CTL8/6, 7, 9GP(YC)

Explosion-proof special type battery electric locomotive

Instructions for use

1 Productsname, model and meaning

1.1Product name and model

Product Name: Explosion-proof special type battery electric locomotive (hereinafter referred to as the electric locomotive)

product model:CTL8/6, 7, 9GP(YC)

1.2Product model meaning

CTL8/6,7,9GP(YC)

permanent magnet variable frequency speed regulation

steel wheel

Gauge:600,762,900mm

adhesion quality:8t

Cab at both ends

Explosion-proof special type battery type

industrial and mining electric locomotive

2. Product use and scope of use

2.1product use

products are used for hauling mine carts, transporting minerals, equipment and personnel in mines with methane and dust explosion hazards in accordance with the "Coal Mine Safety Regulations.

2.2Product use environment

This product should work normally under the following environmental conditions:

a.The altitude does not exceed2000m;

B.is+40℃, the lowest temperature is-25℃;

c.The wettest monthly average maximum relative humidity is90%(the monthly average minimum temperature in the same month is not more+25℃).

d.is used in a mine with gas outburst, the user must install a portable methane detection alarm in accordance with the provisions of the Coal Mine Safety Regulations..

2.3product implementation standards:

MT491-1995 General Technical Conditions for Coal Mine Explosion-proof Battery Electric Locomotive.

3 Product technical characteristics

3.1 product technical parameters

products1.

table1

Serial Number	Namesaid	Listposition	according
1	adhesion quality	t	8
2	battery capacity (5hour rate)	Ah	440
3	Rated voltage	V	140
4	Motor power	kW	15×2
5	hour system speed	km/h	7.8
6	maximum speed	km/h	15.6
7	hours of traction	kN	12.83
8	maximum traction	kN	19.62
9	fixed wheelbase	mm	1130
10	Gauge	mm	600,762,900
11	minimum radius of curvature	m	7
12	Wheel rolling circle diameter	mm	680
13	control mode		permanent magnet variable frequency speed regulation
14	transmission mode		Positive and Bevel Gear Two-pole Transmission
15	braking mode		Mechanical, electrical

3.2electric locomotive

CTL8/6, 7, 9GP(YC)Outline drawing of electric locomotive1.

3.3Electric locomotive characteristic curve

CTL8/6, 7, 9GP(YC)Electric locomotive characteristic curve is shown in Fig.2.

3.4 on Environment and Energy

In order to implement the Environmental Protection Law of the People's Republic of China and control environmental pollution, the following environmental protection measures are proposed for this product during use, maintenance and product scrapping:

3.4.1Treatment of Solid Waste

3.4.1.1Treatment of Recyclable Solid Waste

Recyclable solid waste refers to the product wood packaging, paper packaging, damaged metal parts, waste coils, maintenance waste, waste oil drums, etc., should be classified and recycled. Unified to the recycling publicDivisionsales.

3.4.1.2Disposal of non-recyclable waste

Vulnerable parts and accessories Plastic packaging,The rubber parts, bakelite parts, mica, glass and other insulating materials shall be collected and stored and disposed according to relevant regulations.

3.4.2Oil Pollutants

The mechanical oil used in this product shall be stored safely. No open flame shall be used around the storage point. Oil separation device shall be set at the refueling point to prevent ground pollution. Special attention shall be paid during refueling. After oil leakage, timely maintenance shall be carried out to reduce leakage. Oil pollution on the ground shall be removed in time. Waste oil after use shall be treated and recycled in time to prevent pollution to soil and water body and shall not be scattered on the ground or poured into sewer.

3.4.3Noise Pollution

This product meets the noise standard. If there is abnormal noise, it is a product failure and should be handled in time to eliminate the failure.

3.4.4treatment of electromagnetic radiation

Electronic components replaced during product maintenance should be classified and centrally managed for recycling.

