DQL400/600·35

Bucket Wheel Stacker Reclaimer

Electric Operating
Instruction

(D270 DQSM )

Changsha Heavy Machinery Manufacturing

Co.,Ltd.
March.2010
 Contents
Ⅰ. Summary
Ⅱ. Electric drive
Ⅲ. Operating control system
Ⅳ. Lighting and overhaul power supply
Ⅴ. Communication、interlock、protect system
Ⅵ.Operating program
VII.Installing and debugging caution note
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Changsha Heavy
Instruction for use D270 DQSM
Machinery

Manufacturing DQL400/600·35
Bucket Wheel Stacker Reclaimer Total:23 No.1
Co.,Ltd. (Electric part)

Ⅰ. Summary
The electrical part of DQL400/600·35 bucket-wheel stacker reclaimer is mainly
devided into 4 kinds of operation mode, that is manual control, single control,
semiautomatic control and tripper transformation according to the needs of technology
to met the control demands of the different working condition of stacking and
reclaiming. The control of the whole machine is equipped the necessary protection
measures such as preventions of overload, cut-out, emergency stop, interlocking, null,
limit, anchoring rail clamp, gale warning, belt deviation, anti-crash, etc.. In order to be
convenient for the production operation and management on the work site, the
communication system of the machine with the ground control room and the
interlocking signal feedback system of the machine with the ground control room have
been disposed. Air conditioner is disposed in the cab, it is improved the working
environment of the operating personnel. The whole design is tried to be combined with
the site actuality and met the needs and demands of the user. According to the electrical
illustrative diagram, the basic function and principle of each system of the electrical
part of the machine are introduced separately as follows.
Ⅱ. Electric drive
The whole machine is with installed gross capacity about 210kW, normal power

source from compiler

checking
standardization
supplied approve
department
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remark amount rejigger signature date ratify ratify

No No.
 D270 DQSM Total 23 No. 2

180kW,adopts the power supply mode of 6KV. The power source of power
supply is supplied to the box-type transformer station of the machine from the
ground by the power cable reel(the detail accord to the instruction of the box-type
transformer station). The power electric source is with three-phase 380V, 50Hz,
transmitted and distribute electricity to each electricity used power part by the
total control of P1 power source screen, QM101 automatic air switch. The
illumination is adopted the power source of 220V, 50Hz. The illumination power
source is not controlled by the power electric source, it is equipped
independently. The illumination power source is controlled by the total switch
QM130, transmitted to the left operating platform of the cab by P1 screen
through the switches of SA131,SA133,QM131-QM134,etc. to be controlled the
section illumination separately. The control power source is 220V, 50Hz. The
control switch which controlled the power source is controlled by the air switch
QM120 which is equipped on the left operating platform of the cab. The control
power source is adopted the mode equipped independently, without effect
controlled by the power electric source, to be convenient for control and
debugging. In order to be convenient for the machine maintained and debugged,
the machine is equipped with 6 places of maintenance power source. The
positions of 6 places are separately equipped in the places such as the lower
electric power distribution house, the upper electric power distribution house cab,
the traveling bogie, the head of bucket-wheel, the slewing platform and the
derricking mechanism. The whole electric distribution control system of the
machine is classified according to the control performance, it is adopted the
arrangement mode concentrated by the electric power distribution house.
Table 1. Arrangement Function Table of the Control Operating Platform of the Control Screen

NO. Name Arrangement

Content of Control Porformance
Position
P1 power source, light, power supply light power overhaul rail lower the
overhaul panel clamper spray water power
distribution
room
P2 travelling panel travelling, cable reel,tripper lower the
power
distribution
room
P3 PLC slave station PLC slave station control center lower the
panel power
distribution
room
P4 bucket-wheel head, bucket-wheel head, boom belt Upper the
boom belt panel power
 D270 DQSM Total 23 No. 3

distribution
house
P5 slewing, derricking slewing, derricking Upper the
screen power
distribution
house
P6 PLC slave station PLC slave station control center Upper the
panel power
distribution
house
P7 PLC master station PLC master station control center cab
K1 left operating electric OFF source ON/OFF, slewing, cab
platform derricking, bucket-wheel, belt, illumination
K2 right operating travelling, semiautomatic cab
platform
Table 2. Distribution Condition Table of Electric Drive
Overload
Mechanism Power Protection
Motor Type Amount of Short Control Mode
Name (kW)
Circuit
travelling YP160M2-4 5.5 8 Yes speed-regulating control
by frequency
transformer, two-way
rotation
power reel JDO-300D 1.5 1 Yes direct starting, one-way
rotation
communication JDO-300D 1.5 1 Yes direct starting, one-way
reel rotation
head of bucket- Y2-225M-4 45 1 Yes direct starting, one-way
wheel rotation
boom belt Y2-225S-4 37 1 Yes direct starting, two-way
rotation
slewing YZP180L-8 11 1 Yes speed-regulating control
by frequency transformer,
two-way rotation
luffing Y180M-4 15 1 Yes direct starting, one-way
rotation
Tripper shift Y180M-4 15 1 Yes direct starting, one-way
rotation
 D270 DQSM Total 23 No. 4

