Doc no.

ISTR 10-1
Operation Manual
PVC. Roll-Up Ventilation Door
Rev 1

UNDERGROUND ROLL-UP PVC VENTILATION DOOR

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
Page 1 of 32
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Operation Manual
PVC. Roll-Up Ventilation Door
Rev 1

1) Purpose
Purpose of this document is to describe the operation of the Underground Roll-up PVC Ventilation
Door for the control of air flow underground.

2) Operation Limitations
Underground Roll-up PVC Ventilation Door Unit installed close to any blasting condition, it is
recommended that the doors must be fully opened when blasting take place and then be closed
directly after blast.
This will prevent any damage due to concussion and shock loads.

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
Page 2 of 32
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PVC. Roll-Up Ventilation Door
Rev 1

3) Door Assembly
➢ Door frame manufactured Channel - 230 x 90 x 32.2 kg/m
➢ Top box section for drive assembly manufactured from 4,0 mm plate.
➢ Drive shaft fitted with bearings fixed to Cast Iron ACME Machined Shaft, Coupling & Nut.

➢ Electric Drive unit per Door fitted in Top Box section:

o Direct Drive motor & Gearbox unit (2,2kW Helical-Worm Gearmotor)
o Complete with electric brake.
o 2 x Limit Switches – Full Open / Full Close

➢ Roll-up door Panel:

• Manufactured from Heavy duty PVC (2000 GSM) material with heavy duty
strapping.
• 30 Ø mild steel round bars fixed to the door panel at interval.
• 89,9Ø Pipe x 4,85 Wall Thickness fixed to bottom of door panel

4) Automated Door Electronics

❖ Depending on the system used by the mine fitted to underground vehicles / CAS &
PDS, a system is supplied that will connect to the door control system.

❖ System is a plug-in system into the door control system.

❖ System will pick-up the Censor unit fitted to the vehicle.

❖ When vehicle approach the door, the door system will pick-up the signal from the
vehicle within 8-10 meters (this can be set as per mine requirements) of the door and
the first door will start to open if there is not another vehicle approach through the
other door.

4.1) Activating doors to open and close.

a) Doors fitted with a push button (open and close button) and Emergency stop on both
sides of each door. Close to the vertical column of the door.

b) Pull switch option with pull switches fitted to hang wall 10 meters from door on both
sides of door and both sides of roadway.

c) Remote control is available. Small keyring type with 3 Button and Emergency Stop.

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
Page 3 of 32
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Operation Manual
PVC. Roll-Up Ventilation Door
Rev 1

d) Automated Door Control.

Operation of the ventilation door, consist of preventing two doors to be opened

simultaneously and regulating the traffic within the system.
• Two successive doors are integrated within a system interlock and ventilation
doors are serialized using 2D beacons. 2D beacons are used for ranging, data
logging, and enabling position/direction functionality to be obtained.
• This broadens the functionality of the Ventilation Door Solution, as it would work
for rail-bound systems and TMM’s.
• In order to serialize a door, a 2D beacon has to be placed at each door, each set up
with its designated ID. AM readers +-10m on either side of the door will assist
with the positioning and movement direction and communicate directly with the
2D beacons.

• Below a general layout of the above-mentioned readers and beacons.

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
Page 4 of 32
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PVC. Roll-Up Ventilation Door
Rev 1

❖ Use of a traffic light system assists with regulating traffic and notifying fellow drivers,
that would like to enter the system, of vehicles currently in the system.

❖ System is based on priority levels that will allow access to the vehicle of the highest
priority. In the case of similar priorities, the door system will work on the first in - first
out principle.

❖ Indication lights are on each side of the door. The second vehicle needs to be forced
into a stop state until the current vehicle exits the system.

❖ Ventilation doors are mounted on steel frames, with the rest of the haulage closed with
concrete. On the side, there is a pedestrian walkway, equipped with a sealed turnstile.

❖ Door height is about 2 m and it takes an average of 20 seconds to open and close
respectively.

❖ Interlocked 2-door shares a centralized UPS and Electrical panel with a single mobile
controller, with network capabilities allowing remote access to the door status and
control from the surface.

❖ Controller is used to enable the system to be bypassed by a digital key provided by the
responsible person. Thus, the digital key allows the user to operate the door manually
by push buttons and rope switches.

