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Document No.
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Customer
Similarly for operating the machine in local mode the various push buttons and controls
are provided on local control stations located near respective drive.
1.1.1 LOCAL MODE OF OPERATION
This mode of operation is provided for the purpose of testing and maintenance of
various drives under de-inter lock mode however with necessary safeties and
protections like overload, pull cord switch, Emergency stop push button etc of individual
drives shall be effective.
To operate the machine in this mode, the Local / Control desk selector switch provided
on Control desk located in operators cabin must be kept in Local position. Now the
start / stop operations of individual drives shall be carried out from the respective local
control station.
Document No.
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Customer
To position the Machine for stacking following operations are required to be done.
1. Travel Drives shall be operated by travel master controller to move the machine to
Stacking START position toward drive house DH - 1. Along with the Travel drives
cable reeling drives shall start automatically.
When the machine is moved up-to Stacking START position the operator shall
observe the Travel Stacking START position indication on annunciation / indication
panel (located in operators cabin) and will stop the travel drive by keeping the
master controller in Zero position.
2. Slew drives shall be operated by slew master controller to slew the boom away from
the yard conveyor. When boom is slewed to Slew stacking START position, the
operator shall observe the Slew stacking START position indication on annunciation
/ indication panel and will stop the slew drive by operating the slew master
controller in Zero position. The slew speed of the boom shall be adjusted by the
speed setting potentiometer provided on control desk.
3. Hydraulic Luff Drive shall be operated by Hoist Master Controller to lower the boom.
When the boom reaches the lowest position the Hydraulic Luff Drive shall be
switched off. The lowering operation can be stopped by operating the Hoist Master
Controller in Zero position. The Luffing speed is preset on electronic control card
inturns setting the oil flow by proportional control valve on Boom luffing Hyd.
System.
1.1.3 MANUAL STACKING MODE OF OPERATION
This mode of operation is provided for stacking the material as desired by the operator.
Prior to this the machine has to be positioned a described under 1.1.2. To operate the
machine in this mode the various switches shall be kept in required position as follows:
1.
2.
3.
4.
Document No.
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Customer
Document No.
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Customer
Press the Auto START push button on Control Desk. The following sequence of
operation will take place automatically.
The warning hooter is switched ON automatically for the predetermined time to warn
the persons near the machine. The hooter is switched OFF after the preset time is over.
The Boom Conveyor automatically starts in forward direction and subsequently the
intermediate conveyor starts running. The signal for boom conveyor running in forward
direction & intermediate conveyor running will be given to central control room. The
yard conveyor shall be started from central control room in stacking direction. When
the material starts flowing on the boom conveyor via intermediate conveyor, the
material presence is sensed by the belt starvation switch, the travel drives along with
the cable reeling drives shall be switched ON automatically. The machine moves at slow
speed and commences forming the first layer of the Stock Pile. The Travel Drive is
automatically stopped after pre-set length is completed and reversed after the preset
stand still time is over. This way the formation of first layer continues. The machine
travels To and Fro between the set end limits of the pile. The stock pile detection switch
mounted on the boom detects that the first layer height is reached. The signal is stored
in the PLC memory and machine continues its travel up to the end in that direction.
When this end of the pile is reached, the Hydraulic Luffing Drive lifts the Boom to the
next layer height over a timer circuit in the PLC. When the timer runs out the Luffing
gear automatically switches OFF and the To and Fro travel motion continues for second
layer. This process continues till the desire stock pile height is achieved and the upper
luff limit switch is activated the machine continues to move up to the end of the pile.
However, further Luffing is blocked. After this stage the Boom is slewed automatically
for approx. 2 degrees towards the yard Conveyor by a timer circuit in PLC (slewing
speed is programmed in PLC). When the timer runs out the slewing is stopped and
machine continues To and Fro travel. The travel ends are atomically gets adjusted in
this extreme end of the pile such that the straight edge of the trapezoidal cross section
is achieved instead of drooping of top of stock pile. Once again when the material
touches the stock pile detection switch, the boom is slewed automatically for approx. 2
degree towards the yard conveyor. This way when the desire boom slew angle is
achieved and the material is sensed by the stock pile detection switch, the stock pile
full indication appears on annunciation / indication panel and the stacking process is
stopped.