rail clamp Y90S-4 1.1 2 Yes direct starting, one-way

rotation
dedust water Y160M1-2 11 1 Yes direct starting, one-way
pump rotation
⑴ ． Traveling: traveling mechanism is drove by motors M211-
M218（5.5kW）at the same time. Motor runs by converter controlling positive,
reversal and high, slow speed, there is brake mechanism, There is breaker QM211
against short-circuit and thermorelay FR211-FR218 for unit set motor overload
protection in main circuit.
Traveling has two traveling speed. High-speed is used for ground shunting
traveling fast. Low-speed is used in stacking and reclaiming.
Breaker QM221 is used against brake short-circuit. Thermorelay
FR221、FR222 is used for traveling brake overload protection.
⑵ ． Cable reel is drove by force moment motor M241-M242, Breaker
QM241、QM242 are against short-circuit．Thermorelay FR241-FR242 are used
for overload protection. Motor control is single direction running.
⑶ ． Rail clamper is drove by motor M141 and M142. Breaker QM141 is
used against short-circuit. Thermorelay FR141 and FR142 is used for overload
protection. Motor control is single direction running.
⑷．Water pump is drove by motor M151 (11kW). Breaker QM151 is used
against short-circuit. Thermorelay FR151 is used for overload protection. Motor
control is single direction running.
⑸.Bucket wheel mechanism is drove by motor M311. Breaker QM311 is
used against short-circuit. Thermorelay FR311 is used for overload protection.
Motor control is single direction running.
Bucket-wheel head is controlled by single operated ， manual control and
PLC control, bucket-wheel is started which is delayed 8~10s after boom belt is
started over when bucket-wheel is controlled by manual control.
⑹ ． Cantalever belt is drove by motor M321. Breaker QM321 is used
against short-circuit. Thermorelay FR321 is used for overload protection. Motor
control is double-direction running.
⑺.Slewing mechanism is drove by motor M411. Breaker QM411 is used
against short-circuit. Thermorelay FR411 is used for overload protection. Motor
adopts transducer control. Thermorelay FR412 is used for slewing brake and fan
motor overload protection.
⑻．Luffing is drove by motor M421 ．Breaker QM421 is against short-
circuit ． Thermorelay FR421 is used for overload protection ． motor is direct
started and single direction running.
⑼ ． Tripper mechanism is drove by a oil-pump motor M251.Breaker
QM251 is against short-circuit. Thermorelay FR251 is used for overload
protection. motor is direct started and single direction running.
 D270 DQSM Total 23 No. 5

III. Operation Control System

(1)．Main Power Source Control

Main power source is led to the casing-type substation on the bucket-wheel
machine through by the cable reel from the ground power flat cable, transmitted
into P1 power source screen of the electric power distribution house below the
bucket-wheel machine by the transformer. QM101 is the general power source
switch, with short circuit protection, shunt releases, and remote power operation
function. Under the normal working condition, push SB101(ON) button and
SB102(OFF) button on the left operating platform in the cab to realize ON or
OFF of the general power source. In order to be convenient to cut off the total
power in time when an emergency happens, the machine is equipped with 6
emergency stop buttons, that is SB103 on the left operating platform, SB108 on
the tripper platform.SB106 and SB107 on the two sides of the travelling bogie,
SB105 on the head of the bucket-wheel. SB104 on the slewing platform.. and The
6 buttons are not suitable for using under the normal condition, but SB101,
SB102 should be used usually. The left operating platform is connected with
PV101 alternating voltmeter,which is indicator power voltage
⑵．Control Power supply
Before closing the power electric source, pull out the pin of the anchor from
the anchoring hole, and make the travel switch SQ141 and SQ142 acted, the NO
contact closed.
The control power is the isolate power led into the power source 380V, 50Hz
by QM120, transform 380V down to 220V, 50Hz through the transformer T1.T1
low-voltage is led out the main control power by QM121, PLC control power by
QM122.
Control power closing: first close the automatic switch QM121-122, the
power sources of the signal lamp, warning system and the communication
interlocking are on. Put SA151,SA211,SA212,SA311,SA321,SA411 and SA421
at the zero position. After pushing the button SB161 down, the rail clamp travels
with release the rail automatically. The contact KM141 and KM142, the
electromagnetic valve YV141 and YV142 are acted with power on, M141 and
M142 the oil pump of the rail clamp are on to travel, the rail clamp is begun to
release, when the releasing gets to the limit position, the travel switch SQ143 and
SQ144 are acted, the NO contact is on, the contactor KM141 and KM142 are
releasing, the oil pump stops working( but the electromagnetic valve YV141 and
YV142 are not OFF), the traveling with releasing the rail stops, the indicator
lamp HL1 indicates the signal of releasing the rail. After releasing the rail is over,
the operating return circuit power is on, the indicator lamp HL2 indicates the
signal of control power.
Notes: After the motor of oil pump stopped pumping oil and because of the
internal leakage to the oil path of the rail clamp, which made the original rail
releasing state changed into the rail clamping state gradually, the motor of oil
 D270 DQSM Total 23 No. 6