❖ Each door is equipped with a field bus station collecting the door status from the limit
switches on either side of the door and a safety light curtain to prevent the door from
pinching equipment or possible pedestrians.

❖ Single-phase motor used for operating the door is controlled by a variable speed drive,
minimizing the inrush current and controlling the speed of the motor.

❖ It is important that a VSD is used, as the UPS system is not designed to accommodate
the inrush current as per motor specifications.

❖ Control panel of the door is to be placed at the point where it is most accessible.

❖ On each side of the door, closest to the pedestrian walkway, a switch box containing
an emergency stop and two push buttons is to be placed.

❖ Emergency button is to be always available, whereas the push buttons are only to be
used when maintenance/bypassing or repairs are to be done.

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
Page 5 of 32
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PVC. Roll-Up Ventilation Door
Rev 1

Following figure represents the basic system layout, to better understand the system.

A B B A
UPS Electr
ical

Contr
ol

Field M M Field
Statio D D Statio
o o
Li o o Li
r r
Safe Safe

R R R R

Backup System Power (Yellow), Control System (Blue), Motor Control (Red),
Instrumentation (Green), and the existing infrastructure (Grey).

o Data logging will be done through communication between the 2D beacon and the
vehicle.
o A time and date stamp will be given, along with a short message indicating which door
was operated and by what vehicle.
o This will then be logged by the TMM handset.
o Data will then be taken to the surface through the handset or through the upload
module that is installed on the vehicles.

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
Page 6 of 32
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PVC. Roll-Up Ventilation Door
Rev 1

4.2) Control System Outcomes

Following outcomes were listed for the control system, please note that this does not include
that of the UPS:
● Serialize and automate doors to data logging - the door should automatically open if a
vehicle is in front of it and close automatically after the vehicle has moved through
the door.
● Interlocking of doors - two consecutive doors should not be able to open at the same
time.
● To optimize the workflow of TMM - a status indicator light and buzzer are required
on each side of the door that will be enabled when the door opens or closes.
● Vehicles should be notified of other vehicles entering from the other side.
● Door system works on the first in - first out principle in the case of two vehicles with
equal priority levels.
● Additional vehicles should be forced to brake at the system entrance until the system
is cleared and the vehicle may proceed.
● The following list contains the priority levels from highest to lowest this means that
the vehicle with the higher priority will first move through the system while the other
vehicle will remain in a stop state if fitted with a level 9 interface,
○ LDVs
○ UVs
○ Drill Rigs / Bolters
○ LHDs
● There will be a manual mode if access is given, where the doors can be opened with
either:
○ A push button, located on both sides of the door, closest to the pedestrian
walkway.
○ Rope-pull switches that are fitted to the hanging wall, 10m from the door on
both sides.
● Both doors can be open at the same time even if they have to be opened separately:
○ For manual operation, an open and close button is allocated on the control
screen.
○ The user must also enter the bypass password on the control screen in order
for both doors to be opened. The responsible person on the mine will have the
password for this function.
● Manual system access consists of the manual operations bypass and complete system
bypass, which allow both doors to be open at the same time.
● The mine will be able to see the operational status of the ventilation door on the
surface.
○ Door open / close status.
○ Door error status
○ Operational hours
○ Service status

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
Page 7 of 32
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PVC. Roll-Up Ventilation Door
Rev 1

4.3) Operating Procedures

Following operating scenarios are possible with the vent door solution,
1. Normal Operation
2. Scenario 1: The vehicle triggers the door to open, but reverses back and never enters
the system.
3. Scenario 2: The vehicle moves up to the first door, but reverses back out of the system.
4. Scenario 3: The vehicle moves into the system (Triggers the antenna and safety curtain
simultaneously) but reverses out of the system again.
5. Scenario 4: The vehicle moves into the door’s way as the door is closing.
6. Emergency Stop

4.4) Normal Operation

4.4.1) First operating scenario entails a vehicle moving straight through the system. A vehicle
will approach antenna AM1 and door 1 will open.

4.4.2) Vehicle will then move through the safety curtain of door 1 and the door will remain
open until the safety curtain is not active anymore.

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
Page 8 of 32
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PVC. Roll-Up Ventilation Door
Rev 1

4.4.3) Vehicle will now move past door 1 and move in the range of antenna AM2. Door 1 will
now close and only when door 1 is closed, door 2 opens.

4.4.4) Vehicle will then move through the safety curtain of door 2 and the door will remain
open until the safety curtain is not active anymore.

