Automatic Hydraulic Pressure Tension System

Operating Instruction

 Operating Instruction of Hydraulic Pressure

System

Operating Instruction for Hydraulic Pressure Tension

System of Wet Type SSC Chain

Content

This reference includes the following content:

Pages

General and main performance parameters

System Principle Description

Characteristics and Designed Value

Preparation and adjustment before running

Debugging methods and working conditions

11

Maintenance and management

Appendix

13

List of hydraulic pressure system elements

15

General arrangement of hydraulic pressure system

17

Schematic diagram of hydraulic pressure system

18

Electric schematic diagram

19

Electric Connection Diagram

20

 Operating Instruction of Hydraulic Pressure

System

Section 1 General and Main Performance Parameters
General

This design of hydraulic pressure system is one of the hydraulic schemes,

which are special for the chain tension control of wet type SSC, according to
the current conditions of national market development. It can meet the
requirement of chain tension activity.

The main parts and components of this product will choose the hydraulic
products imported from Bosch Rexroth, Germany.

Because this system is a kind of the precision equipment, precise

debugging, suitable operation and careful maintenance can improve the
efficiency and lengthen the lifespan. Otherwise, bad effect will be occurred.
Therefore, it is suggested that the users should refer to the requirements of
this instruction during the debugging, operation and maintenance of this
hydraulic pressure system.

Main Performance Parameters

1
System pressure

 Operating Instruction of Hydraulic Pressure

System
/
Rated working pressure/Max. pressure can
be set

10Mpa / 18Mpa

21Mpa

Max. pressure with load

2
Gear pump
/
Max.

continuous

pressure/theoretical capacity
3
Electric Motor
/
Power/ rotate speed
4
Capacity of oil tank
5
Environment

Ambient temperature

Environment humidity
6
Working medium
7
Grade of the system cleanness
8
Power supply
9
Control voltage

operation

20Mpa / 3.5mL/r

-1-

Three-phase
asynchronous motor
1.5KW / 1430rpm
30L

15-40
<50%
HM46
HM46

or

antiwear

hydraulic oil in the same

grade
NAS9
NAS9 or the same grade
AC380V 50Hz
Three-phase

three-wire

AC380V 50Hz
DC24V
800( ) X 550( ) X

10mm
Overall size of hydraulic unit

1050()
800(L) X550 (W) X 1050
(H)

11
Protection grade of equipment

IP54

 Operating Instruction of Hydraulic Pressure

System

Section

-2-

Description

of

System

Principles

M6

10

22

15

M7

 Operating Instruction of Hydraulic Pressure

System

Oil feeding state of accumulator means the M6 pressure is lower than the
setup value of it, hydraulic oil flow from the oil pump through the check valve
10, directional valve 22, and check valve 15 to perform the oil feeding to
accumulator until the activity stops when it reaches the M7.(Motor will also
stop.)
M3 M4, 21 ,
M3
21 M3

Automatic tension state means M3 pressure is lower than the set value
-3-

M4 and the electric controls the directional valve 21 to get power. Open the oil
control check valve at the outlet of accumulator and the oil enters into the oil
cylinder without pole to increase the tension pressure. When the M3 pressure
is higher than the set value, directional valve 21 will lose power and the M3
pressure will not raise to keep the set value. When the pressure of
accumulator is low, the motor pump will start and oil feeding can be
performed.
22 10
22
Maintain and repair the manual retraction and the motor pump will start,
so the directional valve 22 can get power. Hydraulic oil flows from the oil
pump through check valve 10 and directional valve 22 to oil cylinder with
pole. Meanwhile, open the check valve to release the load and oil cylinder
retraction can be finished.

-4-

 Operating Instruction of Hydraulic Pressure

System

Section 3 Characteristics and Designed Value

This system has many merits such as integration design, small volume
and easy for maintenance, with the structural features as follows:

The chain tension system of wet type slag conveyor is composed of oil
tank (hydraulic unit), accumulator hung outside and electric control cabinet.
1.

Semi-closed and dustproof cover structure is used for the oil tank to
prevent much dust and other substance from cone into the tank.
2.

Air filter has been set on the top of oil tank to make the oil tank feed oil
upwards through the filter.
3.

Level and temperature indicator has been provided in the face of oil tank
to be easy for watching the level and temperature in the oil tank.
4.

If the oil level is lower than the min. scale of level and temperature
indicator (or oil level can not be seen), it means the level is low.
(Abnormal)
5.

If the oil level is higher than the max. scale of level and temperature
indicator (or overflow of oil), it means the oil level is high. (Abnormal)
6.

70

If the oil temperature is higher than 70, it means the temperature is

high. (Abnormal)
7.