pump should be started automatically again at once to be carried on the rail

releasing traveling when the travel switch SQ143 and SQ144 are just reset
because of the internal leakage for the oil path, till to be made SQ143 and SQ144
acted (the rail releasing state of the rail clamp). The time-delayed setting value of
the releasing time-delayed relay in the internal part of PLC should be far less than
the time when needed from the rail releasing state to just clamp the rail gradually
by the rail clamp, but must be bigger than the time needed by the process of re-
returning to the rail releasing state, that is the reset of the travel switch SQ143-
SQ144 made the oil pump motor started running automatically, the rail clamp
returned to the rail releasing action, till to restrict the travel switch SQ143 and
SQ144, made the oil pump motor stopped and the rail releasing stopped.
⑶．Choice and Operation of Control Mode
The operation mode can be chosen 4 kinds of mode such as single control,
manual control, semiautomatic control and tripper transformation by SA111
change-over switch which is equipped on the right operating platform in the cab.
Single drive Control: turn SA111 to the single drive position, the internal
relay of PLC works, and the electric control of the bucket-wheel machine is in the
single-drive control mode, each mechanism on the operating platform can be
started by the single drive. The single drive control is usually used for checking
and debugging the bucket-wheel machine.
Manual Control: turn SA111 to the hand drive position, the internal relay of
PLC works, the bucket-wheel machine is in the hand drive mode. The operator
can not start the mechanisms all independently. The bucket-wheel, the belt, etc.
have electric interlocking relations with the ground belt.
During the hand drive control, the operator should start the relevant
mechanism separately according to the operation of stacking, reclaiming and flow
direction of material; he must operate the mechanisms to be worked according to
the operation technology of stacking and reclaiming.
The manual control is suitable for stacking, reclaiming operation of the
material piling which is not flat and regular.
Semi-automatic Control: turn SA111 to the semi-automatic control
position, the internal relay of PLC works, the bucket-wheel machine is in the
automatic control mode, push down the semi-automatic starting button SB165,
PLC is started and carried on the semi-automatic operation of stacking and
reclaiming according to the programmed procedure.
⑷．Traveling Control
Traveling control is divided into 4 actions which are slow forward, slow
reverse, fast forward and fast reverse. The control example of slow advance is as
follows:
Operate SA211 to the position of slow advance, through PLC, KA212 is on,
KM221 is on, the brake is released, KM241 and KM242 are on again, the cable
reel is working. KA213、KA215 are on, the starting, slow advance and direction
terminals of the frequency transformer are on, the frequency transformer is going
 D270 DQSM Total 23 No. 7

to be operated, thus the traveling with slow advance is realized. The traveling
signal lamp HL6 is light which indicates the traveling is working. The automatic
air switch QM211,QM221 ， QM241 and QM242 should be closed first before
the traveling work.
If want the traveling stop working: put the change-over switch SA211 at the
zero position, through the internal delay relay of PLC, the traveling brake is
banded brake after it is delayed time for about 5 seconds, the cable reel stops
reeling after it is delayed time for about 5 seconds, then the traveling stops.
SQ211 and SQ213 are the first-grade limit protection switches for traveling
forward and backward.
SQ212 and SQ214 are the second-grade limit protection switches for
traveling forward and backward.
When traveling to the limit position, the limit switch acts the traveling stops.
⑸．Slewing Control
The slewing control is first decided by the toggle switch SA412 whether the
slewing operation is with constant speed or variable speed.
When the toggle switch SA412 is to the position of the constant speed,
operate the change over switch SA411 to the left (left slewing position), through
PLC to make KA411, KM412 be on, the slewing brake released, KA414 is on
again, the main power source of the frequency converter forward terminals is on,
the frequency converter pulls the slewing motor operated to the left with a certain
speed .If want to change the operating speed, adjust the size of the potentiometer
RP411 by hand drive to change the output voltage frequency of the frequency
converter in order to attain the goal of adjusting the rotation speed of the motor.
SQ411 and SQ413 are the first-grade limit protection switches of the left,
right slewing.
SQ412 and SQ414 are the second-grade limit protection switches of the left,
right slewing.
When the slewing turning gets to the limit position on the left or right, the
limit switch acts, the slewing running stops.
Potentiometer adjust speed ：simulation input terminal voltage is offered by
manual setting, used machine adjust.
PLC adjust speed ： Auto reclaiming ： slewing angle≤60° ， 1/COSφ shift
speed，slewing angle＞60°, t is slewing constant velocity at 60°speed.
The automatic speed-regulating control: set the toggle switch SA412 at the
variable speed position, set the change over switch SA111 be in semi-automatic,
control mode, After being processed by the internal of PLC, the slewing angle
value sampled at any time is output through by DA module on PLC to be
controlled the frequency control terminal of the frequency converter, thus to
change the frequency of the output voltage according to the numerical value sent
out by PLC and attain the goal of adjusting the rotation speed of the motor
automatically. During the operation of reclaiming, the automatic speed-regulating
control is made the slewing speed of the boom changed according to the
 D270 DQSM Total 23 No. 8

requirements set by PLC software program.