4.4.5) Vehicle will now move past door 2 and move in the range of antenna AM1. Door 2 will
now close and the system will then turn to its normal state.

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
Page 9 of 32
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PVC. Roll-Up Ventilation Door
Rev 1

4.5) Scenario 1: The vehicle triggers the door to open, but reverses back and never enters the
system

4.5.1)The following scenario represents a vehicle entering the zone of antenna AM1, but
reversing back and exiting the zone. The vehicle will approach antenna AM1 and door 1 will
open.

4.5.2) Vehicle reverses back and never triggers the safety curtain of door 1. The system will
wait 60 seconds for the vehicle to trigger the safety curtain if it does not, the door will close
again. The system will then enter its normal state.

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
Page 10 of 32
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PVC. Roll-Up Ventilation Door
Rev 1

4.6) Scenario 2: The vehicle moves up to the first door, but reverses back out of the system.

4.6.1)The following scenario represents a vehicle driving up to the door, but then reversing
back out of the system after it triggered the safety light curtain. The vehicle will approach
antenna AM1 and door 1 will open.

4.6.2) Vehicle will then move through the safety curtain of door 1 and the door will remain
open until the safety curtain is not active anymore.

4.6.3) Vehicle reverses back and never triggers the antenna AM2. The door will close as soon
as the safety curtain is inactive. The system will wait 30 seconds for antenna AM2 to be
triggered or else the system will then enter its normal state.

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
Page 11 of 32
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PVC. Roll-Up Ventilation Door
Rev 1

4.7) Scenario 3: The vehicle moves into the system (Triggers the antenna and safety
curtain simultaneously) but reverses out of the system again.

4.7.1) The following scenario represents a vehicle driving past the door triggering the safety
curtain and antenna AM2, but then reversing back out of the system. The vehicle will
approach antenna AM1 and door 1 will open.

4.7.2) Vehicle will then move through the safety curtain of door 1 and the door will remain
open until the safety curtain is not active anymore.

4.7.3) Vehicle then moves through the safety curtain and then simultaneously into the zone of
antenna AM2.

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
Page 12 of 32
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PVC. Roll-Up Ventilation Door
Rev 1

4.7.4) Operator then decides to reverse back out of the system. The door will remain open as
long as the safety curtain is active.

4.7.5) Vehicle reverses back past the safety curtain. The door will close as soon as the safety
curtain is inactive. The system will wait 30 seconds for antenna AM2 to be triggered or else
the system will then enter its normal state.

4.8) Scenario 4: The vehicle moves into the door’s way as the door is closing.

4.8.1) Following scenario represents a vehicle driving into the door as the door is busy closing.
Vehicle will approach antenna AM1 and door 1 will open.

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
Page 13 of 32
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PVC. Roll-Up Ventilation Door
Rev 1

4.8.2) Vehicle will then move through the safety curtain of door 1 and the door will remain
open until the safety curtain is not active anymore.

4.8.3) Vehicle will now move past door 1 and move in the range of antenna AM2. Door 1 will
now close.

4.8.4) Operator now decides to reverse back out of the system into the doors way as its closes.
Door will stop and start opening again allowing the vehicle to exit the system.

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
Page 14 of 32
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PVC. Roll-Up Ventilation Door
Rev 1

4.9) Emergency Stop

E-stop function is used to stop the door in case of an emergency. The following will happen
when the E-stop is activated.

● The lights will turn red and the siren of each light will activate for 10 seconds.
● The lights will only turn white again as soon as the E-Stop has been released.

4.10) Possible Faults/Errors

Following faults/error scenarios are possible with the vent door solution:
1. Communication error between Control Panel and Field Stations
2. Door open/close fault
3. Vehicle blocking door
4. Vehicle stuck between the doors

4.11) Communication error between Control Panel and Field Stations

4.11.1) Communication error can be caused due to a CANBUS fault between the control panel
and field stations. The lights will start to flicker purple for 60 seconds.

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
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4.11.2) After 60 seconds the panel will then go into manual bypass mode. The lights will start
to flicker blue. In manual bypass mode, the ventilation doors can only be opened and closed
with the push buttons or pull switches located at each end of the doors. Although, the system
is limited to only operating one door at an instance. Doors still cannot be open simultaneously,
unless a complete system bypass is requested.

