Operation Manual Cable Drum E.pdf

Operation & Maintenance Manual Cable Drum

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O

M Cable Drum E 12.04

TABLE OF CONTENTS

SUBJECT PAGE

Principle of operation 3 Technical data rating plate 5 Accident prevention measures 5 Cable drum commissioning 7 Adjustment of cable limitation (two strain relief windings) 7 Adjustment of drive torque control (half full and full position) 7 Adjustment of the maximum permissible cable deflection 9 Adjustment of the tight and slack cable control device 9 Dryer packs in the cable drum body 9 Drive motor rotor resistance 9 Drive motor connections 11 Travel motion control 13 Maintenance of the cable drum 15


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OM Cable Drum E 12.04


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U • Access to the high voltage area for authorized personnel only.

The local safety regulations must be observed. • Before start any work on the high voltage system, make sure

that the main power supply from the power station is interrupted. Contact your supervisor for further safety instructions.

Principle of Operation Legend for Illustration Z 25058(5M6) Brake motor, for more information refer to the separate manuals

“Operating Instructions Brake Motor and Manual Brake Release Attachment” in the Appendix.

(5S3) Rotation direction indicator (switch) (5R1) Resistor for brake motor torque adjustment (5S4) Gear type cam switch for resistor controlling and monitoring of

the last two cable windings (5S6) Pendulum control cam switch, to detect slack or tight cable (5S8, 5S9) Proximity switch to detect cable deflection to the right and left side (5S1) Service switch for cable drum control Positions of rotary switch (C)

1 – Winding off the cable 2 – Stop drum rotation 3 – Automatic operation 4 – Winding up the cable

IMPORTANT: The cable drum control switch (5S1) is intended to be used by authorized service personnel only. Contact your supervisor for further instructions. For operating the rotary switch (C) insert key (A) into lock (B). For normal operation set switch (C) to position (3) automatic operation.

Purpose and principle of operation The cable drum is utilized to automatically wind up or wind off a suitable cable or support cable, which ensures power supply for a mobile excavator. The cable drum is driven by a transmission brake motor with slip ring rotor (5M6). Torque control of this drive is effected by a rotor resistor (5R1) with 4 taps, which is accordingly activated by a camshaft switch (5S4). Using a rotation sense transmitter (5S3) incorporated into the driving chain, operation of the control device is monitored, and the drum body's sense of rotation is determined. The cable to be wound up is properly arranged by the control device, and then wound up on the drum. A camshaft switch (5S6) mounted to the oscillating crank controls cable pulling and ensures in this way a monitoring of tight and slack cable modes. Two proximity switches (5S8 and 5S9) incorporated in the oscillating crank control the elongation of the pendulum, ensuring in this way a maximum slanting direction of cable pulling of up to 30° to either side. Voltage and signal transmission from the drum cable to the firmly installed cable on the excavator is carried out by a slip ring body incorporated in the drum body.


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OM

Technical data - Rating plate The rating plate is mounted to the removable protection hood of the drum body (non-drive side). This rating plate contains the most important data of the cable drum. Typical rating plate

-

-

Inpecam Ac AlchThmreThnoofth

Elektrotechnische Geräte Böhlitz - Ehrenberg GmbH Ludwig-Hupfeld-Straáe 6, D-04178 Leipzig Telephone: D-341/4481-0, Fax: D-341/4481-200

----------------------------------------------------------------Cable drum Serial Number

---------------------------------------------------------------- Nominal voltage SRK: 3 x 400 A + PE, 10 kV, 100% ED 1 x 200 A, 1 kV, 100% ED Drive: 480 V, 60 Hz, 40% ED Driving speed: 42 m/min Cable: D = 81 mm, m = 12,3 kg/ m, l = 210 m in two Layers

Manufacturer: Elektrotechnische Geräte Böhlitz - Ehrenberg GmbH Ludwig-Hupfeld-Straße 6, D-04178 Leipzig Telephone: D-341/4481-0, Fax: D-341/4481-200

--------------------------------------------------------------- Cable drum Serial Number: 70.209 / PC8000 - .....

