Bucket Wheel Excavator VABE 400 Typical Tec

V V A A M MH H
Technical Specification
Bucket Wheel Excavator
VABE 400

BucketWheelExcavator-VABE-400-Typical-TechnDescription-Rev0 Page 1
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TECHNICAL SPECIFICATION

BUCKET WHEEL
EXCAVATOR

Type VABE 400

VOEST-ALPINE
Materials Handling G.m.b.H.&Co.KG
P.O. Box 2
Alpinestrae 1
A-8740 Zeltweg
AUSTRIA
Phone: +433577755-Ext.
Fax: + 43 3577 756 339
e-mail : vamh@sandvik.com
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Part 1 General

Part 2 Technical Description of Mechanical &
Structural Assemblies

Part 3 Technical Data

Part 4 Technical Specification of Electrical
Equipment

Part 5 General Layout Drawing

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Table of Contents

1.1 General 6
1.2 General Design Data 7
2.1 Bucket wheel with Drive 10
2.2 Undercarriage and Crawlers 11
2.3 Superstructure and Turntable 12
2.4 Bucketwheel Boom 13
2.5 Discharge Boom 14
2.6 Operator's Cabin, Control Desk and Transformers 15
2.7 Power Transmission, Electrics, Control 16
3.1 General 18
3.2 Bucketwheel with Drive 19
3.3 Superstructure and Bucketwheel Boom 21
3.4 Bucketwheel Boom 23
3.5 Luffing Arrangement for Bucketwheel Boom 23
3.6 Discharge Boom 23
3.8 Conveying Line 25
3.9 Crawlers and Undercarriage 28
3.10 Lubrication 28
3.11 Miscellaneous 29
3.12 Power Supply 29
3.13 Motors, Quantity and Rated Power: 30
4.1 General Information 32
4.2 Power Supply and Distribution 34
4.3 Drives 35
4.4 Power Transformer 37
4.5 High-Voltage Switchgear 37
4.6 Resistance Banks 38
4.7 Low-Voltage Switchgear 38
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4.8 Local Devices 38
4.9 Signalling System 38
4.10 Operator's Cab Equipment 40
4.11 Miscellaneous Equipment 41
4.12 Lighting 43
4.13 Communication 43
4.14 Slipring Assembly 43
4.15 Cables and Installation Material 44
4.16 Automatic Control System 44
5. General Arrangement Drawing 47
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Part 1

General
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1.1 General

(a) The bucket wheel excavator will be used to unload copper ore from leaching pads
discharging to a crawler mounted horizontal conveyor (supplied by others).
The machine will excavate copper ore at an theoretical capacity of 2000 lm/h
(3000 t/h) or 1450 m/h (2200 t/h) effective rate (max. density = 1.5 ton/m for power
calculations). The resulting peak capacity will be kept to a minimum.

(b) The bucket wheel excavator will excavate the copper ore in piles of 7 m in height on
a leach pad system.

(c) The machine design includes automatic functions wherever possible / feasible.
Automation is documented in sufficient detail for evaluation of the operational advantages
of the offered features.

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

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

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1.2 General Design Data

(a) The BWE runs on crawlers. It mainly consist of the complete undercarriage and travel
gear, the slewing assemblies, the superstructure, the bucket wheel boom with bucket
wheel, the discharge conveyor, the luffing equipment, the counterweight boom and the
complete electrical installation.

(b) Bucket wheel and discharge booms have separate slewing and luffing action. The height
adjustment of the discharge boom will be designed to suit the transfer parameters of the
horizontal conveyor and the following grasshoppers.

(c) Transfer points will be designed in such a way that material transfer with minimised spillage
will be ensured and plugging under normal conditions is prevented.

(d) The entire machine will be easily accessible through staircases and walkways so that
supervision and maintenance as well as necessary repairs can be easily executed. All
parts of the structure including platforms are to be provided with sufficient and effective
drainage facilities.
The BWE will be supplied with electric power by hook-up connection from the cable reel of
the cable reel car running on the horizontal conveyor.

(e) The maximum operational wind speed will be 72 km/hour, serving as the basis for
structural design. A wind velocity of 130 km/hour has been considered for the out-of-
operation load case. Earthquake activity is considered for equipment design as far as
applicable.