3.4.5 Treatment of waste water

Waste water The waste liquid refers to the electrolyte overflowing during the charging process of the battery of this product. The user should keep it properly. It is strictly prohibited to dump it on the ground and sewer to avoid polluting the soil and water source. It should be recycled centrally, pumped into the neutralization pool, and discharged after neutralization meets the requirements.

3.4.6 Treatment of hazardous chemicals

For this product, chemical dangerous goods mainly refer to industrial sulfuric acid for battery charging. When charging the battery, the electrolyte should be carefully operated. One is to prevent sulfuric acid from splashing and hurting people. The second is to prevent sulfuric acid from pouring into the ground, polluting the ground or water flow.

3.4.7Disposal of Waste Storage Battery

The use of scrap or damaged lead-acid batteries should be stored in a special place for anti-penetration and anti-diffusion and marked. When accumulated to a certain amount, it is disposed of in a manner permitted by law or by a qualified specialized agency.

special tips:

Users are requested to strengthen environmental protection in accordance with national industry and local laws and regulations to avoid environmental pollution.

4 Mechanical Overview

The mechanical part of the electric locomotive consists of the frame, walking device, braking device, sand scattering device, buffer,roof, spring device,Seat and other parts.

Structure diagram of electric locomotive3.

4.1Frame

Frame30mmthicksteel plate is welded into a box-shaped structure, which is the main skeleton component of the electric locomotive and the foundation for installing the electric locomotive electrical equipment and various accessories. The whole frame is divided into three chambers by partitions. The front chamber and the rear chamber and the ceiling together form a double cab. Driver's controller, brake handwheel, seat and other control operation facilities and other electrical equipment are installed in the cab. The middle room is mechanical room, the mechanical room is equipped with electrical equipment such as traveling device, foundation brake execution department, sand spreading device execution department and traction motor. The frame has sufficient rigidity to withstand the normal impact of the electric locomotive without permanent deformation. It transmits the traction and braking force generated by the wheels and is a basic component of the electric locomotive.

4.2 running device

Walking device is shown in the figure4. It is mainly composed of traction motor, elastic boom, elastic coupling, motor bracket, gear box, wheel set and axle box assembly. The torque of the motor is transmitted to the wheel set after being decelerated by the bevel spur gear. Its transmission system is shown in Figure 5.

4.3 spring device

spring system consists of four sets of plate springs through a balanced beam to form a three-point support, which supports the frame on the front and rear wheels, so that the motor and electrical appliances do not directly bear the impact from the rail surface, ensuring the stability of the locomotive energy.

4.4 brake system

Brake System See Fig.6 (handwheel brake).

Mechanical braking refers to the braking and relieving of the electric locomotive through the driver's operation of the brake hand wheel (clockwise turning the hand wheel is braking, and counterclockwise turning the hand wheel is relieving). When the handwheel is turned, the handwheel drives the screw of the brake screw nut pair to rotate. The rotation of the screw causes the nut to move in a straight line, which drives the brake lever and the brake lever to act, so that the brake shoe generates pressure on the wheel, thereby causing the wheel and The friction braking force is generated between the brake shoes, which causes the electric locomotive to slow down or stop. The four brake shoes of the foundation brake balance the pressure between the brake shoes through the coupler between the brake levers, so that the pressure of the four brake shoes of the electric locomotive is basically the same. At the same time, the coupler is used to adjust the brake shoes and the wheels. Gap, so as to ensure the reliable operation of the foundation brake.

4.5 sand

Sand Spreading System See Fig.7

is mainly composed of joystick, connecting rod, sand box and sand blasting pipe. The sanding system is used to improve the adhesion coefficient between the wheel and the track by sanding, so as to improve the traction of the electric locomotive and prevent the wheel of the electric locomotive from slipping. When sand needs to be scattered, step on the foot pedal and drive through the connecting rod to make the sand box swing and impact, and the sand particles are scattered on the rail surface in front of the locomotive through the sand discharge pipe; when the foot leaves the pedal, the sand box relies on its own weight and The action of the spring returns to its original state to block the leakage sand hole to prevent the sand from leaking.