--------------------------------------------------------------- Nominal voltage SRK: 3 x 400 A + PE, 10 kV 1 x 200 A, 1 kV Drive: 480 V, 60 Hz, 40% ED Driving speed: 42 m/min Cable: DIA = 81 mm, m = 12,3 kg/ m, l = 210 m in two Layers

Cable Drum E 12.04

order to ensure a safe operation of the cable drum, observe the rformance parameters contained on the rating plate. When using a ble with different features, the control device and the corresponding drive ust be adapted accordingly. Please contact us for further questions.

cident prevention measures

l movable or quickly rotating parts directly mounted to the cable drum, such as ain drives, are cased in an appropriate manner. e removable casings of the drum body are equipped with safety switches which

ust be connected in such way that the slip ring body voltage is cut off when moving the casing. Any bridging of the switches is not allowed. e last two windings on the drum shell serve as strain relief of the cable and must t be winded off during operation. The switch 5S4 controls this condition and cuts f forward travel of the excavator when the last two windings of the cable are left on e drum.


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Drum commissioning Apply and connect cable: The drum body must be located in such away that the cable entry (1), illustration (Z25057) in the drum shell is on top, and the control device with the oscillating crank is on the left rim. The chain link (2) must be in the outermost left position. This can be carried out by turning the drive motor by means of the crank or manual brake release device, for more information refer to the separate manual “Operating Instructions Brake Release Attachment” in the Appendix. Remove the cover of the drum body and adjust the sealing rubber of the screwed cable gland to the cable diameter. Equip the cable with prefabricated cable end terminations, and route it through the guide rollers (3) of the control device and the screwed cable gland into the drum shell. Fix the cable inside the drum on the existing clamps (strain relief) and the individual cores to the copper rails of the current collectors. When making the connection, look for ring and current collector identification markings. After termination of this work tighten the screwed cable gland, and additionally seal with sealing compound (such as SSW E 105). Clean the drum body after termination of this work, and reinstall the cover removed before. Look to it that sealing rubbers are tight. Now put on two windings onto the drum shell by means of the drive motor or the manual brake release device and adjust cable limitation at the gear type cam switch 5S4, see (5) in the illustration.

NOTE: Ex works the cable drum is pre-adjusted. Prior to putting the cable drum into operation, re-checking of the adjustment is necessary.

Adjustment of cable limitation at the gear type cam switch 5S4, see (5) in the illustration (Z 25057) With the two windings on the cable drum adjust the switching element 11-12 of the cam switch (5) in such a way that in this position the contact opens (cable limitation) and remains open when winding up further cable windings. NOTE: The two windings serve as strain relief and must not be winded off during

operation. Re-check the switching point of element 11-12. Remove the manual brake release device from the drive motor. For further winding up of the cable the drive motor can now be driven electrically. Adjustment of cable drum “HALF-FULL” position (first cable layer on the drum) With the first layer on the cable drum adjust the switching element 21-22 of the cam switch (5) in such a way that in this position the contact opens (torque increase) and remains open when winding up further cable windings. Adjustment of cable drum “FULL” position (both cable layers on the drum) With both layers on the cable drum adjust the switching element 31-32 of the cam switch (5) in such a way that in this position the contact opens (cable drum full).


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NOTE: • The lowest torque will be required for winding off. The lowest torque is activated

on the basis of an information from the rotation sense monitoring device (5S3), which delivers a signal when the cable drum is pulled in the direction of winding-off (forward travel of the excavator).

• Check before commissioning, that the control device moves to the right during winding-up of the cable. Make sure the cable is wound up without kinks assist by hand if necessary.

Adjustment of the maximum permissible deflection of cable pulling: The maximum lateral deflection of the cable is 30°. This condition is monitored by two proximity switches (5S8 and 5S9), see (4) in the illustration (Z 25057) mounted to the oscillating crank. Adjust the metal sheets (8) of the pendulum in such way that the sensor triggers at a deflection of 30° to the right and to the left. The switching point of the proximity switches is indicated by a LED. Make sure, that the cable cannot be over run through the tracks of the excavator. Adjustment of the tight and slack cable control device: The camshaft switch (5S6), see (6) in the illustration controls the tight and slack cable condition. In order to reach idle time of the drum cable that are as long as possible, correct cable pulling is necessary. Deviations from this condition can be caused by excessive driving speeds or defective drive motor torque control devices. • Tight cable adjustment:

Adjust the switching element 11-12 of the camshaft switch (6) in such a way that the contact opens when the oscillating crank with pendulum (7) is moved up more than 25-30°. When the oscillating crank with pendulum moves down in direction of “Slack Cable” the switching element must remain in closed position.