The filter at the inlet of oil pump has been set on the oil tank and needs
to be replaced regularly.

 Operating Instruction of Hydraulic Pressure

System
8.

Power supply is composed of motor gear pump to feed oil to accumulator.

When it is on the normal system tension state, accumulator, solenoid
-5-

valve and oil cylinder make the hydraulic spring to ensure the chain is on
the tension state for a long time.
9.
Piston rod withdrawal: press the button of this function on the control box
while the hydraulic station is in operation.
10. 0bar 200bar
System pressure is set by overflow valve with a value of 0bar no
more than 100bar
11.

Electric
control
includes
following

operation

the

control,

operation stop, automatic tension,

manual withdraw button, operation
indication,
tension

normal

take-up,

force,

low
fault

indicationmotor overload, oil filter

block, as well as normal tension in
a long distance, fault warn.
12.
200bar
Safety valvetake-up with load over pressure overflow
protectionis set 200bar.
13.

60bar
140bar
Accumulator liquid charging pressure and stop liquid

 Operating Instruction of Hydraulic Pressure

System
charging pressure set values are as follows:pressure relay
Accumulator liquid charging pressure:

60bar

set before delivery

instead of on site.
Accumulator stop liquid charging pressure: 140bar set before delivery
instead of on site.
14. 45bar
Accumulator is installed hanging on-6-the wall with the air charging pressure
of 45bar. It is more convenient for inspection and replacement.
1MPa 10bar
Notepressure unit 1MPa 10bar

-7-

 Operating Instruction of Hydraulic Pressure

System

Section 4 Preparation and Adjustment before
Operation

Preparation and adjustment mainly contains the installation of hydraulic

station, oil cylinder equipment, and electric control cabinet and the
connections of hydraulic pipes and electric wires.
1
Installation of hydraulic station, oil cylinder equipment, and electric
control cabinet
1.

The parts, joints and pipes inside of hydraulic station, oil cylinder device and
electric control cabinet shall be taken good care to avoid damage owing to
burden from outside force during hoist and transport.
2.
The oil cylinder shall be installed with a strict restriction on its linearity to
prevent the oil cylinder moving improperly or bearing load of cross directions.
3.

After installation and connections, all fasteners such as bolts, screws, flanges
and pipe joints shall be rechecked to make sure of the firmness and reliability
of the seal.
2
Arrangement, Installation and Flush of Hydraulic Piping
1.

150mm

Pipes should be as short as possible to reduce the abrasion; and the

 Operating Instruction of Hydraulic Pressure

System
connection shall have one loosing bend at least to be adapted to the
temperature change. Bend of the piping should be treated with cold bend with
a radius of no less than 150mm.
2.

Welding of pipes shall be performed in gas shielded way. All welds should be
polished and checked.
3.
-8Pipes shall be performed with direct butt weld.
4.

If there are welding for pipelines, it is supposed to treat the pipelines with acid
bath, neutralization, passivation, phosphorization and flushing in sequence
after tubing, then apply the anti-corrosion paints.
5.
All pipelines shall be properly fixed or supported in some positions, especially
the front and back of bend along the pipeline, and the place before hoses to
be connected.
6.

7m/s 60

Pipelines shall be flushed separately with the washing oil at a minimum speed
of 7m/sturbulent flowand a temperature of 60. In case there is no way
to do the washing, it is recommended to clean with silk and such kind of lintfree wipes after being dipped into coal oil or diesel oil until there is no
sundries visible on the wipes.
7.
All welds, bends and connections shall be stricken with wooden or copper stick
while flushing.
NAS9
Attention: The cleanliness of pipelines should be up to NAS9 at least.
inspected by standard measuring unit
3
Preparation and Adjustment before Debugging
1.

25m

 Operating Instruction of Hydraulic Pressure

System
Oil shall be added into the oil box through air filter by using oil filter
vehicleat least 25m of filter fineness
2.
Liquid level shall be checked to be in a comparatively high position of the
indicator.
3. 0
System pressure set valve should be confirmed to be in a start-up
state adjusting bolts of overflow valves are all loosened, i.e. pressure is
zero
4. 14
Accumulator shall be performed air charging which is to turn to Section Four
Item 14 for the reference of its pressure.
-95. AC380V
Outer connections shall be executed according to the electric drawing. The
connecting wires are to be checked and power voltage should be AC380V.

-10-

 Operating Instruction of Hydraulic Pressure

System

Section 5 Debugging and Status Instruction
1.