(f) As a minimum the following design parameters will apply:

Copper leach pad height 7 m
Side slope 60 -65 degrees
Face slope 65 degrees
Deep-cut below level - 0.5 m
Outreach of bucket wheel boom 8.5 m
Length of discharge boom 15 m
Grade ability
in operation 1:20
in transit 1:10

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Average ground pressure
based on operating weight 100 kpa
Slewing range of superstructure
related to undercarriage 360
Slewing range of discharge boom
related to superstructure +/- 105

(g) Lighting as specified in this specification for the bucket cutting area will be provided to
permit adequate illumination during night operation.
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Part 2

Technical Description
of
Mechanical & Structural
Assemblies

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2.1 Bucket wheel with Drive

(a) The bucket wheel will be designed as a cell-less type with suitably connected shaft
arrangement. The bucket wheel shaft will be supported by spherical roller bearings.

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

(c) The buckets will be designed with exchangeable cutting tools.

(d) The digging teeth are fastened to the buckets in a way which will permit easy and rapid
replacement and which will not loosen during operation. The external rims of the bucket
wheel body will be protected by exchangeable wear bars and the bucketwheel chute and
ring chute by exchangeable wear places.

(e) The bucket design will provide for continuous cleaning of the buckets during wheel rotation.

(f) Considering the material properties, the peripheral speed at the cutting circle of the bucket
wheel will not exceed 75 percent of the critical peripheral speed.

(g) The bucket wheel ring chute will prevent preliminary discharge and undue spillage of the
material and will cover a minimum part of about 1/3 of the full bucket wheel running circle
from fill to discharge points of the buckets.
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2.2 Undercarriage and Crawlers

(a) The undercarriage of the BWE will be sufficiently strong and of rigid design. The machine
will be supported by a two-crawler travel arrangement.

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

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

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

(b) The tension device for the crawler chain will be dimensioned in such a way that in case of
wear in the links of the crawler chain one link can be removed.

(c) Lubrication of the crawlers will be effected by central lubrication and life-time lubrication.

(d) Each crawler is equipped with a drive arrangement. The crawler drives will be protected
against spillage by covers. Dismantling of bogies and wear elements will be possible by
simple means.

(e) For travelling on inclined surface, safe braking of the crawlers must be provided. A ground
clearance of at least 600 mm will be maintained. A turning radius of 10 m will not be
exceeded.

(f) Travel speed will be 8 m/min. Interlocking between the BWE and hopper car will ensure
synchronised travel of the various equipment combinations.
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2.3 Superstructure and Turntable

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

(b) The slewing gear drives will be equipped with a safety coupling or equivalent which stops
all drives if inadmissible high lateral forces occur. The slewing speed will be indefinitely
variable. The slewing ring assembly will be designed for equipment life and suitable
lubrication arrangement. Effective protection against contamination will be provided.

(c) The control of the slewing drive will be via AC motor with VVVF control.

(d) A separate slewing arrangement for the discharge boom is arranged on top of the main
turntable to permit independent movement of this unit.

(e) The counterweight boom will have a rigid connection to the rear end of the turntable. It will
consist of the structure, carrying the counterweight box, electric compartments and
transformer. Free movement against the discharge is insured.

(f) The frame, providing the support of the bucketwheel boom, the transfer chute and the
suspension for the discharge boom will be mounted to the front end of the turntable. It will
be of a torsion-strong design.

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2.4 Bucketwheel Boom

(a) The bucketwheel boom will be of rigid design with suitable cross bracings to prevent
torsioning. The boom is mounted by shaft connection and hinge bearings to the machine
frame. Mounting provisions for the bucketwheel, the bucketwheel drive and the chute
arrangements at the front end of the boom are provided.

The bucketwheel boom has a hydraulic luffing arrangement. The hydraulic system is
equipped with check valves or other suitable safety features to prevent a sudden drop of
the boom in case of pressure loss or oil leakage.

The transfer end of the conveyor will be provided with a sufficiently strong baffle plate in
order to direct the material stream with minimum spillage to the discharge conveyor.

(b) All chutes will be equipped with exchangeable wear plates.