4.6 Ceiling

The driver's cab is welded by thin steel plates and forms the driver's cab together with the front and rear ends of the frame to prevent damage such as dripping water and falling rocks, and to protect the safety of drivers and electrical equipment. In order to facilitate the wiring and maintenance of the driver's control box and the driver's access, hanging doors and push doors are respectively arranged on both sides of the driver's cab, and large glass is arranged at the end to expand the driver's vision.

4.7 buffer

Buffer Figure8. The buffer is an elastic structure, which can play a buffering role in the traction and impact of the electric locomotive, reduce the impact of the electric locomotive and the mine workshop, protect the safety of the driver and the equipment, and is also the connection mechanism between the electric locomotive and the mine car.

4.8 seat

The elastic cushion is composed of artificial leather and foam plastic, which is fastened on the bracket, and forms a folding and up-and-down adjustable seat device with the supporting parts in the driver's room, which is the seat position for the driver when working.

5Electrical partoverviewstated

electric locomotive is composed of power supply device, variable frequency speed regulating device, traction motor, DC power converter, mine flameproof voltmeter, lighting lamp, signal lamp, master switch and connecting wire.

5.1 See Table 3 for main supporting electrical equipment

Electrical schematic diagram is shown in the figure9 Electrical Wiring Diagram as shown in Fig. 10

table3Models and specifications of main electrical equipment

Serial Number	type	Namesaid	Quantity	Gaugegrid
1	TBVF-15YC(100)	mine flameproof typepermanent magnet synchronous variable frequency traction motor	2	Rated voltage:100V, rated power: 15kW
2	KTJ-230	Flameproof variable frequency governor for battery electric locomotive	2	Rated voltage:140V, rated power: 2X15kW
3	QBY1-200	mineFlameproof voltmeter	2	1~200V
4	DXT140/440	Explosion-proof special power supply device	1	Rated voltage:140V, rated capacity: 440Ah
5	DGY12/110L(A)	mine flameproof typeLED lightingsignallamp	2	Rated voltage:24V, rated power: 9W
6	DCB-290/250	Mine Flameproof Pin Connector	2	Rated voltage:250V, rated current: 290A

5.2 Electrical Principles

5.2.1 Control mode

electric locomotive adopts direct vector control, and the working conditions such as forward, backward, starting, traction and braking of the electric locomotive are directly realized by manipulating the driver controller.

5.2.2Turn on the inverter power switch, all low-voltage control circuits enter the standby state, and the battery current passes through the latch connectorenters the inverter and charges the filter capacitor. After entering the inverter, the microcomputer controller (CPU) According to the signal output from the driver's console, IGBT is controlled to be inverted into variable frequency and variable voltage (VVVF) three-phase AC voltage. Output to permanent magnet motor. The system is non-contact control, through the controller to achieve locomotive forward, backward, starting, traction, electric braking conditions. When the microcomputer controller receives the controller instruction, it generates a three-phase PWM signal through software control, and drives the IGPT through the IGPT drive board to generate a three-phase AC voltage to drive the AC motor. The microcomputer controller detects the motor current through the Hall sensor. Through the current vector transformation, the dynamic flux control and torque current closed-loop adjustment are carried out, the voltage space vector PWM signal is generated, the motor traction and braking are realized, and the motor reverse operation is realized by software, so as to realize the non-contact control of the motor. When the protection circuit detects the motor overcurrent, immediately block the PWM control signal, a few microseconds can be closed all IGPT, no three-phase AC voltage output, to achieve system protection.

6 Use of electric locomotive

6.1 electric locomotives

a. Drivers who operate electric locomotives must be trained and qualified before driving electric locomotives, and non-electric locomotive drivers are strictly prohibited from driving electric locomotives.