4.11.3) Once the communications error between the doors has been resolved, the doors will
be switched back to the normal state of operation automatically or by pressing and releasing
the E-stop.

4.12) Door open/close fault

4.12.1) Door open/close fault will arise once the doors have been triggered and fail to
open/close in 40 seconds. This issue will usually be caused by a faulty limit switch or broken
cable. The system will go into manual bypass mode. The lights will then start to flicker blue.

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
Page 16 of 32
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4.12.2) Once the door open/close error has been resolved the doors can be switched back to
the normal state of operation by pressing and releasing the E-stop.

4.13) Vehicle blocking door

4.13.1) If a vehicle has broken down or stopped under the door for more than 10 minutes the
system will go into manual bypass mode. The lights will start to flicker blue.

4.13.2) Once the vehicle has been repaired and moved out of the doors way, the system can
be switched back to the normal state of operation by pressing and releasing the E-stop.

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
Page 17 of 32
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4.14) Vehicle stuck between the doors

4.14.1) Vehicle has broken down or stopped in between the two doors for more than
10 minutes the system will go into auto-bypass mode. The lights will start to flicker blue.

4.14.2) Once the vehicle has been repaired and moved out of the system and there are no other
vehicles in the system, the system can be switched back to the normal state of operation by
pressing and releasing the E-stop.

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
Page 18 of 32
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Rev 1

15.0) Electrical Panel & Control System

Solution consists of a centralized controller with a Fieldbus module at each door. Each door is
equipped with a control panel containing a variable speed drive and the necessary motor protection
as specified by the supplier. The system is powered by a three-phase 525V AC source, converted to
a single-phase supply of 230V AC in the main electrical panel with the necessary MCB’s and shunt
trips for emergency purposes. Therefore the system includes:

● Centralized Mobile Controller

● Fieldbus Modules
● Connection Technologies and Cables as it is a plug-and-play solution
● Power Supplies
● Power Distribution Blocks with Protection
● Enclosure (Control Panels and Electrical Panel)
● 10kVA Transfomer (525V/230V)
● Variable Speed Drives with three-phase power output
● Application modules to directly communicate with the VSD’s
● Motor Protection
● Emergency Stop and Indication
● Mounting Accessories

16.0) In case of a POWER FAILURE:

There are two methods to operate the door during a Power Failure:
16.1) Method -1: Manually Operating Door (Open & Close)
Make sure that Main Power is Turn Off before any work or setting is done on the door.
16.1.1)To Close Door (Manually)
➢ Release Electric Brake (A) with 4mm Allen Key.
➢ Turn it Clockwise (In) to release Electric Brake. Door will Start running
down.
➢ Once door is fully closed, turn Allen key Anti-clockwise to engage electric
brake before power is switch on.

Allen Key
to
Release Electric Brake
after power is switch off

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
Page 19 of 32
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Rev 1

16.1.2) Opening of Door (Manually)

• Make sure that Main Power is Turn Off
• Insert speed drive with Socket Head Allen key into Cap Screw Head Allen
key into the back of the motor on the motor shaft.
• Release Electric Brake (A) with a 4mm Allen Key. Turn this Clockwise (In)
to release electric brake. (Do not turn screw out Completely)
• Start turning the motor with speed drive in correct direction (Clockwise) to
start open the door manually.
• Turn Electrical Brake release with Allen Key (Anti Clockwise) to engage the
brake to prevent the door running down to close position.
• Do not release or remove speed drive unless the Electric Brake is turned on
to engaged position.
• Check that every door is clear of obstruction before Power is Turned On.

Allen Key
to
Engage Electric Brake
Before power is switch on

Speed Drive Wrench

Socket Head Allen Key

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
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16.2) UPS Solution to Operate the Door in case of Power Failure

Installation of a UPS system that will allow normal operating condition of the doors

16.2.1) UPS solution consists of three sizes of battery packs of which the smallest is
102Ah and the largest is 306Ah.

16.2.2) Battery packs consist of different configurations of deep-cycle lead acid

batteries (Raylite - SMF101, 12V, 102Ah).

16.2.3) Battery pack is designed for a 24V supply, with a maximum discharge
percentage of 40% and an efficiency of 80%.