(c) The conveyor will have suitable drive arrangements with fluid couplings and brakes or
holdbacks. The drives will be preferably motor-gearbox arrangements mounted on a
common base with torque arrester. Flange couplings are used to connect pulleys to
gearboxes.

(d) A primary and secondary scraper will be provided at the discharge pulley. A plough scraper
will be installed in front of the return pulley.

(e) An electric driven conveyor belt aligner will be provided. The control of the devise will be
from the operators cab.

(f) Strong overflow guards will be provided along the bucket wheel boom conveyor.

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2.5 Discharge Boom

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

(b) Sufficient tensioning distance will be ensured. The discharge end of the conveyor will be
provided with a sufficiently strong baffle plate in order to direct the material stream with
minimum spillage to the following equipment.

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

(d) The conveyor will have suitable drive arrangements with fluid couplings and brakes. The
drives are shaft mounted motor-gearbox arrangements on a common base with torque
arrester. Flange couplings are used to connect the pulley to gear box output shaft.

(e) A primary and secondary scraper will be provided at the discharge pulley. A plough scraper
will be installed in front of the return pulley.

(f) An electric driven conveyor belt aligner will be provided. The control of the devise will be
from the operators cab.

(g) Strong overflow guards will be provided along the discharge boom conveyor.

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2.6 Operator's Cabin, Control Desk and Transformers

(a) The operator's cabin will be arranged in such a way that the operator has the best possible
visibility over the entire machine. The cabin is equipped with air conditioning, and
ventilation.

(b) The windows will be of tinted safety glass with windshield wipers and washers. One
operator will be able to operate the entire machine on his own. From the control desk it will
be possible to control all activities of the bucketwheel excavator and the hopper/cable reel
car when the beltwagon is not in use.

(c) The BWE will be controlled from the control desk of the machine, but the discharge boom is
also controllable by remote and automated control from the beltwagon.

(d) The cabin will be equipped with a suitable chair incorporating arm rests. Enough space will
be provided to allow the operator free movement around the control desk.

(e) A slewing angle indicator for the height and position of the bucketwheel and an indicator
monitoring the crawler travel direction (and the corresponding advance steps of a cut as
well as the total covered distance) will be in the operator's cabin.

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

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

(h) The transformers are placed on open platforms. Below the transformer, oil collecting
troughs with syphons are to be provided.

(i) Shelters are to be arranged above the transformers. The shelters will protect the
transformers from being damaged by spillage.

(j) A compartment for he storage of spare / wear parts is provided in the vicinity of the
electrical house.
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2.7 Power Transmission, Electrics, Control

(a) For the power transmission from the superstructure to the undercarriage a slipring
arrangement is to be provided which permits a slewing movement of 360 degrees. The
room for the slipring is to be absolutely water proof, dustproof and protected against
vermin.

(b) For electrical interface, refer to Part 4: Technical Specification of electrical Equipment

(c) Electrical components are to be designed in accordance with the applicable international
standards.

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Part 3

Technical Data
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3.1 General

Type of bucketwheel excavator Compact Type -
Heavy Duty Version

Effective capacity 1450 lm/hr
2200 t/h

Theoretical capacity 2000 lm/hr
3000 t/h

Leach pad height max. + 7 m
Deep-cut above level - 0.5 m

Side slope 60 -65 degrees
Face slope 65 degrees

Travelling speed 8 m/min.
Minimum turning radius related to crawler outer edge 12 m

Gradeability
- in operation 1:20
- in transit 1:10

Average ground pressure based on operation weight 120 kpa

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3.2 Bucketwheel with Drive

Bucketwheel
Type of bucketwheel cell-less
Diameter (related to cutting circle) 5.6 m
Number of buckets 10
Discharges per minute
high speed 66 per min
Cutting speed 1.94 m/sec
Revolutions per minute
- maximum 6.6 rpm
- minimum (maintenance) approx 0.3 rpm
Bucket capacity (I
1
) 0.325 m
Ring space capacity (I
2
) 0.150 m
Rated bucket capacity (I
n
) 0.400 m
Rated output at the above number of bucket
discharges with buckets filled 100% 1,880 lm/h

Max. Cutting force 171 N/cm
Tilt of bucketwheel
- related to horizontal plane 8 degrees
- related to vertical plane 0 degrees