⑹．Derricking Control
Operate the change over switch SA421 to the left position (derricking lifting
gear), through PLC make KA421 be on, KM421 works on, the oil pump motor is
on, KA422 ， KA424 are on delay time again, the electromagnetic valve
YV421，YV423 are on, the boom derricking is lifting, the indicator lamp HL10
is light. The control principle of the derricking dropping is basic similar with the
derricking lifting.
SQ421, and SQ423 are the 1st-grade limit protection switches for the lifting,
dropping of traveling derricking.
SQ422 and SQ424are the 2nd-grade limit protection switches for the lifting,
dropping of traveling derricking.
When the derricking operation gets to the limit position of lifting or dropping,
the limit switch acts，then the derricking operating stops.
⑺．Belt control
When stacking by the manual control, set SA111 at the manual control
position, set the change over switch SA321 at the reclaiming position, KA321 is
on, KM321 is on, the boom belt is in stacking state. When turn SA321 at the
manual control reclaiming position, only the ground belt is running(KA164 is
on), KA322 is on, KM322 is on, the boom belt is reclaiming at the same time the
indicator lamp HL8 is light, it indicates that the boom belt is in the working
condition.
⑻．Bucket-wheel Head Control
The turning of the bucket-wheel head is driven to one direction only, which is
turning when it is reclaiming. The operational process is as follows: first set
SA111 at the position of the manual control operation, at this time the motors of
the bucket-wheel head and the boom belt are restricted by the interlocking
relations one after another, only being late for the boom belt started and delayed
time(8 ～ 10 seconds), then turn the change over switch SA311, KA312 and
KA311 are on by PLC, after the signal of oil pump and motor start is outputted,
bucket-wheel is running, at the same time the signal indicator lamp HL7 is light,
the bucket-wheel head is been in the reclaiming condition, bucket-wheel is
running after QM311 and QM312 are must on.
When the bucket-wheel head is adopted the manual control mode, the starting
and stopping of the bucket-wheel head and the front boom belt have a certain
order relations.
The starting order for stacking operation(tripper is in stacking state)：
Start the front boom belt →(the ground belt)
For stopping, operate reverse according to the order above.
The starting order for reclaiming operation(tripper is in reclaiming state)：
Start (the ground belt) →start the front boom belt → start the bucket-wheel For
stopping, operate reverse according to the order above.
Because the motor power of the boom belt 37kW and the bucket-wheel head
 D270 DQSM Total 23 No. 9

45kW are both great, the thing must be permitted attention is that starting the two
motors at the same time and starting them frequently are strictly prohibited
during the operational process.
⑼．Spray water control
In order not to raise a dust during the bucket-wheel machine is stacking or
reclaiming, the machine is equipped with a water pump motor. Water-spraying is
controlled by SA151 pushbutton.
⑽．The Transformation of the Tripper Working Condition
The transformation operation of the tripper working condition must be
carried on beside the single drive box of the tripper K3, turn the switch SA101 on
the operating platform to the change-over gear position of the tripper first, then
operate in front of the single drive box of the tripper K3 ( usually installed near
the coupler device of the tripper) .
a. Reclaiming operation state → stacking operation state. The action order
is just like this: the electromagnet releasing to pos·► the traveling forward to

pos·►the tripper lifting to pos·►the traveling reverse to pos·►the

electromagnet coupling. The detail mention of the circuit principle is as follows:
Turn the change over switch SA251 to the gear position of the stacking, then
push the starting button SB251 (changed into the stacking position), because the
upper limit switch SQ2519, SQ2520 are not acted, the transformation of
working condition starts.Through PLC make the release electromagnet YV253
is acted and released with power on.
When the release is to the position, the travel switch SQ2517, SQ2518 are
acting, the control loop of the traveling forward with slow speed be turned on,
the connector KM211, KM212 and KA203 are ON-closing, the traveling
forward with slow speed.
After traveling forward to the limit position, the travel switch
SQ2511,SQ2512 acts, it is made the connector KM212, KA201 and KA203 be
OFF-releasing, stop traveling forward with slow speed. Then the contactor
KM251 is ON-closing, start the oil pump motor of the tripper derricking, at the
same time the electromagnetic valve YV251,YV252 is on and acted, the tripper is
then with derricking lifting.
When the lifting of the tripper is to the limit position, the travel switch
SQ2519,SQ2520 act, the electromagnetic valve YV251,YV252 are OFF-reset,
the contactor KM251 is OFF-releasing, the derricking lifting of the tripper is
stopped then. Switch in the control loop of the travelling backward with slow
speed, the relay KM212, KA202 and KA203 are ON-closing, the traveling
backward with slow speed. After traveling backward, the travel switch
SQ2511,SQ2512 is reset.
After traveling backward to the limit position, the travel switch
SQ2513,SQ2514 acts, the relay KM212, KA202 and KA203 are OFF-releasing,
 D270 DQSM Total 23 No. 10