16.2.4) Number of operations is based on an average open and close time of 20

seconds, for a 2.2kW AC Motor

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
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16.2.5) UPS system includes:

● Deep-Cycle Lead Acid Batteries
● 5kVA Hybrid Inverter
● Battery Monitoring and Protection
● MCB with shunt
● Manual Change-Over Switch
● Enclosures and Cooling
● Connection Terminals and Cables
● Emergency Stop

17.0) Emergency operating mode

a) Emergency operating mode is built into the electrical system to Override the
Interlock system.

b) This overriding system can only be done by suitable and authorized

personnel. Now both doors can open at the same time.

18.0) PVC Roll-up door installation

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
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18.1) Drawing must be read in conjunction with section 18.2 below:

18.2) PVC Roll-up Door Installation consist of the following:

Number corresponds with numbers on drawing as per section 18.1 above.

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
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1. Make sure all the materials are procured and underground.

2. Make sure the floor or footwall is level.
3. Start by assembling the frames, i.e., 2 Side Frames – Item1 (230x90x32.2kg/m) and
Top Beam Item 2 (230x90x32.2kg/m) and Canopy Bracket.
4. Columns already welded on Base plates.
5. Lift the frame and level the Top Beam (Item 1) and Side Columns (Item 2) to ensure
that the frame is installed square.
6. When the frames are level with the footwall, start drilling the floor with 22mm Drill
Bit for M20 Anchor Bolts.
7. After anchoring the side frames, start drilling the holes in the hanging wall for the
Top Beam.
8. Install long Roof Bolts to anchor and secure the Top Beam to the hanging wall.
9. After the frames are set, check the frames squareness again.
10. Install the Revolving Man Door in place next to the side frames.
11. Only then can the casting of the re-enforced concrete or brick blocks to be build the
wall around the door frames and rotating man door.
12. It must be noted that if concrete brick blocks are used, each row between bricks to be
secured with brick force with the cement.
13. Civil work to build the door & rotating man door can be done by cast concrete or the
use of large building cement brick blocks.
14. Once all concrete is set then the motor drive assembly / canopy can be installed.
15. Lift the canopy with the motor drive assembly in position and bolt it to the frame.
16. Place the Electrical Panel in position and then UVSS electrician to connect all
electrical panels and control system.
17. Once all electrical panels and control systems are connected by UVSS, the mine to
connect main connection to panel and to be witness by UVSS.
18. Once the installation is complete, UVSS will do Commissioning and Training of
PVC Roll-Up Doors

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
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18.3) Max Loads per Rock Bolt per top Door Beam:

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
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19.0) PVC Roll-up Ventilation Door Commissioning:

1. Release the brakes that the curtain is standing halfway in closed position, then, tighten
the brakes.
2. Emergency stop buttons must be unlocked (turn clockwise and release)
3. Then press the green button so that the door will open upwards.
4. Door Opening and Closing
a) When the door is opening and the ACME Nut bypass the Limit Switch, then the main
feed connection is wrong.
b) But, when the ACME Nut touches the Limit Switch and door stops, then the
connection is correct.
c) When the door closes and the Curtain is level with the floor, then Limit Switch is
rightly connected.
d) When the Curtain is not touching the floor, the Limit Switches must be adjusted.
e) When the door is closing, and you press the Emergency Stop Button, the door will
stop. When releasing the stop button, and then the press the green button, the door
will go up. But, if the door closes, then the connection on the motor is wrong.
5. VERY IMPORTANT: Do not adjust anything in the Electrical Panel, otherwise it
will override the connection, and nothing will work.
6. The third Limit Switch in the Canopy acts as an emergency stop. i.e., when the opening
Limit Switch has failed, the third Limit Switch will stop the door.
7. Check all Pull Switches (4 off) if they are working.
8. Robot Lights
a) When the door is opened, the light is Green. When it starts to close, it turns Red.
b) No one or no vehicle is allowed to pass through the door.
c) Once the door is closed, the light stays Red.
d) When the door is opening or closing, then an alarm will be buzzing.

Note
Door commissioning (Mechanical & Electrics) must be done by UVSS and signed off.

20.0) Routine Service and Inspection of Door

i. Please see Doc no FM36 For Inspection and Maintenance Frequency of
Underground Roll-up PVC Ventilation Door.
ii. It must be noted that a planned routine maintenance plan must be put in place by the
mine.