Bucketwheel Shaft

Type/design hollow shaft
Material 42CrMo4V
Bearings - Type/Number spherical roller bearing
- Lubrication grease-central lubrication

Bucket Wheel Drive

Motors
- Type Squirrel cage
- Number 1
- Capacity of each motor - nominal (N
n
) 110 kW
Rated Speed 1500 rpm

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Bucketwheel Reduction Unit

Type planetary gear
Number 1
Number of oil pumps 1

Overload Safety Device

Mechanical
Type fluid coupling
Overload 1.5 -fold
Electrical
Type electronic / PLC
Overload 1.4 -fold

Chutes

Inclination of chutes 55-60 degrees
Type of wear protection high resistant wear plates
- Thickness for ring chute 16 mm
- Thickness for fixed chute 12 mm
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3.3 Superstructure and Bucketwheel Boom

Main Slewing Assembly

Slewing angle of superstructure to undercarriage infinite
Maximum slewing speed related to centre of bucketwheel 36 m/min
Type of slew bearing slew bearing
- Material specification 42CrMo4V
Fastening
- with superstructure bolted
- with undercarriage bolted
Type of sealing V-type
Lubrication grease, central lubr.
Type of rolls for slewing race cylindrical rollers

Slewing Drive Units

Number of slewing drives 2
Type of slewing drive frequency controlled
Type of motors electrical
Voltage 400 V
Rated power of each motor 11 kW
Pinions per unit 1
Type of safety clutch magnetically
Overload factor 1.3
Type of brake double shoe brake
Number of brakes on each slewing drive 2
Acceleration in operation 0,05 m/sec
Deceleration
- in operating 0,05 m/sec
- at emergency stop 0,15 m/sec

Safety Devices

Type of gripping device double shoe brake
- Quantity 2
- Location slew drive
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Slewing Assembly for Discharge Boom

Slewing angle of discharge boom
related to the superstructure +/- 105 degrees
Slewing speed related to centre of discharge pulley 15 m/min

Type of slewing race slew bearing
- Material specification 42CrMo4V
- Type of sealing V-type
- Lubrication grease, central lubr.

Type of slewing drive electrical
Power of slewing drive 2 x 11 kW

Type of slewing gear planetary gear
- Lubrication oil

Type of brake brake motor

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3.4 Bucketwheel Boom

Length of system from slewing centre
to centre of bucketwheel 8500 mm

Conveying angle
- in highest position +18 degrees
- in lowest position -15 degrees

Adjusting speed, related to centre of bucketwheel
- raising approx. 5 m/min
- lowering approx. 5 m/min

3.5 Luffing Arrangement for Bucketwheel Boom

Number of hydraulic cylinders 1

Pressure of each cylinder
- Operating pressure 220 bar
- Maximum pressure 280 bar

Type of luffing drive hydraulical
Power of luffing drive 45 kW

3.6 Discharge Boom

Dimensions

Length in horizontal position from the slewing centre
to the centre of material discharge 16 m

Length from centre of drive pulley to centre of
discharge pulley approx. 17 m

Height of centre discharge pulley related to travelling level
- in highest position 7.6 m
- in lowest position 3.2 m
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Conveying angle, maximum + 12 degrees
- 5 degrees

Lifting and lowering speed of discharge boom 3 m/min

Luffing Arrangement

Number of hydraulic cylinders
Pressure of each cylinder 180 bar
Operating pressure 250 bar
Type of luffing drive hydraulical
Power of luffing drive 45 kW
( same as BW hoist )

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3.8 Conveying Line

Bucketwheel Boom

Belt speed 4.2 m/sec (820 fpm)
Belt width 1200 mm (48)

Troughing angle
- Upper belt 35 degrees
- Lower belt 15 degrees

Length measured from centre of return (take-up)
pulley to centre of discharge pulley
- minimum 10.000 mm
- maximum 10.500 mm

Belt clearance to steel structure on each side 100 mm

Number of pulleys 2
Diameter of pulley (wo. lagging) 630 mm
Face width of pulley min. 1450 mm
Type of lagging herringbone rubber
Thickness of lagging
Drive pulley min. 20 mm (3/4)
Tail pulley min. 15 mm (~1/2)
Type of bearing spherical roller bearing
Make of drive
Type of drive electrical via gear box
Number of drives 1
Drive power 75 kW
Type of brakes double shoe brake

