.1 Transport and storage
On delivery the machines are packed on woods. These woods are intended for loading by means
of stacker.
Lift machines only on lifting eyes provided. The lifting eyes are designed for
machine mass only. Do not add any load to machine. (Weight see 2. Technical
Data).
Machines with cylindrical roller bearings, ball bearings of the type 6328 and
higher and special bearings are protected against bearing damage during
transport by means of a locking device which has to be removed before
putting the machine into operation.
The locking device must also be used for any further transport of the machine!

3.1.1 Storage
All blank parts are protected against corrosion by using special agents (e.g. Tectyl 506).
If the machine has to be stored, because it cant be fitted and started running on arrival at point of
destination, take notice of the storage area. Machines and equipment have to be stored in rooms
which are well-ventilated, dry, dust-free, temperate and vibration proof.

3.1.2 Long time storage (more than 3 months)


For long time storage without operational readiness the machine must be protected against
damages. All blank parts have to be protected against corrosion using special agents (e.g. Tectyl
506). Additionally to the above mentioned arrangements the machine must be packaged in a
plastic cover and Silicagel must be added (desiccant). The transport safeguard must be installed. If
a space heater is available it must be switched on. The ambient temperature should be approx.
20C and the relative air humidity approx. 55 %.
Machines have to be stored in rooms which are vibration proof. The storage at cold walls, stone
floors, heater pipes as well as in surrounding atmosphere with aggressive media is not permissible.
The cooling ducts of water-cooled machines must be filled completely with
coolant (with inhibitor). The cooling ducts of oil-cooled machines must be filled completely with oil.
In order to prevent damage of the bearings caused by non operation, the
machines should be switched on resp. the rotor should be turned for a short
time at least every three months. The transport safeguard must be loosened
before and installed afterwards.
If turning of the rotor is not possible every 3 months, then the bearings must
be renewed before start-up.

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3.1.3 Measures to be taken after prolonged storage


Lubricants tend to age, which is associated with the loss of specific properties. Ensure that the
bearing lubricant is of sufficient quality for its purpose. This reduces the relubricating period until
the next maintenance job! After a storage period of more than 3 years, the bearing lubricant
must be replaced. The bearing grease must be replaced in the course of the replacement of
the bearings. Use only grease of the prescribed grade (see Lubrication shield/2. Technical
Data). Unless the rotor has been rotated ever 3 months, the bearings must be replaced. In
machines that are to be restarted after a prolonged period of storage, check the insulation
resistance (see Control of the isolation resistance/3.7 drying of moist windings). Install the
equipment according to the instructions in the operating manual.

3.1.4 Storage of used motors


Prior to putting the motor into storage, we recommend sending it to an authorised ELIN service
agent for proper dismantling, cleaning and conservation. The motor should subsequently be stored
indoors in a facility with a stable climate. Ensure that the motor is stored in such a way that the
condensation drain holes are opened and facing down (drainage).
There is no guarantee for bearing and grease after a long stop time!

3.2 Coolant mixture


We commend following antifreeze with rust inhibitor:

GlycoShell
Glysantin G-03
Havoline XLC
Mobil antifreeze H

For a temperature range up to - 30 C use 60% water and 40% antifreeze (e.g. GlycoShell).
Antifreeze has always to be thin with water. The frost proof depends of the mixing ratio. Please note
the chapter 3.5 Cooling water!

3.3 Safety measures


The safety instructions must be adhered strictly (see chapter 1)!
Only qualified and authorized personnel are allowed to carry out works on
machines. Refer also to DIN VDE 0105 or IEC 364.
Before carrying out any work on the machines, disconnect and secure it
against restarting.

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3.4 Coupling and installation


Remove corrosion protection at plank parts. Loosen transport locking screw. The fixing bolts have
to be tightened and secured against loosening. The machine is dynamically balanced.
Lift machines only on lifting eyes provided. The lifting eyes are designed for
machine mass only. Do not add any load to machine. (Weight see 2. Technical
data).

Machines with cylindrical roller bearings, ball bearings of the type 6328 and
higher and special bearings are protected against bearing damage during
transport by means of a locking device which has to be removed before
putting the machine into operation.
The locking device must also be used for any further transport of the machine!

Care for a plane mounting place to avoid bracing of the housing. Re-check
alignment with the machine at operating temperature.

3.4.1. Condensation drain holes (only valid for IP56, IP66, IP67!)
The machine is equipped with a number of condensation drain holes with screw plugs. Depending
on the position of installation at DE and NDE, the bottom screw plug must be replaced with the
sintered bronze filters (supplied as loose parts in the terminal box!). The screw plugs with the
sintered bronze filters must be regularly opened to drain off the condensation from the
motor chamber. This should be done at the lubricating intervals laid down in the schedule,
see Appendix.
These connections must be sealed with Loctite 577.
Tightening torque: 15.6 Nm

3.4.2 Installation of the overload clutch (only for drilling head motor)
1. Connect the motor to the gear system.
2. Insert the torsion shaft into the hollow motor shaft (apply a little grease, e.g. gleitmo WSP 5040
Fuchs Lubritech GmbH or equivalent product, onto the gearing) and engage the internal toothing of
the transmission system.
3. Insert the 30x2.65 O-ring into the torsion shaft (after visual inspection).
(O-ring, item 130 in sectional drawing, included with torsion shaft.)
4. Mount and press Safeset according to the instructions in the separate installation manual
onto the hollow and the torsion shaft.
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3.5 Cooling water


3.5.1 Water specification for stator cooled electrical machines
Nominal data
pH value
Water hardness (dH)
Suspended solids (ppm)
Filter aperture width (m)

Recommended quality
7.5 up to 8.5
4 up to 6
< 10
30

Accepted quality
6.5 up to 9.0
< 10
< 30
<100

Remaining specification according to DIN 50930.


Have special attention to the observance of pH-value, water hardness and quantity of suspended
solids.
In the relation quantity of suspended solids to water hardness the following has to be considered:
The higher the water hardness the lower must be the quantity of suspended solids.
Past experience has shown that as long as continuous cooling water through-flow is ensured also
a substantially higher quantity of suspended solids will not cause impermissible soiling of the
cooling channels in the machine.
The Cleaning Instructions for Electrical Machines with Water Cooling should be noted in case of
frequent time of standstill and deviations to the above mentioned approximate values.
In existence of a closed cooling water circuit we recommend the antifreeze GlycoShell or a similar
inhibited antifreeze satisfying grade 1 according to ASTM D 1384-87 in dependence on the
material of the cooling circuit.
For a temperature range up to - 30 C use 60% water and 40% antifreeze. It should be verified
every 5 years that the inhibitor of the coolant is not consumed otherwise the coolant has to be
changed to prevent stopping up because of excessive corrosion. For refilling use the same coolant
system because of the possibility of incompatibility of inhibitors.

3.5.2 Connections
The water in- and outlets are evident on machine dimension drawing.
Before putting into operation the machine must be deaerated and filled with coolant.
Cooling water through-flow must be absolutely ensured.
During operation the permissible inlet temperature of the coolant, the
minimum water through-flow and the allowable water pressure in the cooling
water circulation must be observed (see 2. Technical data).

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3.5.3 Cleaning instructions for electrical machines with water cooling


To guarantee optimal cooling effect of the water the cleaning of the cooling channels of the
machines in corresponding periods is recommended
Machines with open cooling circuit:
Machines with closed cooling circuit:
*

< 1 year*
< 5 years*

The indicated intervals referring to the permissible boundary values for water hardness and
suspended solids of the cooling water depend on the factual soiling of the cooling channels
of the machine.
Signs for impermissible soiling of the cooling channels are e.g.: increasing drop in pressure
and/or increasing heating during constant operation of the machine.

The higher the water hardness (lime content) the sooner a soiling of the cooling channels may be
expected.
An essential difference for the highness of the quantity of suspended solids is also the type of duty:
- continuous duty (WITHOUT time of standstill)
- intermittent duty (WITH time of standstill)
In practice a continuous duty will be hardly realized. In case of continuous duty the quantity of
suspended solids of the cooling water can be substantial higher if the cooling channels of the
machine are entirely drained and flushed at standstill (e.g. maintenance).
In case of intermittent duty with time of standstill of the machine and thus also of the cooling water
flow the quantity of suspended solids has to be kept very low optimum: max. 10 ppm. This is
necessary because in case of standstill the suspended solids have an effect as an absorptionmedium to ions and fine distributed particles (e.g. calcium carbonate) comprised in the water. They
fix themselves on the suspended solids, grow and can thus block off smaller sections in the inside
of the cooling system. Moreover we recommend admixing an inhibitor to the cooling water (for
example Ferrophos 8579 from Henkel).
For rotor cooled machines water hardness and quantity of suspended solids have also an influence
to function and lifetime of the mechanical seal. A clogging of the cooling channels can stop the
cooling and the flushing of the mechanical seal and consequently lead to a break-down.
The higher the quantity of suspended solids of cooling water, the higher is also the rate of wear of
the mechanical seal, which depends also from many factors of the suspended solids (hardness,
grain size, surface form, grain size distribution).
In case of impermissible soiling of the cooling channels of the machines the following cleaning
process is recommended.

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3.5.4 Recommended cleaning process with boiler cleansing compounds

Only qualified personnel are allowed to carry out chemical cleaning!


All cautions and warnings on the products and safety instructions should be
noted!

1.
2.

What type of cleansing compound to be used depends on the composition of the


incrustation and on what materials in the cooling circuit come into contact with the solvent.
Complete drainage and cooling down of the machines to 40 C min.

3.

Connection of the water in- and outlets of the machines for a circuit to a suitable tank
provided with a pump (e.g. decalcification pump EKP 30 / Thermochema). Regarding the size
of the tank the volume of the cooling channel has to be considered.

4.

Cleaning of the cooling channels


Diluting of cleansing compound proportionately with water (e.g. 1 part of boiler cleansing
compound DC 314/1 / Thermochema with 2 parts of water). The diluted solution shall circulate
through the pump for approx. 2 to 3 minutes every hour.
The reaction time depends on quantity and composition of the incrustation. However, the
incrustation should be removed after 12 to14 hours at least.
Great quantity of carbon dioxide may develop make sure that an outlet for the gas escape is
provided on the highest place of the system (exhaustion).
Disposal of waste cleansing compound as described in point 7.

5.
6.

7.

After cleaning, the cooling channels are to be flushed with water for approx. 1 hour.
Preserving of the cooling channels
Installation of a circuit as described in point 3, diluting of the passivator (after treatment main
against rust film) e.g. rust preventing means and passivator DC 500 / Thermochema
proportionately with water and circulation of the diluted solution through the pump for approx. 2
to 3 minutes every 15 minutes. The reaction time is 1 to 2 hours.
The indicated passivator may be let into the public sewer by addition of a more than
proportional quantity of water.
Waste disposal of cleansing compound
Dissolve the neutralizer (e.g. DC 315/3 / Thermochema) proportionately in water (approx.
1:10) and add it to the waste solution until it is pH-neutral. After that the solution may be let
into the public sewer by addition of a more than proportional quantity of water.

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3.6 Electrical connection


Electrical connection must be carried out according connection diagram in the terminal box
(enclosed). Connection of the protective conductor inside the terminal box and/or on the housing
has to be established.
Connections of the additional equipment (e.g. anti-condensation-heater, thermistor for winding and
resistance thermometers for bearings) are established on connection diagrams (enclosed).
After drawing-in of the wires, the inlets must be tightened (dense!).
Work on the electrical connections of machines must be carried out by
qualified and authorized personnel only.
Refer also to DIN VDE 0105 or IEC 364 !
Connection of the supply cables must be done with special care to ensure
a permanent and reliable contact
Supply cables must be stress relieved so that no cantilever loads are exerted
on the terminals.

For shielded cables, ensure that the shielding is connected across a large
cross-section to the ground bolt in the terminal box by means of an EMC cable
screw adapter or a flexible earthing tape (HF potential equalization conductor)
and shielded clip.
Correct cabling and 360-connection of the cable shielding at both ends
significantly improve the EMC behaviour of the installation.
After connection of the machine, make sure that no foreign matter is left in the
terminal box, and that it is clean and dry.
In order to maintain the degree of protection, always make sure to use the
original gaskets when closing the terminal box.
Only valid for IP56, IP66, IP67:
All bolts which are opened in the terminal box area must be protected with
Loctite 577 (243).
Cable entries which are not used have to be sealed up dust and water-tight.
Lay the motor connecting cables so that they are at the base of the unit.
Regularly inspect them for damage, whereby the inspection intervals should
be determined on the basis of the actual load (vibration, moving cable, etc.).

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Connection through screw thread or bars


Permissible constant
current intensity

screw thread
d

Material of
bolts

Tightening torque
Nm

A
16
25
63
100
160
250
315
400
200
315
400
630
800
1000
1250
1600

M4
M5
M6
M8
M10
M12
M16
M20
M10
M12
M16
M20
M24x2
M30x2
M33x2
M36x3

CuZn37 F35

1.2
2
3
6
10
15.5
30
52
10
15.5
30
52
80
150
197
252

CuZn37 F38
E-Cu F25

Winding
180 C switch off temperature independent from used type of sensing device.

3.7 Drying of moist windings


The insulation of the winding has to be checked after long term storage or long periods of standstill
(if anti-condensation heater has not been in operation) and after flooding.
The insulation resistance of the cold winding should be at least 6000 M. In our experience the
insulation resistance is lower after putting into operation. We therefore recommend repeating the
measurement in warm condition. The winding has to be dried in case the insulation resistance
drops below 1 M at a winding temperature of 60 C to 80 C.
For measurement disconnect the machine from all external connections. The drying is effected at
open machine by:
a.

Drying by current, whereas the heating current should be adjusted to approx. 50 % of nominal
current with all phases symmetrically loaded. The stator winding temperature must not exceed
100 C

b.

Drying in an oven, whereas the stator only is dried 100 C for approx. 12 hours.

Space heater* (*Only for machines which are equipped with space heaters)
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By activating the space heater during standstill, the air temperature inside the machine will be kept
some degrees higher then outside the machine. Thus dew formation, also at strong variations in
temperature as well as moist surroundings, will be prevented. Consequently, the machines are
ready for operation at any time.
During operation of the machine the space heater must be switched off.
Activating of the space heater is recommended after a standstill time of
10-12 hours.

The space heater should be activated until the restart of the machine except
the period of standstill is long enough that the drying of the moist winding
(drying by current or in an oven) before putting into operation is more
advantageous.

Work on the electrical connections of machines must be carried out by


qualified and authorized personnel only.

3.8 Bearing lubrication


The machines are ready to operate.

Observance of regreasing intervals is vital for the operational reliability of the


machine
Relubrication plate indicates relubrication quantity and relubrication interval, optimized for an
ambient temperature of -30 C till +50 C

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For lubricants, relubrication quantities, lubrication and replacement intervals


(for drilling head motors only), see Appendix. After the number of specified
relubrication procedures is reached, i.e. 12 relubrications or 10.400 operating
hours, the bearings must be dismantled, the old grease must be removed and
about half as much new grease must be filled in before the bearings are
mounted again. We recommend exchanging the bearings in this process.
Relubrication must be documented; for a form, see Appendix.

The calculated service life of the bearings is 20.000 operating hours.


If heat-stabilised bearings are used, please adhere to the following:
bearing temperature max. 130 C
The bearings must be relubricated irrespective of the motor type or
application and while the machine is running. If possible lubricate the unit
when it is at operating temperature and run at 50% its rated speed.
Always strictly adhere to the prescribed intervals and lubricant quantities.
After the grease has been applied, let the machine run for a short period of
time (approx. 5 minutes).

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3.9 Bearing replacement


Bearing replacement in accordance with enclosed drawings
All work on the machines must be carried out by duly qualified staff and
authorized bodies only. Observe the regulations of DIN VDE 0105 and IEC 364
(see chapter 5. Warranty/Malfunctions/Repair).
Prior to carrying out any work at the machines, they must be shut down and
protected against restarting.

In order not to void the warranty, during the warranty period, do not replace
the bearings without the prior consent of the motor manufacturer.

3.10 Cleaning
Deposits on the surface have to be removed regularly; especially the deaeriation screws and drain
plugs for condense water.
The seals are not suitable for steam-jet cleaning (high pressure cleaning).

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4. Check list for first start up

The machine is surely installed:


Screw firmly attraction?
After longer storage or stop:
Insulation resistances of the windings are ok?
Examine the electrical connections:
Correct connection?
Perfect condition of the terminals?
Terminal distances ok?
Mechanical firmness given?
Electrical conductivity?
Protection device:
Everything ok?
None manipulates?
Function control?
Transport safeguard devices:
Are all devices from the machine shaft removed?
Examine the free movement:
Correct adjustment?
Lock the covers and cover plates:
Are all again properly locked?
Examine the direction of rotation:
The machine turns into the correct direction?
Lock the terminal box cover (only valid for IP56, IP66,
IP67):
Are the screws protected with Loctite 577?

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Condensation drain holes (only valid for IP56, IP66,


IP67):
Are the changed screw connections protected with
Loctite 577?

Abnormal behaviour:
Vibrations?
Noise?
Cooling:
Sufficient cooling ensure?
Bearings:
Function control during operation?
Machine is ready for use!

Confirmation to manufacturer

The first start up was accomplished by:

Name:

Date: .

Company:

Signature:

.........................
.....................

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5. Warranty / Malfunctions / Repairs


In case of any warranty claims, the General Terms of Delivery of the Austrian Electric and
Electronic Industry shall apply for goods supplied within Austria.
For supplies to foreign countries, our General Terms of Delivery shall apply. They are essentially
based on the recommendations of the United Nations Economic Commission for Europe.
We want to emphasize that we will not assume any liability in case of nonobservance of this Installation, Operating and Maintenance Instruction.
We also can not take on the liability resp. guarantee for damages on the
machine which has been caused by independent works resp. not under the
supervision of experts of our company.
Not to loose the right to guarantee, please inform in any way our department Services

ELIN EBG Motoren GmbH


Dep. Services
Elingasse 3
8160 Weiz
Austria
Phone: (+43/3172) 90 606 2463 - 0
Fax: (+43/3172) 90 5850
E-mail : serviceemg@elinebgmotoren.at

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CAUTION: The following instructions apply only to drilling head motors with
integrated overload clutch
5.1 Measures to be taken in the event of failure of individual drive
components
In the event of failure of a drive component (frequency converter, motor, Safeset, gear system) and
resulting standstill of the motor, there is a risk of damage to the motor bearings caused by vibration
from continued propulsion.
The drive stroke can be completed after the following events:
1. Motor standing still and mounted, and
2. Safeset dismantled, and
3. torsion rod (inner shaft) dismantled
Subsequently, the following mandatory measures must be taken:

Failure of a frequency converter:

Deselect the defective frequency converter at the visualisation panel. If required, change
the master selection.
Ensure that the associated Safeset remains activated (motor rotates with gear)
Replace or repair the defective frequency converter without delay.

Failure of a motor:
Deselect the frequency converter of the defective motor at the visualisation panel. If
required, change the master selection.
Deactivate the respective Safeset.
Dismantle Safeset and torsion rod.
Replace or repair the defective motor without delay.
If the motor cannot be repaired while mounted, it must be dismantled!
Safeset triggered:
Reactivate the Safeset without delay.
Turn the drilling head only, if all mounted Safesets are activated!
Replace the defective Safeset without delay.
Failure of a gear system:
Deselect the respective defective frequency converter at the visualisation panel. If required,
change the master selection.
Dismantle the associated motor.
Replace the defective gear system without delay.

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For more detailed instructions regarding repairs and the replacement of parts,
please refer to the relevant supplier documentation, which must at all times be
adhered to!

5.2 Failure
If there occurs any failures you must switch off the machine and please contact
our service-department (address see above). In the appendix there are some failure
reports which you can send us by fax. So we can treat your failure diagnosis faster.

Electronic failure report

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6. Emergency data
Fire fighting

1)
2)
3)
4)

Switch off the machine immediately


Secure against restarting
Contact the fire department and refer to electrical fire
Fight fire with suitable extinction agent (e.g. CO2 - Fire extinguisher)

False

Correct
Attack the fire
in wind
direction!

Put out from


the front to the
rear and from
down upwards!

But: drop- and


flow fires must
be put out from
above
downwards.

Use several fire


extinguishers at
the same time
not one after
another.

Attention to
reflammation
put out glow
nests always
with water!

Used fire
extinguishers
must be filled
don't hang them
up again!

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First aid measures by accidents with electrical current

By accidents with electrical current you should take the following measures:

Interruption of circuit by switching off, by pulling the plug, by taking the safety device out.
If these measures are not immediately possible, casualty must be pulled away from the
electric circuit by using non conductive articles.
Call a doctor!
Emergency call:
Rescue guidance centre ........................................... Phone: ..........................................
Accomplish first aid measures up to the arrival of the doctor.
- immediate placing in rest position
- control of respiration and pulse
- when respiratory arrest then breath donation
- when cycle stop then heart-lung-revival
- when unconsciousness and existing respiration then side storage
- germ-free coverage of the fire wounds

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7. Spare Parts
7.1 Spare parts inventory
A list of the parts subjected to wear is attached to the specification. This list shows those parts
which are usually required. There is a precise distinction between parts subjected to normal wear
and tear, which can therefore be regarded as "required" spare parts, and parts that might become
faulty and are therefore merely "recommended" spare parts.

7.2 Order procedure


Ordering address:

ELIN EBG Motoren GmbH


Dep. Services
Elingasse 3
8160 Weiz
Austria
Phone: (+43/3172) 90 606 2463 - 0
Fax: (+43/3172) 90 5850
E-mail : serviceemg@elinebgmotoren.at

Necessary data for a perfect order processing:

Machine data:
Type:
Serial no..:

MKH735U06
505750A 08001

Data of spare parts: (e.g.: Bearing DE)


Stock no. :
Spare part :
Quantity :

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Cylinder roller bearing
1 piece

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7.3 Spare part list

Spare part which are recommended by manufacturer:


Spare parts inventory necessary
Spare parts inventory recommended

Spare part

Pcs.

Type-Drawing No.

Stock-No.

Bearing DE

Cylinder roller bearing (insul.)

Bearing NDE

Grooved ball bearing

Sealing ring

Shaft sealing ring

10950

KLUEBERPLEX BEM 41-132

11196

Grease

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List of revisions
Date of
issue
01.10.2008

Issue
01

Modified
page
-

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Kind of modification
First edition

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Rem.
gh

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Use confirmation
I confirm that I read the operating manual attentively and I will keep the aforementioned
regulations and references.

I have read the operating manual and fully understand its content:

............................................................

..............................

Signature

Date

............................................................

..............................

Signature

Date

............................................................

..............................

Signature

Date

............................................................

..............................

Signature

Date

............................................................

..............................

Signature

Date

ELIN EBG Motoren GmbH


Elingasse 3
8160 Weiz
Austria
Phone: (+43/3172) 90 606 0
Fax:
(+43/3172) 90 606 499
E-mail: dokucenteremg@elinebgmotoren.at
Internet: http://www.elinebgmotoren.at/en/home

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Appendix

Drawings
Outline drawing

1 page

Sectional drawing + Legend

2 pages

Connection diagram + Lubrication plate

1 page

EC-Declaration of Conformity
Form

2 pages

Failure report
Form

1 page

Actuation for the relubrication


Form

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Legend

10
11
12
13
14
15
16

Stator frame
Stator core
Stator winding
Earthing connection
Air exhaust
Discharge
Condensation drain hole

20
21
22
23
24
25
26

Shaft
Rotor core
Rotor winding
Pushing
Cover for pushing
Connection tube
O-ring for pushing

17
18
19

Fan DE
Cooling hose DE
Labyrinth ring DE

27
28
29

Fan NDE
Cooling hose NDE
Labyrinth ring NDE

30
31
32
33
34
35
36
37
37a

Bearing DE
End shield DE
Bearing cover outside DE
Bearing cover inside DE
Grease sling washer
Lubrication nipple
Star spring
Sealing ring
Sealing ring only if there are 2 diff. sealing elements

40
41
42
43
44
45
46
47
47a

Bearing NDE
End shield NDE
Bearing cover outside NDE
Bearing cover inside NDE
Grease sling washer
Lubrication nipple
Star spring
Sealing ring
Sealing ring only if there are ..

38
39

Pressure plate
Cir clip

48
49

Pressure plate
Cir clip

50

Terminal box (-cover)

60

Terminals

70

Speed acquisition

80

Vibration acquisition

90

Auxiliary terminal box

100

Bearing - PT100, DE, NDE

110 Bearing fan DE


111 Fan cowling DE
112 Used grease reservoir DE

120
121
122
123
125
130

Bearing fan NDE


Fan cowling NDE
Used grease reservoir NDE
Console for slip ring
Protection disk
O-ring for torsion shaft

137 Felt ring

147 Felt ring

140 Safeset coupling


141 Prodection cover for Safeset coupling

150 Lock washer


151 Inductive - sensor

Failure report for industry machines


1. Supplier
Company:
ELIN EBG Motoren GmbH
Elingasse 3
8160 Weiz
Austria

Fax:

(++43/3172) 90 5850

Phone: (++43/3172) 90 606-2463


E-mail: serviceemg@elinebgmotoren.at

Contact persons department services:

Mr. Gnther Pttler, Mr. Josef Nistelberger


Mr. Manfred Schlagbauer

2. Customer
Company:

Fax:
Phone:
E-mail:

Contact person:
Address of the plant:

Description of way

3. Machine data
Serial number:
Project name:

First starting up:


Running hours:

4. Failure description
Date of breakdown:
Failure description:

Initiated by:

Attach possibly existing recordings please!


Plant in operation:

YES

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NO

Date:

Page:
Document:

1 from 1
QC4-EMG02-002E

Actuation for the relubrication

No.

Date

Agent

Operating hours Lubr. quantityt

Commonnes
achieved
Yes / No

1
2
3
4
5
6
7
8
9
10
11
12

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ELIN EBG Motoren GmbH


Elingasse 3
8160 Weiz, Austria

Place of business Weiz,


registered at Handelsgericht Graz under
FN 58429a; UID: ATU1477 3404; DVR 0748897

Tel.: (+43/3172) 90 606- 0


Fax: (+43/3172) 90 606-784

www.elinebgmotoren.at

Page 1 / 1

OPERATINGINSTRUCTIONS
Three-phase-asynchronous motor
with
squirrel-cage rotor
TBM Velingonda India
Mat. no. D107840-1

Type:
Serial no.:
Customer:
Customers order no.:
Our order / project:

MKH735U06
505750B 08001-002
The Robbins Company
0098045
127648 / K.S31-08144

Issue no.:
Date:

01
01.10.2008

This Operating instruction is a translated version of the Betriebshandbuch of ELIN EBG Motoren GmbH. It is understood that in all
cases of mistranslation and/or misinterpretation the German version shall be valid.
This Document must neither be copied nor used in any other way without our written consent. Neither is it to be handed over; nor in other
way communicated to a third party. Infringement will lead to prosecution.
ELIN EBG Motoren GmbH

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ELIN EBG Motoren GmbH


Elingasse 3
8160 Weiz, Austria

Gesellschaftssitz Weiz,
registriert beim Handelsgericht Graz unter
FN 58429a; UID: ATU1477 3404; DVR 0748897

Tel.: (+43/3172) 90 606-0


Fax: (+43/3172) 90 606-784

www.elinebgmotoren.at

1. Safety instructions
This operating instruction contains important warning instructions and safety instructions. The user
has to pay attention to this.
This motor is assigned only for a certain use which is described in the instructions. Besides you
find the most important assumptions and safety measures for use and running the machine to
guarantee a running without complaining.
We dont take the guarantee and responsibility for use outside the described purpose and without
attention to the necessary assumptions and safety measures.
Only specialists are allowed to transport, set up, connect, put into operation, service and operate
motors and generators. The specialist has to know the valid safety regulations and erection
standards.
All work has to be controlled by responsible specialists.
The specialists have to be authorized for their work.
Specialists are people who

are well skilled and have the experience

know the valid standards, instructions, regulations and accident prevention


instructions

know the functioning and operating conditions of the electrical machines

know and may avoid dangers

Non-qualified people and wrong use can lead to dangers for

body and life

the machine and further property of the user

the efficient function of the machine

Its only allowed to operate a machine with the delivered accessories and material from ELIN EBG
Motoren GmbH

The danger warnings characterized in this manual have to be especially


considered.

Warning of dangerous electrical voltage.

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Protection equipment
Insulated tools, isolating protective clothing, protection device, seat belts,
devices and other aids must be received in perfect condition. The isolating
protective clothing must be examined before each use by the user for obvious
damage.
Damage to isolating protective clothing may be eliminated only by technically suitable workshops.
Gloves may not be repaired however. Isolating gloves and shoes must be examined in certain
time intervals also electrically for their protective effect.
Carrying of wrist-watches, rings and bracelets with the work is forbidden.

First aid measures by accidents with electrical current

By accidents with electrical current you should take the following measures:

Interruption of circuit by switching off, by pulling the plug, by taking the safety device out.
If these measures are not immediately possible, casualty must be pulled away from the
electric circuit by using non conductive articles.
Call a doctor!
Emergency call:
Rescue guidance centre ........................................... Phone: ..........................................
Accomplish first aid measures up to the arrival of the doctor.
- immediate placing in rest position
- control of respiration and pulse
- when respiratory arrest then breath donation
- when cycle stop then heart-lung-revival
- when unconsciousness and existing respiration then side storage
- germ-free coverage of the fire wounds

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Table of contents
1. Safety instructions ........................................................................................................ 2
Table of contents............................................................................................................... 4
2. Technical Data ............................................................................................................... 6
3. Operating and maintenance instructions .................................................................... 8
3.1 Transport and storage ..................................................................................................... 8
3.1.1 Storage .................................................................................................................. 8
3.1.2 Long time storage (more than 3 months)............................................................... 8
3.1.3 Measures to be taken after prolonged storage ...................................................... 9
3.1.4 Storage of used motors ......................................................................................... 9
3.2 Coolant mixture................................................................................................................ 9
3.3 Safety measures .............................................................................................................. 9
3.4 Coupling and installation .............................................................................................. 10
3.4.1. Condensation drain holes (only valid for IP56, IP66, IP67!) ............................... 10
3.4.2 Installation of the overload clutch (only for drilling head motor)........................... 10
3.5 Cooling water ................................................................................................................. 11
3.5.1 Water specification for stator cooled electrical machines .................................... 11
3.5.2 Connections......................................................................................................... 11
3.5.3 Cleaning instructions for electrical machines with water cooling ......................... 12
3.5.4 Recommended cleaning process with boiler cleansing compounds ................... 13
3.6 Electrical connection ..................................................................................................... 14
3.7 Drying of moist windings .............................................................................................. 15
3.8 Bearing lubrication ........................................................................................................ 16
3.9 Bearing replacement...................................................................................................... 18
3.10 Cleaning ........................................................................................................................ 18

4. Check list for first start up .......................................................................................... 19


5. Warranty / Malfunctions / Repairs .............................................................................. 21
CAUTION: The following instructions apply only to drilling head motors with
integrated overload clutch .................................................................................................. 22
5.1 Measures to be taken in the event of failure of individual drive components ......... 22
5.2 Failure ............................................................................................................................. 23

6. Emergency data........................................................................................................... 24
Fire fighting .......................................................................................................................... 24
First aid measures by accidents with electrical current .................................................. 25

7. Spare Parts................................................................................................................... 26
7.1 Spare parts inventory .................................................................................................... 26
7.2 Order procedure............................................................................................................. 26
7.3 Spare part list ................................................................................................................. 27
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List of revisions ............................................................................................................... 28


Use confirmation ............................................................................................................. 29
Appendix .......................................................................................................................... 30
Drawings............................................................................................................................... 30
EC-Declaration of Conformity............................................................................................. 30
Failure report ........................................................................................................................ 30
Actuation for the relubrication............................................................................................ 30

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2. Technical Data
Three-phase asynchronous motor MKH735U06
Welded housing / water-cooled stator
330 kW S1, 690 V D, 50 Hz, 989 1/min
IM3001 (B5), IP67, RAL5012
Technical description:
Execution: DIN-EN 60034, IEC 60034, ELIN-motor-lists
Welded housing / water-cooled stator
Type of construction
: IM3001 (B5)
Type of protection
: IP67
Weight (kg)
: appr. 1610
Colour
: RAL5012 - K2
IEC-frame size
: 355
Terminal box
: radial on the housing near NDE
Line entrance
: in DE direction
2x 2 1/2 inch NPT (plugged)
2x 3/4 inch NPT (plugged)
Shaft end
: 1x special glad
Bearings
: NDE (clutch side) -> ball bearing
DE (gear side) -> roller bearing (isol.)
Lubrication
: grease, relubrication device
Insulation class
: H
Water inlet temp. (degr.C)
: max. 25
Water flow (l/min)
: min. 25
Water pressure (bar)
: max. 5
Technical data:
Output [kW]
Duty type
Voltage [V]
Connection
Frequency [Hz]
Speed [1/min]
Current [A]
Torque [Nm]
Efficency [%]
Power factor

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Sinus-Data
: 330
: S1
: 690
: D
: 50
: 990
: 348
: 3183
: 95.7
: 0.83

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VFD-Data
330
S1
690
D
50
989
360
3187

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Additional equipment, -execution:


* Motor protection: 2x 3 bimetallic switches normally closed contact
(3x warning, 3x shutdown)
* Space heater (130 W, 230 V, 50 Hz)
* Shake proofed design (resistant against vibrations up to 5g)
* Seals against entrance of water and oil
* 6 Condensation drain holes on DE and NDE
* Suitable for 6 fitting positions * protection cover for clutch and brake
* second name plate for VFD-operation
* special copper rotor * torsion shaft separate delivered
Comments:
Converter
0- 50 Hz
50- 85 Hz
85-100 Hz

operation:
(989 1/min) -> constant torque 3187 Nm
(1679 1/min) -> constant power 330 kW
(1980 1/min) -> reduced power 270 kW at 100 Hz

Winding isolation for:


Rise time
Voltage rise
0.1 mysec
10.4 kV/mysec
0.8 mysec
1.8 kV/mysec

Peak voltage
1300 V
1800 V

Dimension drawing -> 6184163

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3. Operating and maintenance instructions


3.1 Transport and storage
On delivery the machines are packed on woods. These woods are intended for loading by means
of stacker.
Lift machines only on lifting eyes provided. The lifting eyes are designed for
machine mass only. Do not add any load to machine. (Weight see 2. Technical
Data).
Machines with cylindrical roller bearings, ball bearings of the type 6328 and
higher and special bearings are protected against bearing damage during
transport by means of a locking device which has to be removed before
putting the machine into operation.
The locking device must also be used for any further transport of the machine!

3.1.1 Storage
All blank parts are protected against corrosion by using special agents (e.g. Tectyl 506).
If the machine has to be stored, because it cant be fitted and started running on arrival at point of
destination, take notice of the storage area. Machines and equipment have to be stored in rooms
which are well-ventilated, dry, dust-free, temperate and vibration proof.

3.1.2 Long time storage (more than 3 months)


For long time storage without operational readiness the machine must be protected against
damages. All blank parts have to be protected against corrosion using special agents (e.g. Tectyl
506). Additionally to the above mentioned arrangements the machine must be packaged in a
plastic cover and Silicagel must be added (desiccant). The transport safeguard must be installed. If
a space heater is available it must be switched on. The ambient temperature should be approx.
20C and the relative air humidity approx. 55 %.
Machines have to be stored in rooms which are vibration proof. The storage at cold walls, stone
floors, heater pipes as well as in surrounding atmosphere with aggressive media is not permissible.
The cooling ducts of water-cooled machines must be filled completely with
coolant (with inhibitor). The cooling ducts of oil-cooled machines must be filled completely with oil.
In order to prevent damage of the bearings caused by non operation, the
machines should be switched on resp. the rotor should be turned for a short
time at least every three months. The transport safeguard must be loosened
before and installed afterwards.
If turning of the rotor is not possible every 3 months, then the bearings must
be renewed before start-up.

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3.1.3 Measures to be taken after prolonged storage


Lubricants tend to age, which is associated with the loss of specific properties. Ensure that the
bearing lubricant is of sufficient quality for its purpose. This reduces the relubricating period until
the next maintenance job! After a storage period of more than 3 years, the bearing lubricant
must be replaced. The bearing grease must be replaced in the course of the replacement of
the bearings. Use only grease of the prescribed grade (see Lubrication shield/2. Technical
Data). Unless the rotor has been rotated ever 3 months, the bearings must be replaced. In
machines that are to be restarted after a prolonged period of storage, check the insulation
resistance (see Control of the isolation resistance/3.7 drying of moist windings). Install the
equipment according to the instructions in the operating manual.

3.1.4 Storage of used motors


Prior to putting the motor into storage, we recommend sending it to an authorised ELIN service
agent for proper dismantling, cleaning and conservation. The motor should subsequently be stored
indoors in a facility with a stable climate. Ensure that the motor is stored in such a way that the
condensation drain holes are opened and facing down (drainage).
There is no guarantee for bearing and grease after a long stop time!

3.2 Coolant mixture


We commend following antifreeze with rust inhibitor:

GlycoShell
Glysantin G-03
Havoline XLC
Mobil antifreeze H

For a temperature range up to - 30 C use 60% water and 40% antifreeze (e.g. GlycoShell).
Antifreeze has always to be thin with water. The frost proof depends of the mixing ratio. Please note
the chapter 3.5 Cooling water!

3.3 Safety measures


The safety instructions must be adhered strictly (see chapter 1)!
Only qualified and authorized personnel are allowed to carry out works on
machines. Refer also to DIN VDE 0105 or IEC 364.
Before carrying out any work on the machines, disconnect and secure it
against restarting.

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3.4 Coupling and installation


Remove corrosion protection at plank parts. Loosen transport locking screw. The fixing bolts have
to be tightened and secured against loosening. The machine is dynamically balanced.
Lift machines only on lifting eyes provided. The lifting eyes are designed for
machine mass only. Do not add any load to machine. (Weight see 2. Technical
data).

Machines with cylindrical roller bearings, ball bearings of the type 6328 and
higher and special bearings are protected against bearing damage during
transport by means of a locking device which has to be removed before
putting the machine into operation.
The locking device must also be used for any further transport of the machine!

Care for a plane mounting place to avoid bracing of the housing. Re-check
alignment with the machine at operating temperature.

3.4.1. Condensation drain holes (only valid for IP56, IP66, IP67!)
The machine is equipped with a number of condensation drain holes with screw plugs. Depending
on the position of installation at DE and NDE, the bottom screw plug must be replaced with the
sintered bronze filters (supplied as loose parts in the terminal box!). The screw plugs with the
sintered bronze filters must be regularly opened to drain off the condensation from the
motor chamber. This should be done at the lubricating intervals laid down in the schedule,
see Appendix.
These connections must be sealed with Loctite 577.
Tightening torque: 15.6 Nm

3.4.2 Installation of the overload clutch (only for drilling head motor)
1. Connect the motor to the gear system.
2. Insert the torsion shaft into the hollow motor shaft (apply a little grease, e.g. gleitmo WSP 5040
Fuchs Lubritech GmbH or equivalent product, onto the gearing) and engage the internal toothing of
the transmission system.
3. Insert the 30x2.65 O-ring into the torsion shaft (after visual inspection).
(O-ring, item 130 in sectional drawing, included with torsion shaft.)
4. Mount and press Safeset according to the instructions in the separate installation manual
onto the hollow and the torsion shaft.
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3.5 Cooling water


3.5.1 Water specification for stator cooled electrical machines
Nominal data
pH value
Water hardness (dH)
Suspended solids (ppm)
Filter aperture width (m)

Recommended quality
7.5 up to 8.5
4 up to 6
< 10
30

Accepted quality
6.5 up to 9.0
< 10
< 30
<100

Remaining specification according to DIN 50930.


Have special attention to the observance of pH-value, water hardness and quantity of suspended
solids.
In the relation quantity of suspended solids to water hardness the following has to be considered:
The higher the water hardness the lower must be the quantity of suspended solids.
Past experience has shown that as long as continuous cooling water through-flow is ensured also
a substantially higher quantity of suspended solids will not cause impermissible soiling of the
cooling channels in the machine.
The Cleaning Instructions for Electrical Machines with Water Cooling should be noted in case of
frequent time of standstill and deviations to the above mentioned approximate values.
In existence of a closed cooling water circuit we recommend the antifreeze GlycoShell or a similar
inhibited antifreeze satisfying grade 1 according to ASTM D 1384-87 in dependence on the
material of the cooling circuit.
For a temperature range up to - 30 C use 60% water and 40% antifreeze. It should be verified
every 5 years that the inhibitor of the coolant is not consumed otherwise the coolant has to be
changed to prevent stopping up because of excessive corrosion. For refilling use the same coolant
system because of the possibility of incompatibility of inhibitors.

3.5.2 Connections
The water in- and outlets are evident on machine dimension drawing.
Before putting into operation the machine must be deaerated and filled with coolant.
Cooling water through-flow must be absolutely ensured.
During operation the permissible inlet temperature of the coolant, the
minimum water through-flow and the allowable water pressure in the cooling
water circulation must be observed (see 2. Technical data).