• Slack cable adjustment: Adjust the switching element 21-22 of the camshaft switch (6) in such a way that the contact opens when the oscillating crank with pendulum (7) is moved down more than 25-30°. When the oscillating crank with pendulum moves up in direction of “Tight Cable” the switching element must remain in closed position.

Dryer packs in cable drum body A cage for taking up six dryer packs is located inside the drum body, see illustration (Z 25056) on page 14. Before operating the cable drum, remove the access cover on the non drive end of the drum body and check to make sure that the six dryer packs are inserted in the cage. If the dryer packs are not yet inserted, remove the plastic wrapping from the packs and insert them into the cage. Attach the access cover. Drive motor rotor resistance: This resistor serves as protective resistor for the stop period sliding rotor brake motor. The protective degree is IP 23. The resistor heats up to approximately 125°C during operation, the air temperature at the outlet being up to 175°C. Make sure that there is enough air exchange with the outer environment.


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Connecting the drive motor: The cable drum is driven by a three phase stop period cage rotor motor. The motor works on the sliding rotor principle, and thus constitutes the simplest type of connection between motor and brake. The motor is always connected in a way as to create a torque in the sense of winding up. The motor automatically adapts to all driving speeds of the device until standstill, and is pulled through upon cable winding-off in opposite direction of its rotation sense. When the mains is switched off, the brake working on the sliding rotor principle prevents winding-off of the cable. Observe the data contained on the rating plate, when connecting the motor. For more information refer to the Service Manual of the Excavator and to the electrical diagram. Observe also the instructions in the separate manual “Operating Instructions Brake Motor” in the Appendix.


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Travel motion control, illustration Z 25059

General: The cable drum is equipped with safety switches for the protection of the power supply cable during travelling and turning operations. Movements which could damage the power cable are automatically switched off.

Cable condition Monitored by Switch

Travel response

1. Too tight 5S6 crawler left and crawler right forward motion stopped

2. Too slack 5S6 crawler left and crawler right reverse motion stopped

3. Too strong deflection to the left

5S8 crawler left reverse motion stopped

4. Too strong deflection to the right

5S9 crawler right reverse motion stopped

5. Maximum permissible cable length on the drum

5S4 crawler left and crawler right reverse motion stopped

6. The last two cable windings serving as strain relief are left on the drum

5S4 crawler left and crawler right forward motion stopped

NOTE: The ground contact sensing bar (9), illustration (Z 25057) prevents

the cable drum from hitting the ground or obstacles by stopping reverse travel of the excavator.


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Maintenance

Maintenance Points see illustration Z25056

After the first 100 and 250

operating hours

After every 500 operating

hours

After every 1000 operating

hours

Lubricate bearings of the oscillating crank via grease fittings

X

Lubricate bearings of the oscillating crank rollers and slip ring unit ball bearing via grease fittings

X

Lubricate main drive chains and drive chain of the oscillating crank

X

Check and adjust tension of the oscillating crank drive chain

X

X

Check and adjust tension of the main drive chains

X

X

Check and retighten bolt connections in the slip ring unit

X

X

Check and retighten bolt connections in the terminal box

X

X

Check guide rollers of the oscillating crank for wear and correct alignment

X

Change oil in drive gear box

Change the oil after every 10000 operating hours

Change oil in angular gear box

Change the oil after every 10000 operating hours

(11) Change dryer packs Change the six dryer packs whenever the cable drum has been opened

(continued on next page)


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Recommended Lubricants Grease fittings MPG K3K-20 or KE2K-50 or equivalent greases

Chains Adhesive spray lubricant Molykote or equivalent

Gear boxes Gear oil ISO VG: CLP 220 or equivalent

Remarks to the Maintenance Chart: • For lubrication of the slip ring unit ball bearing (2) remove the cover from the

drum body on the drive end side. • The six dryer packs located in a cage (11) inside the drum body should be

replaced whenever the drum has been opened. Used dryer packs can be re-used one time after drying. For access to the dryer packs remove the cover on the non drive end of the drum body.

Additional Maintenance to be carried out by authorized service staff The slip ring unit (6) inside the drum body should be checked after every 1000 operating hours by authorized service staff as follows:

• Check slip rings, brushes, current collectors and insulators for wear and damage. Replace all worn or damaged parts without delay.

• Make sure that all bolt connections are in good condition. • Check self-locking nuts for sufficient clamping torque. Replace nuts which

have lost their clamping torque.

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Operation Manual Cable Drum E.pdf