Type of take-up hydraulic cylinder
Take-up length 500 mm

Type of carrying idlers 3-roller garlands
Number of idlers per set 3
Spacing of idler sets max. 1200 mm
Diameter 127 mm
Type of bearing ball bearing
Type of sealing labyrinth + V-type

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Type of return idlers 2-roller garlands
Spacing of idlers sets max. 3000 mm
Diameter of idler tube 127 mm
Type of sealing labyrinth + V-ring

Type of impact idlers garlands
Troughing 35 degrees
Number of idler sets at transfer point 8

Type and number of belt cleaners 1 primary belt scraper
1 secondary belt scraper
1 plough scraper

Bucket wheel chute
Type of wear protection wear resistant steel plates
Thickness of wear protection 12 mm

Discharge Boom

Belt speed 4.2 m/sec (820 fpm)
Belt width 1200 mm (48)

Troughing angle
- Carrying belt 35 degrees
- Return belt 15 degrees
Length of discharge boom between pulley centres
- minimum 16 m
- maximum 16.5 m
Belt clearance on each side 100 mm

Number of pulleys 2
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Diameter of pulley (wo. lagging) 630 mm
Face width of pulley min. 1450 mm
Type of lining herringbone rubber
Thickness of lining
Drive pulley min. 20 mm (3/4)
Tail pulley min. 15 mm (1/2)
Type of bearing spherical roller bearing

Type of drive electrical via gear box
Voltage 400 V
Number of drives 1
Type of brakes double shoe brake
Drive power 75 kW

Type of take-up hydraulic cylinder
Take-up length 500 mm


Type of return idlers
Spacing of idlers sets max. 3000 mm
Type of sealing labyrinth + V-type

Type of impact idlers garlands
Troughing 35 degrees
Number of idler sets at transfer point 8
Spacing of idler sets 400 mm
Diameter of idler tube 159 mm (6 in.)

Type of belt cleaners 1 belt scrapers
1 plough scraper
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Number of belt cleaners 2
Angle of chute walls 55 60 degrees
Type of wear protection wear resistance plates
Thickness of wear protection 16 mm

3.9 Crawlers and Undercarriage

Number of crawlers 2
Track gauge 6000 mm
Type of support 4-point
Ground clearance 500 mm
Average ground pressure at service weight 120 kpa

Length of crawler measured from centre of drive tumbler to
centre of return tumbler 5,980 mm

Take-up distance 300 mm

Width of crawler plate 1,700 mm
Load bearing surface 20.4 m
Number of track wheels per crawler 8
Lubrication grease-central lubr.
Number of drives per crawler 2
Drive power per crawler 45 kW

3.10 Lubrication

Automatic grease lubrication
-Type dual line system

-Location platform
- Number of grease pumps 2
- Number of points of lubrication appr. 108

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3.11 Miscellaneous

Walkways
- Type of flooring grating
- Inside width, minimum 500 mm

Stairs
- Type of flooring grating
- Inside width, minimum 500 mm

3.12 Power Supply

Power supply from:
Supply voltage 4.16 kV
HV - Motor voltage 4.16 kV
LV - Motor voltage 400 V
Control voltage 24 V
Lighting voltage 230 V

Frequency 50 Hz

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3.13 Motors, Quantity and Rated Power:

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

- Travelling gears 2 45 15

- Bucketwheel drive 1 110 72
Bucket Wheel Gear - oil pump 1 2.2 2

- Bucketwheel boom
Slewing drive 2 11 13
Hoisting unit (Hydraulic Power Pack) 1 45 15
Conveyor belt 1 75 62

- Discharge boom
Slewing drive electrically
Hoisting unit hydraulically (same as BW Hoist)
Conveyor belt 1 75 62

Others
- Grease pumps 2 0.7 1
- Air Conditioning 2 7 5
- Others lighting, fans... 3

Total Installed Power appr. 450 KW

Average Power Consumption appr. 255 KW

*Average Estimated Consumption = Average Load X Duty Cycle (% of time)
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Part 4

of
Electrical Equipment
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4.1 General Information