Document No.
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Customer
For positioning the machine for reclaiming, Manual de-interlock mode of operation is to
be followed. The various selector switches shall be kept in required position as follows.
1.
2.
3.
4.
To position the Stacker cum Reclaimer machine for reclaiming, following operations are
required to be done
1. Travel drives shall be operated by Travel Master Controller to move the machine
towards DH-1 & stop the machine at the end of stock pile.
2. Hoist & Slew the boom by the Master Controller so that the bucket wheel touches
the top layer of the stock pile end towards yard conveyor.
1.1.6 CONTOUR FORMATION FOR RECLAIMING
For Manual/ Auto reclaiming operation initial contour formation is required to be done
as shown in drawing No
For contour formation it is assumed that the machine is positioned for reclaiming as
explain above point no.1.1.5
Now the De-InterLock/ Stacking/ Reclaiming Selector switch shall be kept in Reclaiming
position. Then the following equipments are set automatically for reclaiming operation.
a. The bucket wheel chute gets lowered down so as to direct the material from
bucket wheel to the boom conveyor.
b. Stock pile detection switch bracket moves upward so as to avoid material
detection during reclaiming.
c. The skirt board gets lowered down so as to guide the material from boom
conveyor to the yard conveyor.
After receiving the instructions from central control room to start reclaiming, the
operator has to start the machine as per the following sequence.
i.
Ensure that the yard conveyor is running in reclaiming direction.
ii.
Press the Start warning Push button on control desk, the hooter will
be switched on for pre-determine time ( Approx. 15 Sec.).
iii.
After the hooter is switched off, start the boom conveyor in reverse
direction & subsequently start the bucket wheel drive.
iv.
The operator shall start the Travel drive by the Master Controller in
forward direction to the desire depth of cut ( 0.9 x height of bucket)
& stop the Travel drive.
v.
vi.
Document No.
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Customer
After the contour formation is completed as explained above the reclaiming can be
done in Manual/ Auto mode.
1.1.7
Now the operator shall follow the sequence of operation as explain in Point No. 1.1.6
(i to vii) above for desired length of stock pile to be reclaimed. However the operator
has to ensure that the contour of the stock pile is maintain same as starting of
reclaiming.
1.1.8
Document No.
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Customer
completes the bite and either reaches the slew end limits or comes out of the stockpile.
To ensure complete bite in the case of uneven peaks in the layer, a time bias is
given when kW transducer momentarily senses less than 15% power. When the active
power confirmed by the bucket wheel drive is less than 15% beyond this time bias,
the bucket wheel has actually come out of the pile after having completed the bite.
The PLC automatically stops further slewing and starts the travel drive to move forward
by fixed bite step. The travel motion is then stopped and the slew gear is automatically
reversed to once again bite into the pile.
The co-ordinated slew left/right and the
travel bite step motions are continued until the preset distance set by thumb wheel
switch is travelled. The machine has now completed reclaiming the top bench of the
preset length of the pile and is automatically brought back to the new starting point
(to take into consideration the pile geometry after the topmost layer is reclaimed, the
machine is automatically moved back by a pre-set amount and the second layer bite is
commenced). The boom is now automatically slewed towards yard conveyor upto slew
end limit for middle bench & then lowered until the limit switch of the middle bench is
actuated after which the luff drive is stopped. Then once again the co-ordinated slew
left/right & the travel bite step motion are continued until the pre-set distance is
travelled. The machine has now completed the reclaiming of middle bench & is
automatically brought back to the new starting point for reclaiming the bottom bench
and the process is repeated for reclaiming the bottom bench. When the machine travels
for the preset distance in forward direction, the reclaiming process is stopped.
Document No.
Customer
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Document No.
Customer
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