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3.5.3 Cleaning instructions for electrical machines with water cooling


To guarantee optimal cooling effect of the water the cleaning of the cooling channels of the
machines in corresponding periods is recommended
Machines with open cooling circuit:
Machines with closed cooling circuit:
*

< 1 year*
< 5 years*

The indicated intervals referring to the permissible boundary values for water hardness and
suspended solids of the cooling water depend on the factual soiling of the cooling channels
of the machine.
Signs for impermissible soiling of the cooling channels are e.g.: increasing drop in pressure
and/or increasing heating during constant operation of the machine.

The higher the water hardness (lime content) the sooner a soiling of the cooling channels may be
expected.
An essential difference for the highness of the quantity of suspended solids is also the type of duty:
- continuous duty (WITHOUT time of standstill)
- intermittent duty (WITH time of standstill)
In practice a continuous duty will be hardly realized. In case of continuous duty the quantity of
suspended solids of the cooling water can be substantial higher if the cooling channels of the
machine are entirely drained and flushed at standstill (e.g. maintenance).
In case of intermittent duty with time of standstill of the machine and thus also of the cooling water
flow the quantity of suspended solids has to be kept very low optimum: max. 10 ppm. This is
necessary because in case of standstill the suspended solids have an effect as an absorptionmedium to ions and fine distributed particles (e.g. calcium carbonate) comprised in the water. They
fix themselves on the suspended solids, grow and can thus block off smaller sections in the inside
of the cooling system. Moreover we recommend admixing an inhibitor to the cooling water (for
example Ferrophos 8579 from Henkel).
For rotor cooled machines water hardness and quantity of suspended solids have also an influence
to function and lifetime of the mechanical seal. A clogging of the cooling channels can stop the
cooling and the flushing of the mechanical seal and consequently lead to a break-down.
The higher the quantity of suspended solids of cooling water, the higher is also the rate of wear of
the mechanical seal, which depends also from many factors of the suspended solids (hardness,
grain size, surface form, grain size distribution).
In case of impermissible soiling of the cooling channels of the machines the following cleaning
process is recommended.

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3.5.4 Recommended cleaning process with boiler cleansing compounds

Only qualified personnel are allowed to carry out chemical cleaning!


All cautions and warnings on the products and safety instructions should be
noted!

1.
2.

What type of cleansing compound to be used depends on the composition of the


incrustation and on what materials in the cooling circuit come into contact with the solvent.
Complete drainage and cooling down of the machines to 40 C min.

3.

Connection of the water in- and outlets of the machines for a circuit to a suitable tank
provided with a pump (e.g. decalcification pump EKP 30 / Thermochema). Regarding the size
of the tank the volume of the cooling channel has to be considered.

4.

Cleaning of the cooling channels


Diluting of cleansing compound proportionately with water (e.g. 1 part of boiler cleansing
compound DC 314/1 / Thermochema with 2 parts of water). The diluted solution shall circulate
through the pump for approx. 2 to 3 minutes every hour.
The reaction time depends on quantity and composition of the incrustation. However, the
incrustation should be removed after 12 to14 hours at least.
Great quantity of carbon dioxide may develop make sure that an outlet for the gas escape is
provided on the highest place of the system (exhaustion).
Disposal of waste cleansing compound as described in point 7.

5.
6.

7.

After cleaning, the cooling channels are to be flushed with water for approx. 1 hour.
Preserving of the cooling channels
Installation of a circuit as described in point 3, diluting of the passivator (after treatment main
against rust film) e.g. rust preventing means and passivator DC 500 / Thermochema
proportionately with water and circulation of the diluted solution through the pump for approx. 2
to 3 minutes every 15 minutes. The reaction time is 1 to 2 hours.
The indicated passivator may be let into the public sewer by addition of a more than
proportional quantity of water.
Waste disposal of cleansing compound
Dissolve the neutralizer (e.g. DC 315/3 / Thermochema) proportionately in water (approx.
1:10) and add it to the waste solution until it is pH-neutral. After that the solution may be let
into the public sewer by addition of a more than proportional quantity of water.

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3.6 Electrical connection


Electrical connection must be carried out according connection diagram in the terminal box
(enclosed). Connection of the protective conductor inside the terminal box and/or on the housing
has to be established.
Connections of the additional equipment (e.g. anti-condensation-heater, thermistor for winding and
resistance thermometers for bearings) are established on connection diagrams (enclosed).
After drawing-in of the wires, the inlets must be tightened (dense!).
Work on the electrical connections of machines must be carried out by
qualified and authorized personnel only.
Refer also to DIN VDE 0105 or IEC 364 !
Connection of the supply cables must be done with special care to ensure
a permanent and reliable contact
Supply cables must be stress relieved so that no cantilever loads are exerted
on the terminals.

For shielded cables, ensure that the shielding is connected across a large
cross-section to the ground bolt in the terminal box by means of an EMC cable
screw adapter or a flexible earthing tape (HF potential equalization conductor)
and shielded clip.
Correct cabling and 360-connection of the cable shielding at both ends
significantly improve the EMC behaviour of the installation.
After connection of the machine, make sure that no foreign matter is left in the
terminal box, and that it is clean and dry.
In order to maintain the degree of protection, always make sure to use the
original gaskets when closing the terminal box.
Only valid for IP56, IP66, IP67:
All bolts which are opened in the terminal box area must be protected with
Loctite 577 (243).
Cable entries which are not used have to be sealed up dust and water-tight.
Lay the motor connecting cables so that they are at the base of the unit.
Regularly inspect them for damage, whereby the inspection intervals should
be determined on the basis of the actual load (vibration, moving cable, etc.).

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Connection through screw thread or bars


Permissible constant
current intensity

screw thread
d

Material of
bolts

Tightening torque
Nm

A
16
25
63
100
160
250
315
400
200
315
400
630
800
1000
1250
1600

M4
M5
M6
M8
M10
M12
M16
M20
M10
M12
M16
M20
M24x2
M30x2
M33x2
M36x3

CuZn37 F35

1.2
2
3
6
10
15.5
30
52
10
15.5
30
52
80
150
197
252

CuZn37 F38
E-Cu F25

Winding
180 C switch off temperature independent from used type of sensing device.

3.7 Drying of moist windings


The insulation of the winding has to be checked after long term storage or long periods of standstill
(if anti-condensation heater has not been in operation) and after flooding.
The insulation resistance of the cold winding should be at least 6000 M. In our experience the
insulation resistance is lower after putting into operation. We therefore recommend repeating the
measurement in warm condition. The winding has to be dried in case the insulation resistance
drops below 1 M at a winding temperature of 60 C to 80 C.
For measurement disconnect the machine from all external connections. The drying is effected at
open machine by:
a.

Drying by current, whereas the heating current should be adjusted to approx. 50 % of nominal
current with all phases symmetrically loaded. The stator winding temperature must not exceed
100 C

b.

Drying in an oven, whereas the stator only is dried 100 C for approx. 12 hours.

Space heater* (*Only for machines which are equipped with space heaters)
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By activating the space heater during standstill, the air temperature inside the machine will be kept
some degrees higher then outside the machine. Thus dew formation, also at strong variations in
temperature as well as moist surroundings, will be prevented. Consequently, the machines are
ready for operation at any time.
During operation of the machine the space heater must be switched off.
Activating of the space heater is recommended after a standstill time of
10-12 hours.

The space heater should be activated until the restart of the machine except
the period of standstill is long enough that the drying of the moist winding
(drying by current or in an oven) before putting into operation is more
advantageous.

Work on the electrical connections of machines must be carried out by


qualified and authorized personnel only.

3.8 Bearing lubrication


The machines are ready to operate.

Observance of regreasing intervals is vital for the operational reliability of the


machine
Relubrication plate indicates relubrication quantity and relubrication interval, optimized for an
ambient temperature of -30 C till +50 C

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For lubricants, relubrication quantities, lubrication and replacement intervals


(for drilling head motors only), see Appendix. After the number of specified
relubrication procedures is reached, i.e. 12 relubrications or 10.400 operating
hours, the bearings must be dismantled, the old grease must be removed and
about half as much new grease must be filled in before the bearings are
mounted again. We recommend exchanging the bearings in this process.
Relubrication must be documented; for a form, see Appendix.

The calculated service life of the bearings is 20.000 operating hours.


If heat-stabilised bearings are used, please adhere to the following:
bearing temperature max. 130 C
The bearings must be relubricated irrespective of the motor type or
application and while the machine is running. If possible lubricate the unit
when it is at operating temperature and run at 50% its rated speed.
Always strictly adhere to the prescribed intervals and lubricant quantities.
After the grease has been applied, let the machine run for a short period of
time (approx. 5 minutes).

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3.9 Bearing replacement


Bearing replacement in accordance with enclosed drawings
All work on the machines must be carried out by duly qualified staff and
authorized bodies only. Observe the regulations of DIN VDE 0105 and IEC 364
(see chapter 5. Warranty/Malfunctions/Repair).
Prior to carrying out any work at the machines, they must be shut down and
protected against restarting.

In order not to void the warranty, during the warranty period, do not replace
the bearings without the prior consent of the motor manufacturer.

3.10 Cleaning
Deposits on the surface have to be removed regularly; especially the deaeriation screws and drain
plugs for condense water.
The seals are not suitable for steam-jet cleaning (high pressure cleaning).

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4. Check list for first start up

The machine is surely installed:


Screw firmly attraction?
After longer storage or stop:
Insulation resistances of the windings are ok?
Examine the electrical connections:
Correct connection?
Perfect condition of the terminals?
Terminal distances ok?
Mechanical firmness given?
Electrical conductivity?
Protection device:
Everything ok?
None manipulates?
Function control?
Transport safeguard devices:
Are all devices from the machine shaft removed?
Examine the free movement:
Correct adjustment?
Lock the covers and cover plates:
Are all again properly locked?
Examine the direction of rotation:
The machine turns into the correct direction?
Lock the terminal box cover (only valid for IP56, IP66,
IP67):
Are the screws protected with Loctite 577?

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Condensation drain holes (only valid for IP56, IP66,


IP67):
Are the changed screw connections protected with
Loctite 577?

Abnormal behaviour:
Vibrations?
Noise?
Cooling:
Sufficient cooling ensure?
Bearings:
Function control during operation?
Machine is ready for use!

Confirmation to manufacturer

The first start up was accomplished by:

Name:

Date: .

Company:

Signature:

.........................
.....................

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5. Warranty / Malfunctions / Repairs


In case of any warranty claims, the General Terms of Delivery of the Austrian Electric and
Electronic Industry shall apply for goods supplied within Austria.
For supplies to foreign countries, our General Terms of Delivery shall apply. They are essentially
based on the recommendations of the United Nations Economic Commission for Europe.
We want to emphasize that we will not assume any liability in case of nonobservance of this Installation, Operating and Maintenance Instruction.
We also can not take on the liability resp. guarantee for damages on the
machine which has been caused by independent works resp. not under the
supervision of experts of our company.
Not to loose the right to guarantee, please inform in any way our department Services

ELIN EBG Motoren GmbH


Dep. Services
Elingasse 3
8160 Weiz
Austria
Phone: (+43/3172) 90 606 2463 - 0
Fax: (+43/3172) 90 5850
E-mail : serviceemg@elinebgmotoren.at

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CAUTION: The following instructions apply only to drilling head motors with
integrated overload clutch
5.1 Measures to be taken in the event of failure of individual drive
components
In the event of failure of a drive component (frequency converter, motor, Safeset, gear system) and
resulting standstill of the motor, there is a risk of damage to the motor bearings caused by vibration
from continued propulsion.
The drive stroke can be completed after the following events:
1. Motor standing still and mounted, and
2. Safeset dismantled, and
3. torsion rod (inner shaft) dismantled
Subsequently, the following mandatory measures must be taken:

Failure of a frequency converter:

Deselect the defective frequency converter at the visualisation panel. If required, change
the master selection.
Ensure that the associated Safeset remains activated (motor rotates with gear)
Replace or repair the defective frequency converter without delay.

Failure of a motor:
Deselect the frequency converter of the defective motor at the visualisation panel. If
required, change the master selection.
Deactivate the respective Safeset.
Dismantle Safeset and torsion rod.
Replace or repair the defective motor without delay.
If the motor cannot be repaired while mounted, it must be dismantled!
Safeset triggered:
Reactivate the Safeset without delay.
Turn the drilling head only, if all mounted Safesets are activated!
Replace the defective Safeset without delay.
Failure of a gear system:
Deselect the respective defective frequency converter at the visualisation panel. If required,
change the master selection.
Dismantle the associated motor.
Replace the defective gear system without delay.

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For more detailed instructions regarding repairs and the replacement of parts,
please refer to the relevant supplier documentation, which must at all times be
adhered to!

5.2 Failure
If there occurs any failures you must switch off the machine and please contact
our service-department (address see above). In the appendix there are some failure
reports which you can send us by fax. So we can treat your failure diagnosis faster.

Electronic failure report

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6. Emergency data
Fire fighting

1)
2)
3)
4)

Switch off the machine immediately


Secure against restarting
Contact the fire department and refer to electrical fire
Fight fire with suitable extinction agent (e.g. CO2 - Fire extinguisher)

False

Correct
Attack the fire
in wind
direction!

Put out from


the front to the
rear and from
down upwards!

But: drop- and


flow fires must
be put out from
above
downwards.

Use several fire


extinguishers at
the same time
not one after
another.

Attention to
reflammation
put out glow
nests always
with water!

Used fire
extinguishers
must be filled
don't hang them
up again!

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First aid measures by accidents with electrical current

By accidents with electrical current you should take the following measures:

Interruption of circuit by switching off, by pulling the plug, by taking the safety device out.
If these measures are not immediately possible, casualty must be pulled away from the
electric circuit by using non conductive articles.
Call a doctor!
Emergency call:
Rescue guidance centre ........................................... Phone: ..........................................
Accomplish first aid measures up to the arrival of the doctor.
- immediate placing in rest position
- control of respiration and pulse
- when respiratory arrest then breath donation
- when cycle stop then heart-lung-revival
- when unconsciousness and existing respiration then side storage
- germ-free coverage of the fire wounds

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7. Spare Parts
7.1 Spare parts inventory
A list of the parts subjected to wear is attached to the specification. This list shows those parts
which are usually required. There is a precise distinction between parts subjected to normal wear
and tear, which can therefore be regarded as "required" spare parts, and parts that might become
faulty and are therefore merely "recommended" spare parts.

7.2 Order procedure


Ordering address:

ELIN EBG Motoren GmbH


Dep. Services
Elingasse 3
8160 Weiz
Austria
Phone: (+43/3172) 90 606 2463 - 0
Fax: (+43/3172) 90 5850
E-mail : serviceemg@elinebgmotoren.at

Necessary data for a perfect order processing:

Machine data:
Type:
Serial no..:

MKH735U06
505750B 08001

Data of spare parts: (e.g.: Bearing DE)


Stock no. :
Spare part :
Quantity :

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1 piece

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7.3 Spare part list

Spare part which are recommended by manufacturer:


Spare parts inventory necessary
Spare parts inventory recommended

Spare part

Pcs.

Type-Drawing No.

Stock-No.

Bearing DE

Cylinder roller bearing (insul.)

Bearing NDE

Grooved ball bearing

Sealing ring

Shaft sealing ring

10950

KLUEBERPLEX BEM 41-132

11196

Grease

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List of revisions
Date of
issue
01.10.2008

Issue
01

Modified
page
-

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Kind of modification
First edition

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gh

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Use confirmation
I confirm that I read the operating manual attentively and I will keep the aforementioned
regulations and references.

I have read the operating manual and fully understand its content:

............................................................

..............................

Signature

Date

............................................................

..............................

Signature

Date

............................................................

..............................

Signature

Date

............................................................

..............................

Signature

Date

............................................................

..............................

Signature

Date

ELIN EBG Motoren GmbH


Elingasse 3
8160 Weiz
Austria
Phone: (+43/3172) 90 606 0
Fax:
(+43/3172) 90 606 499
E-mail: dokucenteremg@elinebgmotoren.at
Internet: http://www.elinebgmotoren.at/en/home

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Appendix

Drawings
Outline drawing

1 page

Sectional drawing + Legend

2 pages

Connection diagram + Lubrication plate

1 page

EC-Declaration of Conformity
Form

2 pages

Failure report
Form

1 page

Actuation for the relubrication


Form

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Legend

10
11
12
13
14
15
16

Stator frame
Stator core
Stator winding
Earthing connection
Air exhaust
Discharge
Condensation drain hole

20
21
22
23
24
25
26

Shaft
Rotor core
Rotor winding
Pushing
Cover for pushing
Connection tube
O-ring for pushing

17
18
19

Fan DE
Cooling hose DE
Labyrinth ring DE

27
28
29

Fan NDE
Cooling hose NDE
Labyrinth ring NDE

30
31
32
33
34
35
36
37
37a

Bearing DE
End shield DE
Bearing cover outside DE
Bearing cover inside DE
Grease sling washer
Lubrication nipple
Star spring
Sealing ring
Sealing ring only if there are 2 diff. sealing elements

40
41
42
43
44
45
46
47
47a

Bearing NDE
End shield NDE
Bearing cover outside NDE
Bearing cover inside NDE
Grease sling washer
Lubrication nipple
Star spring
Sealing ring
Sealing ring only if there are ..

38
39

Pressure plate
Cir clip

48
49

Pressure plate
Cir clip

50

Terminal box (-cover)

60

Terminals

70

Speed acquisition

80

Vibration acquisition

90

Auxiliary terminal box

100

Bearing - PT100, DE, NDE

110 Bearing fan DE


111 Fan cowling DE
112 Used grease reservoir DE

120
121
122
123
125
130

Bearing fan NDE


Fan cowling NDE
Used grease reservoir NDE
Console for slip ring
Protection disk
O-ring for torsion shaft

137 Felt ring

147 Felt ring

140 Safeset coupling


141 Prodection cover for Safeset coupling

150 Lock washer


151 Inductive - sensor

Failure report for industry machines


1. Supplier
Company:
ELIN EBG Motoren GmbH
Elingasse 3
8160 Weiz
Austria

Fax:

(++43/3172) 90 5850

Phone: (++43/3172) 90 606-2463


E-mail: serviceemg@elinebgmotoren.at

Contact persons department services:

Mr. Gnther Pttler, Mr. Josef Nistelberger


Mr. Manfred Schlagbauer

2. Customer
Company:

Fax:
Phone:
E-mail:

Contact person:
Address of the plant:

Description of way

3. Machine data
Serial number:
Project name:

First starting up:


Running hours:

4. Failure description
Date of breakdown:
Failure description:

Initiated by:

Attach possibly existing recordings please!


Plant in operation:

YES

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NO

Date:

Page:
Document:

1 from 1
QC4-EMG02-002E

Actuation for the relubrication

No.

Date

Agent

Operating hours Lubr. quantityt

Commonnes
achieved
Yes / No

1
2
3
4
5
6
7
8
9
10
11
12

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ELIN EBG Motoren GmbH


Elingasse 3
8160 Weiz, Austria

Place of business Weiz,


registered at Handelsgericht Graz under
FN 58429a; UID: ATU1477 3404; DVR 0748897

Tel.: (+43/3172) 90 606- 0


Fax: (+43/3172) 90 606-784

www.elinebgmotoren.at

Page 1 / 1

TORQUE LIMITING SAFETY COUPLING

Installation and
maintenance instruction

Coupling type
Coupling no.
Drawing no.
Voith ref. no.

Voith Turbo Safeset AB


Rnningevgen 8
S-824 34 HUDIKSVALL
Tel. +46-650-540150
Fax. +46-650-540165
E-mail: info.safeset@voith.com
Internet: www.safeset.com

: ST-B 90
: 12908-12911
: 11462
: 52232

Voith Turbo GmbH & Co.KG


Alexanderstr. 2
D- 89522 Heidenheim
Tel. +49-(0)7321-37-4337
Fax.+49-(0)7321-37-7106

8.1-14-3A

Voith Safeset AB

CONTENTS
Important information

Page 2

Safety regulations

Page 3

Assembly instruction

Page 4

Lubricating instruction

Page 5

Pressure setting instruction

Page 6

Important before use

Page 7

Maintenance

Page 8

Warranty

Page 8

Calibration diagram

Page 9

Assembly drawing

Page 10

Pump instruction

Page 11

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Page 2

IMPORTANT INFORMATION

The Safeset torque-limiting coupling has a hydraulic torque setting


system. By adjusting the hydraulic pressure the release torque can be
set to the required level.
When the pre-set torque is exceeded, the Safeset coupling slips and the
top of the shear tube is sheared off by the shear ring, releasing the oil
pressure in the coupling. This happens within a few milliseconds. After
release the coupling will run freely on the shaft.
How to handle the coupling after release is described in the following
pages.

The Safeset coupling is intended for transmission and limiting of torque.


Due to its design it has a limited ability to take up other types of loads, as
bending torque and radial loads. This must be take into account when installing
the Safeset coupling.
At installation it must also be observed that the Safeset coupling has no possibility
to take up alignment faults. In case such faults exist the Safeset coupling
must be installed in combination with another coupling, which can take up these
faults.
The combination must not lead to reaction forces such as loads or bending torque
on the Safeset coupling.
If the drive line where the SAFESET coupling is installed is not continuously
supervised a monitoring system discovering the release of the SAFESET coupling
must be installed.
This system will prevent that the SAFESET coupling rotates freely during a
longer period of time.

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Page 3

SAFETY REGULATIONS

Protection glasses must be worn during pressure


setting and handling of a SAFESET coupling which is under
pressure.
Do not pressurise the SAFESET coupling before installation.
At pressure setting and pressure release the shear tube or the valve
must be tightened before removing the pump.
When the SAFESET coupling releases, parts from the shear tube and
oil is thrown out of the coupling at very high pressure.
Smaller couplings are delivered with a protection band. If the
coupling lacks protection band, a plate cover must be installed
around the coupling. Min. plate thickness 1.5 mm.

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Page 4

ASSEMBLY INSTRUCTION SAFESET ST-B 90


Drawing: 11462 or 21309
Clean the SAFESET coupling inside, outside and the hub inside, with grease dissolvent.
Assemble the shaft sealing, item 15, according to drawing 11462 into the hub.
Push the shear ring, item 11, with protection rubber band, item 13, the spacing ring with
its O-ring, item 7,8, the coupling and the ball bearing on the shaft. Tighten the end plate
with its O-ring on the shaft end. Secure the shear ring with its pinch screw, item 12,. The
axial clearance between the ball bearing and the endplate shall be 0,5 - 1 mm.
Tightening torque for the pinch screw is 52 Nm.
The hub is applied with a small shrink fit on the outer diameter of the Safeset coupling.
It shall therefore be heated up to approx. 80C. Take care not to damage the shaft seal.
Push the hub over the Safeset and the ball bearing. Grease the endplate so the sealing
can enter smoothly onto the cover.
Oil the coupling inside (the sliding contact bearing) between the shaft seals. Note that it
is very important for the function of the SAFESET coupling that the recommended oil is
used. (Also the ball bearings should be lubricated with the recommended oil).
Push the SAFESET coupling with the hub onto the keyway sleeve.
Tighten the ring, item 18, with o-ring to the shaft.
Fill SAFESET oil for the friction surface. See separate instruction, page 5.
Setting the torque;
A calibration diagram is enclosed with every coupling. The coupling has a number close
to the filling connection and the diagram is marked with the same number. In this
diagram the necessary torque can be read.
See separate instruction to set the torque, page 6.
Oil for oiling of sliding contact bearing and pressure setting cavity.
The SAFESET oil which is delivered with the coupling shall always be used both for the
slide bearing and the pressure setting pump.
In Exceptional cases the oils mentioned below can be used.
The couplings transmitted torque might be somewhat lower with
these oils.

BP HLP 32
Esso Univis N46
Mobil DTE 24

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Castrol Huspin AWS 32


Shell Tellus 37
Valvoline Ultra max AW 32

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Page 5

CHECK AND LUBRICANT FILLING PROCEDURE


(Lubrication oil type is recommended on the drawing, page 10)
NOTE! Coupling must be depressurised during the following operation!
Remove the plastic plug from the filling connection, using the M8 screw provided.
Connect the pump to the filling connection. Check if there is enough room in the pump to
evacuate the oil.
Open the unloading valve on the pump (see page 11).
Loosen the sheartube turn to release pressure.
Tighten the sheartube when the pressure has dropped to 0 MPa.
Disconnect the pump.
Turn one lubrication port to an upper vertical position.
Unscrew the lubrication plugs.
Fill SAFESET oil with the lubrication injector until a clear flow of oil emerges from the level
port.
Reinstall the lubrication plugs.
To pressurise the coupling; See separate instruction, page 6.

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Page 6

PRESSURE SETTING OF SAFESET COUPLING

Insert the new sheartube until it reaches the bottom. The top of the sheartube is then formed to fit
the valve seat at the bottom of the hole. Tighten the sheartube carefully (tightening torque 30-35
Nm). Unscrew the sheartube turn.
Pull out the protection plug from the filling connection on the SAFESET coupling using M8
screw. Press the injection fitting on the pump into the filling connection on the SAFESET
coupling.
Pump oil into the coupling until the pressure gauge shows the correct pressure .................... MPa
(see calibration diagram, page 9).
Tighten the sheartube carefully (30-35 Nm). This makes the coupling absolutely leakproof.
Lower the pressure before removing the pump!
Open the unloading valve (see page 11).
Reset the protection plug in the filling connection hole.

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Page 7

IMPORTANT BEFORE USE

Check that the shear ring is secured.


Check that lubrication oil is filled.
Check that the coupling easily can be turned around without pressure.
Check if the coupling is equipped with a protection band, if not, a
protection device must be installed. (See also safety regulations)

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Page 8

MAINTENANCE

After every 15:th release or once a year, new oil for the slide bearing
shall be refilled through the oil port on the SAFESET coupling.

WARRANTY

Warranty conditions are according to the conditions of sale valid for this
order.

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Page 9

SAFESET
Kalibrierdiagramm / Calibration diagram

Kupplung type/Coupling type

Bestell Nr./Order

Kupplung Nr./Coupling No

ST-B 90

18615

12908-12911

Safeset Sach Nr./Dwg. No.

Voith Safeset Ref. No..

Date, Sign

11462

52232

2003-05-13 HW

Kalibrierdiagramm/Calibration diagram
140
130

Einstellung/Setting
T=
kNm
P=
MPa

120

Druck/Pressure ( MPa )

110
100
90
80
70
60
50
40
30
20
10
0
0

2000

4000

6000

8000

10000

12000

Drehmoment/Torque ( Nm )

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Page 11

INSTRUCTION FOR SAFESET PUMP P100B


The pump must be vented before use;
Tighten the unloading valve, item 33. Turn the injection fitting in vertical
position. Pump with the pump handle, until a firm, air free beam shows. The
pump is now ready to use.
When the pump is empty;
Pull the chain with the ring until the filling plug (plastic plug) comes out of the
handle. Unscrew the plug and fill with SAFESET oil. Vent the pump before
use.
The pressure control valve, item 22, is positioned on the pump housing,
item 1.
The pressure control valve shall be set about 5 MPa higher than the required
pressure for the individual SAFESET coupling. (This is to prevent that the
pressure in the SAFESET coupling is exceeded.)
To test the pump and to set the pressure control valve, the protection cap, item
35, can be used as a plug. Push the protection cap onto the injection fitting,
item 29 and start pumping.
Setting the pressure control valve
Below the screw for the pressure control valve there are eleven plates totalling
5 mm thickness; (3 off t=1 mm, 3 off t=0.5 mm and 5 off t=0.1 mm.) By
reducing the number of plates under the pressure control valve screw the
pressure which can be pumped into the coupling is increased.
Plate thickness 5 mm corresponds P 30 MPa
Plate thickness 3 mm corresponds P 65 MPa
Plate thickness 1 mm corresponds P 100 MPa

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Installation, Operation and


Maintenance

Manual
From Dellner Brakes AB

Product:
Spring applied, hydraulically released, disc brake
type SKP 50 and 95
Manual no:
Customer:
Customer order no:
DBAB order no:

M0080-2

Published by:
DELLNER BRAKES AB
Skyfallsvgen 2
SE-791 77 FALUN
SWEDEN
Telephone: + 46 (0)23 78 30 50
Telefax: + 46 (0)23 77 06 90
Internet address: www.dellner-brakes.com
E-mail: info@dellner-brakes.com

8.1-15-3A

TABLE OF CONTENTS
1. TECHNICAL DESCRIPTION........................................................................ 3
1.1 GENERAL DESCRIPTION ...................................................................................3
1.2 TECHNICAL DATA ...........................................................................................3
1.3 FRICTION MATERIAL .......................................................................................4
1.4 SEAL MATERIAL .............................................................................................4
1.5 CORROSION PROTECTION.................................................................................4
1.6 OPTIONS........................................................................................................4
2. ASSEMBLY INSTRUCTIONS........................................................................ 5
3. MAINTENANCE INSTRUCTION.................................................................. 6
3.1 BRAKE FORCE ADJUSTMENT PROCEDURE ..........................................................6
3.2 REPLACEMENT OF SPRING PILE.........................................................................6
3.3 REPLACEMENT OF BRAKE PADS PROCEDURE......................................................7
3.4 DEAERATION PROCEDURE ...............................................................................8
4. HYDRAULIC OIL........................................................................................... 9
4.1 RECOMMENDED OIL........................................................................................9
4.2 OIL VOLUME ..................................................................................................9
5. RECOMMENDED SPARE PARTS .............................................................. 10
5.1 ARTICLE NUMBERS .......................................................................................11
6. PART LIST AND DRAWING SKP 50 ..................................................... 12-13
7. PART LIST AND DRAWING SKP 50 WITH SUPPORT ....................... 14-15
8. PART LIST AND DRAWING SKP 95 ..................................................... 16-17
9. PART LIST AND DRAWING SKP 95 WITH SUPPORT ....................... 18-19

Copyright Dellner Brakes AB, 2002 All rights reserved


The manufacturer reserves the right to modification without special notice
Manual for SKP 50 and 95. First issue.

1. Technical description
1.1 General description
Dellner Brakes spring applied, hydraulically released disc brakes offer a reliable and
safe method of braking a linear or rotation movement. The brakes consists of two
symmetrical brake halves which are delivered either with or without a support
bracket. Each brake half is supplied with two cylindrical guiding pins, which transmit
the tangential braking force from the brake pads to the brake. This means that the
brake pistons is not subjected to any radial force and as a result contributes a longer
life for the brake. The brake halves are also provided with two return springs which
draw back the brake pads whenever braking effect has been achieved. In order to
compensate the brake pad wear the spring pile has to be adjusted a few times during
the life span of the brake pad.

1.2 Technical data


Table 1
Type
Braking Force * Braking Force ** Min Release P Air gap disc / pad
SKP 50-02 2700 N
3600 N
30 bar
2 x 1,0 - 2,5 mm
SKP 50-05 5000 N
6900 N
60 bar
2 x 1,0 - 2,5 mm
SKP 50-06 6200 N
8100 N
70 bar
2 x 1,0 - 2,5 mm
SKP 50-09 9200 N
12400 N
110 bar
2 x 1,0 - 2,5 mm
SKP 95-10
SKP 95-14
SKP 95-18
SKP 95-27

10700 N
14300 N
18200 N
27800 N

12600 N
17800 N
24000 N
33500 N

45 bar
65 bar
90 bar
115 bar

2 x 1,0 - 2,5 mm
2 x 1,0 - 2,5 mm
2 x 1,0 - 2,5 mm
2 x 1,0 - 2,5 mm

*) Minimal tangential braking force before adjustment.


**) Maximal tangential braking force after adjustment.
External losses not accounted for. Values are calculated with =0,42.
Maximal release pressure = 150 bar

Copyright Dellner Brakes AB, 2002 All rights reserved


The manufacturer reserves the right to modification without special notice
Manual for SKP 50 and 95. First issue.

1.3 Friction material


The standard friction material used on the brake pads is a non-asbestos organic
material. Max. continuous rubbing speed is 21 m/s and max. continuous temperature
is 300 C. Other materials is available for more demanding applications. NOTE! To
reach full friction, the brake pads have to be bedded in.

1.4 Seal material


Polyurethane is used as a standard material in seals. If chosen hydraulic oil is not
suitable together with polyurethane, EPDM is available. If the operational oil
temperature is over 100 C, viton is available.

1.5 Corrosion protection


The Dellner Brakes is protected against corrosion due to following:

Return spring material are stainless steel.


All bolts are electrically galvanised.
The pistons are electroless nickel plated.
The brakes are painted with a two pack epoxy paint.

1.6 Options
Support bracket
The support bracket is manufactured to fit a 12 mm thick disc. If the disc is thicker
spacers are used. Together with the support bracket an external T- fitting is supplied
that connects the two brake halves allowing a single pressure connection.
Electric indicator
The indicator comprises of the following; A spring mounted adjustable contact,
which follows the movement of the brakepads, and presses a microswhich which is
mounted to the caliper housing. The electrical signal can be used, dependant on how
the contact is adjusted, to show one of the following: Brake on, Brake off, Brake pads
worn out or Time to adjust the spring pile.

Copyright Dellner Brakes AB, 2002 All rights reserved


The manufacturer reserves the right to modification without special notice
Manual for SKP 50 and 95. First issue.

2. Assembly instructions
Install the brake with the air bleeder screws as high as possible.
The brake unit should be installed and adjusted parallel with the brake disc, installing
tolerance 0,5 mm.
Before finally tightening of the mounting screws, apply the brake, tighten the screws,
release the brake and check the installing tolerance again.
NOTE! Do not forget to tighten the mounting screws finally.
Bleed any air from the brake.
Check that the discs angular throw in relation to the support, do not exceed the
permissible values, see below.

Figure 1
Before the brake is taken into operation the friction material on the brake pads have
to be bedded in. Use the brake and brake the machine down to stop a couple of times.
Do not overheat the brake pads. Max. recommended temperature on the brake disc
surface is 200 C. The brake pads are ready for operation when the entire surface
colour have turned into black from the brand new grey colour.
The hydraulic tubes which are to be connected to the disc brake have to be seamless
steel tubes according to DIN 2391 / c, (St. 35) (dim. see table).
The tubes have to be cleaned internally by compressed air before assembly. Please,
consider your environment when choosing corrosion protection.
Copyright Dellner Brakes AB, 2002 All rights reserved
The manufacturer reserves the right to modification without special notice
Manual for SKP 50 and 95. First issue.

3. Maintenance instruction
3.1 Brake force adjustment procedure
The braking force should be adjusted when the distance between the guide column
and the adjustment nut is max. 1,5 mm or as an alternative when the air gap between
the disc and the brake pads is max. 2x2.5 mm.
The adjustment procedure should be done when the brake is activated (no hydraulic
pressure).
The brake pads should be replaced when min. 2 mm friction material is left.
1. Release the brake from hydraulic pressure.
2. Turn the adjustment nut on the both sides inward until the guide column in the
centre hole of the adjustment nut is flushing with the outer surface of the nut.

3.2 Replacement of spring pile


The spring pile should be replaced before following number of engagements of the
brake.
Table 2
SKP 50-02
SKP 50-05
SKP 50-06
SKP 50-09

2x106
1,8x106
2x105
3x104

SKP 95-10
SKP 95-14
SKP 95-18
SKP 95-27

2x106
2x106
2x106
6x105

Observe the following when replacing the spring pile:


1. Do only use assembled and tested spring piles from Dellner Brakes AB.
2. Do never mix spring washers from different spring piles.
3. Lubricate all spring washers, with molybdenum sulphide based grease, separately
before assembly.
4. Assemble the spring pile due to the drawing for the model in question.
Copyright Dellner Brakes AB, 2002 All rights reserved
The manufacturer reserves the right to modification without special notice
Manual for SKP 50 and 95. First issue.

3.3 Replacement of brake pads procedure


1. Turn the adjustment nut outward, until measure A, see table 3 below.
2. Pressurise the brake.
3. Remove the guide pins and the return spring screws.
4. Slide brake pad up and out.
5. Slide new brake pad in.
6. Install guide pins and return spring screws. Tighten the screws due to the
tightening table on the general drawing.
7. Adjust the brake force.

Figure 2
Table 3
Brake type
SKP 50-02
A max. (mm) 26

SKP 50-05
26

SKP 50-06
26

SKP 50-09
45

Brake type
SKP 95
A max. (mm) 29
NOTE! New brakepads have to be in operation for a while before full friction is
achieved.

Copyright Dellner Brakes AB, 2002 All rights reserved


The manufacturer reserves the right to modification without special notice
Manual for SKP 50 and 95. First issue.

3.4 Deaeration procedure


1. Pressurise the brake.
2. Open the air bleeder nipple carefully and keep it open until all air is exhausted.
3. Close the air bleeder nipple.
4. Repeat 1-3 on all brake cylinders.
NOTE! The brake pads will loose friction if they are contaminated with oil or grease.
The brakepads should be replaced if the friction material have absorbed oil
or grease.

Copyright Dellner Brakes AB, 2002 All rights reserved


The manufacturer reserves the right to modification without special notice
Manual for SKP 50 and 95. First issue.

4. Hydraulic oil
4.1 Recommended oil
Diagram below show the average curves viscosity versus temperature for the most
commonly used oils subdivided in three groups each one with a different viscosity.
Manufactures of hydraulic pumps and motors find their best operating conditions
with an oil having a viscosity around 30 cSt at the operating temperature. Since the
average operation temperature of hydraulic circuits is about 50C, the oil mostly used
is that corresponding to curve B.
Hydraulic oil shall be chosen so that viscosity at working temperature in your system
is 30 cSt.

Table 4
Curve
A
B
C

ISO-VG standard
32
46
68

Figure 3

4.2 Oil volume


Table 5
Type
SKP 50
SKP 95

Volume 1
44 cm3
118 cm3

Volume 2
4 cm3
9 cm3

Min. steel tube diameter.


8x1.0
12x1.5

Volume 1: Max. oil volume in the cylinders.


Volume 2: Moving oil volume when the brake is correct adjusted.
NOTE! Polyurethane is used as a standard material in seals. Please check if chosen
hydraulic oil is suitable together with polyurethane.
Copyright Dellner Brakes AB, 2002 All rights reserved
The manufacturer reserves the right to modification without special notice
Manual for SKP 50 and 95. First issue.

5. Recommended spare parts


For all SKP 50 disc brakes:
Brake pads, two needed / brake
Art no.

215030
218051
217847
217691

Organic (standard)
Low coeffiicient
Semi-metallic
Sinter metallic

Seal kit, one needed / brake


Art no.

216868-1
216868-2
216868-3

Polyurethane seals. (standard)


EPDM-rubber seals.
Viton-rubber seals.

For all SKP 95 disc brakes:


Brake pads, two needed / brake
Art no.

214952
217313
217632
217934

Organic (standard)
Low coeffiicient
Semi-metallic
Sinter metallic

Seal kit, one needed / brake


Art no.

216869-1
216869-2
216869-3

Polyurethane seals (standard)


EPDM-rubber seals.
Viton-rubber seals.

Copyright Dellner Brakes AB, 2002 All rights reserved


The manufacturer reserves the right to modification without special notice
Manual for SKP 50 and 95. First issue.

10

5.1 Article numbers


SKP 50
Standard:
Type
SKP 50-02
SKP 50-05
SKP 50-06
SKP 50-09

Art.no.
215026-B
217606
215026-A
216521-A

With option support:


Type
SKP 50-02
SKP 50-05
SKP 50-06
SKP 50-09

Art.no.
215026-D
217600
215026-C
216521-B

SKP-95
Standard:
Type
SKP 95-10
SKP 95-14
SKP 95-18
SKP 95-27

Art.no.
214959-D
217597
217602
214959-C

With option support:


Type
SKP 95-10
SKP 95-14
SKP 95-18
SKP 95-27

Art.no.
214959-B
217607
217608
214959-A

Copyright Dellner Brakes AB, 2002 All rights reserved


The manufacturer reserves the right to modification without special notice
Manual for SKP 50 and 95. First issue.

11

6. Part list and drawing SKP 50


Drawing no. 52-00331
Det. no.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

*)

Quantity
2
2
2
2
2
4
2
2
2
4
2
4
2
4
4
2
2
2
2
2

Type
50-02, 05, 06
50-09

***) Type
50-05, 06
50-02
50-09

Description
Caliper half
Piston
Adjustment nut
Brake pad
Guide column
Guide pin
U-ring 35x45x7.2
U-ring 60x70x7.2
Spring pile
Washer
Nipple
Seal TT G 1/4"
Stripper
Return spring screw
Return spring
Bleeder
Plug
O-ring nitrile 20x4.5
Plug UT46 Plan G 1/4
Electric indicator (option)

Art. no.
215027
215028
*
215030
**
215032
218315
217546
***
****
215334
5703014000
5755035000
212207
215829
216290
215543
5725200045
5937007000
216840

Art. no.
215029
216522

**)

Type
50-02, 05, 06
50-09

Art. no.
215031
216523

Art. no.
215613-A
215614-A
216524

****) Type
50-02, 06, 09
50-05

Art. no.
215034
217642

Copyright Dellner Brakes AB, 2002 All rights reserved


The manufacturer reserves the right to modification without special notice
Manual for SKP 50 and 95. First issue.