2MPa

Confirm the rotary direction of motor:

Put the two external shut-off valves, shut-off valve at the oil opening of
accumulator, release valve of accumulator in the shut-off state. Power on
the three-phase electricity, Push the button of operation control and
automatic take-up in order; rotate the designed pressure valve clockwise;
inspect whether the pressure of pump rise up to approx 2MPa. If there is
no pressure, stop the equipment, power off immediately and change the
any two external power wires according to the safety operation. Repeat
operating as above mentioned and make sure the motor rotates in a
correct way. (In a word, the pump can supply oil normally.)

2.

System discharge: put the shut-off

valve of

the accumulator opening

and release valve in the shut-off state.

Open the two external shut-off valves
and push the button of operation
control

&

automatic

take-up

to

discharge for system, pipe and oil

cylinder.

Meanwhile,

make

the

oil

cylinder reciprocating operation under the condition of no load.

3.

80%
Accumulator charge: put the two external shut-off valves, shut-off valve of
accumulator opening, release valve of accumulator at the shut-of state.
When charging, the pressure should be not more than 80% of the minimum

 Operating Instruction of Hydraulic Pressure

System
working pressure of accumulator.
4.

When the accumulator starts to charge and stops, the relay has been set.

Keep off!
5.

-11-

Safety valve (unloading, protection of taut cylinder) has been set. Keep off!

6.

18MPa

Take-up pressure setting: put the two external shut-off valves, shut-off
valve of accumulator opening, release valve of accumulator at the cut-off
state. Push the button of operation control and automatic take-up; set the
pump pressure to 10MPa; adjust the take-up pressure and set the pressure
relay to the required value. (It can be observed from the pressure gauge.)

7.

18MPa

Accumulator charging: put the two external shut-off valves, shut-off valve
of opening of accumulator, release valve of accumulator at the cut-off
state. Push the button of operation control and automatic take-up; set the
pump pressure to 10MPa; open the shut-off valve of accumulator opening;
charge; it will end with the motor stopping.

8.

Open the two external shut-off valves, shut-off valve of accumulator

opening and cut off the release valve. It can operate normally if it
switches on.

9.

Electric : Press the button of operation and then it can be controlled by

automatic

tension;

otherwise, it will stop

the automatic state by
press the button of stop.

 Operating Instruction of Hydraulic Pressure

System

-12-

Section
Attentions and Fault Handling
6Maintenance,
check
valve
Overflow valve

Check valve
1

Load relief

valve
21 Directional valve
21
22 Directional valve
It is very important to carry out the daily maintenance and the detailed
22

inspection intervals are as follows:

Intervals

connected parts
Cleaning of filter
Oil quality
Cleaning of oil tank
Oil-drain

Inspection point
Oil level; oil temperature
and pressure
Noise
Leakage
Lose
condition

Date

Wee

Mont

Seaso

Half

Year

Stop

of

Yes
Yes
Yes
Yes

 Operating Instruction of Hydraulic Pressure

System

10
Generally speaking, if there is something wrong with hydraulic system, it is
caused by the uncleanness of oil or the disqualified oil, so pay much attention
-13-

to the storage and protection of oil. Frequently, the oil is often boxed up in the
sustaining pressure chamber, so it is suggested that updating the oil
reciprocating program be performed every season. (Ten times to change the
oil in the sustaining pressure chamber.)
Attentions:

Check the liquid level and be sure to keep it near the middle of level
indicator. If it is below the minimum level, stop charging at once.

It is forbidden to change the designed systemic value at will. If required, it
should be checked and performed by the professionals.

After the equipment has being put into operation for two months, be sure to
change the oil or filter elements.

Once there is a fault alarm, power off the equipment immediately and
inspect whether there is overload for filter or motor. If the filter is blocked,
it should be replaced as soon as possible for fear that the system
elements are blocked, worn or damaged.

Provided that the system is always in the state of low pressure alarm,
please inspect all the pressure values (at the outlet of pump and
accumulator), leakage and oil temperature immediately and power off the
machine. Contact with our company if necessary.
2
Fault handling:

 Operating Instruction of Hydraulic Pressure

System

Breakdown of motor: Check the three-phase electricity and the power

supply; check the setting of take-up pressure relay and debug according to
the procedure in Section four.

Oil cut-off of pump: Check the frequency of three-phase electricity and

interchange the any two electric wires.

List of Hydraulic Pressure

Elements
-14

No.