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
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21.0) Part list per Door

21.1) Control Panel Part Numbers:

Electrical System General critical spares:
● Deep Cycle Lead Acid Battery (Raylite - SMF101, 12V, 102Ah)
● 5kVA Hybrid Inverter
● MEGA-fuse 400A/200A Inverter Input (Battery)
● 1A and 100mA 5x20mm Glass Fuses (Fast Blow)
● Transformer (525/230/115V, 10kVA)
● Centralized Mobile Controller
● Fieldbus Module
● 1-Segment Signal Lamp with build in Sounder (Traffic Light System)
● Power Supply (24V, 10A)
● Safety Light Curtain (Sender and Reciever)
● 2.2kW Variable Speed Drive
● Application Module
● 10A 10x38mm Fuse (100kA, 690V)
● 3A, 10A Automotive Blade Fuses
● 2D Beacon

21.2) CRITICAL Door Spare Part Numbers:

The following spares is critical spares for the doors.
Spare set must always be available in the mine store.

UNDERGROUND PVC ROLL-UP DOOR SPARE PARTS LIST PER DOOR

Qty.
MATERIAL
MATERIAL SHORT DESCRIPTION LONG TEXT Per
NUMBER
DOOR
Helical Worm Gearmotor - S77
PRD-046 2,2kW Helical-Worm Gearmotor 1
DRN100LS4/BE5HF
PRD- 082 Limit Switch MCE-CA12-2-Q Limit Switch 3

Door Panel: 2000 H x 55000 W c/w

PRD-001-3 PVC Door Panel 1
Strapping / 30Ø Round Bar Rods

PRD-ARE-
Control Panel – ARE-System2 Electronic Panel with switches 1 SET
SYS2

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
Page 27 of 32
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Operation Manual
PVC. Roll-Up Ventilation Door
Rev 1

21. 3) Mechanical Door Spare Part Numbers:

UNDERGROUND PVC ROLL-UP DOOR SPARE PARTS LIST PER DOOR

Q'TY.
MATERIAL
MATERIAL SHORT DESCRIPTION LONG TEXT Per
NUMBER
DOOR

PRD-006 EN8 ACME Shaft 50Ø x 415mm long, 5 pitch/ACME threads 1

PRD-004 Cast Iron ACME Nut 100x100x30 thick Cast Iron 1

PRD-029 Small Bush 1 70Ø x 41Ø x 120 Lg Small Bush EN8 1

PRD-030 Belt Rollers c/w Disc Small Bush 2 70Ø x 41Ø x 180 LG Small Bush EN8 1

PRD-031 Small Bush 3 80Ø x 46Ø x 150 LG Small Bush EN8 1

PRD-045 40Ø Shaft 40Ø x 4130mm long Bright Steel Shaft 1

Helical Worm Gearmotor - S77
PRD-046 2,2kW Helical-Worm Gearmotor 1
DRN100LS4/BE5HF
FAG UCFL208-J7 (2 Hole 40mm Oval
PRD-028 FAG Bearing 4
Flange Bearing)
PRD- 082 Limit Switch MCE-CA12-2-Q Limit Switch 3

Door Panel: 2000 H x 55000 W c/w

PRD-001-3 PVC Door Panel 1
Strapping / 30Ø Round Bar Rods
CONSIST of: PVC Bag; Scissors;
CONSIST of: PVC Bag; Scissors; Stapler
PATCH KIT Stapler & Staples; Glue; Mutton Cloth; 1 SET
& Staples; Glue; Mutton Cloth; 1.5m PVC
1.5m PVC
PRD-056 Pull Switch Pull Switch Assembly 1
Poly Webbing - 100 Wide (100 Meter per
PRD-027 Poly Webbing 1
Roll)
PRD-058 Bolt, Toggle, Type Small Spares Keys, Grub Screws, Bolts & Nuts 1
Gear, Girth, Special Lubrication For Roll-
PRD-057 Gear Lubrication 1
Up Vent Doors

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
Page 28 of 32
 Doc no. ISTR 10-1
Operation Manual
PVC. Roll-Up Ventilation Door
Rev 1