12

7. Part list and drawing SKP 50 with support


Drawing no. 52-00341
Det. no.
1
2
3
4
5
6
7
8
9
10
11
12
13
-

Quantity
1
1
1
1
3
3
6
2
2
2
2
2
0.4m
2
1

*) SKP 50-02
SKP 50-05
SKP 50-06
SKP 50-09

Description
Disc brake SKP 50
Brake support
Fitting-T
Fitting-L
Screw M6S 12x140 8.8 FZB
Nut locking M12 8.8 FZB
Washer BRB 13x24x2
Banjo fitting
Banjo fitting cap
Plug UTA6 Plan G 1/4
Seal TT G 1/8
Nipple
Pipe 8x1 FZB
Electric indicator (option)
Spacer (option)

Art. no.
*
207454
5801030800
6042-08-08
000931012140
006924012000
000125130000
216810
215752-1
5931007000
5703012000
215333
7285008010
216840
217587-xx **

215026-D
217600
215026-C
216521-B

**) Depending on the spacer thickness.

Copyright Dellner Brakes AB, 2002 All rights reserved


The manufacturer reserves the right to modification without special notice
Manual for SKP 50 and 95. First issue.

14

8. Part list and drawing SKP 95


Drawing no. 52-0035
Det. no.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21

*) Type
95-10, 27
95-14
95-18

Quantity
2
2
2
2
2
4
4
4
*
2
2
2
2
4
4
2
2
2
2
2
1

Quantity
4st
2st

Description
Caliper half
Brake pad
Piston
Adjustment nut
Guide column
Washer IZ 21 FZB
Return spring screw
Guide pin
Washer
Stripper
U-ring 60x70x7.2
U-ring 95x105x10.2
Spring package
Return spring
Seal TT G 3/8
Bleeder
Plug
Stripper PW
Nipple
Plug UT6 plan G3/8
Electric indicator (option)

Art. no.
214949
217641

Art. no.
214951-A
214952
209452
214954
214957
006798021000
214955
214958
*
217545
217546
217547
**
215685
5703016000
216290
215543
5753040048
215335
5937010000
215046

**) Type
95-10
95-14
95-18, 27

Art. no.
215615-A
217529
215616-A

Copyright Dellner Brakes AB, 2002 All rights reserved


The manufacturer reserves the right to modification without special notice
Manual for SKP 50 and 95. First issue.

16

9. Part list and drawing SKP 95 with support


Drawing no. 52-0036
Det. no.
1
2
3
4
5
6
7
8
9
10
11
12
13
-

Quantity
1
1
1
1
3
3
12
2
2
2
2
2
0.4m
1
1

*) SKP 95-10
SKP 95-14
SKP 95-18
SKP 95-27

Description
Disc brake SKP 95
Brake support
Fitting-T
Fitting-L
Screw MC6S 20x220 8.8 FZB
Nut locking M20 8.8 FZB
Washer NL M20 GK
Banjo fitting
Banjo fitting cap
Plug UT6 Plan G 3/8
Seal TT G 1/8
Nipple
Pipe 12x1 FZB
Electric indicator (option)
Spacer (option)

Art. no.
*
209479
216801
6042-12-12
100912020220
006924020000
217775
216806
215687-1
000910010000
5703012000
215333
7284012015
215046
217630-xx **

214959-D
217597
217602
214959-C

**) Depending on the spacer thickness.

Copyright Dellner Brakes AB, 2002 All rights reserved


The manufacturer reserves the right to modification without special notice
Manual for SKP 50 and 95. First issue.

18

MODEL DS325-322
SECTION 9 Telescopic Shield Assembly
Table of Contents
Level

Drawing

Description

Rev.

Page

D103600-1

TELESCOPIC SHIELD ASSEMBLY


NOTE: SHEET 3 NOT INCLUDED

9.1

D103208-1

CYLINDER ARTICULATION

9.1-6

5750990017 TIGHTENING TORQUE FASTENERS

322tc09

SECTION 3

August, 2008

MODEL DS325-322
SECTION 10 Gripper Shield Assembly
Table of Contents
Level

Drawing

Description

Rev.

Page

D102100-1

GRIPPER SHIELD ASSEMBLY

10.1

D103248-1

CYLINDER AUXILIARY THRUST

10.1-20

D103247-1

CYLINDER PROPEL

10.1-21

D103249-1

CYLINDER GRIPPER

10.1-22

D101604-1

CYLINDER TORQUE ARM

10.1-23

D103129-1

CYLINDER POSITION INDICATING

10.1-24

MANUFACTURERS LITERATURE
2

D103564-1

GRIPPER SHOE LIMIT SWITCH INST.

5750990017 TIGHTENING TORQUE FASTENERS

322tc10

10.1-24A
1

10.1-29

SECTION 3

August, 2008

Temposonics
Magnetostrictive Position Sensors

SENSORS

G-Series Linear Position Sensor


Analog and Digital Pulse Outputs

550966 B

Users Manual

Temposonics Model GP

Figure 1 - G-Series Connector Pin-Outs

Connection Options
Temposonics G-Series sensors are preconfigured at the factory by model
code designation. If needed, a variety of retrofit and replacement options are
available to provide direct backwards compatibility for your application.

Temposonics Model GH

G-Series sensor connection options:

Integral Connector (D6 Male)


(As viewed from end of sensor)

Option D60

Integral 6-pin DIN male connector, (option D60)


Integral cable with pigtail end, standard type (option R _ _ ), and
heavy duty type (option F _ _ )
Integral cable with in-line RB type male connector (option RB _ )
Integral cable with in-line MS type male connector (option FM _ )
Depending on the sensor output selected (Analog, Digital Pulse, or Neuter )
the different wiring required for the applicable combinations are shown in
Tables 1-3. Pin-outs for the above connector types are illustrated in Figure 1.

1
9
10

Notices used in this users manual

6 4
Notes:
These notices provide important tips, guidance or advice.

In-line RB connector

Option RB _

Caution:
These notices indicate situations that can be potentially hazardous to you. A caution
notice is placed just before a description of a potentially hazardous procedure, step or
situation.

G
F

Important:
These notices provide information that might help you avoid inconvenient or problem
situations.

J C

K
E

In-line MS connector

Option FM _

All specifications are subject to change. Please contact MTS for specifications that are critical
to your needs. For additional information go to www.mtssensors.com.

10.1-24A

G-Series Wiring/Connections
Table 1 - Analog Output Connections (Voltage or Current)
Integral cable
wire color
R_ _ or F_ _

Integral
connector
D60 pin no.

In-line
connector
FM_ pin no.

In-line
connector
RB_ pin no.

Notes:
Function (Note 1)

Gray

0 to 10, -10 to +10 Vdc, or


4 to 20 mA, 0 to 20 mA
or reverse acting (note 2):
10 to 0, +10 to -10 Vdc, or
20 to 4 mA, 20 to 0 mA

Pink

Return for pin 1

Yellow

Programming (RS-485 +)

Green

Programming (RS-485 -)

Red or Brown

Supply voltage (+Vdc)

White

DC ground (for supply)

---

---

No connection

---

---

No connection

---

---

No connection

---

---

10

1. The format used to show the voltage


and current output range is: [Value at
Null (Setpoint 1)] to [Value at Span
(Setpoint 2)]. Not all of the available
outputs ranges for voltage are shown.

No connection

2. If the G-Series sensor is replacing a


L-Series sensor where the reverse
acting outputs are being used then
the wire connections must be changed
at the controller. Refer to G-Series
Cross Reference, part no. 550967 for
details.

Table 2 - Digital Pulse Output Connections (Start/Stop or PWM)


Integral cable
wire color
R_ _ or F_ _

Integral
connector
D60 pin no.

In-line
connector
RB_ pin no.

In-line
connector
FM_pin no

Gray

(-) Gate for PWM


(-) Stop for Start/Stop, or
Programming (RS-422 TX -)

Pink

4
(and 8)

(+) Gate for PWM


(+) Stop for Start/Stop, or
Programming (RS-422 TX +)

Yellow

(+) Interrogation for PWM (see note)


(+) Start for Start/Stop, or
Programming (RS-422 RX +)

Green

10

(-) Interrogation for PWM (see note)


(-) Start for Start/Stop, or
Programming (RS-422 RX -)

Red or Brown

Supply voltage (+Vdc)

White

DC ground (for supply)

---

---

No connection

---

---

No connection

---

---

No connection

---

---

---

No connection

Note:
Function
When using PWM output with internal
interrogation both of the interrogation
input signals are not used, and can be
left unconnected or connected to
ground.

Table 3 - Square Wave Neuter Output Connections


The G-Series square wave neuter
output is provided for backwards
compatibility to replace Tempo I,
Tempo II, and L-Series sensors.
These sensors have the neuter
output option for connection to the
Analog Output Module (AOM),
Digital Interface Box (DIB), or to
custom interfaces/controllers.
Reference the G-Series Cross
Reference, part no. 550967, for
additional neuter output connection
information, including adapter
cables and field-installed connectors.

Notes:

Integral cable
wire color
R_ _ or F_ _

Integral
connector
D60 pin no.

In-line
connector
RB_ pin No.

Gray

(-) Stop (note 2), or


Programming (RS-422 TX -)

Pink

8
(and 4)

(+) Stop (Compatible


Neuter Output Pulse), or
Programming (RS-422 TX +)

Yellow

(+) Start (note 3, 4), or


Programming (RS-422 RX +)

Green

10

(-) Start (note 3, 4), or


Programming (RS-422 RX -)

Red or Brown

Supply voltage (+Vdc)

White

DC ground (for supply)

---

---

No connection

---

---

No connection

---

---

7 (note 5)

No connection

Function
(see note 1)

1. The (+) Stop output is used for a compatible square wave


neuter signal.
2. The G-Series output signal, (-) Stop is not used when
providing the backwards-compatible neuter type connection.
However, this signal wire / connector pin is used for RS-422
TX- during serial programming of the sensor. When the
sensor output is active, (not in programming mode), this signal
must be left unconnected to allow the proper neuter type
output.
3. When connecting to an Analog Output Module (AOM), or to a
Digital Interface Box (DIB), or to a custom interface/controller
that requires single-ended interrogation, always connect the
unused interrogation lead, (+) Start or (-) Start, to ground at
the AOM/DIB/Controller.
4. For improved noise rejection when using external interrogation
use the positive and negative interrogation signals, (+) Start
and (-) Start, to provide differential inputs to the sensor.
5. If pin 7 was originally used as DC ground for the Tempo II or
L-Series sensor being replaced then the DC ground connection
at the controller must be changed to use pin 1.

Programming & Diagnostics


G-Series LED Diagnostic Codes
G-Series sensor red and green LEDs are intended to provide basic visual feedback for normal sensor operation and troubleshooting. These LEDs are located
at the end of the sensor where the cable or connector is terminated. The green LED is used to indicate power applied and normal operation while the red LED
is used to indicate programming mode operation and errors. See Table 4 for normal operation and diagnostic LED codes.
Table 4 - G-Series LED Codes
Green

Red

Description

OFF

OFF

No power to sensor

OFF

ON

Self-diagnostic error

OFF

FLASHING

Infrared programming mode (PDA or IR setpoint programmer)

ON

OFF

Normal sensor function

ON

ON

Magnet not detected

ON

FLASHING

Missing (external) interrogation

FLASHING

OFF

Serial programming mode (PC setup software)

FLASHING

ON

Magnet signal weak

FLASHING

FLASHING

Power out of range (high or low) 3

Notes:

1 Missing (external) interrogation - If the sensor is a Start/Stop or PWM output style, with external interrogation,
then no interrogation signal has been received over the timeout period. Standard timeout is 0.5 seconds.
2 Magnet signal weak - Sensor is still operating, but magnet placement should be corrected to assure continued
operation. (May also indicate other problems that cause weak magnet return signals.)
3 Power out of range (high or low) - Supply voltage is nearly beyond the acceptable limits. If voltage is low the
sensor is still operating, but the supply voltage should be corrected to assure continued operation. If the
voltage is high the sensor is still operating, but the sensors over-voltage protection may engage, powering off
the sensor temporarily. The over-voltage should be corrected to assure continued operation and avoid
possible permanent damage.

G-Series External Programming and Diagnostics


Temposonics G-Series sensors are preconfigured at the factory by model code designation. In many applications, the G-Series field programming tools are
not necessary to obtain the desired sensor operation. The three programming tools are described in Table 5.
Table 5 - G-Series Programming & Diagnostic Tools
Digital-pulse outputs

Analog output

Programming & diagnostic tool


Programming

Diagnostics

Programming

Diagnostics

PC setup software
(part no. 625060)

Output parameters

Status variables

Output parameters

Status variables

PDA Palm OS software


(part no. 625061)

Output parameters

Status variables

NA

NA

IR Setpoint programmer
(part no. 380077)

NA

NA

Adjust null and span setpoints

NA

Caution:
Prior to initiating G-Series programming, it is critical that the user ensures that taking the sensor out of normal operating mode or modifying the sensors operating parameters will not cause harm to the process utilizing the G-Series sensor feedback, nor to any persons associated.

Important Note:
Use of G-Series programming tools requires that users operate the sensors in one of the programming modes (serial or infrared) instead of the normal operational mode,
(i.e. sensor providing position feedback). It is critical to understand that the user must switch between programming mode and normal operation mode programming
and normal operation cannot occur simultaneously. The only exception is that the G-Series Analog output sensor will still transmit its analog output over the output pins
(wires) while in programming mode. This is necessary to enable users to adjust the analog null and span setpoints.

G-Series PC Setup Software


The G-Series PC setup software is intended to provide the most comprehensive sensor monitoring and programming user interface available for this
product line. Using this program, it is possible to modify sensor parameters
and view important diagnostic outputs. The Help file within the setup program contains details on program operation, sensor programming and diagnostic features.

Figure 2 - Hardware Connections for the PC Setup Software


PN 380077
P/N 380077
Converter
Converter

G-Series sensor
G-Series Sensor

Sensor
Sensor
Cable
cable

Equipment needed:

Windows
Windows
PC
PC

DB9 Serial
DB9 Serial
cable
Cable

Hardware Setup Notes:

G-Series model sensor


Windows PC with G-Series Setup software installed (see below)
RS-232 to RS-422 or RS-485 serial interface converter (part no.
380077)
Two AAA batteries for the serial interface converter
Dual DB9 connector serial communication cable (male to female)
Sensor power supply (+20.4 to +28.8 Vdc for sensor input voltage
option 1, or +9 to +23 Vdc for option 2)
Mating cable for sensor (if necessary)

1.

A converter is required to communicate via the PCs serial (RS-232) port.


The serial interface converter must be configured for RS-232 to RS-422
communication for the Digital Pulse output sensors, or for RS-232 to RS-485
communication for the Analog output sensors.
Digital-pulse output sensors - Set the dipswitches on the top of the converter such
that 422 and Echo On are selected for full duplex RS-232 to RS-422
communication.
Analog output sensors - Set the dipswitches such that 485 and Echo Off are
selected for half-duplex RS-232 to RS-485 communication.
2. Connect the DB9 communication cable from the PC to the serial interface converter.
3. Make sure sensor is NOT connected to the control or sensor interface. Connect
sensor and converter as shown in Table 6 below.
4. Serial PC communication can only be accomplished if the sensor is powered.
Before applying power to the sensor make sure that the appropriate
power source and ground are connected as indicated in Tables 1-3 on page 2.

The G-Series Setup program is installed by first running the SETUP.EXE file
located on the G-Series Documentation and Software CD ROM (part no.
550971). This software can also be downloaded from
http://www.products.mtslinearsensors.com.
Table 6 - G-Series to Serial Interface Converter Wiring
Function Digital-pulse outputs

PN 380077 Converter
Set for RS-422

Function Analog outputs

PN 380077 Converter
Set for RS-485

Gray

(-) Gate for PWM


(-) Stop for Start/Stop or
Programming (RS-422)

(-) Receive
RD A (-)

Analog output

No connection

Pink

(+) Gate for PWM


(+) Stop for Start/Stop or
Programming (RS-422)

(+) Receive
RD B (+)

Return for pin 1

No connection

Yellow

(+) Interrogation for PWM


(+) Start for Start/Stop or
Programming (RS-422)

(+) Transmit
TD B (+)

Programming
(RS-485+)

(+) Txd/Rxd TD B (+)


[Add jumper to RD B (+)]

Green

(-) Interrogation for PWM


(-) Start for Start/Stop or
Programming (RS-422)

(-) Transmit
TD A (-)

Programming
(RS-485-)

(-) Txd/Rxd TD A (-)


[Add jumper to RD A (-)]

Red or Brown

Supply voltage (+Vdc)


connect to power supply

No connection
on converter box

Supply voltage (+Vdc)


connect to power supply

No connection
on converter box

White

DC ground
connect to power supply

No connection
on converter box

DC ground
connect to power supply

No connection
on converter box

D60
pin no.

Wire color

Establishing PC Serial Communication


Caution:
Prior to initiating G-Series programming, it is critical that the user ensures that taking the sensor out of normal operating
mode or modifying the sensors operating parameters will not cause harm to the process utilizing the G-Series sensor feedback, nor to any persons associated.
Complete the following steps to establish PC serial communication:
1.

Turn sensor power ON. Without prompting from the PC Setup program, the sensor will operate normally and the LED display will indicate the
appropriate normal operation (see LED Codes, Table 4 on page 3).

2.

With the sensor powered, execute the G-Series Setup program; click G-Series Field Setup shortcut on your desktop or in the MTS Sensors Startup
menu). If the serial port detected is correct, the program will automatically initiate serial (PC) programming mode and the sensor LEDs
should flash GREEN only. If there is a communications error, a dialog will appear giving you the options to Abort, Retry or Ignore the error. If the
user is confident the wiring and power to the sensor are correct, click the Ignore button and the correct communications port from the dialog that
immediately follows. This dialog can also be accessed by selecting Communications on the main menu bar and then clicking on Select COM port .

3.

Normal sensor operation is resumed by either shutting down the setup program or by cycling power to the sensor.

4.

Note that normal operation mode will occur when sensor power is cycled even when the G-Series setup program is running. The program must
prompt the sensor before programming mode is initiated. This occurs when the program is first executed or by selecting the Click Here to Refresh
Data at the bottom of the page or by pressing F5.
Refer to the G-Series PC setup software Help file for details on advanced programming and diagnostic features.

Programming & Diagnostics Using a PDA - G-Series Digital Pulse Output Sensors Only.
Using the G-Series infrared (IR) interface, users can program G-Series
digital-pulse sensors using a Personal Digital Assistant (PDA). The PDA
interface can also be used as a monitor for position feedback as well as
diagnostics.

Software can be found on G-Series Documentation and Software CD ROM


(part no. 550971) or downloaded from
http://www.products.mtslinearsensors.com. This software is compatible
with Palm OS version 3.3 and above, with these Palm models only: Palm
III, IIIc, V, m100, m130, and Zire. To load the software to your PDA, select
the program for installation and synchronize the PDA with your PC.

Required Equipment:
G-Series model sensor
Mating cable for sensor (if necessary)
PalmTM OS based PDA and G-Series PDA configuration software
installed (see below)
Sensor power supply (+20.4 to +28.8 Vdc for input voltage option 1, and
+9 to +23 Vdc for option 2)

Hardware Setup Notes:


1. Make sure sensor is NOT connected to the control or sensor interface.
2. Do not apply power to the sensor yet. However, make sure that the
appropriate power source and ground connections are correct as
indicated in Tables 2 or 3 on page 2.

The required software file for G-Series PDA programming is named


MTS_GSeries.prc.

Establishing PDA Communications


Caution:
Prior to initiating G-Series programming, it is critical that the user ensures that taking the sensor out of normal operating mode or
modifying the sensors operating parameters will not cause harm to the process utilizing the G-Series sensor feedback, nor to any persons
associated.
Use of the G-Series IR programming tools requires a clear path from the
programming device to the sensor LEDs. Depending on the PDA device
used, IR communication with the sensor may be limited to 3 inches (75 mm)
from the LED window.
1.

Note:
Once the PDA IR Begin Program input is received, the sensor will enter
and remain in program mode until this mode is exited or the sensor power
is cycled.

Turn the PDA on, (power should not yet be applied to the sensor).
Select MTS G-Series from the main PDA menu.

2.

3. If IR communication is not established before the timeout period, simply


power the sensor down and begin step 2 again.

Align the IR window of the PDA device with the LED window of the
sensor as shown in Figure 3 below. Select Begin Prog then
immediately apply power to the sensor. The LED on the sensor will
flash red only when IR communications is established within the 5
seconds of applying power to the sensor (see Figure 3 below).

Figure 3 - Establishing PDA Communications


Sensor LEDs

IR signal

Programming & Diagnostics Using a PDA - G-Series Digital Pulse Output Sensors Only.
Reading Sensor Parameters (See Figure 4)
Using the PDA configuration program it is possible to read the sensor
parameters listed in Appendix A on page 8. To view these parameters or status variables, in the PDA screen select Select Items Here (just under the
Begin Prog button) and select one of the individual parameters on the scrolling
list. To view the parameter select the < Get button.

Figure 4 - Selecting Sensor Parameters


Display box

Parameter list

For a complete parameter listing, click the Get all Items button and then click
the < Get button and all the parameters and their values will stream across
the program display box. To scroll through the list, tap the up and down
arrow keys on the right of the screen. The PDA screen can be cleared of all
parameters by clicking the Clear List button.

IR communication status

Begin IR communications
Magnet position
Output parameters
Read parameter values

Reading Magnet Position (See Figure 5)


Figure 5 - Reading Magnet Position

The approximate magnet position can be displayed (in mm) to help with sensor setup, or during troubleshooting of a system installation. The values displayed are for diagnostic purposes and are NOT representative of the resolution or
performance of the G-Series sensor. The PDA has a 3 second update time for
displaying magnet position.

Magnet position reading

1. To read magnet position, click the Start Reading button from the
main G-Series Configuration screen. The magnet position will appear on
the PDA screen.

Return to main menu

2. To exit this mode, click the Stop Reading button.


Zero magnet position output

Set (Programming) Mode (See Figure 6)


Figure 6 - Using Set Mode

The Set Mode command is used to program the Digital Pulse output sensor
parameters.

Programmable output
parameters

1. From the main G-Series Configuration screen, select Set Mode. If the
PDA is properly aligned for IR communication, the current output
parameter values will be displayed. If not, position the PDA for IR
communication and select Get Mode Params.
To modify the output parameters simply select the pull-down menus and
select the desired parameter values. Use the down arrow on the right to
view all parameter values available for the following items:

Return to main menu

Output Mode Start/Stop or PWM


Interrogation Type External or internal interrogation for PWM mode
Number of recirculations for PWM mode (1 to 15)

Get current parameter values

2. Once finished with parameter selection, save settings to the sensor by


selecting Send to the right of the mode parameter menu. The
Status line at the bottom of the screen will display Command
Complete when changes have been successfully applied to the sensor.
3. To exit the Set Mode, click the Return to Get Mode button to return to the
main menu. Power to the sensor must be cycled for mode changes to
take effect. If changes are not saved prior to removing sensor power, the
parameters will revert to their last saved values.

Setpoint Programming with the Infrared Setpoint Programmer - G-Series Analog Output sensors only
Using the MTS IR Setpoint Programmer it is possible to adjust the G-Series
Analog sensor output at the ends of stroke for the Null (Setpoint 1) and Span
(Setpoint 2).

Hardware setup notes:


1. Make sure sensor is NOT connected to the control or sensor interface.

Required Equipment:

2. Do not apply power to the sensor yet. However, make sure that the
appropriate power source and ground connections are correct as
indicated in Table 1 on page 2.

G-Series model sensor


Mating cable for sensor (if necessary)
IR Setpoint Programmer (part no. 380078)
Sensor power supply (+20.4 to +28.8 Vdc for input voltage option 1, and
+9 to +23 Vdc for option 2)
Voltmeter or Ammeter (depending on output)

3. Connect your voltmeter or ammeter to the sensor output and output


return signals as shown in Table 1 on page 2.

Setpoint Programming
Figure 7 - Infrared Adjustment Tool

Caution:
Prior to initiating G-Series programming, it is critical that the user ensures
that taking the sensor out of normal operating mode or
modifying the sensors operating parameters will not cause harm to the
process utilizing the G-Series sensor feedback, nor to any persons associated.

IR Signal

For G-Series Analog sensors, the Null (Setpoint 1) value applies to the output
at the beginning of the measurement stroke nearest the sensors electronics
housing. The Span (Setpoint 2) value applies to the output at the opposite
end, nearest the sensors dead zone. For the G-Series model configuration
analog sensor output codes (e.g. V0 = 0 to 10 Vdc), the first value always
refers to the Null (Setpoint 1) output, (See Note 1).
1. Hold the IR Setpoint Programmer with the front facing the sensor LEDs,
no more than 4 inches (100 mm) away without obstruction. Press and
hold the programmers POWER button and then apply power to the
sensor. Once the sensor receives the IR programming command, it will
respond with a continuously flashing red LED. If the sensor does not
enter IR programming mode, power down the sensor and repeat this step
again.
2. Programming inputs are made by pressing AND releasing the
programmers buttons while the device is directed at the sensor LEDs.
When a valid input from the programmer is received and processed by
the sensor, it will display two green LED flashes (see Note 2). To adjust
the sensor setpoints follows the steps below.

RECALL

3. Move the position magnet to the desired Null (setpoint 1) position. Then
select the + or - button below the NULL (SP1) label to increase or
decrease the output as shown on your meter. Select the COARSE or
FINE (1 or 2) buttons for larger or smaller adjustments (See Note 1).
4. Next move the position magnet to the Span (setpoint 2) position and
select the + or - button below the SPAN (SP2) label to increase or
decrease the output.
5. Return the position magnet to the null and span locations and confirm
that the outputs are as expected. Use the FINE adjustment feature if
necessary.

Notes:
1. G-Series Analog sensor outputs are adjustable over the entire sensor span.
The minimum adjustment increment is 0.015 inch (0.35 mm) and the
minimum spacing between null and span is 2 in. (50.8 mm). Do NOT attempt
to reverse the output polarity of the G-Series sensor by adjusting the setpoint
values. (To change the output polarity use the PC Setup Software to program
the sensor for a different output range.)

6. The new setpoint values will remain active until the sensor is powered
down. To save the adjustments to sensor memory, click the SAVE
(Enter) button. Otherwise, the sensor will revert to the last saved values
prior to power down. During programming to recall the last saved
values, click the RECALL (5) button.

2. The sensor will continue to receive and process valid inputs when the
programmers buttons are pressed and held down even after displaying the
two green LED flashes. However, when processing this streaming input
signal from the programmer, the sensor will not provide additional feedback,
(i.e. no additional two green LED flashes). Also, there will be no voltage or
current changes on the output until the programmers button is released.

Note: A second button labelled Recall resides at the lower left side of
the programmer. It has no effect for setpoint programming.
7. Power to the sensor must be cycled to exit the IR setpoint programming
mode.

Appendix A
G-Series LED Diagnostic Code Definitions

G-Series Sensor Parameter Definitions


1. Output style (operation mode) The operation modes for the digital
pulse type sensors can be start/stop output or PWM output. For analog
type sensors, the operation mode can be voltage or current output.

1. Missing (external) interrogation - If the sensor is a Start/Stop or PWM


output style, with external interrogation, then no interrogation signal has
been received over the timeout period. Standard timeout is 0.5 seconds.

2. Interrogation type (mode) Indicates whether the sensor interrogation


is generated internally by the sensor hardware or externally by the
controller interface.

2. Magnet signal weak - Sensor is still operating, but magnet placement


should be corrected to assure continued operation. (May also indicate
other problems that cause weak magnet return signals.)

3. Circulations (commonly referred to as recirculations) - Circulations are


the number of times that the sensor element is interrogated to produce a
position reading. By using multiple circulations strung together under one
internal time measurement, the effective resolution of the controllers
clock is increased, thereby increasing position measurement resolution.
The additional interrogations also increase the sensors update time
proportionally.

3. Power out of range (high or low) - Supply voltage is nearly beyond the
acceptable limits. If voltage is low the sensor is still operating, but the
supply voltage should be corrected to assure continued operation. If the
voltage is high the sensor is still operating, but the sensors over-voltage
protection may engage, powering off the sensor temporarily. The overvoltage should be corrected to assure continued operation and avoid
possible permanent damage.

4. Sensor firmware version The version of firmware inside the sensor.


5. Serial number The serial number of the sensor as originally produced.
6. Gradient The gradient is the inverse of the rate at which a sonic strain
pulse propagates through the magnetostrictive waveguide, (gradient
values are about 9 s/inch or 0.35 s/mm). The sensor interface
hardware used determines the absolute position of the magnet by
dividing the difference in time between the Start signal and Stop signal
by the gradient.
7. Cycle time The cycle time is the amount of time necessary to perform
one internal measurement cycle of the sensor.
8. Manufacture date The date the sensor was originally produced.
9. Automatic threshold Refers to sensor circuitry capable of
automatically adjusting to a specific position magnet.
10. SE threshold voltage / Digital threshold level The voltage level at
which the return signal will be detected.
11. Supply voltage - The input voltage detected by the sensor. Refer to
the sensor model number for the sensors allowed input voltage range.
12. Charge pump stages Circuits responsible for generating the
interrogation current applied to the waveguide.
13. Coil reflection mode Refers to a specific method of generating sensor
output signals. Reserved for an existing OEM interface.
14. Sensor model number (as manufactured) Boxcar model
configuration of the sensor as originally manufactured.

Part Number: 09-04 550966 Revision B


Temposonics is a registered trademark of MTS Systems Corporation.
All other trademarks are the property of their respective owners.
All Temposonics sensors are covered by US patent number 5,545,984. Additional patents are pending.
Printed in USA. Copyright 2004 MTS Systems Corporation. All Rights Reserved.

UNITED STATES

GERMANY

JAPAN

MTS Systems Corporation


Sensors Division
3001 Sheldon Drive
Cary, NC 27513
Tel: 800-633-7609
Fax: 919-677-0200
800-498-4442
www.mtssensors.com
displacement@mtssensors.com

MTS Sensor Technologie


GmbH & Co. KG
Auf dem Schffel 9
D - 58513 Ldenscheid
Tel: +49 / 23 51 / 95 87-0
Fax: +49 / 23 51 / 56 491
www.mtssensor.de
info@mtssensor.de

MTS Sensors Technology


Corporation
Ushikubo Bldg.
737 Aihara-cho, Machida-shi
Tokyo 194-0211, Japan
Tel: + 81 (42) 775.3838
Fax:+ 81 (42) 775.5512
www.mtssensor.co.jp
info@mtssensor.co.jp

MODEL DS325-322
SECTION 11 Conveyor Assembly
Table of Contents
Level

Drawing

Description

Rev.

Page

D107974-1

CONVEYOR ASSEMBLY

11.1

5750011369 TAIL PULLEY ASSEMBLY

11.1-10

5750011372 SNUBBER PULLEY ASSEMBLY

11.1-11

D100898-1

DRIVE PULLEY ASSEMBLY

11.1-12

A92266-1

HYDRAULIC MOTOR

11.1-12-4

MANUFACTURERS LITERATURE
2

D9752254T-T

BELT SCRAPER SECONDARY

11.1-12-4A
3

11.1-14

MANUFACTURERS LITERATURE
MANUFACTURERS LITERATURE
TENSIONER
2

D97521541148T

11.1-14A
11.1-14B

BELT SCRAPER PRIMARY

MANUFACTURERS LITERATURE

11.1-15

11.1-15A

5750005865 CYLINDER LIFT

11.1-16

A20747-3

11.1-17

5750000459 SWITCH SPEED ASSEMBLY

11.1-61

5750000455 SPEED SWITCH

11.1-61-3

CYLINDER BELT TENSIONING

MANUFACTURERS LITERATURE

11.1-61-3A

5750011438 SPLICE KIT 54 BELT

11.1-62

5750011439 TOOLS BELT SPLICING

11.1-63

322tc11

August, 2008

MODEL DS325-322
SECTION 11 Conveyor Assembly
Table of Contents
Level

Drawing

Description

Rev.

5750990017 TIGHTENING TORQUE FASTENERS

322tc11

Page

SECTION 3

August, 2008

11.1-12-4A

  
 #0&
a

 

'.6.'#0'45

11.1-14A

Important
Martin Engineering hereby disclaims any liability for injuries or damage resulting from use or application
of this product contrary to instructions and specifications contained herein. Martin Engineerings liability
shall be limited to repair or replacement of product shown to be defective.
Observe all safety rules given herein along with owner and Government standards and regulations. Know
and understand lockout/tagout procedures as defined by American National Standards Institute (ANSI)
z244.1-1982, American National Standard for Personnel Protection - Lockout/Tagout of Energy Sources Minimum Safety Requirements and Occupational Safety and Health Administration (OSHA) Federal
Register, Part IV, 29 CFR Part 1910, Control of Hazardous Energy Source (Lockout/Tagout); Final Rule.
The following symbols may be used in this manual:

DANGER

Danger: Immediate hazards that will result in severe personal injury or death.

WARNING

Warning: Hazards or unsafe practices that could result in personal injury.

CAUTION

Caution: Hazards or unsafe practices that could result in product or property damages.

IMPORTANT
Important: Instructions that must be followed to ensure proper installation/operation of equipment.

NOTE
Note: General statements to assist the reader.

Section

Page

List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installations without chutework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt cleaner inspection access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Materials required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Before Installing Belt Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Installing CHEVRON/RSV Belt Cleaners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1
1
1
1
1
1

2
3

Finding center point of standard CHEVRON belt cleaner mainframe . . . . . . . . . . . . . . . . . . . . . 3


Finding center point of in-line CHEVRON belt cleaner mainframe . . . . . . . . . . . . . . . . . . . . . . . 4
Finding center point of RSV belt cleaner mainframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

After Installing CHEVRON Belt Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


After Installing RSV Belt Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weekly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting/Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix A. Typical Chevron Belt Cleaner Installations. . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix B. Typical Chevron Belt Cleaner Installations. . . . . . . . . . . . . . . . . . . . . . . . . . .

Martin Engineering M3266-11/02

7
9
11
12
13
A-1
B-1

MARTIN Chevron/RSV DURT TRACKER Belt Cleaners

Table of Contents

Table of Contents

List of Figures/Tables

List of Figures
Figure
1
2
3
4
5
6
7
8
9
10
11

Title

Page

Standard Chevron Belt Cleaner Mainframe Location. . . . . . . . . . . . . . . . . . . . . . 3


In-Line Chevron Belt Cleaner Mainframe Location . . . . . . . . . . . . . . . . . . . . . . . 4
RSV DURT TRACKER Mainframe Location . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removing RSV DURT TRACKER blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chevron Belt Cleaner Changing Belt Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
RSV Belt Cleaner Changing Belt Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DURT TRACKER Mainframe with Chevron Blades, P/N 32266-XXXXXX . . 16
DURT TRACKER In-Line Chevron Mainframe Assembly, P/N 33705-XXX . 18
RSV DURT TRACKER Mainframe Assembly, P/N 33139-XXX . . . . . . . . . . . 20
RSV DURT TRACKER Mainframe Assembly with
Snap-on Blade Holder Adapter, P/N 33139-XXSXXX . . . . . . . . . . . . . . . . . . . . 23
Conveyor Products Warning Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

List of Tables
Table
I
II
III
IV
V
VI
VII
VIII

Title

Page

Belt Width and Blade/Hardware Quantity for Chevron Belt Cleaner. . . . . . . . . . 17


Belt Width and Blade/Hardware Quantity for In-Line Chevron Belt Cleaner . . . 19
Chevron Blade/Assembly Materials and Part Numbers . . . . . . . . . . . . . . . . . . . . 19
RSV DURT TRACKER Part Numbers and Quantities . . . . . . . . . . . . . . . . . . . 21
RSV DURT TRACKER Material and Part Numbers . . . . . . . . . . . . . . . . . . . . . 22
RSV DURT TRACKER Torsion Arm Base Colors . . . . . . . . . . . . . . . . . . . . . . 22
RSV DURT TRACKER with Snap-on Blade Holder Adapter . . . . . . . . . . . . . . 24
RSV DURT TRACKER Snap-on Blade Types and Part Numbers. . . . . . . . . . . 25

Martin Engineering M3266-11/02

ii

MARTIN Chevron/RSV DURT TRACKER Belt Cleaners

General

The MARTIN Chevron Belt Cleaner was designed to control carryback and
material buildup for chevron ribbed or cleated conveyor belts. The MARTIN
Chevron Belt Cleaner consists of special torsion arms on a DURT
TRACKER Track with 90-durometer urethane blades. Each blade has
several independent fingers that flex with the chevron belt, and maintain an
effective scraping contact.
The MARTIN In-Line Chevron Belt Cleaner is available for applications
where tight spacing limits room for installation of cleaning systems. It uses
the same flexible cleaning blades mounted on sliding sleeves to provide a
unitary cleaning edge.

Installations
without chutework

These procedures were written for equipment that is being installed on


enclosed pulley chutework. If the pulley is not enclosed, the equipment should
be installed using the best available field resources and methods to ensure that
the critical dimensions are followed for proper installation.
The MARTIN Hanger Mount Assembly can be used for installations without
chutework. See "Part Numbers" for a list of mounts and part numbers.

Belt cleaner
inspection access

If the belt cleaner is installed on enclosed pulley chutework, a CYA


Inspection Door should be installed. CYA Inspection Doors are available
from Martin Engineering or a representative. See Part Numbers for a list of
MARTIN CYA Inspection Doors and part numbers.

References

The following documents are referenced in this manual:


American National Standards Institute (ANSI) z244.1-1982, American
National Standard for Personnel Protection - Lockout/Tagout of Energy
Sources - Minimum Safety Requirements, American National Standards
Institute, Inc., 1430 Broadway, New York, NY 10018.
Federal Register, Volume 54, Number 169, Part IV, 29 CFR Part 1910,
Control of Hazardous Energy Source (Lockout/Tagout); Final Rule,
Department of Labor, Occupational Safety and Health Administration
(OSHA), 32nd Floor, Room 3244, 230 South Dearborn Street, Chicago,
Illinois 60604.
MARTIN CYA Inspection Door Operators Manual, P/N M3127.
Tensioners operators manuals (see Part Numbers in this manual for a
complete list).

Safety

All safety rules defined in the above documents and all owner/employer safety
rules must be strictly followed when working on the belt cleaner.

Materials required

Only standard hand tools are required to install and service this equipment.

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Introduction

Introduction

Before Installation

Before Installing Belt Cleaner


IMPORTANT
The delivery service is responsible for damage occurring in
transit. Martin Engineering CANNOT enter claims for
damages. Contact your transportation agent for more
information.
1. Inspect shipping container for damage. Report damage to delivery service
immediately and fill out delivery services claim form. Keep any damaged
goods subject to examination.
2. Remove belt cleaner from shipping container. Equipment in container
should include the following:
Chevron Belt Cleaner (mainframe and blades), or In-Line Chevron
Belt Cleaner (mainframe and blades).
Two Conveyor Products Warning Labels, P/N 23395.
3. If anything is missing, contact Martin Engineering or a representative.
!

WARNING

Before installing equipment, turn off and lock out/tag out


energy source to conveyor and conveyor accessories.
4. Turn off and lock out/tag out energy source according to ANSI standards
(see References).
!

WARNING

If equipment will be installed in an enclosed area, gas level or


dust content must be tested before using a cutting torch or
welding. Using a cutting torch or welding in an area with gas
or dust may cause an explosion.
5. If using a cutting torch or welding, test atmosphere for gas level or dust
content. Cover conveyor belt with fire retardant cover.

NOTE
The chute wall that the tensioner will be located on is referred
to as the operator side. The other side of the chute is
referred to as the far side.
6. Determine which side of chute is easiest to access. Locate the tensioner
on the most accessible chute wall.

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IMPORTANT
Read entire section before beginning work.
To install the belt cleaner, follow the procedures corresponding to the
following steps:
1. Find center point of belt cleaner mainframe (standard or in-line).
2. Install tensioner according to the applicable tensioners operators
manual. (See Part Numbers in this manual for tensioner manual part
numbers.)

Finding center
point of standard
CHEVRON belt
cleaner
mainframe

1. See figure 1. On operator side chute wall, draw horizontal and vertical
center lines of pulley to find pulley center point (A). Make sure vertical
center line is perpendicular to belt line.
2. Measure 1 in. (25 mm) past point where belt leaves pulley (B), and mark
vertical line on chute wall perpendicular to belt line.

A. Center point of pulley


B. Point where belt leaves pulley
C. Center point of first belt cleaner
mainframe
D. Center point of second belt
cleaner mainframe

1 (25)
B
90

C
5-1/2 1/8
(140 3)

7-1/2
(190)

16-1/2 (419)

Figure 1. Standard Chevron Belt Cleaner Mainframe Location

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3. Locate cleaner blades where this line crosses bottom (return side) of
conveyor belt. If you cannot install cleaner at this point, install it as close
to it as possible. (If belt is not adequately supported where blade
contacts belt, a belt support must be installed. See step 4 under After
Installing Belt Cleaner.)
3

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Installation

Installing CHEVRON Belt Cleaner

Installation

4. Measure vertically and horizontally as shown in figure 1 and mark


mainframe center point (C).
5. Repeat steps 1 through 4 for far side chute wall.