B.When using the electric locomotive, it shall be strictly implemented in accordance with the provisions of the instructions of the product.

warning! If the connection between the batteries is loose, it should be replaced according to the requirements of the power supply unit manual.

warning! The flameproof surface of the latch coupling shall be inspected according to the latch coupling instructions. If there is any damage, it shall be repaired immediately.

6.2 Electric Locomotive

Check before using the motor car.

6.2.1Check the lubrication of moving parts and components, and keep the oil level of the gearbox5kg(L-AN46 all-loss system oil), you can measure the oil rod oil mark height (25mm) full immersion shall prevail.

6.2.2 Check whether the coupling pin between the power supply unit and the frame is firmly fixed.

6.2.3 Check whether the plug connector of the power supply device is firmly inserted and the polarity is correct.

6.2.4 Check all bolts of removable parts for firmness.

6.2.5 Percussion check the firmness of the tyre and wheel center.

6.2.6 Check whether the brake mechanism is flexible and the clearance between brake shoe and wheel is 2~3mm.

6.2.7 The condition of the connecting wires of the electrical circuit shall be checked regularly. If the insulation of the wires is damaged, the insulation is aged and corroded, it shall be handled or replaced in time to avoid short circuit and damage to the electrical equipment.

6.2.8 Check the flexibility of the reverse handle and main handle of the driver controller.

6.2.9 Check whether the sound of the alarm bell is loud and the lighting lamp is bright.

6.2.10 Check whether the sanding mechanism is flexible. The sand shall be screened and dried, and the sand shall be filled in sufficient quantity.

6.2.11 Check the foundation brake coupling and tighten the lock nut.

6.2.12 After the battery is charged, check whether the voltage meets the requirements, whether the special exhaust bolt on the single battery is tightened, and the battery box ironwhether the cover is closed and locked.

Danger! If the special exhaust bolt is not tightened or screwed on, the power supply device will lose its explosion-proof performance.

there is no fault or problem after the above inspection, indicating that the locomotive is in good condition before entering operation.

Note: During operation, it is not allowed to open the cover of any electrical equipment. If a fault is found, it should be returned to the garage for maintenance. When the lighting glass is occasionally damaged, it must be returned to the garage for repair to ensure the safety of the locomotive.

Danger! Opening the cover of electrical equipment in the roadway for repair is a very dangerous act and must be strictly prohibited.

Inspection of 6.3 shift change

6.3.1 The inspection of shift handover is the same as the inspection before using the motor vehicle. In addition, the bearing temperature should be checked (not more than 95 ℃, when the ambient temperature is +40 ℃). During the shift change, the driver shall clean the dust and sludge of the electric locomotive to keep all parts of the electric locomotive clean. At the same time, the shift driver shall inform the driver of the abnormal situation and damage situation during the use process, and fill in the shift change record.

6.3.2 The driver shall check that all parts of the locomotive are normal before it can be put into use.

6.4 electric locomotive

6.4.1Starting operation of locomotives and general regulations:

This electric locomotive is started by variable frequency speed regulation, which shall be operated according to the operation instruction of frequency converter and the following regulations shall be observed:

preparation before driving:

a) Check whether the locking between the reversing handle and the main handle is reliable.

B)plug the power pin connector correctly.

c) Turn the reversing handle to the forward or backward position according to the driving direction.

6.4.2 electric locomotive

a) The main handle is set to the low position. The electric locomotive is started, and the electric locomotive is in the lowest speed state.

B) When the main handle is sequentially rotated from the low-speed position to the high-speed position, the speed of the electric locomotive will gradually increase.

c) If the electric locomotive does not move at the low speed position, it is allowed to move the main handle slightly to the high speed position. At this time, if the electric locomotive has not been started, the reason must be found out, because turning the handle to the next position may damage the electrical equipment.

d) The electric locomotive can run for a long time when the handle is in any position.

e) When the controller is powered off at any position, the handle must be quickly turned back to the "0" position.