Qty

10

11

12

13

Description

Oil tank

Liquid level indicator

Service cover

Oil release valve

Air filter

Motor

Clock-shaped hood

Coupling

Gear pump

Check valve

Overflow valve

Oil suction filter

Passage

Manufactur
er

Remar
k

Dade

YWZ-100T

Li Ming

DIC01-15,6

Dade

DN10

Dade

QUQ1

Li Ming

-6-

Model

30L

DBH-A90L-Z2.4

Dade

DC-A90L-Z2.4

Dade

Z2.4

Hawe

DCV179-1X/1

Hawe

DPRV179-1X/200

Hawe

A pair
with the
same
precise
casting

Italy

Italy

Italy

DSF01

li Ming

Dade

QA 90L 4P

DD070802501

ABB

 Operating Instruction of Hydraulic Pressure

System
14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

Integration valve

Check valve

Liquid control check

valve

Overflow valve

Throttle valve

Plate check valve

Pressure measuring
joint

Solenoid directional
valve

Solenoid directional
valve

Accumulator

Bracket unit of
accumulator

Fill-air

Check valve

Pressure gauge

Hose assembly

Pressure relay

Hose assembly

Electric control cabinet

External cabinet

DD070802502

Dade

DSC-CXDA-XCN

Rexroth

US

DSC-CKCB-XCN

Rexroth

US

DSC-RDDA-LAN

Rexroth

US

DSC-FTV

Rexroth

KHP06

Hydac

US

Germany

SMK20

Stauff

Germany

3WE6A6X/EG24N9Z4

Rexroth

Germany

4WE6D6X/EG24N9Z4
-15-

Rexroth

DA-B10-S10-M1111M60

Pu Marde

Dade

Hydac

KHM12

Hydac
Hangzhou

Germany

Italy

Germany

Germany

Hawe

Germany

Germany

Stauff

Schneider

Germany

France

YN63 PN25
SMS20-XX-1000A
DG365

SMS20-12-1000A

-16-

Stauff

-17-

D ade

-18-

~220V

Three-phase Power

Motor Connection

Power of Control Circuit~220V

FU3

L1

T02

TC

T04

Motor Control

DC Power

FU1

Overload of Motor or
Blockage of Filter

Control of Startup and Stop

Low Pressure

Automatic Tension

KA1

101

Manual
N o r m a l T e n s i o n M a k e - u p T e n s i o nC o n t r a c t i o n

DCS
To DCS

005

L2

Low Pressure Alarm of Tension

~380V

SB1

QF1

FU2 T01

L3

-19-

Equipment Interface

KA3
QF1

DC

V1

W1

QF1

SF1

KA1

KM1

KA4

009

017

HL1

015
SP3
013

System Failure Alarm

YV2

KA5
KA2

027

SP2
011

KA1

025

019

SP1

KA3

KA5

021
HL4

HL3

SB4

007

003
M

KA2

SP2
023

T03
U1

SB2

KA5

105

001
KA4

103

24V+

AC

SB3

YV1
029

KA4

KA3

HL2

KA5
031

KM1

Input Signal of Internal System

Indicator Lights of Electric Control Cabinet

Button of Electric Control Cabinet

SP1

HL1

HL1

Power Supply Indication

HL2

SP1
SP2

M1
3~

SP2

2.2kW 5A

SP3
SP3
SF1
SF1

Tension Pressure Switch

Control Switch of Accumulator Charging

Switch of Accumulator Charging Off

Blockage Alarm Switch of Filter

HL2 Normal Tension Indication

HL3
HL3 Low Pressure Alarm Indication
HL4
HL4

SB1
SB1

Sudden Stop

SB2
SB2

Power Supply (Startup Button)

SB3
SB3

Automatic Tension

SB4
SB4 Manual Contraction
Hydraulic Failure Indication Overload of Motor or Blockage of Filter

E le c t r ic S c h e m a t ic D ia g r a m o f
H y d r a u lic P r e s s u r e T e n s io n

Terminal Block Connectrion Diagram of SSC Hydraulic Tension

XT1
C a bl e s t o b e pr e p a r ed b y us e r
4 15 V , 3K W
T o t h re e - p ha s e 3 8 0 V p o w er f r e qu e n c y ,3 K W

Ha s be e n c o n ne c t e d b e f o re l e a vi n g th e f a c t or y

T o m ot o r o f o i l p u m p

H a s b e e n co n n e c te d b e fo r e l e av i n g t h e f ac t o r y

L1
L2
L3
U
V
W
021
24V+

1
2
3
4
5
6
7
8

S w i tc h f or b l o c ka g e a la r m of f i l t er

007 9
011 10
013 11

Ha v e b ee n c o n ne c t e d b e f o r e l e a vi n g t h e f a c to r y

DCS
To DCS

015
017
019
M

12
13
14
15

025
027
029
031

16
17
18
19

L owe Pre ss ur e Ala rm o f Te ns io n

Sy ste m F ail u re Al ar m

El e c t r i c Co n ne c t i o n Di a g r am o f
Hy d r au l i c Pr es s u r e Te n s i o n

-20-