NOTE
For maximum cleaning, Martin Engineering recommends
installing Chevron Belt Cleaners in pairs (right and left) with
torsion arm angles set in alternating directions.
6. To install second belt cleaner:
a. On chute wall, measure 16-1/2 in. (419 mm) from center of first
mainframe (C, figure 1) in direction of belt travel.
b. Locate center of second cleaner mainframe (D) at this point. If you
cannot install cleaner at this point, install it as close to it as possible.
(If belt is not adequately supported where blade contacts belt, a
belt support must be installed. See step 4 under After Installing
Belt Cleaner.)
7. If using CYA Inspection Door, install according to MARTIN CYA
Inspection Door Operators Manual, P/N M3127.

Finding center
point of in-line
CHEVRON belt
cleaner
mainframe

1. See figure 2. On operator side chute wall, draw horizontal and vertical
center lines of pulley to find pulley center point (A). Make sure vertical
center line is perpendicular to belt line.
2. Measure 1 in. (25 mm) past point where belt leaves pulley (B), and mark
vertical line on chute wall perpendicular to belt line.

1 (25)

A. Center point of pulley


B. Point where belt leaves pulley
C. Center point of first belt
cleaner mainframe
D. Center point of second
belt cleaner mainframe

B
90

9
(230)
C

10 min.
(254)

5/8 (16)

Figure 2. In-Line Chevron Belt Cleaner Mainframe Location

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NOTE
For maximum cleaning, Martin Engineering recommends
installing Chevron Belt Cleaners in pairs.
6. To install second in-line belt cleaner:
a. On chute wall, measure at least 10 in. (254 mm) from center of first
mainframe in direction of belt travel (see figure 2).
b. Locate center of second cleaner mainframe (D) at this point. If you
cannot install cleaner at this point, install it as close to it as possible.
(If belt is not adequately supported where blade contacts belt, a
belt support must be installed. See step 4 under After Installing
Belt Cleaner).
7. If using CYA Inspection Door, install according to MARTIN CYA
Inspection Door Operators Manual, P/N M3127.

Finding center
point of RSV DURT
TRACKER
Secondary Cleaner
mainframe

1. (See figure 3 for RSV DURT TRACKER Secondary Cleaner.) On


operator side of chute wall, mark vertical and horizontal center line of
head pulley to find pulley center point (A). Make sure center line is
perpendicular to belt line.

1 (25)

90
Belt
A. Center point of pulley
B. Blade-to-belt contact point

5-1/2 (140)

C. Center point of Secondary


Cleaner mainframe

11.92 (303)

Figure 3. RSV DURT TRACKER Secondary Cleaner Mainframe Location

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Installation

3. Locate cleaner blades where this line crosses bottom (return side) of
conveyor belt. If you cannot install cleaner at this point, install it as close
to it as possible. (If belt is not adequately supported where blade
contacts belt, a belt support must be installed. See step 4 under
"After Installing Belt Cleaner.")
4. Measure vertically and horizontally as shown in figure 2 and mark
mainframe center point (C).
5. Repeat steps 1 through 4 for far side chute wall.

Installation

2. Measure 1 in. (25 mm) past point where conveyor belt leaves pulley and
mark vertical line on chute wall perpendicular to belt line.
3. Locate short arm blades where this line crosses bottom (return side) of
conveyor belt: blade-to-belt contact point (B). (If belt is not adequately
supported, a belt support must be installed. See step 4 under After
Installing Belt Cleaner.)
4. Starting from point (B), measure vertically and horizontally as shown in
figure 2, 3, or 4 and mark mainframe center point (C).
5. Repeat steps 1 through 4 for far side chute wall.
6. If using CYA Inspection Door, install according to MARTIN CYA
Inspection Door Operators Manual, P/N M3127.e

Installing
mainframe

1. Remove blades by loosening thumb screw (A, figure 4) on operator side


of belt cleaner and removing end stop (B). Pull lanyard (C) to slide blades
out of sleeve (D).
A
D

A. Thumb screw
B. End stop
C. Lanyard
D. Sleeve

Figure 4. Removing RSV Blades

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IMPORTANT
Read entire section before beginning work.
1. After belt cleaner and tensioner are installed according to the applicable
tensioner manual, measure from pulley shaft to mainframe, on both
operator side and far side, to make sure mainframe is parallel to pulley.
2. Measure from center point of mainframe to face of conveyor belt to make
sure proper dimension is held:
5-1/2 1/8 in. (140 3 mm) for standard cleaner (see figure 1).
9 (230) for in-line cleaner (see figure 2).
3. Measure from center point of pulley to outside edge of first and last blade
to make sure blades are centered on belt.
4. Make sure cleaner is not changing belt line (see figure 5). If it is, install
belt support directly above blade-to-belt contact point.

Belt Line

Figure 5. Belt Cleaner Changing Belt Line


5. Thoroughly wipe outside chute wall clean above tensioner (on both sides
of chute if applicable). Place Conveyor Products Warning Label
(P/N 23395) on chute wall visible to belt cleaner operator.
!

WARNING

Failure to remove tools from installation area and conveyor


belt before turning on energy source can cause serious injury
to personnel and damage to belt.
6. Remove all tools and fire retardant cover from installation area and
conveyor belt.
!

DANGER

Do not touch or go near conveyor belt or conveyor accessories


when conveyor belt is running. Body or clothing can get
caught and pull body into conveyor belt, causing severe injury
or death.
7. Turn on conveyor belt for 1 hour.

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After Installation

After Installing CHEVRON Belt Cleaner

After Installation

WARNING

Before adjusting belt cleaner, turn off and lock out/tag out
energy source to conveyor belt and conveyor accessories.
8. After 1 hour of operation, turn off and lock out/tag out energy source
according to ANSI standards (see References).
9. Make sure all fasteners are tight. Tighten if necessary.
10. Inspect belt cleaner for the following:
Wear. (A small amount of break-in wear may be found. This will
stop once blades wear to conveyor belt contour.)
Material buildup. (No material between blades and return side of
conveyor belt should be found.)
11. If wear or material buildup exists, see Troubleshooting/Installation
Checklist."

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IMPORTANT
Read entire section before beginning work.
1. Measure from pulley shaft to mainframe on both operator side and far
side to make sure mainframe is parallel to pulley.
2. Measure from center point of mainframe to face of conveyor belt to make
sure the proper critical dimension is held. (See figure 1, 2, 3, or 4.)
3. Measure from center point of pulley to outside edge of first and last blade
to make sure blades are centered on belt.
4. Make sure Secondary Cleaner is not changing belt line (see figure 6). If it
is, install belt support directly above blade-to-belt contact point.

Belt Line

Figure 6. Secondary Cleaner Changing Belt Line


5. Thoroughly wipe outside chute walls clean above belt cleaner on both
sides of chute. Place a Conveyor Products Warning Label (P/N 23395) on
each outside chute wall visible to belt cleaner operator.
!

WARNING

Failure to remove tools from installation area and conveyor


belt before turning on energy source can cause serious injury
to personnel and damage to belt.
6. Remove all tools and fire retardant cover from installation area and
conveyor belt.
!

DANGER

Do not touch or go near conveyor belt or conveyor accessories


when conveyor belt is running. Body or clothing can get
caught and pull body into conveyor belt, causing severe injury
or death.
7. Turn on conveyor belt for 1 hour.
!

WARNING

Before adjusting belt cleaner, turn off and lock out/tag out
energy source to conveyor belt and conveyor accessories.
8. After 1 hour of operation, turn off and lock out/tag out energy source
according to ANSI standards (see References).
9. Make sure all fasteners are tight. Tighten if necessary.

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After Installation

After Installing RSV Belt Cleaner

After Installation

10. Inspect belt cleaner for the following:


Wear. (A small amount of break-in wear may be found. This will stop
once blades wear to conveyor belt contour.)
Material buildup. (No material between blades and return side of
conveyor belt should be found.)
11. If wear, material buildup, or some other problem exists, see
Troubleshooting/Installation Checklist.

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10

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IMPORTANT
Read entire section before beginning work.
!

WARNING

Before servicing belt cleaner, turn off and lock out/tag out
energy source to conveyor belt and conveyor accessories.
1. Turn off and lock out/tag out energy source according to ANSI standards
(see References).
2. Make sure all fasteners are tight. Tighten if necessary.
3. Check blades for excessive wear. If blades are worn to wear line, replace
blades as follows:
a. Release tension from mainframe.

NOTE
If blades will not slide off mainframe loosen or remove track
weldments to make blade removal easier.
b. Remove blades as instructed under Installing mainframe.

NOTE
If using split aluminum sleeve and track weldments have been
removed, re-install before sliding new blades onto cleaner.
c. Install new blades as instructed under Installing mainframe.
d. Make sure blades are centered on belt.
e. Apply tension to belt cleaner according to applicable
tensioner manual.
4. Wipe all labels clean. If labels are not readable, contact Martin
Engineering or a representative for replacements.
!

WARNING

Failure to remove tools from installation area and conveyor


belt before turning on energy source can cause serious injury
to personnel and damage to belt.
5. Remove all tools from maintenance area.
!

DANGER

Do not touch or go near conveyor belt or conveyor accessories


when conveyor belt is running. Body or clothing can get
caught and pull body into conveyor belt, causing severe injury
or death.
6. Start conveyor belt.

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11

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Maintenance

Weekly Maintenance

Troubleshooting

Troubleshooting/Installation Checklist

Troubleshooting

If you are experiencing problems with belt cleaner, see below:

Symptom

Corrective Action

High blade wear rate.

Tension is set too high. Reduce tension.

Insufficient cleaning and carryback.

Tension is set too low or too high. Increase or


decrease tension.
Check blades for excessive wear and replace
if necessary.

Material remaining on one side of


belt cleats. (CHEVRON ONLY)

Only one standard cleaner is installed. Install second


cleaner.

Installation
checklist

If after taking corrective actions suggested under Troubleshooting you are


still experiencing problems, check for the following:
Installation Checklist

Distance from center of mainframe to belt surface is 5-1/2 in. (140 mm) on both ends for
standard cleaner or 9 in. (230 mm) for in-line cleaner.
Cleaner blade tip is 1 in. (25 mm) past vertical center line of pulley.
Cleaner is not changing belt line (figure 3).
Blades are centered on belt.

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Notes
This section provides product names and corresponding part numbers for
Chevron Belt Cleaners and related equipment. Please reference part numbers
when ordering parts:

Chevron Belt
Cleaners

DURT TRACKER Chevron Belt Cleaner Assembly (standard):


P/N 36881-XXXXXX. See figure 4.
DURT TRACKER In-Line Chevron Belt Cleaner Assembly:
P/N 33705-XXX. See figure 5.

Recommended
tensioners for
standard Chevron
Belt Cleaners

Belts 18 to 48 in. (400 to 1400 mm) wide:


Twist Tensioner: P/N 31443.
Adjustable "L" Bracket Twist Tensioner: P/N 31443-L.
Flange Mount With AIR-ACTUATEDTM Tensioner: P/N 30691.
Flange Mount Spring Tensioner: P/N 30691-SM.
Adjustable "L" Bracket Air Tensioner: P/N 31291.
Adjustable "L" Bracket Spring Tensioner: P/N 31291-SM.
Shock (Ring) Mount Air Tensioner: P/N 32745.
Belts 54 to 96 in. (1400 to 2400 mm) wide:
Dual Twist Tensioner: P/N 31443-2R.
Dual Adjustable "L" Bracket Twist Tensioner: P/N 31443-L2R.
Dual Flange Mount With AIR-ACTUATEDTM Tensioner:
P/N 30691-2R.
Dual Flange Mount Spring Tensioner: P/N 30691-2S.
Dual Adjustable "L" Bracket Air Tensioner: P/N 31291-2R.
Dual Adjustable "L" Bracket Spring Tensioner: P/N 31291-2S.
Dual Shock (Ring) Mount Air Tensioner: P/N 32745-2R.

Recommended
tensioners for
In-Line Chevron
Belt Cleaners

Reversing Mount Tensioner Assembly for Top or Bottom: P/N 33599.


Reversing Mount Air Bag Tensioner Assembly: P/N 33599-A.
Reversing Mount Air Bag Tensioner Assembly With Plant Air Kit:
P/N 33599-AK. Includes Reversing Mount Air Bag Tensioner Assembly,
P/N 33599-A, with plant air kit parts.

13

Part Numbers

Part Numbers

Part Numbers

CYA Inspection
Doors

With standard door, up to 155 F (68 C):

9 x 12 in. (229 x 305 mm): P/N 27658-0912.


12 x 14 in. (305 x 356 mm): P/N 27658-1214.
12 x 18 in. (305 x 457 mm): P/N 27658-1218.
18 x 24 in. (457 x 610 mm): P/N 27658-1824.
24 x 24 in. (610 x 610 mm): P/N 27658-2424.
With steel door:

9 x 12 in. (229 x 305 mm): P/N 34955-0912.


12 x 18 in. (305 x 457 mm): P/N 34955-1218.
18 x 24 in. (457 x 610 mm): P/N 34955-1824.
24 x 24 in. (610 x 610 mm): P/N 34955-2424.

Operators
manuals

MARTIN CYA Inspection Door Operators Manual: P/N M3127.


MARTIN Spring, Air, and Water Tensioners Operators Manual:
P/N M3263.
MARTIN Twist Tensioner Operators Manual: P/N M3296.
MARTIN Reversing Mount Tensioner Operators Manual: P/N M3368.

Miscellaneous

Hanger Mount Assembly: P/N 27382. Use with standard Chevron Belt
Cleaners to mount Twist Tensioner or Flange Mount Tensioner onto stringer
instead of onto chute wall.
Reversing Hanger Mount Assembly: P/N 33282. Use with In-Line Chevron
Belt Cleaners to mount Reversing Mount Tensioner onto chute wall.
(See below.)

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IMPORTANT
Mandrel Belt Cleaner Mount and Flange Mounting Bracket
cannot be used with the In-Line Chevron Belt Cleaner.
Mandrel Belt Cleaner Mount: P/N 34280-30 or 34280-48. Replaces far side
belt cleaner mount and allows you to service belt cleaner from
tensioner side.
Flange Mounting Bracket: P/N 30537. Use to mount Flange or Hub Mount
Tensioner onto chute wall with 12 x 18-in. (305 x 457-mm) CYA Inspection
Door. (See below.)

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Part Numbers

Reversing "Z" Bracket: P/N 31158. For use with CYA Inspection Door.
(See below.)

Part Numbers

12
4
3

5
11

13
14

10

6
16
17, 18, 19
20, 21, 22

15

Left Torsion Arms

Item

Right Torsion Arms

Description

Part No.

Chevron Blade

Chevron Torsion Arm Weldment

Qty.

See tbl. III

See tbl. I

32268

See tbl. I

DURT TRACKER Mainframe

30360-XX*

DURT TRACKER Sleeve

100339

Screw Set 1/2-13NC x 1.00

22763-03

Stop End

30386

Nut Stop 5/8-11NC

24242

See tbl. I

Washer Flat 5/8

17154

See tbl. I

Nut Jam 5/8-11NC

21652

See tbl. I

10

Bolt Carriage 1/2-13NC x 1.00

21239

See tbl. I

11

CM DURT TRACKER Torsion Base 31032-01

See tbl. I

Figure 7. DURT TRACKER Mainframe With Chevron Blades,


P/N 36881-XXXXXX** (Sheet 1 of 2)

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Description

Part No.

Part Numbers

Item

Qty.

12

L-Clip

32269

See tbl. I

13

Washer Ext./Int. Tooth Lock 1/2

21569

See tbl. I

14

Nut Stop 1/2-13NC

24307

See tbl. I

15

Screw Thumb 3/8-16NC x .62

30574

16

DT Chevron Torsion Arm

17

Assembly

See tbl. III

See tbl. I

Pipe End Weldment (18.00 Lg)

30354-01

See tbl. I

18

Pipe End Weldment (22.00 Lg)

30354-02

See tbl. I

19

Pipe End Weldment (34.00 Lg)

30354-03

See tbl. I

20

Mainframe Weldment (123.00 Lg)

30354-04

See tbl. I

21

Mainframe Weldment (135.00 Lg)

30354-05

See tbl. I

22

Mainframe Weldment (117.00 Lg)

30354-06

See tbl. I

NS

Lanyard Cable

See tbl. I

23395

See fig. 6 Label Conveyor Products Warning

*XX indicates belt width in inches.


**XX indicates belt width. Third X indicates left (L) or right (R) torsion arm.
Fourth X indicates blade material (urethane [U] or rubber [R]). Fifth and sixth X
indicate base color (brown [BR] or green [GR]).
Torsion Arm Assembly consists of base, arm weldment, blade, and hardware (assembled).

Figure 7. DURT TRACKER Mainframe With Chevron Blades,


P/N 36881-XXXXXX** (Sheet 2 of 2)

Table I. Belt Width and Blade/Hardware Quantity for Chevron Belt Cleaner
Belt Width
in. (mm)

Blade
Coverage
in. (mm)

Quantity Items
1, 2, 7, 10, 11,
12, 13, 14, 16

Quantity Items
8 and 9

Weldment Quantity Items


19

20 21 22

Lanyard Cable
P/Ns

17

18

100349-47
100349-53

18 (400-500)

12.5 (318)

24 (500-650)

18.5 (470)

30 (650-800)

24.5 (622)

100349-59

36 (800-1000)

30.5 (775)

10

100349-65

42 (1000-1200)

36.5 (927)

12

100349-71

48 (1200-1400)

42.5 (1080)

14

100349-77

54 (1400-1600)

48.5 (1232)

16

100349-83

60 (1600-1800)

54.5 (1384)

18

100349-89

72 (1800-2000)

66.5 (1689)

11

22

100349-101

78 (1800-2000)

72.5 (1842)

12

24

84 (2000-2200)

78.5 (1994)

13

26

96 (2200-2400)

90.5 (2299)

15

30

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17

1
1

100349-107
100349-113

100349-125

 a *'8410f   a '.6 .'#0'45

Part Numbers

2
3
4

5
7

Item

Description

Part No.

Qty.
1

DURT TRACKER Mainframe Weldment

30709-XX*

Nut Elastic Stop 5/8-11

24242

See tbl. II

Washer Flat 5/8

17154

See tbl. II

Sleeve Spacer

23239-01

See tbl. II

Screw Square Head Set 1/2-13 x 1.00

22763-03

Sleeve End

23458

Sleeve Weldment

33704

See tbl. II

Screw Hex Head Cap 5/8-11 x 2-1/2

22519

See tbl. II

Chevron Blade

See tbl. III

See tbl. II

See fig. 6 Label Conveyor Products Warning

23395

*XX indicates belt width in inches.


**First XX indicates belt width in inches. Third X indicates blade type (urethane [U] or rubber [R]).

Figure 8. DURT TRACKER In-Line Chevron Mainframe Assembly, P/N 33705-XXX**

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Blade Coverage
in. (mm)

Quantity
Items 2, 6,
7, 8 and 9

Quantity
Item 3

Quantity
Item 4

18 (400-500)

14 (356)

24 (500-650)

21 (533)

30 (650-800)

28 (711)

36 (800-1000)

35 (889)

10

42 (1000-1200)

42 (1067)

12

48 (1200-1400)

42 (1067)

12

54 (1400-1600)

49 (1245)

14

60 (1600-1800)

56 (1422)

16

72 (1800-2000)

70 (1778)

10

20

84 (2000-2200)

77 (1956)

11

22

10

96 (2200-2400)

91 (2311)

13

26

12

Belt Width
in. (mm)

Table III. Chevron Blade/Assembly Materials and Part Numbers


Urethane
DURT TRACKER
Blade
Blade Material
Torsion Base
Mainframe Type
Part Number
Color

Torsion Arm
Assembly
Part Numbers*

Chevron Belt
Cleaner Assembly
Part Number**

Standard

Urethane

32262

Orange

32270-XU

36881-XXXU

Standard

Urethane

32262

Brown

32270-XUBR

36881-XXXUBR

Standard

Urethane

32262

Green

32270-XUGR

36881-XXXUGR

Standard

Rubber

32757

Orange

32270-XR

36881-XXXR

Standard

Rubber

32757

Brown

32270-XUBR

36881-XXXUBR

Standard

Rubber

32757

Green

32270-XUGR

36881-XXXUGR

In-Line

Urethane

32262

33705-XXU

In-Line

Rubber

32757

33705-XXR

*Torsion arm assembly consists of base, arm weldment, blade, and hardware (assembled).
**XX indicates belt width. A third X indicates left (L) or right (R) torsion arm on standard Chevron belt cleaner.
X indicates left (L) or right (R) torsion arm.

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Part Numbers

Table II. Belt Width and Blade/Hardware Quantity for In-Line Chevron Belt Cleaner

Part Numbers

1
2
3
4
5
6

11
10

16

12

22

17
18

13

19

25

Item

20

24

15

14

23

21

Description

Part No.

Qty

1 DT Pipe End Weldment (18.00)

30354-01

**

2 DT Pipe End Weldment (22.00)

30354-02

**

3 DT Pipe End Weldment (34.00)

30354-03

**

4 Pipe End Weldment (Continuous 123.00)

30354-04

**

5 Pipe End Weldment (Continuous 135.00)

30354-05

**

6 Pipe End Weldment (Continuous 117.00)

30354-06

**

7 Screw HHC 3/8 -16NC x 1-1/2

15673

See tbl VI

**

8 CM DURT TRACKER Torsion Base


9 Cable Lanyard

**

10 RSV Spacer Blade

33145

**

11 Blade

See tbl V

**

12 Washer Flat 5/8

17154

**

13 Nut Elastic Stop 5/8 -13NC

24242

**

14 Washer Nylon 5/8 ID

33138

**

15 Arm RSV Weldment

33141

**

16 End Stop Plug

30386

34424-XX*

18 DURT TRACKER Split-Frame

34423-XX**

19 Nut Jam 1/2 -13NC

16889

20 Screw HHC 1/2 -13NC x 1-1/4

13835

21 Bolt Carriage 1/2 -13NC x 3

21239

**

22 Lockwasher Int/Ext Tooth 1/2

21569

**

23 Nut Elastic Stop 1/2 -13NC

24307

**

24 Nut Elastic Lock 1/2 -13NC

18577

**

25 Washer Flat 1/2

17328

**

23395

17 DURT TRACKER Mainframe

See fig. 15 Conveyor Products Warning Label

Figure 9. RSV DURT TRACKER Secondary Cleaner Assembly, P/N 33139-XXXXX*


*XX indicates belt width in inches; third X indicates type of blade (see table V.);
last XX indicates urethane base color.
** See table IV.

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#46+0 0)+0''4+0) GFJJgEEfNF

21

 a *'8410f   a '.6 .'#0'45

0
0
0

30 (650-800)

36 (800-1000)

42 (1000-1200)
0

24 (500-650)

54 (1400-1600)

0
0
0
0
0

60 (1600-1800)

48 (1200-1400)

66 (1600-1800)

72 (1800-2000)

78 (1800-2000)

84 (2000-2200)

96 (2200-2400)

30

26

24

22

20

18

16

14

12

10

Qty
Qty
Qty
Qty
Qty
Qty
Qty
Item 1 Item 2 Item 3 Item 4 Item 5 Item 6 Item 14

18 (400-500)

Belt Width
in. (mm)

15

13

12

11

10

Qty Items
8,10,11,
12,13,15,
21,22,23

100349-125

100349-113

100349-107

100349-101

100349-95

100349-89

100349-83

100349-77

100349-71

100349-65

100349-59

100349-53

100349-47

Part No.
Item 9

39 (991)

33 (838)

27 (686)

21 (533)

15 (381)

Length
Item 18
in. (mm)

14

12

12

10

10

10

Qty
Item
24, 25

Part Numbers

90.5 (2299) 93 (2362)

78.5 (1994) 81 (2057)

72.5 (1842) 75 (1905)

66.5 (1689) 69 (1753)

60.5 (1537) 63 (1600)

54.5 (1385) 57 (1448)

48.5 (1232) 51 (1295)

42.5 (1080) 45 (1143)

36.5 (927)

30.5 (775)

24.5 (623)

18.5 (470)

12.5 (318)

Blade
Coverage
in. (mm)

Table IV. RSV DURT TRACKER Secondary Cleaner Part Numbers and Quantities

Part Numbers

Table V. RSV DURT TRACKER Blade Material and Part Numbers


Assembly Part
No.*

Part No.
Item 11

Material

33139-XXTXX

Tungsten-Carbide

27924

33139-XXSXX

Stainless Steel Blade

16960

*XX indicates belt width in inches; last XX indicates torsion base color.

Table VI. RSV DURT TRACKER Torsion Arm Base Colors


Color

Assembly
Part No.*

Base Part No.

Orange

33139-XXX

31032-01

Brown

33139-XXXBR

31032-01BR

Green

33139-XXXGR

31032-01GR

*XX indicates belt width in inches; third X indicates type of


blade (see table V.); last XX indicates torsion base color.

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 a *'8410f   a '.6 .'#0'45

11
12
13

15
11

10

16

10

21

12

17

13

18

22

20

23
Long arm with
urethane blade

19

14

Short arm with


steel blade

24

Item

Description

Part No.

Qty

1 DT Pipe End Weldment (18.00)

30354-01

**

2 DT Pipe End Weldment (22.00)

30354-02

**

3 DT Pipe End Weldment (34.00)

30354-03

**

4 Pipe End Weldment (Continuous 123.00)

30354-04

**

5 Pipe End Weldment (Continuous 135.00)

30354-05

**

6 Pipe End Weldment (Continuous 117.00)

30354-06

**

7 Screw HHC 3/8 -16NC x 1-1/2

15673

See tbl VII

**

8 CM DURT

TRACKER

Torsion Base

9 Cable Lanyard

**

10 Adapter Blade Holder

See tbl VIII

**

11 Blade

See tbl VIII

**

12 Washer Flat 5/8 SS

17154

**

13 Nut Stop/Jam 5/8 -11NC

24242

**

14 Arm RSV Weldment

35402

**

15 End Stop Plug

30386

16 DURT

TRACKER

Mainframe

34424-XX*

17 DURT

TRACKER

Split-Track

34423-XX**

18 Nut Jam 1/2 -13NC

16889

19 Screw HHC 1/2 -13NC x 1-1/4

13835

20 Bolt Carriage 1/2 -13NC x 3

21239

**

21 Lockwasher Int/Ext Tooth 1/2

21569

**

22 Nut Elastic Lock 1/2 -13NC SS

24307

**

23 Nut Elastic Lock 1/2-13NC

18577

**

24 Washer Flat 1/2

17328

**

23395

See fig. 15 Conveyor Products Warning Label

TRACKER

Figure 10. RSV DURT


Secondary Cleaner Assembly
with Snap-on Blade Holder Adapter, P/N 33139-XXSXXX*
*XX indicates belt width in inches; S indicates Snap-on Blade, last two X indicates color urethane blade/Torsion
Base (see table VIII).
**See table VII.

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Part Numbers

1
2
3
4
5
6

#46+0 0)+0''4+0) GFJJgEEfNF

24

 a *'8410f   a '.6 .'#0'45

0
0
0

30 (650-800)

36 (800-1000)

42 (1000-1200)
0

24 (500-650)

54 (1400-1600)

0
0
0
0
0

60 (1600-1800)

48 (1200-1400)

66 (1600-1800)

72 (1800-2000)

78 (1800-2000)

84 (2000-2200)

96 (2200-2400)

15

13

12

11

10

Qty Items
Qty
Qty
Qty
Qty
Qty
Qty
8,10,11,
Item 1 Item 2 Item 3 Item 4 Item 5 Item 6 12,13,14,
20,21,22

18 (400-500)

Belt Width
in. (mm)

100349-125

100349-113

100349-107

100349-101

100349-95

100349-89

100349-83

100349-77

100349-71

100349-65

100349-59

100349-53

100349-47

Part No.
Item 9

39 (991)

33 (838)

27 (686)

21 (533)

15 (381)

Length
Item 17
in. (mm)

90.5 (2299) 93 (2362)

78.5 (1994) 81 (2057)

72.5 (1842) 75 (1905)

66.5 (1689) 69 (1753)

60.5 (1537) 63 (1600)

54.5 (1385) 57 (1448)

48.5 (1232) 51 (1295)

42.5 (1080) 45 (1143)

36.5 (927)

30.5 (775)

24.5 (623)

18.5 (470)

12.5 (318)

Blade
Coverage
in. (mm)

14

12

12

10

10

10

Qty
Item
23, 24

Table VII. RSV DURT TRACKER Secondary Cleaner with Snap-on Blade Holder Adapter
Part Numbers and QuantitiesTable VII. RSV DURT TRACKER with Snap-on Blade Holder Adapter

Part Numbers

Assembly
Part No.*

VIII. Snap-on Type Blades and Part Numbers


Blade Type

Part No. Item


8

Part No.
Item 10

Part No.
Item 11

33139-XXSU

Urethane - Orange

31032-01

34711-GR1

32364-SS

33139-XXSUBR

Urethane - Brown

31032-01BR

34711-GR1

32364-BR

33139-XXSUGR Urethane - Green

31032-01GR

34711-GR1

32364-GR

33139-XXSSXX

Stainless Steel

**

34711-GR

30340

33139-XXSTXX

Tungsten Carbide

**

34711-GR

30337

33139-XXSAXX

Abrasion Resistant

**

34711-GR

30339-AR

33139-XXSHXX

Heat Treated

**

34711-GR

30339-HT

*First two X indicates belt width in inches, S indicates Snap-on Blade, next character indicates Blade Type,
last two X indicates color Urethane Blade/ Torsion Base.
** Can be used in combination with any color Urethane Torsion Base.

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 a *'8410f   a '.6 .'#0'45

Part Numbers

.Table

ADVERTENCIA

WARNING

Lock out and/or tag out all energy sources to


conveyor system and loading system before
performing any work on conveyor or conveyor
accessories. Failure to do so could result in
severe injury or death.
Cierre y/o rotule todas las fuentes de energa al
sistema transportador y al sistema de carga antes
de realizar cualquier trabajo en el transportador
o sus accesorios. El no hacerlo puede resultar
en heridas serias o muerte.
Label P/N 23395

Figure 11. Conveyor Products Warning Label

#46+0 0)+0''4+0) GFJJgEEfNF

26

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Appendix

Appendix A
Typical Chevron Belt Cleaner Installations

#46+0 0)+0''4+0) GFJJgEEfNF

A-1

 a *'8410f '.6 .'#0'45

Appendix

DURT TRACKER Chevron Belt Cleaner with Twist Tensioner


Mounted on L-Bracket with CYA Door
6.0
(152)

6.0
(152)

4.5
(114)

1 (25)
min.

4.5
(114)
90

Far Side Mount


(same bolt hole pattern
for Twist Tensioner)
5.5 .12
(140 3)

4.50
(114)

7.5
(190)

7.88
(200)

4.50
(114)

16.5 (419)

C
8.94
(227)
A.
B.
C.
D.
E.

Chevron Blade, P/N 32262 (Urethane) or 32757 (Rubber)


L-Bracket, P/N 33706
Twist Tensioner Assembly with Adjustable L-Bracket, P/N 31443-L
18 x 24-in. CYA Inspection Door, P/N 27658-1824
DURT TRACKER Chevron Belt Cleaner Assembly, P/N 32266-XXXXXX

A
C

#46+0 0)+0''4+0) GFJJgEEfNF

A-2

 a *'8410f '.6 .'#0'45

A. Fabricated Z-Mount, P/N 31158


B. Chevron Blade, P/N 32262 (Urethane)
or 32757 (Rubber)
C. 9 x 12-in. CYA Inspection Door, P/N 27658-0912
D. DURT TRACKER Chevron In-Line
Assembly, P/N 33705-XXX
E. Reversing Mount Tensioner Assembly
for Top or Bottom, P/N 33599

1 (25)
min.

9.00 (230)
.12 (3)
4.50 (114)

7.38 (187)

3.00
(76)
6.00
(152)

.63 (16)

6.00
(152)

E
B
D

#46+0 0)+0''4+0) GFJJgEEfNF

A-3

 a *'8410f '.6 .'#0'45

Appendix

DURT TRACKER Chevron In-Line Belt Cleaner with Reversing Spring


Tensioner Mounted on L-Bracket with CYA Door

Appendix

DURT TRACKER Chevron Belt Cleaner with Spring


Tensioner and Hanger Mount

10 (254)
16.5
(419)

8.25 (210)
3 (76)

4.5
(114)

2.62
(67)
1 (25)
min.

6.5
(165)
6.0
(152)

6.0
(152)

4.5
(114)

B
7.5
(190)
16.5 (419)

4.5
(114)
Far Side Mount
(same bolt hole pattern
for Twist Tensioner)

A. Hanger Mount Assembly, P/N 27382


B. Spring Tensioner, P/N 30691-SM
C. DURT TRACKER Chevron Belt Cleaner
Assembly, P/N 32266-XXXXXX
D. Chevron Blade, P/N 32262
(Urethane) or 32757 (Rubber)
D

#46+0 0)+0''4+0) GFJJgEEfNF

A-4

 a *'8410f '.6 .'#0'45

Typical RSV DURT TRACKER Secondary Belt Cleaner Installations

#46+0 0)+0''4+0) GFJJgEEfNF

B-1

 a *'8410f '.6 .'#0'45

Appendix

Appendix B

Appendix

RSV DURT TRACKER Secondary Cleaner


With Twist Tensioner and Flange Bracket

1.00 (25)
min
5.50
(140)

A. Twist Tensioner, P/N 31443


B. RSV DURT TRACKER Secondary Mainframe
Assembly, P/N 33139-XXXXXX
C. Flange Bracket, P/N 30537
D. 12 x 14-in. CYA Door, P/N 27658-1214

7.50
(191)
14.50
(368)

D
6.00
(152)
16.50
(419)

13.62
(346)

5.50
(140)

Cleaner
mainframe
position

4.50
(114)
.75
(19)
3.25
(83)

5.50
(140)

4.50
(114)

3.25
(83)

6.00
(152)

3.25 (83)

#46+0 0)+0''4+0) GFJJgEEfNF

B-2

 a *'8410f '.6 .'#0'45

Conveyor Stringer

6.0
(152)
1.0
(25)
6.0
(152)

4.5
(114)

5.5 to 12.5 adj.


(140 to 318 adj.)

5.5 .12
(140 3)
4.5
(114)
Far Side Mount
(same bolt hole pattern
for Twist Tensioner)

A
B

C
10.0
(254)
6.5
(165)

A. RSV DURT TRACKER Secondary Mainframe


Assembly, P/N 33139-XXXXXX
B. Twist Tensioner Assembly, P/N 31443
C. Hanger Mount Assembly, P/N 27382-2R

.88
(22)

3.5
(89)
9.1
(232)

Conveyor Stringer
7.63
(194)

3.0
(76)

1.6
(41)

A
3.25
(83)

#46+0 0)+0''4+0) GFJJgEEfNF

B-3

 a *'8410f '.6 .'#0'45

Appendix

RSV DURT TRACKER Secondary With Twist Tensioner and Hanger Mount

1RWHV

Form No. M3266-11/02

One Martin Place


Neponset, IL 61345-9766 USA
Phone: 309-594-2384 or 800-544-2947
FAX: 309-594-2432
www.martin-eng.com
MARTIN ENGINEERING 1998, 2002

MARTIN QC #1
Heavy-Duty Belt Cleaners

We Make Your Bulk Materials Handling


Cleaner, Safer and More Productive
Through Personalized Performance.

with MARTIN TWIST and


Internal Spring Tensioners
Go to MARTIN QC #1 Heavy-Duty Belt Cleaners web page

Form No. M3618-01/07


MARTIN ENGINEERING COMPANY 1998, 2007

One Martin Place


Neponset, IL 61345-9766 USA
800-544-2947 or 309-594-2384
FAX: 309-594-2432
www.martin-eng.com

Operators Manual
M3618

11.1-15A

Important
MARTIN ENGINEERING HEREBY DISCLAIMS ANY LIABILITY FOR: DAMAGE DUE TO
CONTAMINATION OF THE MATERIAL; USERS FAILURE TO INSPECT, MAINTAIN AND TAKE
REASONABLE CARE OF THE EQUIPMENT; INJURIES OR DAMAGE RESULTING FROM USE OR
APPLICATION OF THIS PRODUCT CONTRARY TO INSTRUCTIONS AND SPECIFICATIONS
CONTAINED HEREIN. MARTIN ENGINEERINGS LIABILITY SHALL BE LIMITED TO REPAIR
OR REPLACEMENT OF EQUIPMENT SHOWN TO BE DEFECTIVE.
Observe all safety rules given herein along with owner and Government standards and regulations. Know
and understand lockout/tagout procedures as defined by American National Standards Institute (ANSI)
z244.1-1982, American National Standard for Personnel Protection - Lockout/Tagout of Energy Sources Minimum Safety Requirements and Occupational Safety and Health Administration (OSHA) Federal
Register, Part IV, 29 CFR Part 1910, Control of Hazardous Energy Source (Lockout/Tagout); Final Rule.
The following symbols may be used in this manual:

DANGER

Danger: Immediate hazards that will result in severe personal injury or death.

WARNING

Warning: Hazards or unsafe practices that could result in personal injury.

CAUTION

Caution: Hazards or unsafe practices that could result in product or property damages.

IMPORTANT
Important: Instructions that must be followed to ensure proper installation/operation of equipment.

NOTE
Note: General statements to assist the reader.

Section

Page

List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installations without chutework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt cleaner inspection access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt cleaner blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MARTIN High-Performance Urethanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Materials required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Before Installing Belt Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Installing Belt Cleaner and Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Finding center point of belt cleaner mainframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing MARTIN QC #1 Belt Cleaner and MARTIN TWIST Tensioner . . . . . . . . . . . . .
Installing MARTIN QC #1 Belt Cleaner and MARTIN Internal Spring Tensioner . . . . . . . .

ii
ii
1
1
1
1
1
1
2
2
2

3
4
4
5
5
6
6

After Installing Belt Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12


Weekly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting/Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Appendix A. MARTIN QC #1 Heavy-Duty Belt Cleaner Assembly with
MARTIN TWIST Dual Tensioner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Martin Engineering M3618-01/07

MARTIN QC #1 Heavy-Duty Belt Cleaners

Table of contents

Table of Contents

List of Figures/Tables

List of Figures
Figure
1
2
3
4
5
6
7
8
9
10

Title

Page

Belt Cleaner Mainframe Location (Heavy-Duty, P/N 36898-XXXXXXXXX) . . . 4


Removing Blade (Heavy-Duty Blade shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Belt Cleaner Mainframe Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removing Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Tensioner Mounting Plate Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cutting Belt Cleaner Mainframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
MARTIN Internal Spring Tensioner Label, P/N 36185. . . . . . . . . . . . . . . . . . . . . 10
MARTIN TWIST Tensioner Label, P/N 33383 . . . . . . . . . . . . . . . . . . . . . . . . . 11
MARTIN QC #1 Heavy-Duty Pre-Cleaner Assembly with MARTIN TWIST
Tensioner, P/N 36898-XXXXXXXXT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
MARTIN QC #1 Heavy-Duty Pre-Cleaner Assembly with MARTIN Internal
Spring Tensioner, P/N 36898-XXXXXXXXI . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

11

MARTIN QC #1 Heavy-Duty Pre-Cleaner Assembly Less Pipe End Weldments,

12

P/N 36899-XXXXXXXX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
MARTIN Conveyor Products Warning Label, P/N 23395 . . . . . . . . . . . . . . . . . . 24

List of Tables
Table

Title

Page

MARTIN QC #1 Belt Cleaner Blade Colors, Materials and Specifications . . . . . 2

II

Urethane Shelf Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

III

Part Numbers and Dimensions for MARTIN QC #1 Heavy-Duty Belt Cleaner


Assembly with MARTIN TWIST Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . 19

IV

Part Numbers and Dimensions for MARTIN QC #1 Heavy-Duty Belt Cleaner


Assembly with MARTIN Internal Spring Tensioner . . . . . . . . . . . . . . . . . . . . . . 21

Part Numbers and Dimensions for MARTIN QC #1 Heavy-Duty Pre-Cleaner less


Pipe End Weldments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Martin Engineering M3618-01/07

ii

MARTIN QC #1 Heavy-Duty Belt Cleaners

General

The MARTIN QC #1 Belt Cleaner combines effective removal of


carryback with quick-change one-pin replacement of a long-lasting, onepiece blade. To introduce product back into the product flow, the MARTIN
QC #1 Belt Cleaner is installed on the face of the head pulley. On a dualcleaner system, the Secondary Cleaner is installed immediately following the
Pre-Cleaner to remove stubborn material left on the conveyor belt. If a PreCleaner cannot be used because of space limitations, the Secondary Cleaner is
installed alone. If the material-handling process or product could be affected
by contamination from the use of these belt cleaners, the user is responsible
for taking the necessary steps to prevent contamination. Consult Martin
Engineering or a representative for alternate belt cleaners or belt cleaner
locations to use where contamination may be an issue.
MARTIN QC #1 Belt Cleaner Blades are manufactured under patent
4,917,231. Another patent that applies to products listed in this manual is:
MARTIN TWIST Tensioner patent 4,925,434. MARTIN QC #1
Blades are available in Heavy-Duty and Extra Heavy-Duty (XHD). For
information on the MARTIN QC #1 XHD Belt Cleaner and Tensioner, see
operators manual P/N M3504.