4.1.1 Operation Conditions

Ambient Temperature min. +0C outdoor
max. +35C

Altitude: 900 m

4.1.2 Standards

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

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4.1.3 General Data of Electrical Equipment

Supply voltage: 4.16 kV, 3-phase

Frequency: 50 Hz

Allowable range of rated
voltage: 10%

Motor voltage: 4.16 kV,, 3-phase
400 V, 3-phase

Control voltage, general: 24 V, 1-phase

PLC voltage: 24 V, DC

Indications lamp voltage: 24 V, DC

Grounding:

- 4.16 kV-Network
ungrounded, with earth-leakage monitoring
located in substation of the open pit mine

- 400 V Main distribution network
ungrounded, with earth-leakage monitoring

- 400 V Auxiliary network B
ungrounded, with ear-leakage monitoring

- 230/400 V Auxiliary network A
grounded neutral

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4.2 Power Supply and Distribution

The 4.16 kV power supply of the BWE will come from the belonging belt wagon or directly
from the cable reel car via the cable loop at the discharge boom to the 4.16 kV-Switchgear
in the superstructure E-House.

The 4.16 kV-power supply and switchgear can be isolated by switching-off the 4.16 kV-
Loadbreak switch on the cable reel car.

For the power distribution on the BWE a

- main distribution network
- auxiliary network A
- auxiliary network B

will be provided.

The auxiliary network A will comprise all the consumers (such as lighting, heating, main
control and monitoring voltages, but not drives) which will remain powered after
emergency-off.

The auxiliary network B will comprise the consumers which are necessary for repair
purposes, such as cranes and oil pumps, etc. In case of necessity, these consumers can
be disconnected.
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4.3 Drives

The drive motors with their data are specified in the motor list. This list also contains
information about the control details as well as associated brake thrustors.

The superstructure slew drive will be furnished with A.C. Motors.

The motors are parallel-connected and fed by a frequency converter.

The actual speed values are measured by one tacho-generator, which is attached to one
motor.
All squirrel cage rotor motors will be started directly, the slipring motors will be started by
time-delayed gradual variation of the rotor resistance.
Unintentional starts of drives after power voltage failure and recovered is prevented by
suitable design of the control system.

The drives of bucket wheel, the conveyors 1 and 2 are electrically interlocked among each
other and with the associated conveyor route, that they allow being started in a segment
only in a sense reverse to the direction of conveyance.

Should anyone of these drives fail, all other feeding conveyors will be cut out immediately.
In case of locally switch-on the conveyors by means of interlocking release, the drives
cannot be started from operator's cabin.

In addition, an interlocking will be provided for normal operation to allow connection of the
excavator drives, hoist, slew and travel and only then will the bucket wheel drive be
connected.

For transportation of the excavator, the interlocking can be by-passed in the main
operator's cabin by means of an unlocking switch. In this case, the bucket wheel drive
cannot be started.

Oil pump and grease pumps will be started in accordance with the main drives.

The starting of the conveyor route from the operator's cabin is only possible, when the
according conveyor system is running. This will be indicated by a signal-lamp on the
operator's cabin.
The main breaker will be opened with time lag with regard on the slew converter (also be
emergency-off).
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The following protection and monitoring equipment will be provided:

- Short circuit and overload protection,

- Insulation monitoring,

- Overcurrent monitoring.

- Speed monitoring devices for some drives,

- Slip monitoring device and Belt deviation monitoring for conveyor drives.

The heater for the bucket wheel drive gear will be interlocked with the oil pump. The heater
will be disconnected in case the oil pump is disconnected. The thermostat-controlled
heaters will remain in operation.

A.C. motors will be employed for the slewing drive. The slewing speeds will be controlled
according to the function of l/cos alpha in the automatic mode.

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4.4 Power Transformer

The bucket wheel excavator will be equipped with a vibration-proof power transformer
suitable for vibration and inclination applications.

The transformer tank will be of a welded plate design and resistant to pressure. Supply of
the transformer will include the first oil filling. Bushing insulators and port insulators will be
outdoor types of the relevant voltage class.

Cable Terminal Boxes will be of protection IP 54.
Voltage Tap-changing will be provided in variation of the voltage tap changer: 2.5%, 5%,
Voltage tap-changing be of off-load type.