so switch out the control loop of the traveling with slow speed, stop traveling
backward with slow speed, the release electromagnet YV254 is on and hooker
hydraulic mechanism be off to release the pothook. When the pothook is to the
limit position, the travel switch SQ2515, SQ2516 are acted, the transformation of
the tripper automatic working condition is over.
b. Stacking operation state → reclaiming operation state. The action order is like
this: the electromagnet releasing to pos·► the traveling run forward to pos·► the

tripper dropping to pos·► the traveling reverse to pos·► the electromagnet

coupling. The detail mention of the circuit principle is as follow:

Turn the change over switch SA251 to the position of the stacking, then push
the starting button SB252 (changed into the stacking position), because the down
limit switch SQ2521, SQ2522 are not acted, the transformation of working
condition starts. Through PLC make the electromagnetic YV254 of tripping
gear draulic mechanism be ON, the tripping gear is acted and released with
power on.
When the release to the position, the travel switch SQ2517, SQ2518 are
acted, control loop of the traveling forward run in slow speed, the connector
KM211, KM212, KA201,KA203 are ON, the machine travel forward with slow
speed.
After traveling forward to the limit position, the travel switch
SQ2511,SQ2512 acts, it is made the connector KM212,KA201 and KA203 be off
to shut off, the machine stop traveling forward with slow speed;Then the
contactor KM251 is ON-closing, start the oil pump motor of the tripper
derricking, at the same time the electromagnetic valve YV252,YV253 is on and
acted, the tripper is down with derricking lifting.
When the lifting of the tripper is to the limit position, the travel switch
SQ2521,SQ2522 act, the electromagnetic valve YV252 is off and reset,YV254 is
on, the contactor KM251 is OFF-releasing, the derricking lifting of the tripper is
stopped then. Switch in the control loop of the traveling backward with slow
speed, the connector KM212, KA202 and KA203 are ON-closing, the traveling
run backward with slow speed. After traveling backward, the travel switch
SQ2511,SQ2512 is reset.
After traveling backward to the limit position, the travel switch
SQ2513,SQ2514 acts, the connector KM212, KA202 and KA203 are OFF-
releasing, so the control loop of the traveling with slow speed shut off, stop
traveling backward with slow speed, the release electromagnet YV254 is OFF
and releasing the coupler. When the coupler is to the limit position, the travel
switch SQ2515, SQ2516 are acted, the transformation of the tripper automatic
working condition is over.
c. Inching operation: turn the change-over switch SA251 to the inching gear in
the single-drive box K3, push down the button SB259 and SB260; it can be made
 D270 DQSM Total 23 No. 11

the release electromagnet action and releasing. Push down the button SB256,
SB255 which can be started the oil pump and the electromagnet valve to be
controlled the derricking lifting or dropping of the tripper. Push down the button
SB258, SB257 which can be controlled the traveling forward and backward of
the bridge with slow speed. Notes: During the operation, push the button down,
and the mechanism is then started and running, relieve it, the mechanism is
running down. When inching operation is over, the change over switch SA251
should be turn to the gear which is appropriate with the tripper position.
After the transformation of the tripper working condition is over, the single
drive box should be closed, turn the change-over switch SA111 on the operating
platform of the cab to the hand drive gear.
Note: A. Strictly prohibit the transformation operation of the tripper working
condition when the ground belt is running.
B. The operation of the tripper should be monitored by the working
personnel.
⑾．Belt boom protection and alarm system
① Deviation switch SQ321-SQ324 （ 13-14 joints ） are cantilever belt
deviation I grade protection.
② SQ325, SQ326 are cantilever belt pulling rope switches.
③ SQ327, SQ328 are cantilever belt block switch.
④ SQ329 is cantilever belt pile detector switch.
⑤ BV321 is cantilever belt speed switch
⑥ EV321 is cantilever belt portrait laniate protect switch.
When belt II grade deviation switch starts to act (23-24 joints of SQ321-
SQ324 are closed), it makes relay KA321- KA323 be off by PLC inner. Then
contactor KM321-KM323 are off and release and it makes duct pilot of belt
machine be off and belt machine stops working. If there appears malfunction,
should reset all control switches and remove the faults.
Owing to the action of boom anti-collision switch SQ418 、 SQ419, when
alarm, if it is difficult to solve scene fault, go on to adjust controlling. Start boom
running and prevent it from collision. Reset anti-collision switch SQ418、SQ419
and the operation principle is as follows: When there appears fault, reset all
control switches and then put work type selection switch SA111 to single control
file. Press fault reset button SB162 and make slewing mechanism control loop be
on for the moment. When operate slewing, SQ418 and SQ419 reset. After that,
reset SA411 switch and put work type selection switch SA111 to manual control
file. The bucket wheel machine anti-collision is finished. When adjust control
operation, operator must watch field situation at any moment. It must be operate
by operator who not knows well about electric control operation principle.
⑿．Span ground belt protection
SQ415、SQ416、SQ417 are cantilever span ground belt protection switches.
 D270 DQSM Total 23 No. 12