Installations
without chutework

These procedures were written for equipment that is being installed on


enclosed pulley chutework. If the pulley is not enclosed, the equipment
should be installed using the best available field resources and methods to
ensure that the critical dimensions are followed for proper installation.
The MARTIN Hanger Mount Assembly, P/N 27382, can be used for
installations without chutework.

Belt cleaner
inspection access

If the belt cleaner is installed on enclosed pulley chutework, a MARTIN


CYA Inspection Door should be installed. MARTIN CYA Inspection
Doors are available from Martin Engineering or a representative. See Part
Numbers for a list of MARTIN CYA Inspection Doors and part numbers.

Belt cleaner blades

MARTIN QC #1 Heavy-Duty Belt Cleaner Blades are available in five


different materials (see Table I for specifications). Only standard (orange)
MARTIN QC #1 Belt Cleaner Blades are made of materials that meet
Mine Safety and Health Administration (MSHA) requirements under Interim
Fire and Toxicity Criteria for Products Taken Into Underground Mines,
March 22, 1977 (MSHA acceptance number MSHA-IC-95/1,
MSHA-IC-95/7).

MARTIN HighPerformance
Urethanes

Martin Engineering is the leader in the development of high-performance


urethanes for specialized applications. These color-coded urethanes can be
supplied in blades for any MARTIN Pre-Cleaner, as well as pre-cleaners
from other manufacturers.
To specify high-performance urethane, add the appropriate suffix to the part
number of the cleaner assembly or replacement blade.

Martin Engineering M3618-01/07

MARTIN QC #1 Heavy-Duty Belt Cleaners

Introduction

Introduction

Introduction

Table I. MARTIN QC #1 Belt Cleaner Blade Colors, Materials and Specifications


URETHANE
APPLICATION DESCRIPTION
SELECTION

TYPICAL
MATERIALS

Standard MARTIN Urethane


Suitable for 80% or more of all belt cleaner
applications, including abrasive conditions.

Brown
(BR)

Limestone

-40 to 160F
(-40 to 71C)

Clinker

-40 to 300F
(-40 to 149C)

Gravel,
Dry Sand

-20 to 160F
(-29 to 71C)
-20 to 160F
(-29 to 71C)

High-Temperature Urethane
For exposure to intermittent temperatures up
to 350F (177C).

Clear
(CL)

-20 to 160F
(-29 to 71C)

Chemical-Resistant Urethane
Improves resistance to chemicals; reduced
absorption of water in high-moisture environments.

Green
(GR)

Bauxite, Coke,
Coal, Overburden Refuse

Cement, Glass,
Wood Chips

Orange

CONTINUOUS
TEMPERATURE

Low-Rigidity Urethane
For dry products such as sand and gravel.

Navy Blue
(NB)

Low-Adhesion Urethane
For sticky or tacky materials.

References

The following documents are referenced in this manual:


American National Standards Institute (ANSI) z244.1-1982, American
National Standard for Personnel Protection - Lockout/Tagout of Energy
Sources - Minimum Safety Requirements, American National Standards
Institute, Inc., 1430 Broadway, New York, NY 10018.
Federal Register, Volume 54, Number 169, Part IV, 29 CFR Part 1910,
Control of Hazardous Energy Source (Lockout/Tagout); Final Rule,
Department of Labor, Occupational Safety and Health Administration
(OSHA), 32nd Floor, Room 3244, 230 South Dearborn Street, Chicago,
IL 60604.
MARTIN CYA Inspection Door Operators Manual, P/N M3127.
MARTIN Tensioners Operators Manuals:
MARTIN TWIST Tensioner Operator Manual, P/N M3296
MARTIN Internal Spring Tensioner Operator Manual, P/N M3517
MARTIN Spring, Air and Water Tensioners Operator Manual,
P/N M3263

Safety

All safety rules defined in the above documents, and all owner/employer
safety rules, must be strictly followed when working on the belt cleaner.

Materials required

Only standard hand tools are required to install and service this equipment.

Martin Engineering M3618-01/07

MARTIN QC #1 Heavy-Duty Belt Cleaners

IMPORTANT
The delivery service is responsible for damage occurring in
transit. Martin Engineering CANNOT enter claims for
damages. Contact your transportation agent for more
information.
1. Inspect shipping container for damage. Report damage to delivery service
immediately and fill out delivery services claim form. Keep any
damaged goods subject to examination.
2. Remove belt cleaner from shipping container. Equipment in container
should include the following:
MARTIN QC #1 Belt Cleaner (mainframe and blade).
Two Conveyor Products Warning Labels, P/N 23395.
3. If anything is missing or damaged, contact Martin Engineering or a
representative.
!

WARNING

Before installing equipment, turn off and lock out/tag out


energy source to conveyor and conveyor accessories.
4. Turn off and lock out/tag out energy source to conveyor belt and
accessories according to ANSI standards (see References).
!

WARNING

If equipment will be installed in an enclosed area, test gas level


or dust content before using a cutting torch or welding. Using
a cutting torch or welding in an area with gas or dust may
cause an explosion.
5. If using a cutting torch or welding, test atmosphere for gas level or
dust content.

NOTE
The chute wall that the tensioner will be located on is referred
to as the operator side. The other side of the chute wall is
referred to as the far side.
6. Determine which side of chute wall is easiest to access. Locate tensioner
on most accessible chute wall.

Martin Engineering M3618-01/07

MARTIN QC #1 Heavy-Duty Belt Cleaners

Before Installation

Before Installing Belt Cleaner

Installation

Installing Belt Cleaner and Tensioner


IMPORTANT
Read entire section before beginning work.
To install the belt cleaner and tensioner, follow the procedures in this section
corresponding to the following steps:
1.
2.
3.
4.
5.

Finding center
point of belt
cleaner
mainframe

Find center point of belt cleaner mainframe.


Install mounting plates.
Remove blade from mainframe.
Install mainframe and tensioner.
Install blade.

1. On operator side of chute, find pulley center point (A).


2. Measure radius of head pulley including lagging and belt thickness (B).
To this dimension, add dimension X from the Table in Figure 1 or 2.

Pulley Diameter*
in. (mm)

X Dimension
in. (mm)

12 to 15 (300 to 375) 4.0 (102)


A

16 (400) and up

3.50 (89)

*Includes lagging and belt.


8.50
(216)
min.
A. Center point of pulley

B. Radius of head pulley


including lagging and belt
C. Center point of belt
cleaner mainframe

Figure 1. Belt Cleaner Mainframe Location (Heavy-Duty, P/N 36898-XXXXXXXXX)


3. Starting from center point (A), measure the total distance calculated in
step 2 (B + X) and draw an arc on chute wall.
4. Measure down from pulley's horizontal centerline the distance shown in
Figure 1 or 2 and draw a horizontal line parallel to it. Locate center point
of belt cleaner mainframe (C) where this line intersects the arc on the
chute wall.

Martin Engineering M3618-01/07

MARTIN QC #1 Heavy-Duty Belt Cleaners

NOTE
Tensioner may be bolted or welded to chute wall. Martin
Engineering recommends bolting for ease of maintenance and
accessibility.
8. Install each mounting plate onto chute wall with four screws, flat
washers, compression washers and nuts.
9. If using MARTIN CYA Inspection Door, install according to
MARTIN CYA Inspection Door Operator's Manual, P/N M3127.

Removing blade

1. Remove lock pin from operator side of mainframe and blade.


2. Pull blade away from stationary pin on far side of mainframe, and remove
from mainframe. Make sure lock pin remains attached to mainframe.

Operator side
Stationary pin
Blade
Mainframe

Far side

Lock pin

Figure 2. Removing Blade (Heavy-Duty Blade shown)

Installing blade

Martin Engineering M3618-01/07

1. Position blade (Figure 2) on mainframe with blade curve facing conveyor


belt. Push far side end of blade against stationary pin until it locks.
2. Insert lock pin in mainframe and blade.

MARTIN QC #1 Heavy-Duty Belt Cleaners

Installation

5. Make sure mainframe and blade do not lie in path of material unloading
from conveyor belt. Make sure blade tip of MARTIN QC #1 Belt
Cleaner is at or below pulley's horizontal centerline.
6. Repeat steps 1 through 5 for far side chute wall.
7. Drill or cut one 4-5/8-in. (118-mm) hole for mainframe and four 9/16-in.
(14-mm) holes for screws in both operator side and far side chute walls.
Remove burrs and sharp edges.

Installation

Installing
MARTIN QC
#1 Belt Cleaner
and MARTIN
TWIST
Tensioner

1. Slide locking collar and washer onto far side end of belt cleaner
mainframe. Insert far side end of mainframe through nylon bushing in
flange plate weldment. Slide locking collar onto far side end of
mainframe.
2. Slide self-relieving coupling onto operator side end of mainframe.
3. Insert operator side of mainframe into UHMW bushing in base weldment.
4. Slide self-relieving coupling against locking gear and twist until the two
coupling halves engage. Adjust mainframe to center blades on belt.
5. Bolt or weld self-relieving coupling to mainframe as follows:
a. If bolting, tighten three square head set screws on self-relieving
coupling.
b. If welding, do the following:
(1) Mark location of self-relieving coupling on mainframe.
(2) Remove operator side end of mainframe from base weldment.
(3) Weld self-relieving coupling to mainframe with three 1-in.
(25-mm) fillet welds evenly spaced around end of self-relieving
coupling.
(4) Repeat steps 3 and 4 above (beginning with Insert operator
side).
6. Make sure blades are centered on belt and mainframe is parallel to belt.
7. Slide locking collar against washer and locking collar against nylon
bushing. Tighten two square head set screws on each locking collar.
8. Turn tensioning gear until you feel resistance of blades against belt. Refer
to MARTIN TWIST Tensioner Operators Manual, P/N M3296 for
installation and tensioning instructions or MARTIN TWIST Tensioner
Label, P/N 33383 on tensioner.

Installing
MARTIN QC
#1 Belt Cleaner
and Internal
Spring Tensioner

1. Mark center point of belt cleaner mainframe on chute wall. (See Figure 3
below.)

Pulley Diameter*
in. (mm)
X
A

X Dimension
in. (mm)

12 - 15 (300 - 375)
16 (400 and up)

4.0 (102)
3.50 (89)

*Includes lagging and belt.


8-1/4
(210)
min.

A. Center point of pulley


B. Radius of head pulley
including lagging and belt
C. Center point of belt
cleaner mainframe

Figure 3. Belt Cleaner Mainframe Location


Martin Engineering M3618-01/07

MARTIN QC #1 Heavy-Duty Belt Cleaners

Blade
Far side
Lock pin
Mainframe

Operator side
Stationary pin

Figure 4. Removing Blade

Martin Engineering M3618-01/07

MARTIN QC #1 Heavy-Duty Belt Cleaners

Installation

2. Make sure mainframe and blade do not lie in path of material unloading
from conveyor belt. Blade tip must be at or below pulleys horizontal
centerline.
3. Remove blade from mainframe:
a. Remove lock pin from operator side of mainframe and blade. (See
Figure 4 below.)
b. Pull blade away from stationary pin on far side of mainframe and
remove from mainframe. Make sure lock pin is secured to mainframe
with cable.

Installation

4. Using mounting plate as template, mark location of holes for belt cleaner
mounting plates on both sides of chute as shown in Figure 5 below.

C
L
4.50
(114)
4.50
(114)
Center point
of mainframe

Figure 5. Tensioner Mounting Plate Location

NOTE
Tensioner may be bolted or welded to chute wall. Martin
Engineering recommends bolting for ease of maintenance and
accessibility.

5. Repeat steps 1 through 4 for far side chute wall.


6. Drill or cut one 4-5/8-in. (118-mm) hole for mainframe and four
9/16-in. (14-mm) holes for screws in both operator side and far side chute
walls (see Figure 6). Remove burrs and sharp edges.

Martin Engineering M3618-01/07

MARTIN QC #1 Heavy-Duty Belt Cleaners

Installation
X

1-1/2 in. (38.1 mm)

X + 1-1/2 in. (38.1 mm)

Figure 6. Cutting Belt Cleaner Mainframe


7. Install each mounting plate onto wall with four screws, flat washers,
compression washers and nuts.

8. Check mainframe location:


a. Insert mainframe into mounting plates.
9. Install blade:
a. Position blade on mainframe with blade curve facing conveyor belt.
Push far side end of blade against stationary pin until it locks.
b. Insert lock pin into mainframe and blade.

Martin Engineering M3618-01/07

MARTIN QC #1 Heavy-Duty Belt Cleaners

Installation

10. If mainframe is too long to fit inside of chute for installation, cut one or
both ends of mainframe. Mainframe must fit inside housing of tensioner
on operator side of chute wall. (See Figure 6.)
11. Install blade:
a. Position blade on mainframe with blade curve facing conveyor belt.
Push far side end of blade against stationary pin until it locks.
b. Insert lock pin into mainframe and blade.

Figure 7. MARTIN Internal Spring Tensioner Label, P/N 36185

Martin Engineering M3618-01/07

10

MARTIN QC #1 Heavy-Duty Belt Cleaners

Installation
Figure 8. MARTIN TWIST Tensioner Label, P/N 33383

Martin Engineering M3618-01/07

11

MARTIN QC #1 Heavy-Duty Belt Cleaners

After Installation

After Installing Belt Cleaner


IMPORTANT
Read entire section before beginning work.
1. Thoroughly wipe chute walls clean above belt cleaner on both sides.
Place Conveyor Products Warning Label, P/N 23395 on outside chute
walls visible to belt cleaner operator.
2. Measure from pulley shaft to mainframe on both operator side and far
side to make sure mainframe is parallel to pulley.
3. Measure from center point of mainframe to face of conveyor belt to make
sure the proper dimension is held (see table in Figure 1).
4. Measure from center point of pulley to each end of blade to make sure
blade is centered on belt.
!

WARNING

Failure to remove tools from installation area and conveyor


belt before turning on energy source can cause serious injury
to personnel and damage to belt.
5. Remove all tools and fire retardant cover from installation area and
conveyor belt.
!

DANGER

Do not touch or go near conveyor belt or conveyor accessories


when conveyor belt is running. Body or clothing can get
caught and pull body into conveyor belt, causing severe injury
or death.
6. Turn on conveyor belt for 1 hour.
!

WARNING

Before adjusting belt cleaner, turn off and lock out/tag out
energy source to conveyor belt and conveyor accessories
according to ANSI standards (see References).
7. After 1 hour of operation, turn off power to conveyor belt and accessories.
8. Make sure all fasteners are tight. Tighten if necessary.
9. Inspect belt cleaner for the following:
Wear. (A small amount of break-in wear may be found. This will
stop once blade wears to conveyor belt contour.)
Material buildup. (No material between blade and return side of
conveyor belt should be found.)
10. If wear or material buildup exists, see Troubleshooting/Installation
Checklist.

Martin Engineering M3618-01/07

12

MARTIN QC #1 Heavy-Duty Belt Cleaners

NOTE
Maintenance inspection should be performed no less than
weekly. Your application may require more frequent
maintenance inspections.

IMPORTANT
Read entire section before beginning work.
!

WARNING

Before servicing belt cleaner, turn off and lock out/tag out
energy source to conveyor belt and conveyor accessories.
1. Turn off and lock out/tag out energy source according to ANSI standards
(see References).
2. Remove any material from belt cleaner.
3. Make sure all fasteners are tight. Tighten if necessary.
4. Check blade for damage, missing parts or excessive wear. If blade is worn
to wear line, replace as follows:
a. Release tension on mainframe.
b. Remove blade as instructed under Removing blade.
c. Install new blade as instructed under Installing blade.
d. Apply tension to belt cleaner according to applicable tensioner
operators manual.
5. Remove equipment from service if there is any indication it is not
functioning properly. Call Martin Engineering or a representative for
assistance. Do NOT return equipment to operation until the cause of the
problem has been identified and corrected.
6. Wipe all warning labels clean. If labels are not readable, contact Martin
Engineering or a representative for replacements.
!

WARNING

Failure to remove tools from maintenance area and conveyor


belt before turning on energy source can cause serious injury
to personnel and damage to belt.
7. Remove all tools from maintenance area.
!

DANGER

Do not touch or go near conveyor belt or conveyor accessories


when conveyor belt is running. Body or clothing can get
caught and pull body into conveyor belt, causing severe injury
or death.
8. Start conveyor belt.

Martin Engineering M3618-01/07

13

MARTIN QC #1 Heavy-Duty Belt Cleaners

Weekly Maintenance

Weekly Maintenance

Weekly Maintenance

Table II. Urethane Shelf Life


Blade Color

Shelf Life

Blue

1 Year from Code Date

Brown

2 Years from Code Date

Clear

1 Year from Code Date

Green

2 Years from Code Date

Maximizer (orange) 1 Year from Code Date


Orange (A-9)

1 Year from Code Date

NOTE
Code Date is written near bottom of blade as mm/dd/yy-x. In
addition to or in place of this date, you may see an imprinted
date medallion similar to the example shown below. In this
example, 07 stands for the year 2007. The small circles
represent the months of the year and are punched to
indicate what month your blade was produced. In the example
below, the lines in the circles represent the punches and in
this example seven circles are punched. This signifies the
seventh monthJuly. If code date on your blade(s) is not
legible or is missing, contact Martin Engineering or a
representative.

Date Medallion Example

Martin Engineering M3618-01/07

14

MARTIN QC #1 Heavy-Duty Belt Cleaners

Troubleshooting

If you are experiencing excessive blade wear or insufficient cleaning and


carryback, see below.

Symptom

Corrective Action

High blade wear rate.

Tension is set too high. Reduce tension.

Unusual wear or damage to


blades.

Check belt splice(s) and repair as necessary.

Bent or broken mainframe or If blades are worn to or past the wear line, replace blades. If blades are not
support frame due to blade worn, check mainframe location.
slipping through.
Noise or vibration.

Tension is not sufficient or is set too high. Correct tension as necessary. If


this does not correct problem, blade urethane may not match application.
Contact Martin Engineering or a representative.

Corrosion or chemical
degradation.

Blade urethane may not match application. Contact Martin Engineering or a


representative.

Too much blade coverage.

Use 6 less blade.

Insufficient cleaning and


carryback.

Tension is set too low or too high. Increase or decrease tension. Cleaner is
mounted too high on head pulley and is in path of material flow. Lower
cleaner. Check blades for excessive wear and replace if necessary.

NOTE
Conveyor equipment such as conveyor belt cleaners are
subject to a wide variety of bulk materials characteristics and
often have to perform under extreme operating or
environmental conditions. It is not possible to predict all
circumstances that may require troubleshooting. Contact
Martin Engineering or a representative if you are
experiencing problems other than those listed in the
Troubleshooting chart above. Do not return the equipment
to operation until the problem has been identified and
corrected.

Installation
checklist

If after taking the corrective actions suggested under Troubleshooting you


are still experiencing problems, check for the following:

Installation Checklist
Correct distance is maintained from center of belt cleaner mainframe to belt surface on both ends of
mainframe according to table in Figure 1.
Belt cleaner blade tip is at or below horizontal centerline of pulley and does not lie in path of material
flow.
Blade is centered on belt.
Martin Engineering M3618-01/07

15

MARTIN QC #1 Heavy-Duty Belt Cleaners

Troubleshooting/Installation Checklist

Troubleshooting/Installation Checklist

Part Numbers

Part Numbers
This section provides product names and corresponding part numbers for
MARTIN QC #1 Belt Cleaners and related equipment. Please reference
part numbers when ordering parts:

MARTIN QC
#1 Belt Cleaners

MARTIN QC #1 Heavy-Duty Belt Cleaner Mainframe Assembly with


MARTIN TWIST Tensioner: P/N 36898-XXXXXXXXT.
See Figure 9.
MARTIN QC #1 Heavy-Duty Belt Cleaner Mainframe Assembly with
Internal Spring Tensioner: P/N 36898-XXXXXXXXI. See Figure 10.
MARTIN QC #1 Heavy-Duty Belt Cleaner Assembly less Pipe End
Weldments: P/N 36899-XXXXXXXX. See Figure 11.
XHD MARTIN QC #1 Assembly (blade 6 in. less than belt width):
P/N 35899-XXXXXXX. See Operator's Manual P/N M3504.
XHD MARTIN QC #1 Assembly (blade 12 in. less than belt width):
P/N 35899-XXXXXXXXX. See Operator's Manual P/N M3504.

MARTIN QC
#1 Belt Cleaner
Tensioners

Belts 18 to 48 in. wide:


MARTIN TWIST Tensioner: P/N 31443.
MARTIN TWIST Tensioner with L Bracket: P/N 31443-L.
MARTIN Internal Spring Tensioner: P/N 36176
Belts 18 to 54 in. wide:
MARTIN Shock (Ring) Mount Air Tensioner: P/N 32745.
MARTIN Spring Tensioner With Shock Ring: P/N 33404-S.
Belts 54 to 96 in. wide:
MARTIN TWIST Dual Tensioners: P/N 31443-2R.
MARTIN TWIST Dual Tensioners with L Bracket:
P/N 31443-L2R.
MARTIN Dual Internal Spring Tensioner: P/N 36176-2
Belts 60 to 96 in. wide:
MARTIN Dual Shock Mount Air Tensioners: P/N 32745-2R.
MARTIN Dual Spring Tensioners With Shock Rings: P/N 33404-2S.

Operators
manuals

MARTIN Spring, Air, and Water Tensioners Operators Manual:


P/N M3263.
MARTIN TWIST Tensioner Operators Manual: P/N M3296.
MARTIN CYA Inspection Door Operators Manual: P/N M3127.
MARTIN QC #1 XHD Belt Cleaner and Tensioner Operators
Manual: P/N M3504.

Martin Engineering M3618-01/07

16

MARTIN QC #1 Heavy-Duty Belt Cleaners

With standard door, up to 155F (68C):


9 X 12 in. (229 X 305 mm): P/N 27658-0912.
12 X 14 in. (305 X 356 mm): P/N 27658-1214.
12 X 18 in. (305 X 457 mm): P/N 27658-1218.
18 X 24 in. (457 X 610 mm): P/N 27658-1824.
24 X 24 in. (610 X 610 mm): P/N 27658-2424.
With steel door:
9 X 12 in. (229 X 305 mm): P/N 34955-0912.
12 X 18 in. (305 X 457 mm): P/N 34955-1218.
18 X 24 in. (457 X 610 mm): P/N 34955-1824.
24 X 24 in. (610 X 610 mm): P/N 34955-2424.

Martin Engineering M3618-01/07

17

MARTIN QC #1 Heavy-Duty Belt Cleaners

Part Numbers

MARTIN CYA
Inspection Doors

Part Numbers

Dim. A

6
7

Dim. B

10.16
(258)

8.41
(214)

11.36
(289)

2.5 (64)

Figure 9. MARTIN QC #1 Heavy-Duty Belt Cleaner Assembly with


MARTIN TWIST Tensioner, P/N 36898-XXXXXXXXT
Item

Description

Part No.

Qty.

MARTIN QC #1 Mainframe Weldment

Table III

MARTIN

Table III

Pipe End Weldment

Table III

QC #1 Heavy-Duty Blade

MARTIN QC #1 Lock Pin Lanyard Assembly

34166

Pin Slotted Spring 5/16 x 2 ZP

32774

Nut Hex Jam 1/2 - 13 NC ZP

16889

Screw SHS 1/2 - 13NC x 1-1/2 SS

33190

38048

MARTIN

8*

Label

9*

Label Conveyor Products Warning

23395

10*

Manual Operators

M3618

11*

MARTIN

31443/31433-2R

Products

TWIST Tensioner Assembly

* Part not shown in drawing.

Martin Engineering M3618-01/07

18

MARTIN QC #1 Heavy-Duty Belt Cleaners

Weight
(lbs.) w/o
Tensioner

Standard Blade
Assy. Part No.

Dim. A

Dim. B

Item No.
1

Item No.
2

Item No. 3
One Each

36898-18XX12XXT

12(305)

44(1118)

36897-18

35381-18 XX 12

30354-01

30354-02

33.1

36898-18XX16XXT

16(406)

44(1118)

36897-18

35381-18 XX 16

30354-01

30354-02

35.2

36898-24XX18XXT

18(457)

50(1270)

36897-24

35381-24 XX 18

30354-02

30354-02

42.3

36898-24XX22XXT

22(559)

50(1270)

36897-24

35381-24 XX 22

30354-02

30354-02

44.4

36898-30XX24XXT

24(610)

62(1575)

36897-30

35381-30 XX 24

30354-02

30354-03

53.1

36898-30XX28XXT

28(711)

62(1575)

36897-30

35381-30 XX 28

30354-02

30354-03

55.2

36898-36XX30XXT

30(762)

68(1727)

36897-36

35381-36 XX 30

30354-02

30354-03

60.5

36898-36XX34XXT

34(864)

68(1727)

36897-36

35381-36 XX 34

30354-02

30354-03

62.6

36898-42XX36XXT

36(914)

74(1880)

36897-42

35381-42 XX 36

30354-02

30354-03

67.8

36898-42XX40XXT

40(1016)

74(1880)

36897-42

35381-42 XX 40

30354-02

30354-03

70.0

36898-48XX36XXT

36(914)

80(2032)

36897-42

35381-42 XX 36

30354-03

30354-03

71.3

36898-48XX42XXT

42(1067)

80(2032)

36897-48

35381-48 XX 42

30354-02

30354-03

75.2

36898-48XX46XXT

46(1168)

80(2032)

36897-48

35381-48 XX 46

30354-02

30354-03

77.3

36898-54XX48XXT

48(1219)

86(2184)

36897-54

35381-54 XX 48

30354-02

30354-03

82.5

36898-54XX52XXT

52(1321)

86(2184)

36897-54

35381-54 XX 52

30354-02

30354-03

84.6

36898-60XX54XXT

54(1372)

98(2489)

36897-60

35381-60 XX 54

30354-03

30354-03

93.3

36898-60XX58XXT

58(1473)

98(2489)

36897-60

35381-60 XX 58

30354-03

30354-03

95.5

36898-66XX60XXT

60(1524)

104(2642)

36897-66

35381-66 XX 60

30354-03

30354-03

100.7

36898-66XX64XXT

64(1626)

104(2642)

36897-66

35381-66 XX 64

30354-03

30354-03

102.8

36898-72XX66XXT

66(1676)

110(2794)

36897-72

35381-72 XX 66

30354-03

30354-03

108.1

36898-72XX70XXT

70(1778)

110(2794)

36897-72

35381-72 XX 70

30354-03

30354-03

110.1

36898-78XX72XXT

72(1829)

117(2972)

36897-78

35381-78 XX 72

30354-06

135.1

36898-78XX76XXT

76(1930)

117(2972)

36897-78

35381-78 XX 76

30354-06

137.2

36898-81XX81XXT

81(2057)

123(3124)

36897-81

35381-81 XX 81

30354-04

145.0

36898-84XX78XXT

78(1981)

123(3124)

36897-84

35381-84 XX 78

30354-04

144.2

36898-84XX82XXT

82(2083)

123(3124)

36897-84

35381-84 XX 82

30354-04

146.3

36898-96XX90XXT

90(2286)

135(3429)

36897-96

35381-96 XX 90

30354-05

162.6

36898-96XX94XXT

94(2388)

135(3429)

36897-96

35381-96 XX 94

30354-05

164.7

Notes:
All dimensions are given in inches (mm). All dimensions are for reference
only. The first XX indicates belt width. The third X indicates a blade with (0)
or without (1) slits. The next X indicates a blade with (0) or without (1)
segments. The next XX indicates blade color and the last X indicates if a
tensioner is included.

Martin Engineering M3618-01/07

19

MARTIN QC #1 Heavy-Duty Belt Cleaners

Part Numbers

Table III. Part Numbers and Dimensions for MARTIN QC #1 Heavy-Duty


Belt Cleaner Assembly with MARTIN TWIST Tensioner

Part Numbers

Dim. A

2
3

6
7
Dim. B

10.16
(258)

8.41
(214)

11.36
(289)

2.5 (64)

Figure 10. MARTIN QC #1 Heavy-Duty Belt Cleaner Assembly with


MARTIN Internal Spring Tensioner, P/N 36898-XXXXXXXXI
Item
1

Description

Part No.

MARTIN QC #1 Mainframe Weldment

Qty.

Table IV

MARTIN QC #1 Heavy-Duty Blade

Table IV

Mainframe End Tube

Table IV

MARTIN

34166

Pin Slotted Spring 5/16 x 2 ZP

32774

Nut Hex Jam 1/2 - 13 NC ZP

16889

Screw SHS 1/2 - 13NC x 1-1/2 SS

33190

QC #1 Lock Pin Lanyard Assembly

8*

Label MARTIN Products

38048

9*

Label Conveyor Products Warning

23395

10*

Manual Operators

M3618

11*

Internal Spring Tensioner Assembly

36176/36176-2

* Part not shown in drawing.

Martin Engineering M3618-01/07

20

MARTIN QC #1 Heavy-Duty Belt Cleaners

Item No.
2

Item No. 3
One Each

Weight
(lbs.) w/o
Tensioner

Standard Blade
Assy. Part No.

Dim. A

Dim. B

Item No.
1

36898-18XX12XXI

12(305)

44(118)

36897-18

35381-18

XX 12

36979-02

36979-02

30.1

36898-18XX16XXI

16(406)

44(1118)

36897-18

35381-18

XX 16

36979-02

36979-02

32.2

36898-24XX18XXI

18(457)

50 (1270)

36897-24

35381-24

XX 18

36979-02

36979-02

37.4

36898-24XX22XXI

22(559)

50 (1270)

36897-24

35381-24

XX 22

36979-02

36979-02

39.5

36898-30XX24XXI

24(610)

62 (1575)

36897-30

35381-30

XX 24

36979-02

36979-03

47.7

36898-30XX28XXI

30(762)

62 (1575)

36897-30

35381-30

XX 28

36979-02

36979-03

49.8

36898-36XX30XXI

30(762)

68 (727)

36897-36

35381-36

XX 30

36979-02

36979-03

55.1

36898-36XX34XXI

34(864)

68 (1727)

36897-36

35381-36

XX 34

36979-02

36979-03

57.2

36898-42XX36XXI

36(914)

74 (1880)

36897-42

35381-42

XX 36

36979-02

36979-03

62.4

36898-42XX40XXI

40(1016)

74 (1880)

36897-42

35381-42

XX 40

36979-02

36979-03

64.5

36898-48XX42XXI

42(1067)

80 (2032)

36897-48

35381-48

XX 42

36979-02

36979-03

69.8

36898-48XX46XXI

46(1168)

80 (2032)

36897-48

35381-48

XX 46

36979-02

36979-03

71.9

36898-54XX48XXI

48(1219)

86 (2184)

36897-54

35381-54

XX 48

36979-02

36979-03

77.2

36898-54XX52XXI

52(1321)

86 (2184)

36897-54

35381-54

XX 52

36979-02

36979-03

79.2

36898-60XX54XXI

54(1372)

98 (2489)

36897-60

35381-60

XX 54

36979-03

36979-03

87.4

36898-60XX58XXI

58(1473)

98 (2489)

36897-60

35381-60

XX 58

36979-03

36979-03

89.5

36898-66XX60XXI

60(1524) 104 (2642)

36897-66

35381-66

XX 60

36979-03

36979-03

94.8

36898-66XX64XXI

64(1626) 104 (2642)

36897-66

35381-66

XX 64

36979-03

36979-03

96.9

36898-72XX66XXI

66(1677)

110 (2794)

36897-72

35381-72

XX 66

36979-04

36979-04

105.1

36898-72XX70XXI

70(1880)

110 (2794)

36897-72

35381-72

XX 70

36979-04

36979-04

107.2

36898-78XX72XXI

72(1829)

117 (2972)

36897-78

35381-78

XX 72

36979-04

36979-04

112.4

36898-78XX76XXI

76(1930)

117 (2972)

36897-78

335381-78 XX 76

36979-04

36979-04

114.5

36898-84XX78XXI

78(1981) 123 (3124)

36897-84

35381-84

XX 78

36979-04

36979-04

119.8

36898-84XX82XXI

82(2083)

123(3124)

36897-84

35381-84

XX 82

36979-04

36979-04

121.9

36898-96XX90XXI

90(2286)

135(3429)

36897-96

35381-96

XX 90

36979-04

36979-04

134.5

36898-96XX94XXI

94(2388)

135(3429)

36897-96

35381-96

XX 94

36979-04

36979-04

136.6

Notes:
All dimensions are given in inches (mm). All dimensions are for reference
only. The first XX indicates belt width. The third X indicates a blade with (0)
or without (1) slits. The next X indicates a blade with (0) or without (1)
segments. The next XX indicates blade coverage and the last XX indicates
blade color.

Martin Engineering M3618-01/07

21

MARTIN QC #1 Heavy-Duty Belt Cleaners

Part Numbers

Table IV. Part Numbers and Dimensions for MARTIN QC #1 Heavy-Duty


Belt Cleaner Assembly with MARTIN Internal Spring Tensioner

Part Numbers

Dim. A
2
3

5
6
Dim. B

10.16
(258)

8.41
(214)

11.36
(289)

2.5 (64)

Figure 11. MARTIN QC #1 Heavy-Duty Belt Cleaner Assembly


Less Pipe End Weldments, P/N 36899-XXXXXXXX
Item

Description

Part No.

Qty

MARTIN

Table V

Table V

QC #1 Mainframe Weldment

MARTIN QC #1 Heavy-Duty Blade

MARTIN QC #1 Lock Pin Lanyard Assembly

34166

Pin Slotted Spring 5/16 x 2 ZP

32774

Nut Hex Jam 1/2 - 13 NC ZP

16889

Screw SHS 1/2 - 13NC x 1-1/2 SS

33190

38048

MARTIN

7*

Label

8*

Label Conveyor Products Warning

23395

9*

Manual Operators

M3618

Products

* Part not shown in drawing.

Martin Engineering M3618-01/07

22

MARTIN QC #1 Heavy-Duty Belt Cleaners

Part No.

Dim. A

Dim. B

Item No.1

Item No.2

Weight (lbs.)

36899-18XX12 XX

12(305)

16(406)

36897-18

35381-18 XX 12

18.2

36899-18XX16 XX

16(406)

16(406)

36897-18

35381-18 XX 16

20.3

36899-24XX18 XX

18(457)

22(559)

36897-24

35381-24 XX 18

25.6

36899-24XX22 XX

22(559)

22(559)

36897-24

35381-24 XX 22

27.7

36899-30XX24 XX

24(610)

28(711)

36897-30

35381-30 XX 24

32.9

36899-30XX28 XX

28(711)

28(711)

36897-30

35381-30 XX 28

35.0

36899-36XX30 XX

30(762)

34(864)

36897-36

35381-36 XX 30

40.3

36899-36XX34 XX

34(864)

34(864)

36897-36

35381-36 XX 34

42.4

36899-42XX36 XX

36(914)

40(1016)

36897-42

35381-42 XX 36

47.6

36899-42XX40 XX

40(1016)

40(1016)

36897-42

35381-42 XX 40

49.7

36899-48XX42 XX

42(1067)

46(1168)

36897-48

35381-48 XX 42

55.0

36899-48XX46 XX

46(1168)

46(1168)

36897-48

35381-48 XX 46

59.8

36899-54XX48 XX

48(1219)

52(1321)

36897-54

35381-54 XX 48

62.3

36899-54XX52 XX

52(1321)

52(1321)

36897-54

35381-54 XX 52

64.4

36899-60XX54 XX

54(1372)

58(1473)

36897-60

35381-60 XX 54

69.6

36899-60XX58 XX

58(1473)

58(1473)

36897-60

35381-60 XX 58

71.8

36899-66XX60 XX

60(1524)

64(1626)

36897-66

35381-66 XX 60

77.1

36899-66XX64 XX

64(1626)

64(1626)

36897-66

35381-66 XX 64

79.1

36899-72XX66 XX

66(1677)

70(1880)

36897-72

35381-72 XX 66

84.4

36899-72XX70 XX

70(1880)

70(1880)

36897-72

35381-72 XX 70

86.5

36899-78XX72 XX

72(1829)

76(1930)

36897-78

35381-78 XX 72

91.7

36899-78XX76 XX

76(1930)

76(1930)

36897-78

35381-78 XX 76

93.8

36899-84XX78 XX

78(1981)

82(2083)

36897-84

35381-84 XX 78

99.1

36899-84XX82 XX

82(2083)

82(2083)

36897-84

35381-84 XX 82

101.2

36899-96XX90 XX

90(2286)

94(2388)

36897-96

35381-96 XX 90

113.8

36899-96XX94 XX

94(2388)

94(2388)

36897-96

35381-96 XX 94

115.9

Notes:
All dimensions are given in inches (mm). All dimensions are for reference
only. The first XX indicates belt width. The third X indicates a blade with (0)
or without (1) slits. The next X indicates a blade with (0) or without (1)
segments. The next XX indicates blade coverage and the last XX indicates
blade color.

Martin Engineering M3618-01/07

23

MARTIN QC #1 Heavy-Duty Belt Cleaners

Part Numbers

Table V. Part Numbers and Dimensions for MARTIN QC #1 Heavy-Duty


Belt Cleaner Assembly Less Pipe End Weldments

Part Numbers

ADVERTENCIA
!

WARNING

Lock out and/or tag out all energy sources to


conveyor system and loading system before
performing any work on conveyor or conveyor
accessories. Failure to do so could result in
severe injury or death.
Cierre y/o rotule todas las fuentes de energa al
sistema transportador y al sistema de carga antes
de realizar cualquier trabajo en el transportador
o sus accesorios. El no hacerlo puede resultar
en heridas serias o muerte.
Label P/N 23395

Figure 12. MARTIN Conveyor Products Warning Label, P/N 23395

Martin Engineering M3618-01/07

24

MARTIN QC #1 Heavy-Duty Belt Cleaners

Appendix A

Pulley Diameter*
in. (mm)

Appendix A

MARTIN QC #1 Heavy-Duty Belt Cleaner Assembly with


MARTIN TWIST Dual Tensioner Assembly

X Dimension
in. (mm)

12 to 15 (300 to 375) 4.0 (102)


16 (400 and up)

3.50 (89)

*Includes lagging and belt.


7.50 (191)
A
6.00
(152)
4.5
(114)
A. MARTIN TWIST Dual Tensioner Assembly,
P/N 31443-2R
B. MARTIN QC #1 Heavy-Duty Belt Cleaner Assembly,
P/N 36898-XXXXXXXXX

4.625
(119)

4.5
(114)

0.625 (16)
Chute wall cutout detail

7.13
(181)

Martin Engineering M3618-01/07

A-1

MARTIN QC #1 Heavy-Duty Belt Cleaners

Notes

MARTIN QC #1
Heavy-Duty Belt Cleaners

We Make Your Bulk Materials Handling


Cleaner, Safer and More Productive
Through Personalized Performance.

with MARTIN TWIST and


Internal Spring Tensioners
Go to MARTIN QC #1 Heavy-Duty Belt Cleaners web page

Form No. M3618-01/07


MARTIN ENGINEERING COMPANY 1998, 2007

One Martin Place


Neponset, IL 61345-9766 USA
800-544-2947 or 309-594-2384
FAX: 309-594-2432
www.martin-eng.com

Operators Manual
M3618

INSTRUCTIONS

BULLETIN

808

SPEED SWITCHES
PRECAUTIONS IN PLUGGING APPLICATIONS - T h e r e a r e m a n y
advantages in plugging a motor to a stop, however, care must
be taken that these advantages are not lost through misapplications. The following information should be considered before
deciding to use a plugging control.
1.

When plugging a motor to a stop, full load motor current


may be greatly exceeded. The electrical supply must be
able to handle the excess load.

2.
Rear View of Speed Switch
Less Lockout Solenoid and
Mounting Bracket
NEMA Type 1, 4 and 13 Enclosure

Front View of Speed Switch


Less Lockout Solenoid and
Mounting Bracket
NEMA Type 1, 4 and 13 Enclosure

DESCRIPTION- The Bulletin 808 speed switch is a pilot device

which is used with an automatic starter arranged for reversing


or plugging duty to provide plugging orantiplugging of squirrel
cage motors. This device can also be used as a speed sensing
switch, or to indicate direction of rotation of a driven shaft.
Plugging is a control function that provides braking by
reversing the motor. The phase sequence is reversed so that
the motor develops a counter-torque that exerts a retarding
force. Antiplugging protection is the effect of a control device
that operates to prevent the application of counter-torque by
the motor until the motor speed has been reduced to an
acceptable value.

PLUGGING - When applied in a suitable plugging application


such as the circuit shown in Figure 1, the switch with normally
open contacts is used. The Bulletin 808 speed switch is
designed to automatically interrupt reverse braking power as
the motor approaches zero speed. The speed at which the
contacts operate can be adjusted so as to avoid coasting or
reverse rotation of the motor. The contacts can be wired for
plugging in either or both directions.

The resultant forces of a plugged stop may be too great for


the driven machine to withstand. For example, a twisted or
broken shaft may result.
.3. The motor may not withstand braking duty. The duty cycle
and load must be considered and the motor manufacturer
should be consulted to determine if a particular motor is
adequate for plugging duty.