Oil conservator with oil level gauge and air dryer (silicagel filling) will be provided as well as
thermometer pocket and drainage valve.

4.5 High-Voltage Switchgear

A high-voltage switchgear will be provided in the superstructure E-House with a

- Transformer feeder consisting of a fused load-break switch

- Motor feeder for bucket wheel main drive consisting of a
- fused load break switch with motor drive and under voltage trip (switched off in
case of emergency-off)

- Contactor

- Current transformers with overload relay and ammeter

- Power capacitor for compensation of lower factor, located locally

The power capacitor will be parallel connected with the B.W. motor so that it is switched on
and off by the stator contactor together with the B.W. motor.

The reactive power of the capacitors will be approximately 90% of the no-load reactive
power consumption of the motor. The power capacitors will be anti-vibration and suitable
for outdoor operation.
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4.6 Resistance Banks

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

4.7 Low-Voltage Switchgear

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

4.8 Local Devices

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

4.9 Signalling System

A signalling system will be provided for transmitting all required information concerning
malfunction and operating conditions of the machine. All detected malfunctions and
operating conditions will be displayed on a monitor in the operator's cab as single or
collective indication.

The control signals between BWE and central control station will be transmitted via the
nearest belt conveyor control substation (switch station at head drive station).

(1) Signals from BWE to the central control station:
- Ready for operation;
- BWE in operation;
- BWE malfunction;
- BWE out of operation.

(2) Signals from central control station to BWE:
- Ready for operation;
- Running signal, conveyor;
- Stop excavation.
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Among others, the following indications are envisaged:

- Circuit breaker on/off
- Control voltage on/off
- Operational limit switch
- Safety limit switch
- Emergency stop
- Fuse supervision (conveyor route)
- Oil pressure supervision
- Ground connection
- Wind warning

The rest indications are mentioned in the list of local control devices.

A PLC (Programmable controller) for control and processing of annunciation signals, with
all necessary components, interface, I/O racks, special cables, remote I/O adapters for
remote I/O in operator's cab and/or control rooms, etc. will be provided.

The PLC will perform all necessary operations as timing, counting, arithmetic operations,
comparisation, data manipulation etc.

The PLC will be provided with required power source and battery back-up to maintain
memory contents during power loss.

The required special relays of proximity switches, ground fault relays, lubricating system
malfunction relays, selsyn indication units, inclination monitoring devices, will be provided.
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4.10 Operator's Cab Equipment

Operator's Desks
1 Control desk for operator's cabin, consisting of left and right side panel and driver's chair,
containing:

Control and master control-switches for the drives of the excavator.

Further controls are:

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

Indication- and Instrument Panels
1 Monitor panel, containing:
1 Monitor
also for indications of
- crawler position
- slew position
- hoist position
- total distance travelled
- step advance
- slew speed
- wind speed
1 Voltmeter for 6 kV
1 Ammeter for bucket wheel drive
1 Clock
1 Loudspeaker for communication equipment

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4.11 Miscellaneous Equipment

The main items are specified in the list of local control devices.

Among other the following items will be provided:

Lever-type limit switches, heavy duty design.

Inclination measuring device, with indication in the operator's cab, alarm and stop at
inclinations of 1:10 (change of location) and 1:20 (operation).

Anemometer indicating wind velocity, with alarm and stop at max. wind velocities (visible
and audible alarm at a wind pressure of approx. 20kg/m, max. wind pressure at 80 kg/m
with equipment at standstill), anemometer transducer with heating, make: Lamprecht or
equal; stop is effected when the maximum wind pressure persists for a period in excess of
6 seconds.

Air-conditioning units for the cab, including intake filter and accessories.

Miscellaneous emergency stop buttons with red mushroom-type button, to be unlatched by
turning, type of enclosure IP 56, heavy iron-clad design, to be distributed over the
machines.

Required heating elements for gearing, cab, electrical room, etc. including the necessary
accessories, such as thermostats, switches etc.

Miscellaneous power plugging devices for connecting of vulcanising equipment, welding
equipment and tools.

Several high-power floodlights, suitable for outdoor use, also for illuminating of the BWE
digging area of the bucket wheel.
Several lighting fixtures with fluorescent lamps, complete with reflector, ballasts, starter, as
required for adequate illumination of the walkways, stairways, suitable for outdoor
installation.