If front-boom is above level, SQ417 is normally off, and slewing can turnover
right and left. When front-boom is below level, the SQ417 is normally on. At this
time front-boom is slewing left on the right of rail and approaches slewing center,
that is to say approaches ground surface belt frame, make SQ416 be normally on.
Make KA411,KA412,KA414 and left slewing duct pilot be off, and stop slewing
left. At this time must hoist front-boom to be over horizontal position. SQ417 is
normally off and slewing duct pilot is on. It can be turned over by ground belt
and it protect effectively ground belt. The principle that front-boom is slewing
right on the left of rail and approaches slewing center, is the same as the above.
⒀．Anemometer
Anemometer inspects wind power, when sign sends to brainpower wind
speed wind speed alarm meter. When wind power is 8 lever, brainpower wind
speed alarm meter FSY101 contact works and make control power supply be off
by PLC inner relay. Rail clamper is loosen, bucket wheel machine stops working.
⒁. Traveling detection device
UE201 increment type encoder that detects traveling distance of bucket
wheel machine is installed on bucket wheel machine traveling detection wheel,
get traveling distance of bucket wheel machine by input PLC. SQ221 is
correction traveling switch of traveling position.
⒂．Pile height detection device
The device is ultrasonic object position meter. When automatically stacking,
and pile reaches a certain height, ultrasonic device UB1 sends sign that makes
boom rise or traveling back.
⒃．Amplitude of variation angle and slewing angle detection device
These two detection device are used rotary encoder and obliquity sensor for
detecting element. Encoder and obliquity sensor transforms mechanical angle
change to telecom signal and delivers to PLC for display and control signal.
Installation and debugging precision of these two part will influence direct that if
display is correct and automatic operation proceed. So pay special attention to it
when installing.
⒄．Semiautomatic control working
①Semiautomatic control working for reclaiming
Working technology is layering slewing reclaiming technology. Firstly local
bucket wheel head beside material on the top of the pile. When traveling doesn't
move, start boom slewing, and make bucket wheel scoop material that proceed
reclaiming. When slewing to a certain position (bucket wheel backs out from pile
that doesn't dig material or reclaim little), stop the slewing of boom and then start
traveling forward a step ( about 328mm).Start boom reverse slewing, and bucket
wheel go on reclaiming. When boom slewing to a end and bucket wheel can't
reclaim, start traveling forward a step. Do repeat until reclaiming the top material
of the pile. Then make bucket wheel machine back to material start position, and
 D270 DQSM Total 23 No. 13

start boom fall a distance (about 1.7m). Repeat the above working, until
reclaiming the last material. The operation of program control is as follows ：
Traveling top operational zone, Local bucket wheel head to the first reclaiming
pile layer (layer height is about 1.7m) and approach to the side of the pile.
Slewing is on by manual again, setting slewing angle by button SB167 during the
slewing, keep the slewing angle to the PLC, Reset control switch of bucket
wheel, belt, amplitude of variation, traveling, slewing and other mechanisms,
spin SA111 switch to the semiautomatic file, Thus program control preparation
work finish, When the start of working, press SB165 button (semi-automatic
start),buzzer is auto ring by PLC and PLC control bucket wheel machine
automatically to start bucket wheel and belt orderly. Start PLC automatically
traveling forward a step slowly and then boom reverse turnover to reclaim. When
boom slewing to the other end of start position, (The angle data has been stored
in PLC), stop slewing. Start traveling forward, and then start boom reverse
slewing to reclaim. Repeat the above until first layer reclaiming finishes . Press
SB166 button to stop program. After reclaiming the first layer, bucket wheel
machine is from program control to manual control. Operator control bucket
wheel machine manually to the traveling position when the start of PLC program
control reclaiming. Operate SA421 to falling position, and then front-boom falls
a distance. After resetting SA421, operator can reclaim the second layer. The
operation method is the same as the above.
When bucket wheel reclaiming superabundance or little, press SB169
button. Meanwhile operate SA211. Make travel slowly forward or back slowly,
amplitude of variation rising or falling to be greatest working state.
Must declaration: A. When semiautomatic control reclaiming, start and end of
boom slewing is ensured by angle position that kept when press button SB167
and first slewing end SB167. B. When reclaiming the lowest layer, usually can't
be used program control generally. C. In program control working, strictly
prohibit to operate control switch of traveling, slewing, amplitude of variation,
belt, bucket wheel and other mechanism (expect When SB169 working at the
same time).In semiautomatic control working, operator should watch working
condition at any moment. D. When manual working, reclaiming technology is the
same with this reclaiming technology．
②semiautomatic control stacking
Stacking technology is cart fixing stacking. That is to say local boom to
stacking site. Fall boom to the position from ground 4.0m, and then start
stacking. When stacking to a certain height, ultrasonic switch UB1 sends off a
signal of action to controller. Then front boom raise a certain height (about 1.2m)
and keep on stacking. Owing to material stacks a certain height step by step, press
SB168 button (set pile height). When ultrasonic switch acts again, cart moves
back a step (about 1.0 m) and keep on stacking. When material stacks a certain
height again and ultrasonic switch sends signal that makes cart moves back a step
again, stack back step by step until material finishes. Program control operation is
 D270 DQSM Total 23 No. 14