NOTE: See applicable standards, codes, and laws for all


applications.

ANTIPLUGGING

- For this application, the switch with normally


closed contacts is used. The speed switch is designed to keep
the reverse circuit open until the speed of the driven machine
has decreased to a predetermined value. At this speed the
contacts are designed to close, permitting reverse energization
to be applied manually, or automatically when using a second
speed switch arranged for plugging duty. Mechanical braking
can also be used. The speed switch can be used for
antiplugging control in either or both directions. See Figure 2.
PRECAUTIONS IN ANTIPLUGGING APPLICATIONS - The speed switch
must be adjusted so that contact closure does not occur before
the speed of the machine is reduced to a safe level for
secondary braking.

TYPICAL ANTIPLUGGING CIRCUIT This circuit is used in cases


-

with a reversing starter to bring a motor to a fast stop.

where damage would result from a sudden reversal of power.


The speed switch contacts are designed to keep the reverse
circuit open until the motor has coasted to a preset speed.

NOTE: See applicable standards, codes, and laws for all

NOTE: See applicable standards, codes, and laws for all

TYPICAL PLUGGING CIRCUIT - Bulletin 808 speed switch used

applications.

applications.

L2

L1
Forward

Reverse

FIGURE 1

FIGURE 2

11.1-61-3A
Publication 808-5.1 - June, 1980
Supersedes Publication 8084.1 Dated July, 1978

COUPLING - Speed switch coupling must be positive to avoid

SPEED SENSING AND DIRECTION OF ROTATION - in these applications,

slippage. A direct flexible coupling is best. This type of coupling


also minimizes bearing wear on both the speed switch and the
driven shaft of the machine due to the unavoidable difficulties
of accurate alignment of separate shafts. Gears, chain, or
timing belt can be used successfully. A rigid coupling should
not be used. (See Table 1 for driving torque and maximum
speed specifications.)

the device with either normally open or normally closed contacts can be used depending upon the requirements of the circuit. For example, when connected to an alarm circuit, the
speed switch can be used to sense belt breakage. The speed
switch can also be used to sequence conveyors where it is
essential for one conveyor to be in motion or up to a preselected
speed before a second conveyor is started. See Figure 3. The
switch will also indicate thedirectional movement of a conveyor
by monitoring the rotation of a suitable driven shaft. See Figure 4.

PRECAUTIONS - It is important not to overload the shaft of the


speed switch or shortened bearing life may result. Radial loads
on the NEMA Type 1,4, 13 speed switch should not exceed 50
pounds and axial loads (thrust loads) should not exceed 20
pounds. Radial loads on the NEMA Type 7 & 9 speed switch
should not exceed 25 pounds and axial loads (thrust loads)
should not exceed 20 pounds.

PRECAUTIONS - The shaft of the speed switch should be driven

at the highest available speed within the maximum speed


specified in Table 1 below. The continuous driven speed should
be at least 2 times the speed at which the contacts are set to
operate. This will provide high contact force and reduce the
possibility of contact chatter and erratic operation of the
switch.

TYPICAL CONVEYOR SEQUENCING CIRCUIT - M2 starts automati-

In speed sensing or direction of motion applications, a timing


or V belt may be used. Proper belt tension must be maintained
to keep slippage at a minimum. The maximum belt tension must
not exceed 25 pounds.

NOTE: See applicable standards, codes, and laws for all

SPEED SWITCH WITH COVER REMOVED

cally when Ml comes up to speed.


applications.

Clockwise Shaft
Rotation
(Front View)

L1

Stop
Q-I-Q

Terminal
Adjustment

Rev.

Counterclockwise
Shaft Rotation

(Front View)

Screw

Terminal

Screw

Screw

FIGURE 3

TYPICAL DIRECTION OF ROTATION CIRCUIT


NOTE: See applicable standards, codes, and laws for all
applications.

Rear View
L1

L2

ADJUSTMENT The speed switch is easily adjusted by means of


-

two external adjusting screws - one for each set of contacts.


One screw controls clockwise rotation, the other counterclockwise. Use 5/3* hex wrench.
Prior to adjustment run the speed switch at operating speed
until the switch reaches its normal operating temperature.

FIGURE 4

TABLE 1 - S P E E D S W I T C H C H A R A C T E R I S T I C S
Styles with Normally Open Contacts
Styles with Normally Closed Contacts
Contact Operating Speed Range (RPM)

Maximum Shaft Ooeratina Soeed (RPM)


Maximum Driving Torque (Inch-Pounds)
Temperature Rise (Degrees F)

-80
1200
3.5
120

15e

PLUGGING - Turn adjusting screw(s) in or out to achieve


stopping at zero speed. Adjust both screws when circuit requires
switch to be wired for plug stopping in both directions.
Adjustment depends upon the speed of the machine. Improper
adjustment will cause the machine to either:

50-1000
2000
3.5
140

1. Coast to a stop, caused by not providing enough countertorque;

When mounted with


adjustment screws not at the
same level, minimum adjustable speed IS 20 R PM

2. Permit a back-spin (shaft rotating in opposite direction),


caused by providing too much counter-torque.

IMPORTANT: Do not run the speed switch at any time at a speed higher than the
indicated maximum speed since permanent damage to the switch may result.
-TABLE 2 - CONTACT RATING

Adjustment of the speed switch must be made between these


two conditions to achieve zero shaft speed.

AC NEMA Rating Oesignation 8600

ANTIPLUGGING - Turn adjusting screw(s) out 7/16, measuring


from end of hex socket head toenclosure (lowest speed setting).
When circuit requires switch to be wired for antiplugging control
in both directions, both screws will require adjusting.
1. Turning screw(s) in will permit reverse energization to be
applied manually or automatically at a higher shaft speed.
2. Adjust to desired speed as determined by trial runs.
2

CAUTION: Do not apply reverse energization during trial runs


until it has been determined that the speed switch contacts
in the reverse circuit are re-closing at a safe speed for the
particular application.

Lockout
Cover

SPEED SENSING AND DIRECTION OF ROTATION - T u r n a d j u s t i n g

screw(s) out for lower speed, and in for higher speed sensing of
shaft. Adjust both screws when contacts are wired for sensing
shaft speed in each direction of rotation.

WIRING

INSTRUCTIONS - Remove cover with nameplate, exposing contact block. Use wire suitable for at least 90 C. Check
application notes for recommended wiring diagrams.

Solenoid Fork

NOTE: Contact blocks are supplied with a common jumper


which may be removed if isolated contacts are desired. Replace
cover, torque cover screws 8-10 in.-lbs.
INTERCHANGEABLE MOUNTING BRACKETS

Speed Switch
With Lockout Solenoid
NEMA Type 1, 4
and 13 Enclosure

4 Point Flange

3 Point Flange

Exploded View of
Speed Switch with Lockout Solenoid

MOUNTING - Three types of interchangeable mounting brackets

LOCKOUT SOLENOID - The Bulletin 808 can be equipped with a

Brackets, except on NEMA Type 7 & 9 switches, can be


mounted to the switch in any of eight positions, one position of
which is used to locate the conduit opening in the most
convenient position for the electrical connection. Bracket X268875 used on NEMA Type 7 & 9 switch is mounted in one
position. Mounting brackets are attached with four slotted
screws and lock washers.These screws should be torqued to
20-24 in.-lbs.

lockout solenoid which consists of solenoid and cover


mounted on top of the switch. To add a lockout solenoid,
remove the top plate (4 screws) and mount the solenoid bracket
to the housing with two #10-32 x yB screws provided. These
screws should be torqued to 20-24 in.-lbs. The lockout solenoid
fork must straddle the copper operating lever (see exploded
view). Mount cover as shown in exploded view with two #8--32 x
1 screws provided. Be sure the top plate gasket is in place
before torquing cover screws, 8-10 in.-lbs.

are available for NEMA Type 1,4 and 13 speed switches. NEMA
Type 7 & 9 switches are available with base type mounting
bracket only. (See Table 3.)

TABLE 3 - MOUNTING BRACKETS


Oescriotion

Base Mounting (NEMA Type 1, 4 and 13)


3 Point Flange Mounted
4 Point Flange Mounted
1

Base Mounting (NEMA Type 7 & 9)

Catalog

Number

120
110
208
240
220

808-N1
808-N2
808-N3
Part Number
X-268875

TABLE 4 - L O C K O U T SOLENOID

60
50
60
60
50

480
440
600

808-NLA1
808-NLA20

KITS
60
50
60

808-N LA4

TYPICAL LOCKOUT SOLENOID CONNECTIONS


(if used)

MAINTENANCE - Periodic inspection of the shaft seal is


suggested. If seal wear is evident, replace with external bearing
seal kit. Catalog Number 808-N5 Installation instructions are
included with replacement kit.

NOTE: See applicable standards, codes, and laws for all


applications.

not attempt to disassemble the shaft assembly.


attempt may permanently damage the speed

T
1

MOTOR
T2
To3

Bearings are sealed and are of the permanently lubricated


type. In severe environments, such as cement dust, the shaft
seal should be cleaned and lubricated with Anderol 757 or
equivalent. Anderol 757 is a synthetic diester multi-purpose
grease.

LO
i::i

FIGURE 5

MODEL DS325-322
SECTION 12 Ground Support Equipment
Table of Contents
Level

Drawing

Description

Rev.

Page

D103855-1

SEGMENT ERECTOR ASSEMBLY

12.1

B64540-1

HOSE REEL

12.1-16

D103063-1

BRAKE FAILSAFE

12.1-17

D103064-1

GEAR REDUCER

12.1-18

B103061-1

HYDRAULIC MOTOR

12.1-23

B103111-1

CYLINDER PITCH/ROLL

12.1-40

D103082-1

CYLINDER RADIAL

12.1-41

C103083-1

CYLINDER YAW

12.1-42

D103038-1

CYLINDER AXIAL

12.1-43

D104033-1

VACUUM ERECTOR

12.1-57

MANUFACTURER S LITERATURE
D104256-1

CYLINDER POSITIONING INDICATING 0

12.1-205

MANUFACTURER S LITERATURE

12.1-57A

SEE 10.1-24A

D104583-1

12.1-210

A104672-1

ENCODER ABSOLUTE PROFIBUS

12.1-210-8

D103859-1

ENCODER INSTALLATION
SEGMENT ERECTOR

PROBE DRILL ASSEMBLY

12.2

5750006069 GEAR REDUCER

12.2-4

5750006246 BRAKE

12.2-5

A103889-1

12.2-25

322tc12

DRILL RIG
1

August, 2008

MODEL DS325-322
SECTION 12 Ground Support Equipment
Table of Contents
Level

Drawing

Description

Rev.

Page

D103131-1

CYLINDER FEED ADVANCE

12.2-39

D103970-1

CYLINDER FRAME EXTENSION

12.2-52

5750011750 CYLINDER RADIAL

12.2-72

5750005540 HYDRAULIC MOTOR

12.2-132

D103370-1

ERECTOR PLATFORM ASSEMBLY

12.2-133

D104289-1

HYDRAULIC SCHEMATIC PROBE DRILL 1

12.3

A104948-1

ELECTRIC MOTOR

12.3-6

A105112-1

PUMP VARIABLE VOLUME

12.3-8

A105113-1

PUMP MOTOR WATER

12.3-9

A105114-1

PUMP LUBRICATION

12.3-10

A98941-1

PRESSURE FILTER

12.3-46

A105132-1

RETURN FILTER DOUBLE ELEMENT

12.3-47

5750990017 TIGHTENING TORQUE FASTENERS

322tc12

SECTION 3

August, 2008

ACIMEX ZI Nord Bat. 6- 77200 TORCY Tel : 0160066527 Fax : 0160064696

VACUUM ERECTOR
N9798

ROBBINS
12.1-57A

ACIMEX ZI Nord Bat. 6- 77200 TORCY Tel : 0160066527 Fax : 0160064696


SUMMARY
Certificat of conformity
P.1

General characteristics

P.2

Working

P.3

Putting into service

P.4

Instructions for use

P.5

Periodic checks

P.6

Maintenance
P.6A
P.6B
P.6D
P.6E

Vacuum pump
Magnetvalve
Vacuum switch
Erecting of the rubber sealing

P.7

Spare part list

P.8

Test list
Electrical diagrams
Hydraulic diagram
Vacuum circuit
Part list vacuum erector
Part list vacuum pump
Vacuum erector drawing
Vacuum pump drawing

DECLARATION CONFORMITY
OF
((

We,

ACIMEX
SOCIETE
ZONE
INDUSTRILLE
NORD
BATIMENT
6
77200
TORCY
France

Doclare
underour responsability the product:
that
VACUUM
ERECTOR
N'9629YEAR:2006
To whichthis declaration
relates in conformity
is
with the
followingstandards othernormative
or
documents
:

EN13155-2003
lf applicablefollowing the provisionsof europeandirectives

98/37/EEC 89/336/CEE 73t23tCEE


Torcy the,lSjuly2008

Grant

ACIMEX ZI Nord Bat. 6- 77200 TORCY Tel : 0160066527 Fax : 0160064696


GENERAL CHARACTERISTICS

P.1

ORDER N S 017
COMMANDE N
LIFTING GEAR PRODUCT

: LV 1500 INT

SAFE WORKING LOAD

: 10T

APPROXIMATIVE WEIGHT

: 5000kg

NUMBER OF SUCTION CUPS

:5

TYPE OF SUCTION CUPS

: 16061

NUMBER OF ELECTROVALVES

:4

VACUUM PUMP

: 14015

POWER TAKEN UP

: 5kw

SUPPLY VOLTAGE

: 400V/50HZ

MAXIMUM VACUUM

: 99%

HYDRAULIC PRESSURE

:150 bar

FACTORY NUMBER

: 9798

YEAR

: 2008

ACIMEX ZI Nord Bat. 6- 77200 TORCY Tel : 0160066527 Fax : 0160064696


WORKING

P.2
1

The vacuum pump (1) effects suction in the reserve (3) via the non-return valve (2) and maintains a
vacuum level which is greater than or equal 80%.
The electrovalve (4) effects communication between the reserve and the suction cup or between the
suction cup and the open air.
By pressing on the HOLD button the slide is moved in position A.The cup (5) is in junction with
the reserve; vacuum is instantaneous and the load can be lifted.
By pressing on the RELEASE button, the slide is moved in position B; the cup (5) is in
communication with open air and the load is instantaneously release, in this position the reserve (3) is
isolated from the cup and vacuum is avaible for next lifting.
In case of loss of current, the electrovalve will not change it position which prevents the load of any risk
of falling.

ACIMEX ZI Nord Bat. 6- 77200 TORCY Tel : 0160066527 Fax : 0160064696


PUTTING INTO SERVICE

P.3

INITIAL PUTTING INTO SERVICE


Connect the equipment to the main power supply by means of it socker.
Turn the ON/OFF commutator switch which controls starting up of the
pump and press on the button marked RELEASE.

If the direction of the rotation of the pump is correct then the percentage of the
vacuum, indicated by the vacuum gauge, has to increase and the pump has to
emit a regular sound.
In the opposite case, the direction of rotation of the pump is not correct and the
phases have to be reversed.
When the value of 80% is reached, the green lamp lights up indicating that the
equipment is ready for use.The red lamp goes out and the audible signal stops.
By pressing on the HOLD lifting of the load is effected.

ACIMEX ZI Nord Bat. 6- 77200 TORCY Tel : 0160066527 Fax : 0160064696


INSTRUCTIONS FOR USE

P.4

IT IS COMPULSORY TO COMPLY WITH TWO INSTRUCTIONS FOR


USE:
The vacuum pump has to get into service in the course of material
handling.
When the red lamp lights up, the load must be put down immediately.
If there is a power cut, then the load will be maintained in position by the
vacuum reserve. The duration of this holding in position is dependent
upon of the surface.
AREAS WHERE IT MAY BE LIABLE TO FALL MUST, THEREFORE,
BE OBLIGATORILY CLEARED OF ALL PERSONS.
Other general instruction which are to followed in the course of material
handling are as follows:
Do not exceed the maximum load
Do not loads assimetricaly

ACIMEX ZI Nord Bat. 6- 77200 TORCY Tel : 0160066527 Fax : 0160064696


PERIODIC CHECKS

P.5

MONTHLY PERIODIC INSPECTION


The aim of this inspection is to check that the equipment is in perfect working
order.
The equipment has to be at rest and has to be without a load.The pump
has to be switched on, and the RELEASE position of the electrovalve has to
be done; within several seconds (according to the volume of the reserve) the
vacuum pump should indicate 80% vacuum.
If this value is not attained then, that indicates the oresence of a leakage in
the suction circuit.The pipework has to be checked between the reserve and
the pump, and the seal on the filter has to be checked also.
When the value of 80% has been reached, then the power supply will be
cut off from the pump.
The needle of the vacuum gauge should not move. If the needle moves back
towards zero, then, this indicates that there is a leakage in the reserve. The
following are to be checked in turn: sealing of the suction pipework in the
reserve, the seals of the non return valve, of the filter and of the electrovalve.
After the reserve circuit has been checked the suction cup circuit has to be
checked. A load has therefore to be selected (it is not necessary to have the
maximum load) this load has to be completely smooth and with a perfect
seal, there should have no defects and the cup has to be cleaned.
The load will therefore be suspended to the equipment and, when a value
of 90% is reached, the pump will be switched off. The permitted loss (wear of
the joint being taken into account) will be to 80% in 10 minutes. In case of
greater leakage the condition of the pipework has to be checked as well the
suction cup and lastly the electrovalve. After all repairs have been made, the
tests as detailed above will be carried out, once more, in order to check the
seals of the equipment.
When doing this inspection, the filter will be changed.

ACIMEX

TORCY rel : 0160066527 : 0160M6s2?


- Fax
-zI Nord-Bat.6-??200

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ACIMEX

TORCY rel : 0160066527 : {n60066s27


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ACIMEX

loRcY*Tel:0160066527-Fax:
-ZI Nord
-Bat.6-77200
0160066s27

V A CUUM U M P 4 0 1 5
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000
Pidinlfluot6urd6 nivoau

0947 22
51
0362
516619

152

0432 010 196


000

1 53

0247 222 197 Oring


Uk

0486516620

A,bschiderd.koldichtung
cder
154 Sallorsepaior
Jointo. couvgrcle
soaraluf

0440000123 198

0413000113

091
516r/7 205

0247NO t29

0481502719

0414512869

O-Ring

1 59

Dichlung

0247
&3720 26

161
Dichlung

0441503 785

162
163

207

0413 428
000

0413Atm442

204

u32 AOO
462

* Fax
TORCY Tel: 0160066527 : 0r60o66s27
-zI Nord-Bat.6-77200
-

ACIMEX

14015
PUMP
VACUUM
schwenkverschraubuf
fifting
225 Hydraulic

0443000 051 266

000012
0432

0,t41
505 138 2TO

224

P.6no

0415 0!a
000
Dichting

Gemdsinschm'rbvercchaubung

000
0484 029

0441 045 271 Sealng


000
nng

224 SlLshlshld fitling


Olleilung

0414000 201

234

0327503 794

23E

503
flan(50 Hz)
0413 035 300l\4otor

239

0.132 062 300 fi.lolorflang(60 Hz)


000

0247515 612

0520 440 307


513

536
0410000

242 o- ng

000
0486 587 2

000
0432 018

244

0713516732

247

(60
Kupduns Hz)
(60
0413 318 311 Coupling Hz)
000

gf
Sau lnsch-Unlrloil
lbngE,
low houhg
250 Inlst

(50
Kupplung Hz)
(50
0246coo
474 312 co'rpling Hz)

000
0512 005

251

(60
Kuppluns Hz)
(60
523421 312 Coupling Hu)
0710

0512 007
000

252

0710523020

(50
Kupplung Hz)
(50
3'13Coupling Hz)

d'asDlmlion
Guids claol
de
O-Ring
253 O{ing

0486000 5?6

(60
313 Couplins Hz)

254

0435
523022 321

?95

0247509 245

nol6u (50tlzi
Flasouede
(60
Flasou6 inolur Hz)
d

Kh16l

241
O-Ring

(50
Kupplung Hz)

O-Rin9
255 O+ing

Kuppung Hz)
{60

0512000155

311 Coupling(50H2)
1

0512 162
000

0512000187
051200 0161
05249 237

0la6 000 511

322

260

0246 476
000

326

0432510792

261

0534 041 331


000

04'14512472

265

0 4 1 0000209 !33

0414512472

Zacken-Ring

TORCY Tel: 0160066s27 : 0160066s27


77200
-zrNor.t --Brl..6- -!'x

ACIMEX

P
1
V A CUUM U M P 4 0 1 5

P.6rz

Gewindeslift

353

0413000486
417

3m

0432 062
000

190 HarEing

0320 721
000

0414 3
000

421

0561 005
000

423

0432 025
000

1 Lifriru bolt
eye

0416 019 424


000

'I

0420 040
0m

0432 01E 425 Slud


000

04120313

0418 015
000

0665 081
0m

0566 m3
000

0441 203
0m

Schwingrnetalburer

S1inchfaube
Boulon
filsl

04'100572 429 Psnheed


tppng
scrw
Vb 616 ttecvlindqus

390
(50
ElktronEtd Hz)
400 Mdor(50Hz)
Ivot6ur
lctiou fE)
l5O
Elklronolor Hz)
1
400 [/otor(60Hz)
(60
Nlotu|
lclriou Hz)
(50
Klllmbrtl Hz)
400.1
Trninl
boad(50Fb)
(50
Bomil Hz)
(m
Xbnrnbrfl Hz)
(60
440.1
Tomindboafd Hz)
Bn$ (60Hz)
Klsnhklen Hz)
{50
4.2Teminl {50Hz)
ox

Bote bars(50Hz)
Kkmn*asbn(60l-lz)
(60
T6
4rn.2 rinlbox Hz)
(m
Bolte bornos Hz)

LuRflgel{so
l-lz)
Fan
4{X).3 (50Hz)
(60
Lufrflusel Hz)
400.3 (60Hz)
Fan
Vrtilateur Hz)
{60

Typnschild

4.30
0622510139
Dr6hrichlungspbil

06000421

431
Flh6
36rE d rotlon

Schwnkvrschuburg
0448 580
507

4m Hydraulic
fitllng

Ollituru
ota 507
589 471 OiltLrb
G6rad
inschrLvrschr.
472 SlEight fting
stlld

0648507 581

s07
0648 5e0

0648507 582

475

m507 577

0648507 592

476 Elbow

0456000 891

0&a 507587 477 BI vlve

C.ol d venlilleur Hz)


{50
(O
Elk'omoiorhaube Hz)
.100.4
l\4otor covl ( Hz)
fn
Caoolde venliheur {60 HzJ

0441 008
000

Filr
0945516611
Bfsligungswinkl

(50
Elekbomrtorhub Hz)

400.4
.loto{ cover(50 Hz)
fan

o3z7516612

Ttb huilo

KLlhahn
0544512 8

Robinet bcisseausDhio|

0644507 503

47E

401

0413 547
000

479

402

04000068

0410000017

0432 010
000

Scheibe

ACIMEX

TORCY rel : 0160066527 : 0160066527


-zI Nord-Bat.6-77200
- n'ax

VACUUM
PUMP14015

PRECONIZED
O]LS
. AralmdanolGM100
. Fina
DC
eolan 100
. BPenergdGsl00
. MobilDTEoil hqry
. Shell
enshmdoroil 30
. Shell
vitrea
1fl)
.. Randooil
F
. C@lmegna
100
. Toal
dh ZS 1l
.'Esso nuto
1fi)
. To(acoursaoil P 100

| P.6ae

ACIMEX ZI Nord Bat. 6- 77200 TORCY Tel : 0160066527 Fax : 0160064696


ELECTROVALVE
CODE 05014

P.6B1

OPERATION
The three way magnet valve controls the operational functions HOLD and
RELEASE of the suction cup.
Commutation is effected by a solenoid which is placed in each extreme
position by means of a pulse lasting approx. 1 second.
Once it is this position, the magnet valve is idle:due to this, if there is a power
cut, there is no change in state of the position.
In the position HOLD the load is maitained in position.
In the position RELEASE the reserve does not empty.
CHARACTERISTICS
Voltage :24VDC
Power: 118W
Intensity: 5A
Working time: 20%
Permissible variation in voltage :5%
Connection: 1
CONNEXION
Connecting the voltage at the item 1 (positif) and item 3 (negatif) we get the
commutation HOLD (connection beetween the reserve and the cup).
In changing the way of the current with item 1 (negatif) and item 3 (positif) we
get the commutation RELEASE (connection beetween the cup and the
atmospheric pressure).

ACIMEX ZI Nord Bat. 6- 77200 TORCY Tel : 0160066527 Fax : 0160064696


ELECTROVALVE
CODE 05014

P.6B2

MAINTENANCE
The vacuum electrovalve is maintenance free.
The puher rod and it guide should not be oiled or lubrificated in any case

DEFECT
Insufficient vacuum in the reserve.
Possible causes:
Leakages due to accumulation of the body of the valve or else due to
wear of the plate.
Clean and replace the electrovalve plate.
The solenoid is worn, the force for maintenance is insufficient.
Replace the solenoid.
The position of the rod is floating.
Voltage is too low
Check the power supply and the rectifier

ACIMEX ZI Nord Bat. 6- 77200 TORCY Tel : 0160066527 Fax : 0160064696


ELECTROVALVE
CODE 05014

REP

DESIGNATION

P.6B3

CODE

REP

DESIGNATION

O5015

ELASTIC WASHER

CODE

SOLENOID

O5008

CONNECTOR

NUT HM6

WASHER 6,5x10

O RING

O5006

UPPER VALVE SEAT

O5004

10

LOWER VALVE SEAT

O5005

O RING

O5006

11

SCREW HM6x80

ELECTROVALVE BODY

O5003

ACIMEX ZI Nord Bat. 6- 77200 TORCY Tel : 0160066527 Fax : 0160064696


VACUUM SWITCH

P: -1....0 bar
U: DC 10....30V
Is: 2,0A (max DC30V)
S# 2813741
P# 7241527

P.6D

ACIMEX ZI Nord Bat. 6- 77200 TORCY Tel : 0160066527 Fax : 0160064696


ERECTING OF THE RUBBER

P.6E

1. PUT ON THE CORNER OF THE


RUBBER IN THE PROFILE

2. WITH A TOOL PUT THE RUBBER


COMPLETELY IN THE PROFILE

3. KEEP THE RUBBER IN POSITION


THEN TAKE OUT THE TOOL

4. THE JUNCTION BEETWEEN THE


TWO EXTREITIES OF THE
RUBBER WILL BE GLUED WITH
NEOPRENE GLUE

ACIMEX ZI Nord Bat. 6- 77200 TORCY Tel : 0160066527 Fax : 0160064696


SPARE PART LIST

P.7

We preconize to keep in stock on the jobsite for a quick maintenance the following parts:
Quantity

Part

Code

100m

PAD SEALING RING

16061

REPAIR PUMP SET

12081

REFILL AIR FILTER for pump

07069

REPAIR ELECTROVALVE SET

05005+05006

OIL FILTER for pump

07016

VACUUMETER

09006

INTERNAL FILTER for pump

07012

REFILL AIR FILTER for valve

07005

REFILL AIR FILTER for valve

07004

1set

SEALING for cylinder

VAL20.100

VACUUM SWITCH

09009

1m

VACUUM HOSE

15036

5m

VACUUM HOSE

15004

VACUUM PUMP

14015

AIR FILTER for pump

07068

AIR FILTER for electrovalve

07001

AIR FILTER for electrovalve

07002

MAGNET for electrovalve

05015

VACUUM SWITCH

09009

VACUUM COUPLING

1049K

ACIMEX ZI Nord Bat. 6- 77200 TORCY Tel : 0160066527 Fax : 0160064696


TEST LIST

P.8

EQUIPMENT : vacuum erector beam n9629

TEST

RESULT

REMARK

Checking of the hydraulic circuit

OK

Checking all hydraulic mouvements

OK

the speeds should be


regulated on site

Checking all electrical sensor

OK

all sensors are in right


place

Maximal vacuum level of pump

99%

Checking of radius of the pads

OK

Checking the seal of vacuum tank

OK

test of 20mn no leakage

Checking the seal of fix pad on steel gabarate

OK

test of 20mn no leakage

Checking the seal of movable pads on steel gabarate OK

test of 20mn no leakage

"

"

PRESSURE
PLUG

TEL : (33) 01 60 06 65 27
FAX : (33) 01 60 06 46 96 DES :
acimex.beea@free.fr

FLOW VALVE
DGMFN 3Y A2W B2W 41

SIDE PAD CYLINDERS


100x56x100

RELIEF VALVE
EMVBSODE
cetop3

E.FERREIRA

DRAWING
No : 01

All pipes are 14S

10

11

12

10
HYDRAULIC DIAGRAM

CONTROL VALVE
DG4V36CMUH760
cetop3

"

"

11

12

MIDDLE PAD CYLINDERS


100x56x485

DATE : 2006/09/04

13

13

14

14

16

17

01
01

15

19

16

17

18

19

Hydraulic pressure supplyed


by ROBBINS
150B - 25l/mn

CLIENTE: ROBBINS Q 279

"

18

Coil voltage supplyed by


ROBBINS
24VDC

SIDE PAD CYLINDERS


100x56x100

15

10 SCREW CHc M30x110

24 SCREW CHc M6x25

4A

6A

9A

10

11

12

13

14

15

16

16A

17

18

18A

19

20

21

22

23

23A

VISA :

STOP PLATE

DATE :13-09-2006

CLAMP

WASHER

SENSOR

SENSOR SUPPORT

SENSOR SUPPORT

SCREW CHc M16x30

STOP PLATE

PIN

SUPPORT SPHERICAL BEARING

HYDRAULIC CONNECTING

CONNECTION BOX

FILTER

FILTER

MAGNET VALVE

PROTECTION

SCREW CHc M8x20

PROTECTION

VACUUMETER

VACUUM SWITCH

SCREW HM16x30

GUIDE

LASER SWITCH

SCREW CHc M8x25

LASER SUPPORT

SCREW CHc M8x25

3A

FRONT CYLINDER PIN

FRAME

LIST

NB

by :E.F

Q 279-1112

Q 279-1111

Q 279-1120

Q 279-1105

Q 279-1109

Q 279-1108

Q 279-1107

Q 279-1130

Q 279-1129

Q 279-1128

Q 279-1104

Q 279-1103

Q 279-1114

Q 279-1101

DRAWING N

Q 279

Z.I NORD BATIMENT 6 TORCY 77200


TEL: 01.60.06.27 FAX: 01.60.06.46.96

REP :

ORDER N

ACIMEX
PAGE :

07001

O7002

05014

09006

09009

REMARKS

VACUUM
ERECTOR
CODE

DEVICE

ROBBINS

CUSTOMER

CONTRINEX

FLUIDAP

SAREL

WENGLOR

SUPPLYER

PROJECT

DW AS 623 M18 120

4403

ZD2003

REFERENCE

LV 1500 INT

TYPE

10 T

SWL

DEAD WEIGHT

400V/50HZ

TENSION

30

30A

31

32

12 SCREW HM12x25

37

38

39

39A

40

41

42

43

43A

43B

44

VISA :

36

WASHER

Q 279-1125

Q 279-1123

Q 279-1122

Q 279-1121

Q 279-1120

Q 279-1133

Q 279-1118

Q 279-1117

Q 279-1116

Q 279-1115

Q 279-1127

Q 279-1126

DRAWING N

BY :E.F

FRONT CYLINDER PIN

DATE :13-09-2006

O RING

Q 279-1106

CYLINDER PIN

HYDRAULIC CYLINDER

SENSOR

O RING

SCREW F/90CHc M6x20

COVER

SPRING

COLUMN

WASHER

SCREW CHc M12x30

35

35A

34

RUBBER SEALING

MIDDLE PAD

SCREW CHc M16x50

FRONT CYLINDER FIXATION

NUT HM30

CONE

29A

FRONT CYLINDER PIN

HYDRAULIC CYLINDER

SCREW CHc M20x110

TARGET

SCREW CHc M16x50

29

33

28

CYLINDER SUPPORT

26A

27

26

27A

SCREW HM6x25

25A

COLUMN

25

COLUMN

24

LIST

NB

Q 279

Z.I NORD BATIMENT 6 TORCY 77200


TEL: 01.60.06.27 FAX: 01.60.06.46.96

REP :

ORDER N

ACIMEX
PAGE :

16061

REMARKS

VACUUM
ERECTOR
CODE

DEVICE

ROBBINS

CUSTOMER

ARDEN VERIN

CONTRINEX

METEFRAM

ARDEN VERIN

SUPPLYER

PROJECT

LV 1500 INT

XP70 65x4

VAL20.100.56.56TE.TR26

DW AS 623 M12 120

XP70 50x3

C20.26.32

VAL20.100.56.365TO180A15

REFERENCE

TYPE

10 T

SWL

DEAD WEIGHT

400V/50HZ

VOLTAGE

12 SCREW HM12x25

48

48A

48B

49

50

51

52

53

54

VISA :

47

DATE :13-09-2006

RUBBER SEALING

SENSOR

RUBBER SEALING

RING EXT.40

PAD PIN

SIDE PAD

O RING

ARM PIN

ARM

RING EXT.50

46

WASHER

45

LIST

NB

BY :E.F

Q 279-1110

Q 279-1132

Q 279-1124

Q 279-1131

Q 279-1113

DRAWING N

Q 279

Z.I NORD BATIMENT 6 TORCY 77200


TEL: 01.60.06.27 FAX: 01.60.06.46.96

REP :

ORDER N

ACIMEX
PAGE :

16061

16061

REMARKS

VACUUM
ERECTOR
CODE

DEVICE

ROBBINS

CUSTOMER

SCHNEIDER

SUPPLYER

PROJECT

XCMD2102L

XP70 65x4

REFERENCE

LV 1500 INT

TYPE

10 T

SWL

DEAD WEIGHT

400V/50HZ

VOLTAGE

VISA :

DATE :22-12-2005

CHECK VALVE

VACUUM ROTATING COUPLING

HOSE

FILTER

VACUUM PUMP

SCREW HM24x60

BEARING SUPPORT

3A

BEARING

SUPPORT

by :E.F

Q 279-2102

Q 279-2101

DRAWING N

Q 279

LIST

NB

Z.I NORD BATIMENT 6 TORCY 77200


TEL: 01.60.06.27 FAX: 01.60.06.46.96

REP :

ORDER N

ACIMEX

O3011

15036

O7068

14015

CODE

VACUUM PUMP

DEVICE

separetly

REMARKS

PAGE :

IHI

CUSTOMER

GAUTHIER

CSR

SUPPLYER

PROJECT

UCP214

REFERENCE

TYPE

SWL

DEAD WEIGHT

400V/50HZ

TENSION

MODEL DS325-322
SECTION 13 Operator Station Assembly
Table of Contents
Level

Drawing

Description

Rev.

Page

D110297-1

OPERATORS CAB ASSEMBLY

13.1

D104491-1

OPERATORS CONSOLE ASSEMBLY


NOTE: SHEET 4 NOT INCLUDED

13.1-3

A81885-8

QUICKPANEL

13.1-3-19

MANUFACTURERS LITERATURE
5750990017 TIGHTENING TORQUE FASTENERS

322tc13

13.1-3-19A
SECTION 3

August, 2008

Hardware Users Guide


12 QuickPanel View & QuickPanel Control
IC754CBL12CTD
IC754OBL12CTD
IC754CGL12CTD
IC754CSF12CTD
IC754CSL12CTD
IC754VBL12CTD
IC754VGL12CTD
IC754VSL12CTD

February 2004
GFK-2284A

13.1-3-19A

All rights reserved. No part of this publication may be reproduced in any form or by
any electronic or mechanical means, including photocopying and recording,
without permission in writing from GE Fanuc Automation Americas.

Disclaimer of Warranties and Liability


The information contained in this manual is believed to be accurate and reliable.
However, GE Fanuc Automation Americas assumes no responsibilities for any errors,
omissions or inaccuracies whatsoever. Without limiting the forgoing, GE Fanuc
Automation Americas disclaims any and all warranties, expressed or implied,
including the warranty of merchantability and fitness for a particular purpose, with
respect to the information contained in this manual and the equipment or software
described herein. The entire risk as to the quality and performance of such
information, equipment and software, is upon the buyer or user. GE Fanuc
Automation Americas shall not be liable for any damages, including special or
consequential damages, arising out of the use of such information, equipment and
software, even if GE Fanuc Automation Americas has been advised in advance of the
possibility of such damages. The use of the information contained in the manual and
the software described herein is subject to GE Fanuc Automation Americass
standard license agreement, which must be executed by the buyer or user before the
use of such information, equipment or software.

Notice
GE Fanuc Automation Americas reserves the right to make improvements to the
products described in this publication at any time and without notice.
2004 GE Fanuc Automation Americas. All rights reserved. QuickPanel,
QuickPanel View, and QuickPanel Control are trademarks of GE Fanuc Automation
Americas. Any other trademarks referenced herein are the property of their
respective owners and used solely for purposes of identifying compatibility with the
products of GE Fanuc Automation Americas.
The 12 QuickPanel View/Control has been tested and found to meet or exceed the
requirements of U.S. (47 CFR 15), Canadian (ICES-003), Australian (AS/NZS 3548)
and European (EN55022) regulations for Class A digital devices when installed in
accordance with guidelines noted in this manual.
The FCC requires the following note to be published according to FCC guidelines:
This equipment has been tested and found to comply with the
limits for a Class A digital device, pursuant to Part 15 of the
FCC Rules. These limits are designed to provide reasonable
protection against harmful interference when the equipment is
operated in a commercial environment. This equipment
generates, uses, and can radiate radio frequency energy and, if
not installed and used in accordance with the instruction
manual, may cause harmful interference to radio
communications. Operation of this equipment in a residential
area is likely to cause harmful interference in which case the
user will be required to correct the interference at his own
expense.

Industry Canada requires the following note to be published:


This Class A digital apparatus complies with Canadian ICES003.

The following statements are required to appear for Class I Div 2 Hazardous
Locations.
1. EQUIPMENT LABELED WITH REFERENCE TO CLASS I, DIVISION 2, GROUPS
A, B, C, and D, HAZARDOUS LOCATIONS IS SUITABLE FOR USE IN CLASS I,
DIVISION 2, GROUPS A, B, C, D, OR NON-HAZARDOUS LOCATIONS ONLY.
2. WARNING - EXPLOSION HAZARD -SUBSTITUTION OF COMPONENTS MAY
IMPAIR SUITABILITY FOR CLASS I, DIVISION 2.
3. WARNING - EXPLOSION HAZARD - DO NOT CONNECT OR DISCONNECT
EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS
KNOWN TO BE NON-HAZARDOUS.

We want to hear from you. If you have any comments, questions, or suggestions
about our documentation, send them to the following email address:
doc@gefanuc.com.

Contents
1 Welcome

Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Basic Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
QuickPanel View/Control Unit Runtime Setup
. . . . . . . . . . . . .3
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Panel Cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

2 Overview

QuickPanel View/Control Hardware . . . . . . . . . . . . . . . . . . . . . . . .8


Layout Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Block Diagram
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
QuickPanel View/Control Software . . . . . . . . . . . . . . . . . . . . . . . .10
Windows CE.NET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Working with Windows CE . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Pocket Internet Explorer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Storage Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Microsoft File Viewers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Copy Project to Flash Card . . . . . . . . . . . . . . . . . . . . . . . . . . .16
HTTP File Transfer Utility . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

3 Detailed Operation

19

Touch Screen Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20


Touch Screen
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
External Keyboard (optional) . . . . . . . . . . . . . . . . . . . . . . . . . .25
Soft Input Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
External Mouse (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Communication Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
COM1- Serial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
COM2 - Serial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Working with COM ports . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

GFK-2284A

12" QuickPanel View & QuickPanel Control

Contents

CF Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Universal Serial Bus (USB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Expansion Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DIP Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Flash Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
SRAM Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
DRAM Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Boot Loader ROM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Memory Expansion Slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Other Subsystems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Power Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Battery Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Real-time Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

A1 Design Specifications

49

Physical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
DC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Display
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Touch Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Memory Expansion Slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Expansion Ports
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Communication Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Environmental
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Calendar/Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Agency Qualifications
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

A2 Troubleshooting

55

Power up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Pocket Internet Explorer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Index

vi

12" QuickPanel View & QuickPanel Control

57

GFK-2284A

Welcome
Congratulations on your purchase of a QuickPanel View/Control, the most
advanced compact control computer available. The QuickPanel View/Control is
available in different configurations to suit your requirements, either as a fullfeatured HMI, or as a combination of HMI and controller for local and distributed
control applications. Equally at home in a networked environment or as a standalone unit, the QuickPanel View/Control is the ideal solution for factory floor HMI
and control.
Powered by Microsoft Windows CE.NETTM, todays embedded control operating
system of choice, the QuickPanel View/Control provides a fast track for application
program development. The commonality with other versions of Windows
simplifies porting your existing program code. Another benefit of Windows CE is
the familiarity of the user interface, shortening the learning curve for operators and
developers alike. The availability of third-party application software makes this
operating system even more attractive.
The 12" QuickPanel View & QuickPanel Control is an all-in-one microcomputer
designed for maximum flexibility. The design, based on an advanced Intel
microprocessor, brings together a high-resolution touch-screen operator interface
with a variety of I/O options. With many standard ports and expansion busses from
which to choose, you can connect to most industrial equipment.
The QuickPanel View/Control is equipped with several memory types to satisfy
even the most demanding applications. A 32 MB section of DRAM is split between
the operating system, an object store, and application memory. Functioning as a
virtual hard drive, a 32 MB or 64MB section of non-volatile FLASH memory
(depending on your model) is divided between the operating system and persistent
storage for application programs. The retentive memory consists of 512 KB of
battery-backed SRAM for data storage, ensuring your valuable data will never be
lost, even during a power failure.
The many features of the QuickPanel View/Control make it an obvious choice for a
world of applications. Your smart choice will provide reliable operation for years to
come.