21.4) Helical-worm Gearmotor Details – 2,2 kW Motor

Helical-worm gearmotor
S77 DRN100LS4/BE5HF

Technical data
Speed [r/min] Wiring diagram
: 1450 / 51 : R13 / 680010306
Total ratio [i] Thermal cl.[°C]/Enclosure[IP]
: 28,41 / infinite : 180(H) / 65
Ma max [Nm] International efficiency class
: 1050 : IE3
Output torque [Nm] Efficiency
: 365
Service factor SEW-FB at 50/75/100% Pn [%]
: 2,90 : 86,4 / 87,5 / 86,9
Mounting position CE mark
: M1A : Yes
Term.box.pos.[°] / cable entry Brake
: 90 (B) / normal : BE5
Lubricant / -volume [l] Brake release
: CLP 680 Miner.Oil / 1,90 : HF = lockable manual brake release
Paint coat Position brake release [°]
: Top coat RAL7031 (blue gray) : 303
Brake voltage [V]/-torque [Nm]
: 525 / 55
Gear unit Brake rectifier
: S77 : BME1.5
Output shaft end Brake wiring diagram
: 45x90mm lg. : B101 / 690020006
Output shaft design Terminal assignment diagram
: with keyway/with key : 669650407
Design Terminal box
: Foot-mounted version : Terminal box lower part made of aluminum
Documentation no. A with tapped hole 2xM32, 1xM16
: 27784460
Parts list Documentation no. A
: 022550996 : 25957074
26861313
Motor 26864282
: DRN100LS4/BE5HF
Motor power [kW]
: 2.2

Motor frequency [Hz] Nameplate

: 50 : English
Cyclic duration factor S1-S10 Nameplate position
: S1 : 180°
Motor voltage [V] / conn. type Opera.instr. A lang./quantity
: 304/525 delta/star : English / 0
Rated current [A] Parts list/language/quantity
: 6,30 / 3,65 : English / 0
cos phi Commodity code
: 0,76 : 85015220

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
Page 29 of 32
 Doc no. ISTR 10-1
Operation Manual
PVC. Roll-Up Ventilation Door
Rev 1

22.0) IF IN DOUBT, PLEASE CONTACT UVSS.

NOTE:
Due to our continuous quest to improve on the performance and the safe operation of the
PVC ROLL UP DOOR
we Unique Ventilation & Support Systems (Pty)Ltd reserves the right to change this
specification at any time without
notification to existing end users,

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
Page 30 of 32
 Doc no. ISTR 10-1
Operation Manual
PVC. Roll-Up Ventilation Door
Rev 1

SEE BELOW CONTENT OF FM 36

Inspection and Maintenance Frequency: Twice a week A, Weekly B, Monthly C
Frequen Inspected
Item Comments Date Signature
cy by
1. Overall condition of
vent door and frame
Check if door frame is
secure and in place (PRD- C
022)
Check door frame for
damage and if door is level B
(PRD-022)
Check door for damage
A
(PRD-001)
Check if road area is clean
B
and level
2. Gearbox
Check oil level on gearbox
(CLP 680 Mining oil) see C
attached drawing (PRD-046)
3. Roll up straps
Check condition of straps
A
(PRD-027)
Check the tension on straps A

4. Limit Switches
Condition of limit switches
B
(PRD-082)
Setting correct B

Are they secure B

5. Vent door curtain

Round bars in place and
B
secure (PRD-023)
Are all round bars straight
B
(PRD-023)
Do the door roll up correct
B
(PRD-001)
Do the door open and close
B
fully (PRD-001)
Do the door seal well B
Are all bolt on brackets for
B
door in place and secure

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
Page 31 of 32
 Doc no. ISTR 10-1
Operation Manual
PVC. Roll-Up Ventilation Door
Rev 1

6. ACME limit switch

drive
Is this unit still secure A

Fastened all grup screws A

Spray lubricant on threaded
A
area (Twice weekly) Grease
7. All electrical items
Condition of all connections
B
and switches
Check if all switches are
B
working
Are all switches secure to
B
wall or frame
Condition of all cables C

Condition of electrical box C

Can electrical box lock A

Are all emergency stops
A
working
Is siren/hooter working A
Is interlocking system
A
working (Optional)
Is safety beams still active A

8. Drive system
See that all belt rollers are
B
in line with back strap clamp
Fasten all grup screws on
A
rollers and couplings
Grease bearings (once a
C
month)
Check hold down bolts on
C
motor and gearbox
Check if drive shaft is secure
and straight
C
(PRD-045: Ø40) (PRD-002:
Ø30)
Check if door box bolts are
fastened and all there (PRD- C
040/041)
Check if motor gearbox is
C
dry and clean

This document is the property of UVSS. The document is supplied on the condition that it may not
be disclosed to third parties without authorisation.
Page 32 of 32