as follows: Spin work mode selector switch SA164 to stacking file, and then
traveling fast to working zone. Local front-boom to stacking spot, and spin
selector switch SA111 to PLC program control file. After receive the command
from ground control room, press SB165 (program start) button. PLC controls belt
start orderly. When material stacks to a certain height, ultrasonic switch acts and
sends pile position signal to PLC. PLC controls automatically boom amplitude of
variation, and when rising a certain distance (about 1.2m), keep on stacking.
When material stacks a certain height, press pile height set switch SB168.
Ultrasonic switch acts and sends pile position signal to PLC. PLC controls
traveling back a step automatically (about 1.0m) and keep on stacking. So get
back stacking until material stacking finishes. After receive command that
stacking finishes from ground control room, press SB166 button. When program
control stopping, bucket wheel machine is from PLC program to a manual
control. Attention: A. In semiautomatic control working, strictly prohibit to
operate control switch of traveling, slewing, amplitude of variation, belt, bucket
wheel and other mechanisms. In semiautomatic control working, operator should
watch stacking condition that is especially at traveling back automatically. B. In
manual working controls, stacking technology is the same with this stacking
technology.
IV．Illumination and Maintenance Power Supply
The illumination power supply is adopted the power of 220VAC, 50Hz, it
gets from the front of the main switch QM101 of P1 screen and is controlled by
the switch QM130 installed on P1 screen. 6 change-over switches and the single-
pole air switch installed on the left operating platform in the cab are separately
controlled the illumination of the bucket-wheel machine.
In order to be convenient to maintain, the maintenance power supply
380V/220V/36V 50Hz is equipped on the places such as the lower power
distribution room, the upper power distribution room ， the cab ， the traveling
bogie, the head of bucket-wheel and the slewing platform
V．Communication，interlock，protection system
⑴．Comunication System
The signal transmission of the communication and the machine-ground
interlocking between the machine and the ground control room is led to the
machine by from the ground communication terminal box through the
communication flat cable to the communication cable reel．the working pressure
of the wire circuit is 220VAC ， the signal mode of the communication
interlocking is for the relay switch contact. The function of the communication
interlocking signal is shown as the following table.

The Number Function Table of

 D270 DQSM Total 23 No. 15

the Communication Interlocking Signal on the Machine

No. in the
No. on the
control Signal Function Remarks
machine
room

1 1 Power live wire on the machine Supplied by the machine

2 2 Exigent stop for the ground Supplied by the ground centre control
room

3 3 Stacking command Supplied by the ground centre control

room

4 4 Reclaiming command Supplied by the ground centre control

room

5 5 Ground belt reclaiming Supplied by the ground centre control

room

6 6 Spare Spare

7 7 Spare Spare

8 8 Power live wire on the ground Supplied by the ground centre control
room

9 9 The machine fault Supplied by the machine

10 10 Stacking operation of the machine Supplied by the machine

11 11 Reclaiming operation of the Supplied by the machine

machine

12 12 Tripper transforming Supplied by the machine

13 13 Spare Spare
23 23 Communication between the machine
Telephone wire
24 24 and ground

⑵Interlock and protection

In order to ensure the safety operation of the whole machine, the machine is
equipped with all kinds of protection devices. They are: the short circuit,
overload protections, the limit protection of the running mechanism, the
protection of prevention of the belt deviation, the protections for the first-grade
alarm, the 2nd-grade stop, the protections of the pulling switch and exigent stop
button, when something emergency happens, pull the pulling switch or push the
exigent stop button to stop the machine running and avoid the accident taken
place, the gale warning protection, when the wind force is to the 8-grade, the
alarm warns and stops the machine working, the electric zero protection, before
starting, all the change over switches should be at the zero position and avoid the
 D270 DQSM Total 23 No. 16

false operation starting, the machine and the ground interlocking protection
(according to the technique order) is equipped for prevention of the false
operation, the spanning belt protection for the boom slewing and the anti-crash
protection for the boom, etc. The indicator lamps and touch screen which indicate
the working condition of the some part of the machine are equipped on the
operating table as well, they could be responded the working condition all the
time.