GFK-2284A

12" QuickPanel View & QuickPanel Control

Welcome

Getting Started

GETTING STARTED
Basic Setup
Your QuickPanel View/Control is shipped ready for use after a few configuration
steps. To power up all you need to do is connect a DC power supply via the
supplied quick-connect plug. Depending on your application, you may also want
to connect and configure optional input devices (see page 25), communications
ports (see page 27) and expansion adapters (see page 40).
Optional Ethernet Connection

Optional Expansion I/O

Power Supply
Optional USB Keyboard
Caution - Electrical Shock Hazard: To avoid personal injury or damage to
equipment, ensure that the DC supply is disconnected from power and that the
leads are not energized before attaching them to the unit's power supply plug.

To con nect a DC po we r su pply


1. Using the three screw terminals shown in the following diagram, attach a 24VDC, 48W power supply to the plug
supplied with the QuickPanel View/Control (see specifications on page 49 for conductor size requirements).
2. Insert the plug into the power supply socket and securely tighten the attaching screws.
Power Supply Plug
ou
Gr
Fra
me

0V

24

VD
C

nd

Bottom

Insert leads in screw end

Power Supply Socket

12" QuickPanel View & QuickPanel Control

GFK-2284A

Welcome

Getting Started

QuickPanel View/Control Unit Runtime Setup


To download a Cimplicity Machine Edition application to a QuickPanel
View/Control unit, you must set up a data link between your development
workstation and the QuickPanel unit. For more information, see Communication
Ports (page 27) and look up Downloading a Machine Edition Project in the
Machine Edition online help.

Startup
When you first start up the QuickPanel View/Control, a few configuration steps are
necessary.

T o st a rt th e Q u i ck P a ne l V i e w /C on t rol
1. Apply DC power to the QuickPanel View/Control.
Once power is applied, the QuickPanel View/Control begins initializing. The first
thing to appear on the display is the splash screen.

2. To skip running any programs included in the StartUp folder, tap Dont run StartUp programs.
The splash screen disappears automatically after about 5 seconds. The Windows
CE desktop then becomes visible.
3. Tap

Start, point to

Settings and then tap

4. In the Control Panel, double-tap


5. In the Control Panel, double-tap
6. In the Control Panel, double-tap
7. In the Control Panel, double-tap
page 37).
8. On the desktop, double-tap

GFK-2284A

Control Panel.

Display to configure the LCD display (see page 20).


Stylus to configure the touch screen (see page 22).
Date and Time to configure the system clock (see page 47).
Network and Dial-up Connections to configure network settings (see

Backup to save any new settings through a power cycle (see page 13).

12" QuickPanel View & QuickPanel Control

Welcome

Getting Started

Shutdown
There are no specific dangers associated with a power failure or other unplanned
shutdown of the QuickPanel View/Control. In general, programs are retained in
FLASH memory and user data can be retained in battery-backed SRAM. Some
operating system settings are retained only with user intervention, so in order to
carry out a graceful shutdown of the QuickPanel View/Control, we recommend
you perform the following procedure.

T o shu t d o wn t h e Q u i ck P a ne l V i e w /C on tr ol
1. Quit any programs that are running and wait for all file operations to complete (no busy or wait cursor displays).
2. On the desktop, double-tap
Backup to save any operating system settings through a power cycle (see
page 13) and wait for it to complete. Tap OK.
3. Remove AC power from the 24VDC supply.

Panel Cutout
For enclosure mounting, cut an opening in the panel according to the
specifications given with the following diagram.
Panel Cutout
Height: 8.96 (+0.10, -0)
(227.6mm [+2.5mm, -0mm])
Width: 11.88 (+0.10, -0)
(301.8mm, [+2.5mm, -0mm])

8.96
227.6mm

Depth 2.37 (60.2 mm)


Bezel Dimensions
Height: 10.34 (262.6mm)
11.88
301.8mm

Width: 13.26 in. (336.8mm)


Panel thickness range:.063
to.196 (1.6mm to 5mm)

Notes:

For compliance to ATEX agency qualification, the unit must be mounted in an


IP66 panel or enclosure.

For compliance to NEMA 4, 4x, and 12 qualification, the unit must be mounted
in a comparably NEMA rated (IP56 equivalent) panel or enclosure.

To avoid gasket degradation, limit repeated insertions or removals of the unit


and retightening of the mounting clips. For full protection, always use a fresh
gasket.

12" QuickPanel View & QuickPanel Control

GFK-2284A

Welcome

Getting Started

The unit will not fit through this cutout with a CF card inserted in the port, with any
cables connected, or with the power supply plug inserted in the socket.
To secure the QuickPanel View/Control to a panel, use the 10 included mounting
clamps. They hook into openings located on the top, bottom, and sides of the
housing.
Top
Left

x 10

Right

Bottom

To mo un t th e Qu ick Pan el View/ Co ntro l in a pan el


1. Insert the unit into the panel cutout (without a CF card in the CF port).
2. Insert the hook of each mounting clamp into the housing openings as shown below.
3. Ensure that the gasket is properly seated in the bezel channel and firmly tighten the clamp screws.
Note: The torque range for the mounting clamp screws is 2.6-4.4 inch/lbs
(0.3-0.5 Nm)
The mounting clamps hold the unit in place by tension alone. No drilling is
required.

Do not damage the gasket attached to the back of the QuickPanel View/Controls
bezel. This gasket prevents shock hazards and damage caused by liquids
accidentally entering the unit after installation.
GFK-2284A

12" QuickPanel View & QuickPanel Control

Welcome

Technical Support

TECHNICAL SUPPORT
If you have technical problems that cannot be resolved with the information in this
guide, please contact us by telephone, fax, or email; or visit one of the links on our
website:
Telephone: 1-800-GE-FANUC (1-800-433-2682)
Fax: (780) 420-2049
Email: support@gefanuc.com
Comments about our manuals or help: doc@gefanuc.com
Web: www.gefanuc.com/support (to locate the Technical Advisor page and a
listing of supported devices (USB devices, CF cards, etc.) click on the QuickPanel
Product Family link, or choose QuickPanel from the Product List).
For GE Fanuc support, you can also visit:
http://iglobalcare.gefanucautomation.com.

12" QuickPanel View & QuickPanel Control

GFK-2284A

Overview
This chapter provides introductory information on the 12" QuickPanel View &
QuickPanel Control hardware and software with descriptive procedures for
completing some of the most common tasks you will encounter.
In this chapter:

Layout Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Windows CE.NET . . . . . . . . . . . . . . . . . . . . . . . . .10
Working with Windows CE . . . . . . . . . . . . . . . . . .10
To place a program in the Start menu . . . . . . . . . . . . . . . . . . . .11

Pocket Internet Explorer . . . . . . . . . . . . . . . . . . . .11


To establish a dial-up connection . . . . . . . . . . . . . . . . . . . . . . . .11
To configure a Proxy server . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Backup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
To run the Backup program . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
To reboot the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Storage Manager . . . . . . . . . . . . . . . . . . . . . . . . .14


System Information . . . . . . . . . . . . . . . . . . . . . . .14
To run the System Information program . . . . . . . . . . . . . . . . . . .14

Microsoft File Viewers . . . . . . . . . . . . . . . . . . . . .15


To access the Microsoft file viewers . . . . . . . . . . . . . . . . . . . . . . .15

Copy Project to Flash Card . . . . . . . . . . . . . . . . . .16


To copy a Machine Edition project onto a CF card. . . . . . . . . . . . .16
To update a Machine Edition project . . . . . . . . . . . . . . . . . . . . . .16

HTTP File Transfer Utility . . . . . . . . . . . . . . . . . . .16


To use the HTTP utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

GFK-2284A

12" QuickPanel View & QuickPanel Control

Overview

QuickPanel View/Control Hardware

QUICKPANEL VIEW/CONTROL HARDWARE


Layout Diagram
In addition to the primary touch screen interface, the 12" QuickPanel View &
QuickPanel Control supports a variety of communication ports including an
expansion bus to allow great flexibility in application. The following diagram
shows the physical layout of the QuickPanel View/Control and the locations of
ports and connections
The bottom LED is green when power is applied and amber if both backlights fail;1
the top LED is tricolor (green, red, or amber) and programmable.
Front

Right Side

CF Port. See page 34


LEDs

Touch screen LCD display


See page 20
Bottom
RS-232 Port (COM 2)
See page 28

RS232/485 port
(COM1)
See page 27

Power supply socket.


See page 2

USB ports.
See page 35
Hinged access cover for
expansion (see page 40), and
battery (see page 46)

Not to scale

Ethernet ports
See page 36

Backlights are not field replaceable.

12" QuickPanel View & QuickPanel Control

GFK-2284A

Overview

QuickPanel View/Control Hardware

Block Diagram
The 12" QuickPanel View & QuickPanel Control is based on the Intel XScale
PXA255 microprocessor, and employs large-scale integration to provide high
performance with a small footprint. The following block diagram illustrates the
major functional areas of the QuickPanel View/Control and the interfaces between
them.

GFK-2284A

12" QuickPanel View & QuickPanel Control

Overview

QuickPanel View/Control Software

QUICKPANEL VIEW/CONTROL SOFTWARE


Windows CE.NET
Microsoft Windows CE.NETTM is the operating system for the QuickPanel
View/Control. It is a full 32-bit O/S with a graphical user interface. This operating
system is finding widespread application in hand-held PCs and embedded
controllers, such as the QuickPanel View/Control. The familiar look and feel of
Windows CE shortens the learning curve for users having experience with
Windows 95/98/NT/2000/ME/XP. From a software developers perspective, the CE
environment is a subset of the WIN32 application programming interface,
simplifying the porting of existing software from other versions of Windows.
The QuickPanel View/Control operating system is stored in an 16 MB block of
FLASH memory and copied to a block of DRAM for execution. The operating
system starts automatically following a power-up or reset of the QuickPanel
View/Control.
For more on Windows CE visit www.microsoft.com/windows/embedded/ce.

Working with Windows CE


Although the main user input device when working with Windows CE is the touch
screen, it can often be convenient to use keyboard shortcuts, such as those
described in the following table.
Keyboard Shortcut

Action

CTRL+ESC

Opens the Windows CE Start menu. Use arrow keys


to select a program and ENTER to run it.

or

ALT+TAB

Starts the Task Manager. Use it to quit unresponsive


programs.

CTRL+ALT+=

Equivalent to single-tap.

ENTER

Equivalent to double-tap. In a dialog box, equivalent


to OK.

TAB

In a dialog box, select next control.

SHIFT+TAB

In a dialog box, select previous control.

CTRL+TAB

In a tabbed dialog box, open the next tab.

ESC

Close dialog box, discarding changes.

ARROW KEYS

10

Starts the touch screen calibration.

SPACEBAR

In a dialog box, select controls or items from a list


box.

12" QuickPanel View & QuickPanel Control

GFK-2284A

Overview

QuickPanel View/Control Software

To place a prog ram in the

S ta r t m e nu
1. Start

Windows Explorer.

2. Navigate to the program you want to place in the

Start menu.

3. Tap the programs icon to select it.


4. From the Edit menu, choose Copy.
5. Navigate to the \Windows\Programs\ folder.
6. From the Edit menu, choose Paste Shortcut.
7. Run the

Backup program to retain the change through a power cycle (see page 13).

Pocket Internet Explorer


Microsofts Pocket Internet Explorer is a full-featured browser that is fully
integrated with the Windows CE operating system. This browser allows you to
connect with an internet service provider, view web pages and download from
FTP sites.
Pocket Internet Explorer supports VBScript and JScript. Java support can be added
from third-party sources.
A connection can be established over an Ethernet network (default) or a dial-up
connection. The Ethernet or dial-up connection must first be properly configured.

To es tablis h a dial- up co nn ection


1. Start

Pocket Internet Explorer.

2. From the View menu, choose Options.


The Options dialog box appears.

3. On the Auto Dial tab, select the Use AutoDial check box.
4. Choose either the default or a user-defined connection from the list.
5. Tap OK.
6. Run the
GFK-2284A

Backup program to save the settings through a power cycle (see page 13).
12" QuickPanel View & QuickPanel Control

11

Overview

QuickPanel View/Control Software

T o con f i g ure a Pr ox y se rv e r
1. Start

Pocket Internet Explorer.

2. From the View menu, choose Options.


The Options dialog box appears.

3. On the Proxy Server tab, select the Use Proxy Server check box.
4. In the Proxy Server box, type the URL of your proxy server (see your ISP or network administrator).
5. In the Port box, type the servers port number for HTTP access.
6. Select the Bypass Proxy for Local Addresses check box to connect directly to sites like your intranet.
7. Tap OK.
8. Run the

12

Backup program to retain the new settings through a power cycle (see page 13).

12" QuickPanel View & QuickPanel Control

GFK-2284A

Overview

QuickPanel View/Control Software

Backup
Backup is a utility that saves any changes made to the Windows Registry or
Desktop. This utility is required because, unlike typical handheld Windows CE
platforms, the QuickPanel View/Control is not battery powered. Specifically, the
Backup command does the following:

The Windows CE registry (including any control panel settings) is stored in


the Flash registry

Any changes (additions) made to the Windows subtree of the file system
are stored in the user block of FLASH memory.

The Backup program should be run whenever configuration changes are made to
the operating system or installed applications, and prior to shutting down the
QuickPanel View/Control.

T o run t h e B ack up prog ram


1. On the desktop, double-tap

Backup.

The Backup dialog box appears.

2. Tap OK.
Caution: Ensure that backup is complete (i.e., no busy or wait cursor displays)
before disconnecting power.

T o re b oo t t he sy st e m
1. Run the
2. Tap

Backup program to retain any changes.


Start, point to

Programs, then the

System folder, and tap

Reboot .

A confirmation dialog box appears.

3. Tap Yes
The operating system restarts.

GFK-2284A

12" QuickPanel View & QuickPanel Control

13

Overview

QuickPanel View/Control Software

Storage Manager
Use Storage Manager to repair or format lost or corrupted data volumes. Storage
Manager can repair data volumes existing either in Compact Flash (CF) or batterybacked SRAM (BBSRAM). Data volumes existing in the main flash file system of
the QuickPanel may not be repaired by Storage Manager.
Storage Manager, accessed from the Control Panels folder, is a Microsoft product
for which on-line help is available.

System Information
System Information is a custom utility that displays a splash screen with the
following information:

Operating System version. For example, Windows CE.NET.

Platform. Identifies the host hardware, its version and build number.

Tapping More Info on the splash screen opens the Advanced System Information
window, which provides information such as hardware version and serial number,
CPU type and specifications, etc. This information can be especially useful if you
are contacting GE Fanuc Support.

T o run t h e S ys te m In form at io n pro gram


1. On the desktop, double-tap

System Information.

The System Information splash screen appears.

14

12" QuickPanel View & QuickPanel Control

GFK-2284A

Overview

QuickPanel View/Control Software

2. Tap More Info to open the Advanced System Information window, or tap Close to continue.
Network information alone can be viewed by double-tapping the
displayed on the taskbar for each connection.

LAN icon

Microsoft File Viewers


Included with Windows CE are applications that enable you to view files in three
popular formats: Microsoft Word, Excel, and Adobe PDF. Each application
provides online help for its use.

T o acce ss t h e M icro sof t fi le v ie we rs


1. Tap
Start, point to
following:

Programs, point to

Microsoft Excel Viewer

Microsoft PDF Viewer

Microsoft File Viewers, then choose one of the

Microsoft Word Viewer

File Viewer Limitations


Microsoft Excel:

Hyperlinks are not supported.


Data Tables in charts are not supported.
WordArt is not supported. Plain text will be substituted.
Surface charts. An image representing an unsupported chart will appear in the
chart's location.
Certain types of 3D charts will be mapped to equivalent 2D charts.
Supported 3D charts are only shown at a fixed camera angle.
Vertical text in the worksheet is mapped to 90 degree rotated text.

Microsoft Word:

WordArt is not supported.


Hyperlinks are not supported.
Some types, styles, and groupings of AutoShapes will not appear.
Word forms for Text boxes are not supported. Elements from the form may be
visible but will not be available for input.

Microsoft PDF:

GFK-2284A

Advanced features, such as PDF forms, annotations, and transitions are not
supported.

12" QuickPanel View & QuickPanel Control

15

Overview

QuickPanel View/Control Software

Copy Project to Flash Card


RestorePCCard is a custom utility for transferring CIMPLICITYTM Machine EditionTM
Projects between compatible QuickPanel View/Control units via CF cards.
Caution: Ensure that the copy or update operation is complete (i.e., no busy or
wait cursor displays) before disconnecting power.

To copy a Ma chi ne Editio n pro ject onto a CF c ard


1. Ensure there is a blank CF card in the in the CF port.
2. Double tap the

Copy Project to Flash Card icon on the desktop.

3. Tap Yes when the Proceed with Copy to CF Card confirmation dialog box appears.
The system copies the project onto the blank CF Card.

To update a Mach in e Ed ition pr oject


You can update a Cimplicity Machine Edition application currently stored on the
QuickPanel View/Control with a revision stored on a CF Card.
1. Insert the CF Card containing an upgraded version of the Machine Edition project in the CF port.
2. Reboot the machine (see page 13).
The QuickPanel View/Control automatically loads the new project from the CF
Card, overwriting the old project on the machine.
3. Remove the CF Card from the slot.

HTTP File Transfer Utility


The HTTP File Transfer Utility (HFTU) is a small, standalone command line
program that allows you to send and delete files to and from computers over a
network. The HFTU uses the HTTP protocol, so you can even send files to
computers over the Internet.
Run the HTTP utility from a command line prompt, from a batch file (.BAT) or as
an application call in a script. The HTTP utility is an executable (.EXE) file included
in the 12" QuickPanel View & QuickPanel Controls operating system.
The HTTP utility currently supports two file transfer commands: COPY and
DELETE.
Note: In order to function, the HTTP File Transfer utility requires both computers to
have web servers that support PUT functionality. (Most web servers support PUT,
including the CIMPLICITY Machine Edition web server installed with the runtimes
for View and Logic Developer - PC.) If in doubt, check the documentation for your
web server.
16

12" QuickPanel View & QuickPanel Control

GFK-2284A

Overview

QuickPanel View/Control Software

T o use t he HT T P u ti li t y
1. From the

Start menu, choose

Programs, then choose

Command Prompt.

The Command Line editor appears.

2. Type commands as required.


3. Use the following syntax:
HTTPUTIL COPY source destination
Where source is the URL of the source file, and destination is the URL of the
destination file. For example:
HTTPUTIL COPY \MyFile.txt http://MyServer/webfiles/MyFileBACKUP.txt

Copies a file called MyFile.txt on drive C: of the local computer to the webfiles
folder under the web server at //MyServer. Note that you can rename a file as you
copy it.
HTTPUTIL DELETE url
Where url is the remote URL of the file you want to delete. This URL must use
the // or HTTP:// syntax. For example:
HTTPUTIL DELETE http://MyServer/webfiles/MyFileBACKUP.txt

Deletes a file called MyFileBACKUP.txt from the webfiles directory under the web
server at HTTP://MyServer.

GFK-2284A

12" QuickPanel View & QuickPanel Control

17

Detailed Operation
In this chapter:

Touch Screen Display . . . . . . . . . . . . . . . . . . . . . .20


To adjust the display brightness . . . . . . . . . . . . . . . . . . . . . . . . .20
To configure backlight auto turn off . . . . . . . . . . . . . . . . . . . . . .21
To calibrate the touch screen . . . . . . . . . . . . . . . . . . . . . . . . . . .22
To set the double-tap sensitivity . . . . . . . . . . . . . . . . . . . . . . . . .23

Keyboard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
To show/hide the Soft Input Panel . . . . . . . . . . . . . . . . . . . . . . .25
To display the Soft Input Panel icon in the system tray . . . . . . . .26

Communication Ports . . . . . . . . . . . . . . . . . . . . . .27


To add a new remote networking connection. . . . . . . . . . . . . . . .28
To add a virtual private network or PPP over Ethernet. . . . . . . . .29
To change the default device properties . . . . . . . . . . . . . . . . . . .31
To change the default TCP/IP settings. . . . . . . . . . . . . . . . . . . . .31
To add a terminal session . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
To start a terminal session . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

CF Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Universal Serial Bus (USB) . . . . . . . . . . . . . . . . . .35
Ethernet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
To set an IP address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
To set up access to a Windows network . . . . . . . . . . . . . . . . . . . .38
To access a remote resource on a Windows network . . . . . . . . . .39

Expansion Bus . . . . . . . . . . . . . . . . . . . . . . . . . . .40


DIP Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
To configure startup behavior. . . . . . . . . . . . . . . . . . . . . . . . . . .42

Memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
To add Flash memory with a CF Card . . . . . . . . . . . . . . . . . . . . .43
To change the DRAM memory allocation . . . . . . . . . . . . . . . . . . .44
To install additional DRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Other Subsystems . . . . . . . . . . . . . . . . . . . . . . . .46


To access the Power Properties control panel. . . . . . . . . . . . . . . .46
To remove the internal battery. . . . . . . . . . . . . . . . . . . . . . . . . .47
To set the real-time clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
To display the time on the taskbar . . . . . . . . . . . . . . . . . . . . . . .48

GFK-2284A

12" QuickPanel View & QuickPanel Control

19

Detailed Operation

Touch Screen Display

TOUCH SCREEN DISPLAY


The QuickPanel View/Control has an integrated flat-panel display providing 15 bits
per pixel for a total of 32,768 colors. The back-lit 12-inch diagonal panel employs
TFT technology to provide a bright operator interface. To extend the backlights
life, it can be set to turn off automatically.
The display supports a resolution of 800 by 600 pixels.

600 pixels

800 pixels

To adju st th e di splay b righ t ne s s


1. In the Control Panel, double-tap

Display and choose the Brightness tab.

The Brightness dialog box appears.

2. Drag the Brightness slider between Lowest and Highest.


3. Tap OK to exit the control panel.
4. Run the

20

Backup program to save settings through a power cycle (see page 13).

12" QuickPanel View & QuickPanel Control

GFK-2284A

Detailed Operation

Touch Screen Display

To con fig ure back lig ht aut o t u rn off


1. In the Control Panel, double-tap

Display and choose the Backlight tab.

The Backlight dialog box appears.

2. Select Auto turn off backlight while on external power.


3. Tap OK to exit the control panel.
4. Run the

Backup program to save settings through a power cycle (see page 13).

Note: Backlight failure notification displays in this dialog box if one of the backlights
fails. If both backlights fail, the bottom LED flashes amber and the screen is blank.

GFK-2284A

12" QuickPanel View & QuickPanel Control

21

Detailed Operation

Touch Screen Display

Touch Screen
The QuickPanel View/Control display is coupled to a resistive touch panel with 12bit resolution. When the QuickPanel View/Control is properly calibrated, this
translates into a grid of touch cells on the face of the display. Although you can use
your finger to actuate the touch screen, use of a blunt stylus is recommended.

600 cells

800 cells

T o cali b ra t e t h e t ou ch s cre e n
1. In the Control Panel, double-tap

Stylus.

The Stylus Properties dialog box appears.

2. Choose the Calibration tab


3. Tap the Recalibrate button.
A cross hair target is displayed.

22

12" QuickPanel View & QuickPanel Control

GFK-2284A

Detailed Operation

Touch Screen Display

4. Follow the directions given to calibrate the touch screen.


5. Tap the screen to preserve the new setting or wait out the time limit to revert to previous settings.

6. Run the

Backup program to save the settings through a power cycle (see page 13).

To set t h e do uble- t ap s e ns it ivit y


1. In the Control Panel, double-tap

Stylus.

The Stylus Properties dialog box appears.

GFK-2284A

12" QuickPanel View & QuickPanel Control

23

Detailed Operation

Touch Screen Display

2. Choose the Double-Tap tab.


3. Double-tap the grid to enter a setting.
4. Double-tap the test icon to check the setting.
If the test icon doesnt change when you double-tap it, double-tap the grid again.
5. Tap OK to finish.
6. Run the

24

Backup program to save the settings through a power cycle (see page 13).

12" QuickPanel View & QuickPanel Control

GFK-2284A

Detailed Operation

Keyboard

KEYBOARD
The QuickPanel View/Control can be configured to use either or both a hardware
keyboard and a software emulation keyboard as a operator data input devices.
Typically, an external hardware keyboard is used when in a development mode,
while the included Soft Input Panel is more applicable in a operational
environment.

External Keyboard (optional)


Any USB keyboard compatible with the QuickPanel View/Control can be used as
an input device for the unit. The USB driver for the keyboard is included with the
operating system and no setup is required. To use an external keyboard, simply
plug and play.
A list of keyboards (and other devices) that have been tested and are compatible
can be found by visiting www.gefanuc.com/support and choosing QuickPanel
from the Product List.

Soft Input Panel


The Soft Input Panel (SIP) is a touch screen version of a standard keyboard, that can
be used in place of a standard hardware keyboard.

An icon in the system tray lets you view or hide the SIP.
Show Input Panel icon

T o sho w/ h i d e t h e S of t In p ut Pa ne l
On the system tray of the task bar, double-tap the

icon. The Soft Input Panel appears/disappears.

Note: When the SIP is visible, it can be dragged around the screen by its title bar to
reveal different parts of the screen that would be obstructed from view by the SIP.
GFK-2284A

12" QuickPanel View & QuickPanel Control

25

Detailed Operation

Keyboard

Us ing S HI FT , C AP , CT R L, an d ALT on t h e S oft Inp ut Pan e l


Uppercase characters are accessed by pressing the SHIFT key once. This is
equivalent to holding down the SHIFT key on a conventional keyboard. The SHIFT
key is active while the next key is pressed then reverts back to its unselected state.
The CAP key does the same thing as SHIFT but does not revert to lower case after
another key is pressed. Rather, the Soft Input Panel remains in the Uppercase mode
until the CAP key is pressed again. The CTRL and ALT keys behave the same as the
SHIFT key.

T o displ ay t he

S oft Inp ut P an e l icon in t he sy st e m t ray


1. In the Control Panel, double-tap

Input Panel.

The Input Panel Properties dialog box appears.

2. Select or clear the Allow applications to change the input panel state check box.
3. Select or clear the Show Input Panel in system tray check box.
4. Tap OK.
5. Run the

Backup program to retain the new setting through a power cycle (see page 13).

External Mouse (optional)


Any USB mouse compatible with the QuickPanel View/Control can be used as an
input device for the unit. The USB driver for the mouse is included with the
operating system and no setup is required. To use an external mouse, simply it into
the appropriate port.
A list of mouses (and other devices) that have been tested and are compatible can
be found by visiting www.gefanuc.com/support and choosing QuickPanel from the
Product List.

26

12" QuickPanel View & QuickPanel Control

GFK-2284A

Detailed Operation

Communication Ports

COMMUNICATION PORTS
The QuickPanel View/Control has two serial data communication ports, COM1
and COM2.

COM1- Serial
The COM1 port is a general purpose bidirectional serial data channel that supports
the EIA232C and EIA485 electrical standards. The COM1 port can be accessed
and configured:

as a direct or dial-up remote networking connection.

as the port used by a terminal session (modem link only).

from a user-created application program.

A connection can be configured to reside on a network supporting a TCP/IP


protocol.
A DB25S (female) connector, mounted on the bottom of the enclosure, provides
standard signals as described in the following table.
Bottom
1
2
3
4
5
6
7
8
9
10
11
12
13

GND - Frame Ground


TX - (EIA232C)
RX - (EIA232C)
RTS - (EIA232C)
CTS - (EIA232C)
DSR - (EIA232C)
SG - Signal Ground
DCD - (EIA232C)
TRMRXB (EIA485)
RXA (EIA485)
TXA (EIA485)
n/c
n/c

14
15
16
17
18
19
20
21
22
23
24
25

VCC - 5VDC, 0.5A


TXB (EIA485)
RXB (EIA485)
n/c
CSB (EIA485)
ERB (EIA485)
DTR (EIA232C)
CSA (EIA485)
ERA (EIA485)
n/c
n/c
n/c

Notes:

Twisted-pair cable is required when using the EIA485 connections.

When using in EIA485 mode, RXA/RXB termination should be used if the


QuickPanel View/Control is the last node on the 485 network. An RX
termination resistor is included, and used by connecting pin 9 to pin 10.

GFK-2284A

Pin 14 is fused with a field-replaceable, 1.0A fast-blow fuse.

When using in EIA485 mode, pin 7 (ground) should not be used.

12" QuickPanel View & QuickPanel Control

27

Detailed Operation

Communication Ports

COM2 - Serial
A DB9P (male) connector, mounted on the side of the enclosure, provides standard
signals as described in the following table.

Bottom
1
2
3
4
5
6
7
8
9

n/c
RX
TX
n/c
SG - Signal Ground
n/c
RTS
CTS
n/c

Working with COM ports


T o a d d a n e w re m ot e n e t wor ki ng co nn e ct i on
1. From the

Start menu, tap

Settings and then

Network and Dial-up Connections.

The Connection window appears.


2. Double-tap

Make New Connection.

The Make New Connection wizard appears.

3. Type a name for the new connection.


28

12" QuickPanel View & QuickPanel Control

GFK-2284A

Detailed Operation

Communication Ports

4. Choose a connection type.


5. Tap Next.
The Modem or Device dialog box appears, depending on the connection type.

or
6. From the list, choose the device or modem you want to use. (If a CF card is inserted, it is available in the device list.)
You can Configure your device or TCP/IP Settings at this time if you wish.
7. Tap Finish for direct connection (Device dialog box) or Next for dial-up (Modem dialog box).
If you are adding a dial-up connection the following dialog box appears.

8. Type the destination Country/region code, Area code, and Phone number in the appropriate boxes.
9. Select or clear the Force Long Distance or Force Local check boxes.
10. Tap Finish.

To add a v irtu al priv ate n etw ork or P PP over E th e rn et


1. From the

Start menu, tap

Settings and then

Network and Dial-up Connections.

The Connection window appears.


2. Double-tap

GFK-2284A

Make New Connection.

12" QuickPanel View & QuickPanel Control

29

Detailed Operation

Communication Ports

The Make New Connection wizard appears.

3. Type a name for the new connection.


4. Choose a connection type.
5. Tap Next.
The VPN or PPPoE Connection window appears, depending on the connection
type.

or
6. Enter the Host Name or IP address for a VPN connection, or a PPPoE Service Name for a PPPoE connection.
You can configure your TCP/IP Settings at this time if you wish.
7. Tap Finish.

30

12" QuickPanel View & QuickPanel Control

GFK-2284A

Detailed Operation

Communication Ports

To cha nge the defau lt dev ice prop er ties


1. From either the Device or Modem dialog box, tap Configure.
The Device Properties dialog box appears.

2. In the Port Settings tab, choose settings for all connection preferences.
3. If the connection is for terminal emulation, select or clear the terminal-related check boxes.
You can use the QuickPanel View/Control to emulate a terminal attached via a
modem link (Hayes compatible) to COM1. A terminal emulation definition is
added as a unique session.

T o cha nge t he d e fau lt T C P/ IP se t t ing s


1. Obtain correct TCP/IP settings from your network administrator.
2. From either the Device, Modem, PPPoE Connection, or VPN Connection dialog box, tap TCP/IP Settings.
The TCP/IP Settings dialog box appears.

3. Clear the Use server-assigned IP address check box.


4. Enter the TCP/IP settings from your network administrator and then click OK.

GFK-2284A

12" QuickPanel View & QuickPanel Control

31

Detailed Operation

Communication Ports

To add a termin al ses sion


1. From the

Start menu, tap

Programs, then Communication, and then tap Terminal.

The Terminal window appears.

2. Double tap

Make a New Session.

The Session Properties dialog box (Communications tab) appears.

3. In the Session Name box, type a name for your session.


4. Enter the Country Code, Area Code and Telephone number of the remote modem you will connect to.
5. Tap the Emulation tab and choose an emulation type (DEC-VT-100 or TTY (Generic)).

6. From the Code page selection box, select the coding type to employ.
7. Select the Inbound and /or Outbound check boxes to add LF characters to each CR.
8. Select the Vertical and/or Horizontal check boxes to specify automatic scrolling.

32

12" QuickPanel View & QuickPanel Control

GFK-2284A

Detailed Operation

Communication Ports

9. Tap OK.
10. The new session is added to the Session window.
11. Run the

Backup program to retain the new session definition through a power cycle.

To start a termin al ses sion


1. From the

Start menu, tap

Programs, then Communication, and choose Terminal.

The Terminal window appears.

2. Double-tap the

GFK-2284A

session you want to start.

12" QuickPanel View & QuickPanel Control

33

Detailed Operation

CF Port

CF PORT
To enhance the QuickPanel View/Controls capabilities with additional flash
memory, the unit is equipped with a CF (Compact Flash) Type 2 port on its side.
Right Side

Compact Flash Port

A CF card is inserted in this port with the cards front facing the back of the unit
(the narrow side slot on the card should be toward the bottom).
Note: For full protection from electrostatic discharge, peel off the paper label on
the side of the CF card facing the bezel to allow contact between the card and the
internal frame ground contacts on the CF connector.
The card should slide in easilyto avoid damage, do not force it.
The Copy Project to Flash Card utility (see page 16) lets you transfer Cimplicity
Machine Edition projects between QuickPanel View/Control units via CF Cards.
No Compact Flash cards are supplied with the QuickPanel View/Control. A list of
cards (and other devices) that have been tested and are compatible can be found
by visiting www.gefanuc.com/support and choosing QuickPanel from the Product
List.

34

12" QuickPanel View & QuickPanel Control

GFK-2284A

Detailed Operation

Universal Serial Bus (USB)

UNIVERSAL SERIAL BUS (USB)


The QuickPanel View/Control has two full-speed USB v1.1 host ports. A variety of
third-party USB peripheral devices are available.
Each connected USB device requires a specific driver. The driver supplied with the
QuickPanel View/Control is for optional keyboard supportother devices require
the installation of custom driver software.
Bottom

USB Ports

1 5V
2 Data 3 Data +
4 GND

For a list of compatible keyboard types, mice, and other USB devices, visit
www.gefanuc.com/support and choose QuickPanel from the Product List.
Note: These USB ports are defined as maintenance ports and are intended to be
temporary connections used for configuration and upload/download of software or
data.
Use of a device in the USB port may compromise CE Mark and UL certifications.
Before using an application requiring the use of a USB device, verify that the USB
device installed in the QuickPanel View/Control meets the desired agency
certifications.
Warning: For compliance to UL1604, DO NOT connect or disconnect while
power is applied unless the area is know to be nonhazardous.

GFK-2284A

12" QuickPanel View & QuickPanel Control

35

Detailed Operation

Ethernet

ETHERNET
The QuickPanel View/Control is equipped with two auto-negotiate, full or half
duplex Ethernet ports (IEEE802.3). You can connect an Ethernet network cable
(unshielded, twisted pair, UTP CAT 5) to the unit via the RJ45 connector on the
bottom of the enclosure. LED indicators on the port indicate channel status. Access
to the port is possible either by Windows CE network communications, or by your
custom application. The following diagram shows the location, orientation, and
pin out of the Ethernet port.
Bottom

LAN2: 10Mb

LAN1: 10/100Mb

Ethernet Ports

Activity
LED

1
2
3
4
5
6
7
8

TX_D1 +
TX_D1 RX_D2 +
B1_D3 +
B1_D3 RX_D2 B1_D4 +
B1_D4 -

Link
LED

There are two methods for setting an IP address on the QuickPanel View/Control:

DHCP (Dynamic Host Configuration Protocol). This is the default method for
Port 1 that is carried out automatically.
Note: There must be a DHCP server on the connected network for a valid IP
address to be assigned. Contact your network administrator to ensure correct
DHCP server configuration.

Manual method. This is the default method for Port 2. You uniquely specify the
numeric addresses for the QuickPanel View/Control, the Subnet Mask, and the
Default Gateway (if applicable).
Note: Use a crossover cable to connect the QuickPanel View/Control to a PC
directly; when connecting to a LAN HUB, use a straight through cable.
Contact your network administrator if you require further information.

36

12" QuickPanel View & QuickPanel Control

GFK-2284A

Detailed Operation

Ethernet

To set an IP add ress


1. From the Control Panel, tap

Network and Dial-up Connections.

The Connection window appears.

2. Select a

connection and choose

Properties.

The Built-in Ethernet Port Settings dialog box appears.

3. Select a method:

Obtain an IP address via DHCP (automatic).

Specify an IP address (manual).

4. Enter the IP Address, Subnet Mask and Default Gateway numbers obtained from your network
administrator (manual method only).
5. Tap OK.
6. Run the

Backup program to retain the new settings through a power cycle (see page 13).

7. Restart the QuickPanel View/Control.


If the DHCP method was selected, the network server will assign an IP address
while the QuickPanel View/Control is initializing. (You must be connected to the
network).
After setting an IP address for the QuickPanel View/Control, you can access any
network drives or shared resources for which you have permission.

GFK-2284A

12" QuickPanel View & QuickPanel Control

37

Detailed Operation

Ethernet

T o se t u p a cce ss t o a Win dow s ne t wo rk


1. In the Control Panel, double-tap

System.

The System Properties dialog box appears.

2. On the Device Name tab, in the Device name box, type a unique name for your QuickPanel View/Control. In the
Device description box, type a description.
3. Tap OK.
4. In the Control Panel, double-tap

Owner.

The Owner Properties dialog box appears.

5. On the Network ID tab, type your assigned User name, Password and Domain.
6. Tap OK.
7. Run the

38

Backup program to retain the settings through a power cycle (see page 13).

12" QuickPanel View & QuickPanel Control

GFK-2284A

Detailed Operation

Ethernet

Using Windows CE Explorer, you can now access anything on your local network
for which you have permission.

T o acce ss a re m o te re so urc e on a Wi ndo ws n e tw ork


1. Start

Windows Explorer.

The Explorer window appears.

2. Type in the Address box, or choose from a list, the path to a remote resource.
For example \\MyRemoteComputer\MyFolder specifies the folder named
MyFolder on a computer with the name MyRemoteComputer.
3. Press ENTER.
The resource specified is displayed as a collection of files and folders. It can take a
few moments to retrieve the data from your local network.
Note: You can use the NET command from the shell to map a network resource to
the QuickPanel View/Control for frequent access. The resource then appears in the
Network folder.

GFK-2284A

12" QuickPanel View & QuickPanel Control

39

Detailed Operation

Expansion Bus

EXPANSION BUS
An expansion bus is included with the QuickPanel View/Control, and optional
modules that mount directly to it are available. For more information on expansion
modules, contact your distributor.
The expansion bus connectors are accessed by opening the back of the unit.
Back (open)
Expansion Bus

Note: To ensure compliance to CE Mark, the mounting screws must be used when
installing an expansion card.
Caution: Disconnect the AC power from your 24 VDC power supply before
opening the QuickPanel View/Control. Working on a live unit may result in
damage to equipment and injury to personnel. Always use anti-static precautions
(i.e. grounded wrist strap) when accessing the interior of the unit.
Caution: Ensure all pins are properly aligned when inserting expansion cards.
Misalignment could cause damage to the QuickPanel View/Control and/or the
expansion card.

40

12" QuickPanel View & QuickPanel Control

GFK-2284A

Detailed Operation

DIP Switches

DIP SWITCHES
The QuickPanel View/Control is equipped with four DIP switches that each control
separate functions.
DIP switches are set to OFF by default in the factory. DIP switch 2 is the Force
Startup switch. Turning this switch on forces the startup applications to run when
the operating system is started.
Back (open)

Dip Switches

Force Startup
When the switch is set to OFF, the QuickPanel View/Control operates normally,
displaying the startup splash screen. You can skip running the startup applications
by tapping the Dont run StartUp Programs button on the startup splash screen.

When the switch is set to ON, the startup programs are forced to run and the
Dont run Startup Programs button is not available on the startup splash screen.
Note: Do not adjust switches other than switch 2. They are reserved for factory
functions. Also note that the Off position of the switches is toward the DIMM
connector, On toward the COM1 connector.

GFK-2284A

12" QuickPanel View & QuickPanel Control

41

Detailed Operation

DIP Switches

T o con f i g ure st a rt u p b eh a vi or
Caution: Disconnect the AC power from your 24VDC power supply before
opening the QuickPanel View/Control. Working on a live unit may result in
damage to equipment and injury to personnel. Always use anti-static precautions
(i.e. grounded wrist strap) when accessing the interior of the unit.
1. Open the back cover of the QuickPanel View/Control.
2. Locate the DIP switches and set DIP switch 2 to ON.
The startup applications are now forced.
Note: Do not adjust the other switches. They are reserved for factory functions.