Several plastic fittings for fluorescent lamps, complete with glass well, reflector, ballasts,
starter etc., for adequate illumination of the cab and E-house and collector ring room,
workshops.

Miscellaneous items for lighting and heating circuits, such as switches, push-buttons

Several signal horns for outdoor installation, also for start-up alarm.

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Several fans and filters for the electrical room.
Magnetic powder couplings for BWE superstructure slew drive, approx. 60 v, Amp., D.C.

Slewing angle indicator with accessories for BWE slew drive, indication in operator's cab.

Boom hoist height indicators mounted at pivot points, with indication of height from the
ground to the bottom of bucket wheel, indication in operator's cab.

BWE travel indication, indicating the travel distances and advance steps of the cuts and the
total covered distances, indication in operator's cab.

All necessary control valves, 24 V, DC (for hydraulic systems)

Pull cord switches, 2 per conveyor and for cable tension monitoring of cable to other
machine, including necessary ropes and accessories.

Proximity limit switches for speed control and position limitation.

Belt alignment switches.
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4.12 Lighting

Outdoor lighting will be divided into general and operational lighting. Quick ignition
floodlights will be used for illumination of the boom and crawler areas.

The operational lighting will be provided for the important working areas, such as on the
surface areas around the machine and the belt conveyor transfer point, etc.

The general lighting will only be provided for the walkways, platforms and stairs etc., so
that safety conditions will be guaranteed for operations and inspections.

The E-house and operator's cab will be equipped with lighting installations according to the
respective illumination requirements.

4.13 Communication

The following communication equipment will be provided for the BWE:

- Telephone systems for internal communications

- One loudspeaker calling system

- Space will be reserved for radio communication system between BWE and central control
station.

4.14 Slipring Assembly

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

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4.15 Cables and Installation Material

Cables
4.16 kV power cables type NTSCgEwu will be used for the infeeding primary side of
power transformer and B.W. main drive motor.

For LV power transmission rubber sheathed flexible cable will be used.

Control cables will also be rubber sheathed flexible cable with a conductor cross Part of at
least 2,5mm as well as special cable, also shielded cables.

Installation Material
Fastenings and small installation material including terminal boxes, cable trays, conduits,
cable grips, cable shoes, switches for lighting and heating, will be provided.

4.16 Automatic Control System

An automatic control system will be provided for

a) Automatic operation
Consisting of automatic control of bucket wheel main drive, conveyor drives,
hydraulic pump, oil pumps, grease pumps, slew drive frequency converter.

b) Automatically adjusting of bucket wheel height

c) Automatic control system of slewing angle

d) Automatic control of slewing speed

e) Automatic cutting depth control

The detail principles of the automatic height adjustment and slewing angle control are as
follows:

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Automation of Wheel Height Adjustment

The wheel boom luffing angle relative to the excavator superstructure is determined
digitally with a shaft encoder. The determined angle value can be corrected digitally in
order to fix the grade level as zero reference for the boom lift. The angle value is converted
to elevation values which indicate the difference in elevation between the lowest peripheral
point of the bucket wheel and grade level.

The desired luffing height is adjusting by hand on a digital setpoint station. Signal lamps
indicate when the pre-stop position is reached.

Automatic Slewing Angle Control System

The wheel boom slewing angle relative to the crawler is determined digitally with an
absolute angle coder or similar device. The angle obtained is recorded in order to
represent the slewing angle alpha T and alpha S as defined. The zero point can be
adjusted digitally within reasonable limits.

When a predetermined pre-stop position is reached, the slewing speed is reduced, and the
slewing mechanism is stopped when the setpoint stop position is reached.

The momentary slewing angle is indicated.

Setpoint adjustment can be effected by making the first slewing pass through the slice by
manual control. The actual limiting slewing angle values are used as setpoint input by
pressing a key when the slewing mechanism is at a standstill. The boom movement will
then stop when the stored set point values are reached.

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Part 5

General
Layout Drawing

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5. General Arrangement Drawing

Dwg. No. 415.33951.000 A

Bucket Wheel Excavator VABE 400 Typical Tec

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