6.4.3 electric locomotive

a)The main handle can be placed in a lower speed position when the electric locomotive needs to slow down or run at a constant speed when going downhill.

B) Warning: When the electric locomotive is in operation, reverse traction is strictly prohibited to stop.

c) To stop the locomotive, simply move the main handle to the "0" position. Mechanical braking must be used only when parking for a long time or when power is off on a ramp.

d) Note: If the force is too strong during mechanical braking, the brake shoe will lock the wheel and cause sliding. At this time, the braking distance will increase instead. For this reason, the braking should be quickly relieved to stop the sliding, and then re-brake. At this time should be sand, increase adhesion, stop sliding.

e) When operating the locomotive, the driver should control the speed of the electric locomotive well according to the slope of the line, the traction weight and the required stopping distance to ensure the safe and reliable stop of the electric locomotive.

6.4.4 Precautions for driver operation:

a) When connecting the power plug pin: ① The reversing handle must be set to the zero position; ② Note that the positive and negative polarities of the power supply must not be inserted incorrectly.

B) The driver shall operate the main handle not to move too fast, but to translate and slide to make the motor voltage increase smoothly.

c) The commutation of the electric locomotive must be carried out after the electric locomotive has been stopped. Otherwise, the motor will be damaged due to reverse braking of the electric locomotive.

d) When it is found that the mechanical braking is abnormal and cannot be reliably braked, stop the vehicle to check all parts of the braking system and eliminate the fault in time. If the braking system has a fault, the electric locomotive is not allowed to operate reluctantly.

7 Maintenance and repair of electric locomotive

7.1 bearing housing and adjustment of roller bearings

remove the axle housing cover, whether the grease is dirty, generally every6 months. Whether the bearing clearance is too small, the clearance can be kept within 0.15~0.20mm by adjusting the shim. Check the inner and outer rings of the bearing and the surface of the roller. If wear or fatigue (small or local pitting) is found, replace the bearing with a new one.

7.2 wheelset

7.2.1 When checking the electric locomotive every day, knock the wheel hoop to check its integrity and tightness with the wheel center (tightness can be observed whether the marks of the wheel hoop and the wheel center are staggered).

7.2.2 The wear of the outer circle and rim of the wheel shall be checked regularly every month. When the wheel tread has dents deeper than 3mm and longer than 5mm, the wheel set shall be removed and rotated on the lathe. When the thickness of the tire is worn to 25mm, the tire must be replaced. But must be done to eachwheelset shall not be greater1mm, the diameter deviation of wheel rolling circle on the same locomotive shall not be greater2mm.

7.2.3If there is heat, abnormal noise, oil leakage, etc. during the operation of the reduction gearbox, the inspection and treatment are as follows.

a) If the gear is loose, tighten the bolt;

B) If the gear clearance or contact area changes, it should be adjusted to make the tooth side clearance of the bevel gear reach0.175mm ~0.4mm; Ensure that the axial clearance of the small bevel gear is less0.15mmand large bevel gears is less0.1mm;

c) Carefully check the bearing, and replace the bearing with a new one in case of wear or fatigue;

d) If the oil leakage at the coupling and the axle is serious, check the oil seal at this part, and replace it in time if it is severely worn or burned.

7.3 brake system (see Fig. 6)

7.3.1 Always check whether the working condition of the brake system is normal. If parts with excessive wear limit are found, they must be replaced. Adjust the adjusting screw "5" under the connecting rod according to the wear degree of the brake pad to reach the distance between the brake pad and the wheel of 2~3mm. The adjusting screw "8" makes the brake pad and the wheel concentric by the force of the spring "7.

7.3.2Note: If you find that the thickness of the brake pad is worn to lessis 10mm, it must be replaced with a new one. When replacing, it is only necessary to pull out the oblique pin "4" upward, remove the brake block, replace the brake shoe, and adjust according to Article 6.5.4.1.