VI．Operating program

⑴．Weigh anchor:
Draw anchor in bolt that is beside traveling bogie from anchoring hole.
⑵．Power supply on：
Press power supply power-on button SB101 and breaker QM101 is
electromotion on. When low voltage electromotion power is on, voltage is
normal.
All switch are on zero position.
Breaker QM120 is on manually, and control power is on.
Aftet local press control power supply button SB161,control power supply is
on. Rail clamper looses rail, Operator can control the action of very mechanism
by PLC.
⑶．Working and control type:
Spin control mode selection switch SA111 to the needed file, and then
operate every mechanism control switch. It is as followes.
 D270 DQSM Total 23 No. 17

SA111 Single control Manual control Semiautomatic control

switch
position
Manual control：
1. There is connection between some mechanisms and
ground belt, and control start and stop in order.
2. When operate every mechanism control switch, go
on with manual working according to stacking and
reclaiming.
3. It is suitable for smallness, inequality and
irregularity pile stacking and reclaiming.
Semiautomatic control Semiautomatic control
reclaiming: 1. bucket stacking: 1. bucket wheel
wheel machine locating machine locating 2. After
Every 2. After receive receive reclaiming order,
mechanisms reclaiming order, press press PLC program
can start or stop PLC program control control start button
Stacking
running solely. start button (SB165). 3. (SB165). 4.Ensure the pile
and
It is suitable for Set slewing angle height according to pile
reclaiming
debugging and (SB167)．4. After height button (SB168) 4.
overhauling working, press stop After stacking, press stop
faults. button (SB166). button (SB166).

It is suitable for large scale and level pile to stack and

reclaim.

1．Operate start and stop of every mechanism in bucket wheel machine

according to control principle ． 2. Before operate control switch, must
Notice alarm. 3．When program control working, operators must watch working
condition at any moment. 4 ． When traveling fast, put front-boom at 0
degree slewing angle.

⑷．Stop working
 D270 DQSM Total 23 No. 18

Every operation control switches reset and key switch SB161 is on.
Disconnect automatic switch QM120, and control power supply. Rail clamper
clips rail. When press power supply power-off button（SB102）,power supply is
off.
If don't use bucket wheel machine for a long time, must go on with the
below operation: Insert anchor bolt in hole. Notice: If stop working for a long
time, should put it at traveling rail intermediate level position

VII．Installing and debugging caution note

(1) Electric installation proceed according to related standards, rules and must
accord with design drawing.
(2) To thermorelay, adjust recloser shunt current reliably and accurately
according to design requirements and practical situation. Limit device must fix
firmly and action must be accurate and reliable. All kinds of detection display
unit should accord with working condition requirements.
⑶ All outdoor electric appliances should notice waterproof. Lighting,
equipments and connector lug should notice waterproof.
⑷ Bucket wheel machine traveling rail must be earthing repeatedly.
⑸ When front-boom frame is wiring, the cable that transiting amplitude of
variation joint should be through flexible tube and there is sufficient active
allowance to meet the requirements of boom amplitude of variation.
⑹ Strictly prohibit bucket wheel motor and boom belt motor start at the
same time and frequently.
⑺ Before bucket wheel, belt, slewing , traveling start and luffing, must
press ring to alarm.
⑻ Power-off and prolonging relay of rail clamper duct pilot delay power-off
setting value that must be correct. And inspect regularly to ensure rail clamper
working normally.
⑼ Traveling brake adjustment: Brake force can't be so large that when
parking bucket wheel machine shakes greatly, but it can't be too small, which
causes an accident because traveling slipping distance is too long.
⑽ After debug PLC equipments, converter and peripheral equipments well,
it's not allowed to fiddle with that avoid unmoral working and spoilage
⑾ Leave bucket wheel machine cable at tripper cable hanging device part
some suitable allowance. When boom corner is the maximum (±110°) cable
shouldn't be too tight. When it is 0°, cable shouldn't be too relaxation. Avoid the
impact and friction between not hanging cable and iron board.
⑿ Should inspect travel switch regularly and brake , and ensure its normal
working.
 D270 DQSM Total 23 No. 19

⒀ The earthling bolt of the tripper platform,luffing platform,slewing

platform and front boom frame should be welded at the body of machine.
⒁ When stacking slewing, should pay attention to that prevent boom lower
from touching pile and traveling can't running slowly for a long distance
continually. When machine working at the end, operator must pay attention.
When PLC program control, operator must watch seriously. If find danger, stop
traveling to prevent accident.
⒂ When debugging, should inspect every operating mechanism, whether
button action is normal and universal switch zero position interlock of control
power supply takes effect, whether on-off button of power supply master switch
and scram button accord with requirements, and whether traveling motor starts
and rotation direction is unity.