42

12" QuickPanel View & QuickPanel Control

GFK-2284A

Detailed Operation

Memory

MEMORY
The QuickPanel View/Control supports a variety of memory subsystems to ensure
the requirements of your application are met. All system memory is tied directly to
the microprocessors address and data busses for fastest access. To increase DRAM
by up to 64 MB, a 100-pin DIMM memory expansion slot is also included.

Flash Memory
This block of non-volatile memory (32MB or 64MB, depending on your model) is
the main long-term program storage for the QuickPanel View/Control, operating
like a virtual hard drive from the point of view of Windows CE. It is divided into
two areas, of which only one is accessible from Windows CE Explorer.
The
Flash Storage folder represents a block of memory (16MB or 48MB,
depending on your model) available for long-term storage of user application
programs. Another 16MB block is used to store the Windows CE operating system,
and is not directly accessible from Windows CE Explorer.
The operating system and all user application programs are transferred from Flash
to DRAM for execution. Any user additions to the
Windows folder are retained
in
Flash Storage when the
Backup utility is run.
FLASH memory has a limited write-cycle lifetime. That is, the physical memory
devices wear out after approximately 100,000 cycles (minimum), so it is advisable
to limit file operations such as copy, delete, etc.
The write cycle is much slower for FLASH than it is for other portions of RAM,
therefore FLASH is not recommended for the storage of program variables, or any
data items whose values are dynamic.
Flash memory can optionally be added with a CF Card, which will appear as the
PCFlash Storage folder.

To add Fla sh memory w ith a CF C ard

Insert a Compact Flash card into CF Port (see page 34).

The unit immediately reads the new secondary storage. If the disk requires
formatting, you will be prompted to do so.
New memory appears in Windows CE Explorer as

GFK-2284A

PCFlash Storage.

12" QuickPanel View & QuickPanel Control

43

Detailed Operation

Memory

SRAM Memory
This 512 KB block of static RAM is battery-backed to provide data retention
through a power cycle. This memory block is shared by the operating system and
user applications. A portion of the SRAM memory operates as a virtual hard drive
and is accessible from the Windows CE Explorer. It is represented as the
SRAM
Storage folder. A typical application program would create a file in this folder and
store any critical program data in that file.

DRAM Memory
The QuickPanel View/Control is equipped with 32 MB of dynamic RAM. Part of
the DRAM (14 MB) is reserved for the Windows CE operating system and is not
accessible by user applications. The other 18 MB is split between two functions: an
object store for temporary file storage, and the main memory for running programs.
Typically, compressed programs stored in FLASH are expanded and moved to
DRAM for execution. Temporary storage of program variables or data files is also
provided by DRAMany data stored in DRAM will not be retained through a
power cycle or reboot.
The split between program memory and storage memory may be adjusted as
necessary to make more room for one or the other, depending on your specific
application needs. For example, if you find that an application is short of memory,
use the System Properties dialog box to alter DRAM memory allocation.
Caution: Setting Program Memory too low may prevent additional applications
from starting, or may cause currently running applications to fail due to lack of
memory. Setting Storage Memory too low may prevent the saving of files into the
object store portion of the file system, which may also cause application failures.

T o cha nge t he DR AM m e m or y a llo cat i on


1. In the Control Panel, double-tap

System.

The System Properties dialog box appears.

44

12" QuickPanel View & QuickPanel Control

GFK-2284A

Detailed Operation

Memory

2. On the Memory tab, drag the slider to divide the DRAM into Storage and Program memory.
The amount of memory allocated to and used by each area is shown on the dialog
box.
3. Tap OK to apply the new setting.
4. Run the

Backup program to retain the new setting through a power cycle (see page 13).

Boot Loader ROM


The Boot Loader ROM provides 512 KB of non-volatile storage for the QuickPanel
View/Controls initialization program. This program configures the QuickPanel
View/Control hardware then starts the operating systems execution. This memory
is not accessible from Windows CE Explorer, nor should any attempts be made to
modify the contents of this ROM.

Memory Expansion Slot


The QuickPanel View/Control is equipped with a 100-pin DIMM memory
expansion slot which lets you increase DRAM to a total of 96 MB.
Rear (open)

Memory Expansion Slot

Caution: Disconnect the AC power from your 24VDC power supply before
opening the QuickPanel View/Control. Working on a live unit may result in
damage to equipment and injury to personnel. Always use anti-static precautions
when accessing the interior of the QuickPanel View/Control.

To ins t all additi ona l D R AM


1. Disconnect AC power from the 24VDC supply.
2. With a small screwdriver carefully remove the top rear access cover.
3. Insert the new DIMM carefully into the expansion slot, noting the orientation of the pin locators. When the DIMM is
fully seated, lift each side clip until it clicks into place.
4. Snap the access cover back into place.

GFK-2284A

12" QuickPanel View & QuickPanel Control

45

Detailed Operation

Other Subsystems

OTHER SUBSYSTEMS
Power Management
The QuickPanel View/Controls Power Properties control panel displays the status
of the backup battery. The
Battery Very Low Or Missing icon displays in the
taskbar when the battery is either missing or very low.

T o acce ss t h e P ow e r Pr ope rt ie s co nt ro l pane l


1. In the Control Panel, double-tap

Power.

The Power Properties dialog box appears.

Battery Backup
Auxiliary backup power for the real-time clock and SRAM is provided by a nonrechargeable, internal lithium battery (+3VDC, CR2032), ensuring that no loss of
data occurs when the main 24VDC supply is removed. Backup power is enabled
or disabled by installing or removing the battery, accessed via the rear panel as
shown in the following illustration.
Rear (open)

Internal Battery

Caution: Disconnect the AC power from your 24VDC power supply before
opening the QuickPanel View/Control. Working on a live unit may result in
damage to equipment and injury to personnel. Always use anti-static precautions
when accessing the interior of the QuickPanel View/Control.

46

12" QuickPanel View & QuickPanel Control

GFK-2284A

Detailed Operation

Other Subsystems

T o re m ove t he i nt e rn a l b a t t e ry
1. Disconnect AC power from the 24VDC supply.
2. Open the rear access panel.
3. Release the battery by gently lifting it from the completely exposed side, past the small protrusions. To avoid
breaking the battery retainer clips, do not apply excessive upward pressure.
4. Slide the battery out of its carrier, noting the arrow on the carrier indicating the direction of removal.

Real-time Clock
The QuickPanel View/Control has a programmable real-time clock capable of
reporting the current time in Year/Month/Day/Hour/Minute/Second. The time is set
from the Windows CE interface and retained through a power cycle if battery
backup is available. Daylight saving time is enabled by a check box within the
dialog box. The time can be displayed in the system tray on the task bar.

T o se t t h e re a l -t i m e cloc k
1. In the

Control Panel, double-tap

Date/Time.

The Date/Time Properties dialog box appears.

Note: Tap Apply after making changes in any box.


2. Tap the year to choose a new year; tap the month to choose a new month.
3. Tap a date to specify the day of month.
4. From the Time Zone box, choose your zone.
5. Select DST in effect to configure the clock to automatically compensate for daylight savings time.
6. In the Current Time box, adjust the hours, minutes and seconds.
7. Tap OK to finish.
8. Run the
page 13).
GFK-2284A

Backup program to save Time Zone or Daylight Savings changes through a power cycle (see

12" QuickPanel View & QuickPanel Control

47

Detailed Operation

Other Subsystems

T o d i spl ay t he t i m e on th e t a s kb a r
1. From the

Start menu, choose

Settings and then

Taskbar and Start Menu Properties.

The Taskbar Properties dialog box appears.

2. On the Taskbar Options tab, select Show Clock.


3. Tap OK.
An hours and minutes display now appears in the taskbar.
Clock Display

48

12" QuickPanel View & QuickPanel Control

GFK-2284A

A1

Design Specifications
The specifications listed in this appendix are the design goals for the QuickPanel
View/Control. In most cases the as built or tested specifications are identical. See
page 54 for a list of agency approvals for environmental service and safety.

Physical
Item

Specification

Enclosure dimensions
(actual - see page 4 for panel
cutout specifications)

Height: 8.93 in (226.8 mm)


Width: 11.85 in (301.1 mm)
Depth: 2.37 in (60.1 mm)

Bezel dimensions

Height: 10.34 in (262.6 mm)


Width: 13.26 in. (336.8mm)
Depth: 0.38 in (9.7 mm)

Weight

2.5lb (1.16 kg)

DC Power
Item
Input Voltage

12 VDC (@ +/- 20% regulated power supply; or


24 VDC (@ +/- 20% regulated power supply)

Real Power

48 W

Power Supply Conductor Size

12 to 18 AWG
For compliance to CE Mark, the isolated frame
ground must be connected.
Recommended frame ground connection is via
the shortest possible route, using 14 AWG.

Connector (Vendor, p/n)

GFK-2284A

Specification

Phoenix Contact, 1777992

12" QuickPanel View & QuickPanel Control

49

A1

Design Specifications

Display
Item

Specification

Size

12 30.5 cm

Colors

32,768 (15 bits/pixel)

Resolution

800 X 600

Fabrication

TFT

Backlight

Cold Cathode Fluorescent (CCFL) - rated half


life: 50,000 hours1

Front Panel
Item

Specification

Bezel Material

Valox 357U 2

Membrane Material

Lexan HP60 3

LEDs

Bottom

Power status indicator (green with power


applied, flashes amber if both backlights fail)

Top

Programmable tri-color (green, red, amber)

Touch Screen
Item

Specification

Type

Resistive, 12 bit

Resolution

X axis- 800 cells


Y axis - 600 cells
(after calibration)

CPU
Item

Specification

Processor

Intel XScale PXA255

Clock speed

400 Mhz

Backlight not field replaceable.


For material specifications, visit www.gepolymerland.com
3
For material specifications, visit gestructuredproducts.com
2

50

12" QuickPanel View & QuickPanel Control

GFK-2284A

Design Specifications

Memory
Item

Specification

FLASH

32MB or 64MB

SRAM

512KB (Battery Backed)

DRAM

32MB

ROM

512KB (Boot loader)

Memory Expansion Slot


Item

Specification

Form Factor

100 pin DIMM

Memory Type

SDRAM

Maximum DRAM

64 MB

Maximum Devices/Module

Bus Width

32 bits

Bus Speed

100 MHz or faster

Voltage

3.3 VDC

CAS Latency

CL=3

Refresh Cycle Time

64 ms maximum

Error Correction

Non-ECC

Error Detection

No parity

Buffering

None

Device Row Addressing

12 Address Lines (A0 to A11)

Expansion Ports
Item
Compact Flash Memory

One slot (type 2)

FieldBus

One slot

Universal Serial Bus (USB) (2)

GFK-2284A

Specification

V1.1 compatible

12" QuickPanel View & QuickPanel Control

51

A1

Design Specifications

Communication Ports
Item

Specification

Ethernet (x 2)

IEEE 802.3
10/100BaseT (LAN1), 10BaseT (LAN 2)
Auto-negotiate
Full or half duplex
RJ45 connectors
Two status LEDs per connector

Serial COM1
Speed
Mounting h/w

EIA232C/EIA485, DP25S (female)


300 bps - 115200 bps
M2.6 jackscrew

Serial COM2
Speed
Mounting h/w

EIA232C, DP9P (male)


300 bps - 115200 bps
#4-40 screw

Environmental
Item
Operating Temperature

32F to 122F
(0C to 50C)

Operating Humidity

10% to 90% RH, non-condensing

Storage Temperature

-4 to 158F
-20 to 70 C

Storage Humidity

10% to 90% RH, non-condensing

NEMA Rating

4, 4x, and 12 when mounted in a comparably


rated NEMA panel (NEMA 4 is approximately
equivalent to IP56; visit www.nema.org)

Operational Vibration

IEC 68-2-6
10 - 57Hz, 0.012 peak to peak displacement
57 - 500Hz, 1.0g acceleration

Operational Shock

52

Specification

IEC 68-2-27
15g, 11ms (sine wave)

12" QuickPanel View & QuickPanel Control

GFK-2284A

Design Specifications

Battery
Item

Specification

Type

CR2032 (3V, 190mAh, lithium)

Life (Approximate)

5 years

Calendar/Clock
Item
Resolution

1 second

Accuracy

+/-5 seconds/month

Retention

GFK-2284A

Specification

Life of battery

12" QuickPanel View & QuickPanel Control

53

A1

Design Specifications

Agency Qualifications
Model # ES1222
Description

Agency Standard
or Marking

Comments

North American Safety


for Industrial Control
Equipment

Certification by
Underwriters Laboratories
to UL standard and
equivalent CSA standard

North American Safety


for Hazardous
Locations Class I, Div.
2, Groups A, B, C, D

UL 1604/C-UL

Certification by
Underwriters Laboratories
to UL standard and
equivalent CSA standard

Explosive Atmospheres
Directive
European Safety for
Hazardous Locations
Equipment Group II,
Category 3

ATEX (when
mounted in an IP66rated panel)

Certification in accordance
with European directives;
refer to Declaration of
Conformity and
Independent 3rd Party
Assessment Certificate

Low Voltage Directive


European Safety for
Industrial Control
Equipment

CE

Self-declaration in
accordance with European
directives; refer to
Declaration of Conformity

Electromagnetic
Compatibility Directive
European EMC for
Industrial Control
Equipment

54

UL 508/C-UL

CE

Certification by competent
body in accordance with
European directives; refer to
Declaration of Conformity

12" QuickPanel View & QuickPanel Control

GFK-2284A

A2

Troubleshooting
The tables contained in this appendix can be used to identify and remedy
problems that can occur with the 12" QuickPanel View & QuickPanel Control.

Power up
Problem

Suggested remedy

Blank screen.

No power: Check all power connections to the


QuickPanel CE.
Backlight failed: This is further indicated when the
bottom LED glows amber. The LED will only light if both
top and bottom backlights have failed.
Backlight timer expired: Touch screen to reactivate.

Pocket Internet Explorer


Problem
Cannot access any URLs when using
a dial-up connection to an ISP.

GFK-2284A

Suggested remedy
If you have previously set up an IP address on a local
Ethernet Network, it must be cleared. Disconnect your
Ethernet cable and reboot.
Your ISP will reassign an IP address when you reconnect
the cable.

12" QuickPanel View & QuickPanel Control

55

Index
A
accessing
Windows network 38, 39
adding
connections 28, 29
addresses
IP 37
adjusting
display brightness 20

B
backlight
(note) 8, 50
set for auto turn off 21
backup 13
battery 46
specifications 53
status 46
baud rate 31
bezel 50
block diagram 9
boot loader ROM 45
brightness 20

C
calibrating
touch screen 22
CIMPLICITY Machine Edition 16
clock 47
COM1 27
COM2 28
communication ports 27, 52
locations 8
compact flash
adding memory 43
configuring
set IP address 37

GFK-2284A

TCP/IP settings 31
terminal session 32
connections
adding 28, 29
set IP address 37
TCP/IP settings 31
terminal session 32
Windows network 38
cutout 4
see also design specificatons

D
design specifications 49
device properties, configuring 31
DHCP (Dynamic Host
Configuration Protocol) 36
dial-up connection 28
dip switches 41
displaying
real-time clock 48
double-tap sensitivity
setting 22, 23
DRAM 44
partition DRAM memory 44
partitioning 44

E
Ethernet 36
port settings 37
Excel
Microsoft file viewer 15
viewer limitations 15
expansion bus 40
expansion busses
locations 8
expansion ports 51
Explorer, Internet 11

F
flash 43
flow control 31
front panel 8, 50
bezel 50
LEDs 8, 50
membrane 50

I
input panel 25
displaying 25, 26
Internet Explorer 11
IP address
setting 37

K
keyboard 25
external 25
keyboard shortcuts 10

L
LEDs
Ethernet 36, 52
front panel 8, 50

M
Machine Edition 16
membrane 50
memory 43, 51
adding with CF card 43
boot loader ROM 45
DRAM 44
flash 43
partition DRAM memory 44
SRAM 44
memory expansion slot 45

12" QuickPanel View & QuickPanel Control 57

Index

Microsoft file viewers 15


accessing 15
limitations of 15
modem configuration 28
mounting
dimensions 4
hardware 5
mounting directions 5
mounting brackets 5
mouse, external 26

PPPoE 29
product support 6
programs
start menu 11
proxy server 12

R
real-time clock 47
displaying 48
setting 47

panel cutout 4
see also design specifications
parity 31
partitioning
DRAM 44
PDF
Microsoft file viewer 15
viewer limitations 15
physical layout 8
Pocket Internet Explorer 11
ports
communication 27, 52
Ethernet 36
expansion 51
keyboard 25
locations 8
serial 27
power management 46
control panel 46
power supply 2
power supply terminals
location 8

serial ports 27
setting
double-tap sensitivity 23
sensitivity 22
IP address 37
real-time clock 47
setup
basic 2
runtime 3
shutdown 4
specifications 49 to ??
SRAM 44
start menu 11
startup 3
configuring behavior 42
force startup switch 41
stop startup programs 41
storage card 43, 44
storage manager 14
support 6
switches, dip 41

58

12" QuickPanel View & QuickPanel Control

System Information 14

T
Technical Advisor 6
technical support 6
terminal
add session 32
start session 33
terminal emulation 31
touch screen 22
calibrating 22
troubleshooting 55

U
USB (Universal Serial Bus) 35
utilities
backup 13
System Information 14

V
viewers
see Microsoft file viewers 15
virtual private network 29

W
Windows CE 10
Windows network
accessing 38, 39
Word
Microsoft file viewer 15
viewer limitations 15

GFK-2284A

MODEL DS325-322
SECTION 14 Lube System Assembly
Table of Contents
Level

Drawing

Description

Rev.

Page

D107811-1

LUBE SCHEMATIC

14.1

A105052-1

ELECTRIC MOTOR 75 HP 55KW

14.1-4

A105053-1

PUMP DOUBLE GEAR CCW

14.1-5

A105054-1

PUMP DOUBLE GEAR CW

14.1-6

A98950-1

PRESSURE FILTER

14.1-13

A105060-1

PRESSURE TRANSDUCER

14.1-18

A105061-1

FLOW METER/SWITCH INLINE

14.1-20

A105062-1

FLOW METER/SWITCH INLINE

14.1-21

A101002-1

MOTOR HYDRAULIC

14.1-28

A103125-1

PUMP LUBE RETURN

14.1-29

5750001302 STRAINER

14.1-34

A62306-1

RETURN FILTER

14.1-36

A105072-1

RETURN FILTER

14.1-37

A93380-1

PUMP TRANSFER

14.1-48

5750001825 FILTER

14.1-55

B62272-1

14.2

CUTTERHEAD SUPPORT
PRESSURIZATION ASSEMBLY

5750990017 TIGHTENING TORQUE FASTENERS

322tc14

SECTION 3

August, 2008

MODEL DS325-322
SECTION 15 Hydraulic System Assembly
Table of Contents
Level

Drawing

Description

Rev.

Page

D107812-1

HYDRAULIC SCHEMATIC

15.1

A104947-1

ELECTRIC MOTOR 30HP 25KW

15.1-7

A104948-1

ELECTRIC MOTOR 75HP 55KW

15.1-8

A104949-1

ELECTRIC MOTOR 100HP 75KW

15.1-9

A104950-1

ELECTRIC MOTOR 125HP 90KW

15.1-10

A104951-1

DOUBLE VANE PUMP

15.1-13

A104952-1

VARIABLE VOLUME PUMP TRIPLE

15.1-14

A104953-1

VARIABLE VOLUME PUMP DOUBLE

15.1-15

A104954-1

VARIABLE VOLUME PUMP

15.1-16

A63843-1

RETURN FILTER

15.1-183

A105040-1

PRESSURE FILTER DOUBLE ELEMENT

15.1-184

A98937-1

TEMPERATURE TRANSDUCER

15.1-187

A105045-1

HEAT EXCHANGER WATER/OIL

15.1-199

A93380-1

TRANSFER PUMP

SEE 14.1-48

A98942-1

ACCUMULATOR

15.1-209

A98943-1

BREATHER

15.1-210

5750990017 TIGHTENING TORQUE FASTENERS

322tc15

SECTION 3

August, 2008

MODEL DS325-322
SECTION 16 Electrical System Assembly
Table of Contents
Level

Drawing

Description

Rev.

Page

D107809-1

ELECTRICAL SYSTEM ASSEMBLY

16.1

D104415-1

TBM SWITCHGEAR CABINET ASSY.

16.1-2

D104504-1

CABINET ASSEMBLY
LUBE & HYDRAULIC POWER UNIT

16.1-3

D104501-1

CABINET ASSEMBLY TBM FORWARD

16.1-4

D104502-1

CABINET ASSEMBLY GRIPPER SHIELD 2

16.1-5

D104503-1

CABINET ASSEMBLY TBM AFT

16.1-6

D104409-1

CONTROL STATION
AUXILIARY STATION

16.1-7

D104528-1

ERECTOR ELECTRICAL ASSEMBLY

16.1-9

D104551-1

CABINET ASSEMBLY ERECTOR

16.1-9-3

D104552-1

INDICATOR PANEL ERECTOR

16.1-9-4

A104593-1

RADIO CONTROLLER ERECTOR

16.1-9-7

D101418-1

JOG STATION

16.1-10

B104706-1

SEGMENT FEEDER AFT STATION

16.1-11

D104295-1

ELECTRICAL SYSTEM CABLING


3PH POWER CABLES

16.1-13

D104299-1

PLC INSTALLATION

16.1-14

D104463-1

ETHERNET ROUTER WIRELESS

16.1-14-23

D104486-1

FIRE ALARM SYSTEM ASSEMBLY

16.1-15

D107945-1

CABLE REEL HIGH VOLTAGE

16.1-18

D107943-1

TRANSFORMER 3000 KVA

16.1-19

322tc16

August, 2008

MODEL DS325-322
SECTION 16 Electrical System Assembly
Table of Contents
Level

Drawing

Description

Rev.

Page

33KV/690V/50HZ DELTA WYE


2

D107944-1

TRANSFORMER 3000 KVA


33KV/690V/50HZ WYE WYE

16.1-20

D107942-1

TRANSFORMER 2000 KVA


33KV/400V/50HZ DELTA WYE

16.1-21

D104416-1

ELECTRICAL CABINET GENSET

16.1-22

A104686-1

GENSET 85KVA 400V 50HZ

16.1-23

D107948-1

VFD CABINET ASSEMBLY

16.1-27

B76733-1

METHANE MONITOR ASSEMBLY

16.1-34

MANUFACTURERS LITERATURE

16.1-34A

5750006605 METHANE CALIBRATION KIT

16.1-36

A98898-1

16.1-37

OXYGEN MONITOR
MANUFACTURERS LITERATURE

16.1-37A

A98899-1

CARBON MONOXIDE MONITOR

16.1-40

A98900-1

CARBON DIOXIDE MONITOR (C02)

16.1-44

MANUFACTURERS LITERATURE

16.1-44A

C67309-8

TRANSDUCER TILT

16.1-48

D104292-1

COMMUNICATION SYSTEM

16.1-49

D104293-1

TV SYSTEM 240V PAL

16.1-51

A98575-2

VIDEO PROCESSOR

16.1-51-6

MANUFACTURERS LITERATURE

322tc16

16.1-51-6A

August, 2008

MODEL DS325-322
SECTION 16 Electrical System Assembly
Table of Contents
Level

Drawing

Description

Rev.

Page

D104301-1

ELECTRICAL SCHEMATIC ERECTOR

16.2

D107813-1

ELECTRICAL SCHEMATIC TBM

16.3

5750990017 TIGHTENING TORQUE FASTENERS

322tc16

SECTION 3

August, 2008

Polytron 2 XP Ex
Transmitter for Catalytic Combustion Sensors
Operating Manual

16.1-34A

For Your Safety

For Your Safety


Strictly follow the assembly and installation instructions
Any use of the transmitter requires full understanding and strict observation of
these instructions. The transmitter is only to be used for the purposes specified
here.
Maintenance
The transmitter must be inspected and serviced regularly by trained service
personnel at six month intervals (and a record kept.)
Repairs may only be done by trained service personnel.
We recommend that a service contract be obtained with Draeger Service and
that all repairs also be carried out by them.
Only authentic Drger spare parts may be used for maintenance.
Observe Section 4 Maintenance.
Use in areas subject to explosion hazards
Equipment or components which have been tested and approved according to
the national or European regulations on electrical equipment in areas subject to
explosion hazards, may be used only under the conditions specified in the
approval.
Modifications of components or the use of faulty or incomplete parts are not
permitted.
In the case of repairs to equipment or components of this type, the national
regulations must be observed.
To prevent explosions, whenever removing any part of the transmitter with the
unit powered, a portable combustible gas monitor should be used to determine
that the area is non-hazardous.
Liability for proper function or damage
The liability for the proper function is irrevocably transferred to the owner or
operator to the extent that the transmitter is serviced or repaired by personnel
not employed or authorized by Draeger Service or if the transmitter is used in a
manner not conforming to its intended use.
Drger cannot be held responsible for damage caused by noncompliance with
the recommendations given above. The warranty and liability provisions of the
terms of sale and delivery of Drger are likewise not modified by the
recommendations given above.
Draeger Safety, Inc.

Contents

Contents

For Your Safety ......................................................................................................... 1


1 Introduction .......................................................................................................... 4
1.1 Intended Use ......................................................................................................... 4
1.2 Design .................................................................................................................... 4
2 Operation .............................................................................................................. 5
2.1 Installation .............................................................................................................. 5
2.1.1 Installation Restrictions ......................................................................... 6
2.2 Installation Diagrams ........................................................................................... 7
2.2.1. Installing Electrical Connections at the Transmitter ....................... 7
2.2.1.1 4 to 20 mA Loop Installation ................................................ 7
2.2.1.2 HART Multidrop Installation ............................................. 8
2.2.1.3 RS 485 Multidrop Installation .............................................. 9
2.2.2 Relay Option ......................................................................................... 10
2.2.3 Installing Electrical Connections at the Controller ...................... 10
2.2.3.1 Connecting the Transmitter
to a Controller from Drger ............................................... 10
2.2.3.2 Connecting the Transmitter
to Other 4 to 20 mA Controllers ...................................... 10
2.2.3.3 Connecting Several Transmitters
to Other HART Multidrop Controllers ......................... 11
2.2.3.4 Connecting Several Transmitters
to a RS 485 Interface ......................................................... 12
2.2.4 RS 485 Interface Setup ..................................................................... 13
2.3 Initial Operation ................................................................................................. 18
2.3.1 Analog Signals ..................................................................................... 18
2.3.2 The Display ............................................................................................ 19
3 Menu Navigation ................................................................................................ 20
3.1 Menu Structure .................................................................................................. 21
3.1.1 Maintenance Menu .............................................................................. 21
3.1.2 Configuration Menu ............................................................................ 22
3.2 Entering Passwords ......................................................................................... 23
3.3 Entering Numbers ............................................................................................. 24
3.4 Entering Text ...................................................................................................... 24
3.5 Entering Decisions ........................................................................................... 24
3.6 Entering Options ............................................................................................... 25
3.7 Handling Messages .......................................................................................... 25
4 Maintenance Menu ............................................................................................ 26
4.1 Diagnostics ......................................................................................................... 26
4.1.1 Display Faults ........................................................................................ 27
4.1.2 Display Warnings ................................................................................. 28
4.1.3 Display Date of Last Calibration ....................................................... 29
4.1.4 Display Date for Next Calibration ..................................................... 29
4.1.5 Display Temperature of Sensor ........................................................ 29
4.2 Calibration .......................................................................................................... 30
4.2.1 Zero Point Calibration ........................................................................ 30
4.2.2 Sensitivity Calibration ......................................................................... 31
4.3 Sensor Replacement ........................................................................................ 33
4.4 Setting 4 to 20 mA Analog Interface ............................................................ 34
4.4.1 Set Analog Output to a Value Between 3 and 22 mA ................ 34
4.4.2 Set Analog Output to a Value Proportional
to a Gas Concentration ...................................................................... 34
4.4.3 Output of a Fault Signal ..................................................................... 35

Contents

4.4.4 Output of a Warning Signal .............................................................. 35


4.4.5 Output of a Maintenance / Calibration Signal .............................. 35
4.5 Set Date and Time ............................................................................................ 36
4.5.1 Changing the Date .............................................................................. 36
4.5.2 Changing the Time .............................................................................. 36
4.6 Display Sensor-Specific Information ............................................................ 37
4.7 Display Transmitter-Specific Information ..................................................... 37
4.8 Relay Test ........................................................................................................... 38
5 Configuration Menu .......................................................................................... 39
5.1 Setting Language .............................................................................................. 39
5.2 Initialization of Factory-Set Values ................................................................. 39
5.3 Configuring Gas Type, Units and Measuring Range ................................ 40
5.4 Configuring Calibration Parameters ............................................................. 41
5.4.1 Configuring Calibration Gas ............................................................. 41
5.4.2 Configuring Calibration Interval ....................................................... 41
5.5 Sensor Lock ....................................................................................................... 41
5.6 Switching Measured Value Display On/Off ................................................ 42
5.7 Switching Special Signal On/Off .................................................................. 42
5.8 Configuring Special Signals ........................................................................... 43
5.8.1 Switching the Warning Signal On/Off ........................................... 43
5.8.2 Warning Level ....................................................................................... 43
5.8.3 Warning Repeats ................................................................................. 44
5.8.4 Warning LoStrobe ............................................................................... 44
5.8.5 Maintenance Low Level ...................................................................... 44
5.8.6 Maintenance High Level ..................................................................... 45
5.8.7 Maintenance Level Repeats .............................................................. 45
5.8.8 Maintenance LoStrobe ....................................................................... 45
5.9 Changing the Password .................................................................................. 46
5.9.1 Changing the Maintenance Password ............................................ 46
5.9.2 Changing the Configuration Password .......................................... 46
5.10 Communication ................................................................................................ 46
5.10.1 Configuring Polling Address ............................................................ 47
5.10.2 Read Unique Identifier ....................................................................... 47
5.10.3 Configuring Tag ................................................................................... 47
5.11 Programming the Relays ................................................................................ 48
5.11.1 Set the Alarm Settings for Alarm 1 .................................................. 48
5.11.2 Set the Alarm Settings for Alarm 2 .................................................. 49
5.11.3 Set Mode of Acknowledging Alarms ............................................... 50
6 Technical Information ....................................................................................... 51
6.1 Approvals ............................................................................................................ 51
6.2 Signal Transmission to Central Control Unit .............................................. 51
6.3 Voltage of Power Supply ................................................................................. 51
6.4 Physical Specifications .................................................................................... 51
6.5 Environmental Parameters .............................................................................. 52
6.6 Relay Specification (optional) ........................................................................ 52
6.7 Ambient Influences ........................................................................................... 52
7 Default Values .................................................................................................... 53
8 Sensor Principle ................................................................................................ 54
8.1 Operating Principle .......................................................................................... 54
8.2 Contaminating Gases ...................................................................................... 54
9 Order Information .............................................................................................. 55
9.1 Calibration Supplies ......................................................................................... 55
9.2 Replacement Parts ........................................................................................... 55
9.3 Accessories ........................................................................................................ 56
Addresses ................................................................................................................ 63

Introduction
Intended Use
Design

Introduction

1.1

Intended Use

The Polytron 2 XP Ex continuously monitors combustible gases and vapors in


ambient air. The unit is housed in a rugged, metal, explosion-proof enclosure
for indoor and outdoor applications. The transmitter can be connected through
a sealed conduit or suitably approved cable gland to a Drger monitoring
system or a Programmable Logic Controller (PLC) to warn of hazardous
conditions.
The Polytron 2 XP Ex can be operated by the internal keys (declassified area),
by the infrared remote control or HART hand held terminal for calibration and
configuration. Using the infrared remote control or HART hand held terminal,
a non-intrusive, one-man calibration can be performed without declassifying
the area. With the optional alarm relay configuration, the transmitter can be
operated as a stand-alone unit.
The transmitter display shows warnings (e.g., maintenance required) or
instrument faults. The transmitter also has a special calibration mode which
inhibits alarm relays, and provides a unique output signal to prevent false
alarms.
The Polytron 2 XP Ex is intended to be used in the oil and gas industry (both on
and off shore), chemical, automotive and other general industrial areas where
reliable, accurate gas monitoring is required.

1.2

Design

The Polytron 2 XP Ex is designed to be powered by and interfaced with a


Drger Polytron, Regard or QuadGard monitoring system. It can be situated up
to 10,000 feet (3000 m) from the interface/controller, using a 16 AWG (1.5
mm2) three-conductor shielded cable. See Section 2.2.3, Installing Electrical
Connections at the Controller for more information.
The transmitter can also be connected to any monitoring/controller system if it
accepts: industry standard 4 to 20 mA input, bi-directional communication via
HART or bi-directional communication via RS 485, and provides 10 to 32 VDC.
The transmitter is designed to be installed in permanent locations and is
approved for use in hazardous, classified areas (Class I, Div 1, Groups B, C, D
and EEx d IIC T6).

Polytron is a registered trademark of Drger Sicherheitstechnik.


HART is a registered trademark of HCF, Austin, Texas, USA

Operation
Installation

Operation

2.1

Installation

To ensure overall system performance and effectiveness, the selection of an


installation site for the transmitter is the most important factor. Considerable
thought must be given to every detail of installation, particularly:
The local, state, federal codes and requirements that govern the installation
of gas monitoring equipment.
The electrical codes that govern the routing and connection
of electrical power and signal cables to gas monitoring equipment.
For non-conduit installations, an approved cable gland to EEx d IIC must be
used (e.g. Hawke A501/421/A or equivalent). It might be necessary to
connect the shield of the cable to the cable gland and to the controller in
order to improve RFI immunity. Entry thread size is M20 or 1/2" NPT. Cable
size is 11.0mm minimum and 14.3mm maximum.
The full range of environmental conditions to which the transmitters will be
exposed.
The physical data of the gas or vapor to be detected.
The specifics of the application, (e.g. possible leaks, air movement/draft etc.)
The degree of accessibility required for maintenance purposes.
The types of optional and accessory equipment that will be used with the
system.
Any other limiting factors or regulations that would affect system
performance or installations.

Mounting diagram

Operation
Installation
Installation Restrictions

2.1.1 Installation Restrictions

1. The transmitter must have between 10 to 32 VDC at the unit. This ultimately
determines the distance the transmitters can be mounted from the controller/
monitor or power supply. The unit accepts wire sizes of 16 to 22 AWG
(0.5 to 1.5 mm2). Use at least a three-conductor, shielded cable.
2. The transmitters must not be exposed to radiant heat that will cause the
temperature to rise above 167 F (75 C) within the enclosure. The use of a
reflecting shield is recommended.
3. Preferably mount in vertical position (sensor pointing downward).
4. The enclosure is weatherproof and suitable for outdoor installation. The use
of the optional splash guard is recommended to protect the sensor from
water, dust and wind.
5. Each transmitter must be installed and operated in an environment that
conforms to the specifications in Section 6, Technical Information.
NOTE
The transmitter may be equipped with a dust plug at the conduit entry.
This plug is not meant to be watertight, and must be removed before
connecting the unit to a sealed conduit.

Installation of transmitter

Operation
Installation Diagrams
Installing Electrical Connections at the Transmitter
4 to 20 mA Loop Installation

2.2

Installation Diagrams

2.2.1. Installing Electrical Connections at the Transmitter

Only properly trained personnel should route and connect the electrical
installation. Follow all applicable regulations.
2.2.1.1 4 to 20 mA Loop Installation
Unscrew cover from transmitter.
Lift the handle and pull the bucket with the electronics out of the enclosure.
Turn the bucket over and pull off the 5-pin connector.
Simply connect the three wires for power and signal to the appropriate
terminal, as indicated on the label on the bottom of the bucket.
Plug connector back into socket.
The cable shielding should be connected at the controller only.
Place the bucket back into the enclosure.
Screw the cover back on, until it is seated.

Bucket bottom; electrical connections; 4 to 20 mA loop installation

Operation
Installation Diagrams
Installing Electrical Connections at the Transmitter
Hart Multidrop Installation
2.2.1.2 HART Multidrop Installation
Unscrew cover from transmitter.
Lift the handle and pull the bucket with the electronics out of the enclosure.
Turn the bucket over and pull off the 5-pin connector.
Simply connect the incoming and outgoing three wires for power and signal
to the terminal, as indicated on the label on the bottom of the bucket.
Plug connector back into socket.
The cable shielding should be connected at the controller only.
Place bucket back into the enclosure.
Screw cover back on, until it is seated.
NOTE
All transmitters need to be setup individually. Transmitters on the same
multidrop line must each be configured to a different polling address
which is between 1 and 15 (Section 5.9, Communication). The
address numbers should start with 1, be consecutive, and may not be
used twice. The number of transmitters on one loop may not exceed
15 and is dependent on the power supply and cable used.
The permissible loop resistance of the cable is shown in
Section 2.2.3, Installing Electrical Connections at the Controller.

Bucket bottom; electrical connections; HART multidrop installation

Operation
Installation Diagrams
Installing Electrical Connections at the Transmitter
RS 485 Multidrop Installation
2.2.1.3 RS 485 Multidrop Installation
Unscrew cover from transmitter.
Lift the handle and pull the bucket with the electronics out of the enclosure.
Turn the bucket over and pull off the 5-pin connector.
Simply connect the incoming and outgoing four wires for power and signal to
the terminal, as indicated on the label on the bottom of the bucket.
Plug connector back into socket.
The cable shielding should be connected at the controller only.
Place bucket back into the enclosure.
Screw cover back on, until it is seated.
NOTE
The maximum number that can be connected on one
twisted-pair line is 32 (Section 2.2.3, Installing
Electrical Connections at the Controller).

Bucket bottom; electrical connections; RS 485 multidrop installation

Operation
Installation Diagrams
Relay Option
Installing Electrical Connections at the Controller
Connecting the Transmitter to a Controller from Drger
Connecting the Transmitter to Other 4 to 20 mA Controllers

2.2.2 Relay Option

If the relay option has been purchased, the wires for the alarm devices will be
connected to the 9-pin connector.
Turn the bucket over and pull off the 9-pin connector.
Simply connect the wires for alarm 1, alarm 2 and fault to the terminal,
as indicated on the label on the bottom of the bucket.
During normal operation, the relays are energized. This provides fail-safe
operation. The terminals indicated on the label are shown in the normal
operation mode.
Plug connector back into socket.
Bucket bottom;
To make sure that a warning or a fault is recognized - without having to look
electrical connections with relay option at the display - you must connect an alarm device to the fault relay.

2.2.3 Installing Electrical Connections at the Controller

Connect the shield of the wires to the earth ground of the controller
(e.g. chassis, ground busbar, etc.)
2.2.3.1 Connecting the Transmitter to a Controller from Drger
(e.g. Regard, QuadGard or Polytron)
For hook-up information, please refer to the manual which was included with
your Drger controller.
2.2.3.2 Connecting the Transmitter to Other 4 to 20 mA Controllers
The cable resistance (loop) must not exceed 800 W when powered by
24 volts.
When HART digital communication is to be used, the load resistance of the
supply unit must be between 230 W and 500 W.

Installing electrical connections at the controller

10

Operation
Installation Diagrams
Installing Electrical Connections at the Controller
Connecting Several Transmitter to Other Hart Multidrop Controllers
2.2.3.3 Connecting Several Transmitters to Other HART Multidrop Controllers
The information that can be inquired by other HART devices is only the top level
HART protocol header.
Up to a maximum of 15 transmitters can be daisy-chained on one 3-wire cable.
The maximum permissible loop resistance of the cable, plus load resistor is
500 W. See Section 6, Technical Information for transmitter current
requirements and inrush current ratings.
For more detailed information on the industry standard HART commands,
please contact the:
HART Communication Foundation
9390 Research Boulevard
Suite I-100
Austin, Texas 78759

Bucket bottom; electrical connections; HART multidrop installation; general HART controller

11

Operation
Installation Diagrams
Installing Electrical Connections at the Controller
Connecting Several Transmitters to a RS 485 Interface
2.2.3.4 Connecting Several Transmitters to a RS 485 Interface
Polytron 2 XP Ex can be connected to a RS 485 bus to communicate data
between the transmitter and a PLC or DCS. This bi-directional communication
uses HART commands, which will return the actual gas concentration, the
engineering units and the type of gas to be detected. In addition, the status
flag for warnings and faults can be interrogated. The maximum number that
can be connected on one twisted pair line is 32. With increasing number of
transmitters on the line, the cycling time will increase. E.g. 32 transmitters on
one line, cycling time 16 seconds.
It is important that the power supply driving the transmitter and the RS 485
interface have the same ground. For more detailed information on the industry
standard HART commands, please contact the
HART Communication Foundation
9390 Research Boulevard
Suite I-100
Austin, Texas 78759

Bucket bottom; electrical connections; RS 485 multidrop installation

12

Operation
Installation Diagrams
RS 485 Interface Setup

2.2.4 RS 485 Interface Setup

In order to communicate with the transmitter the RS 485 Protocol is 1200 baud, 8 bit, odd parity, 1 stop bit.
RS 485 Communication
To interrogate and retrieve data from the transmitter, defined HART commands in hexadecimal bytes have to be sent
and received.
The messages for the HART commands have the following structure:
PREAMBL