7.3.3Note: The locomotive braking distance shall be measured at least once a year, and the braking distance shall comply with the requirements of "Coal Mine Safety Regulations.

7.4 Power Supply Unit

7.4.1 It is strictly forbidden to open the box cover during operation, and no heavy objects are allowed on the box cover.

7.4.2 In order to prevent the temperature of the battery from being too high, the power supply device must be well ventilated, and no dust and dirt should block the ventilation slot and the ventilation holes at the bottom.

7.4.3 Use of Power Supply Unitmaintenance, please refer to the instruction manual of power supply unit.

attention! The storage period of the battery in the power supply unit shall not exceed two years from the date of manufacture of the battery.

7.5 can be found in their respective product manuals.

7.6 should regularly check the electrical circuit components and cables, found that the problem, timely treatment.

7.7 electric locomotives can only be overhauled in garages and other places without gas explosion, and the overhaul of electrical equipment can only be carried out when the controller handle is in zero position.

7.8 Electric Locomotive

Electric locomotive should be in accordance with the table3.

table3 Lubrication schedule

Serial Number	lubrication part	lubrication cycle	Run Sliding agent	addition amount
1	Brake screw bearing chamber	once a year and a half	calcium-sodium base grease3.	30g
2	brake screw	once a week	L-AN46 total loss system oil	20g
3	brake nut	once a week	L-AN46 total loss system oil	20g
4	Brake Cross Arm Rod Pin	once a week	calcium-sodium base grease3.	5g
5	reduction gearbox gear	once a month	L-AN46 total loss system oil or gear oil	5kg
6	connector pin	once a week	calcium-sodium base grease3.	5g
7	Brake Lever Support Pin	once a week	calcium-sodium base grease3.	5g
8	Brake shoe support pin	once a week	calcium-sodium base grease3.	5g
9	bearing seat	once a month	calcium-sodium base grease3.	20g
10	Brake lever pin	once a week	calcium-sodium base grease3.	5g
Note: Oil with similar performance is allowed, but mixed use is not allowed.

8 Product Spare Parts and Data with Vehicle

8.1 spare parts

8.1.1spare parts

Refer to the packing list of the electric locomotive for details of the accessories and the data accompanying the electric locomotive.

8.1.2The spare parts of motor and electrical equipment are shown in the instruction manual of motor and electrical equipment.

8.2Product Documentation

a.Electric locomotive certificate1 part

B.Operating Instructions for Electric Locomotive1 part

c.Flameproof Frequency Conversion Device Operation Manual1 part

d.Variable frequency speed traction motor instruction manual1 part

e.Power Supply Unit Instruction Manual1 part

f.Packing List1 part

9 Ordering Instructions

When ordering, the user must propose the product model, name, voltage, gauge, number of vehicles, etc.

Example: Purchase8tThere are 10 explosion-proof special permanent magnet frequency conversion speed regulating battery locomotives with 600 gauge, double driver's cab and driving in the direction. Please write according to this formula: CTL8/6 GP(YC) 140V,10.

10 Drawings

B(vehicle width)	1050	1212	1350
K(Gauge)	600	762	900
Model	CTL8/6GP(YC)	CTL8/7GP(YC)	CTL8/9GP(YC)

Serial Number	generation	Namesaid	type	Quantity
1	M	mine flameproof typepermanent magnet synchronous variable frequency traction motor	TBVF-15YC(100)	2
2	KTJ	battery electric locomotive flameproof frequency converter	KTJ-230/192	2
3	V1V2	mineFlameproof voltmeter	QBY1-200	2
4	XC	Explosion-proof special power supply device	DXT140/440	one for use and one for standby
5	ZD1-2XD1-2	mine flameproof typeLED lightingsignallamp	DGY12/110L(A)	2
6	CLCL-	Mine Flameproof Pin Connector	DCB-290/250	2
7	GJC4( B)	Vehicle-mounted methane alarm power cut-off instrument	GJC4( B)

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