CTL12/6.7.9GP Instruction Manual

SMS/SL-2019-010

Instructions for use

CTL12/6,7,9GP(A)

Explosion-proof special type battery electric locomotive

Product Execution BidquasiMT491-1995

Before installing and using the product

Please read the instruction manual

2019year10month

Purposerecording

1.Product model, name and contentrighteousness...............................................................1

2.product use and use rangecircumference..................................................................1

3.Product Technology Specialsign...........................................................................2

4.Mechanical parts overviewstated...........................................................................3

5.Electrical parts overviewstated...........................................................................4

6.the use of electric locomotivesused........................................................................6

7.Maintenance and repair of electric locomotive..................................................................7

8.Product spare parts, vehicle capitalmaterial..................................................................8

9.Ordering requiredknow...............................................................................9

10.Instructions Attacheddiagram..............................................................................9

CTL12/6,7,9GP(A)

Explosion-proof special type battery electric locomotive

Instructions for use

1Product name, 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:CTL12/6,7,9GP(A)

1.2Product model meaning

CTL12/6,7,9GP(A)

variable frequency speed regulation(forward driving)

steel wheel

Gauge:600,762,900mm

adhesion quality:12t

Cab at both ends

Explosion-proof special type battery type

Coal Mine Electric Locomotive

2product 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.

2.2products

This product should work normally under the following environmental conditions:

a)The altitude does not exceed2000m;

B)shall not exceed+40°C, minimum not less-20°C;

c)the wettest monthly average relative humidity maximum is not more95%(the monthly average minimum temperature in the same month is not more+25°C).

d)Warning: When used in the main transportation roadway of high-gas mine air intake, it must comply with the provisions of the "Coal Mine Safety Regulations" and install a portable methane detection alarm.

2.3product execution standard

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

3products

3.1: seetable1

table1

Serial Number	Namesaid	Listposition	according
1	adhesion quality	t	12
2	battery capacity (5hour rate)	Ah	560
3	Rated voltage	V	192
4	hour system power	kW	2×22
5	hour system speed	km/h	8.7
6	maximum speed	km/h	17.5
7	hour traction	KN	16.48
8	maximum traction	KN	29.43
9	Gauge	mm	600,762,900
10	fixed wheelbase	mm	1220
11	minimum radius of curvature	m	10
12	Wheel rolling circle diameter	mm	680
13	Total transmission ratio		17.5
14	speed regulation mode		variable frequency speed regulation
15	transmission mode		positive bevel gear two-stage reduction
16	braking mode		Mechanical, electrical

3.2electric locomotive

CTL12/6,7,9GPOutline drawing of electric locomotive1.

3.3Electric locomotive characteristic curve

CTL12/6,7,9GPThe characteristic curve of electric locomotive is shown indiagram2.

3.4on Environment and Energy

In order to implement the Environmental Protection Law of the People's Republic of China and control environmental pollution, the following treatment measures should be taken when the product is used, repaired and scrapped:

3.4.1Treatment of Solid Waste

3.4.1.1Treatment of Recyclable Solid Waste

Solid wastes such as waste batteries, product wood packaging, paper packaging, damaged metal parts, waste coils, maintenance waste, waste oil drums containing oil, etc. should be classified and recycled.,unified sales to recycling companies.

3.4.1.2Disposal of non-recyclable waste

Vulnerable parts, plastic packaging of accessories, rubber parts, bakelite parts, mica, glass and other insulating materials damaged by peeling paint residue, aging shall be stored centrally. The electronic components replaced during product maintenance shall be stored by category and disposed of in accordance with relevant regulations.

3.4.2Oil Pollution and Waste Acid

The mechanical oil used in this product should be stored safely. It is forbidden to use open flame around the storage point. Oil separation device should be set up at the refueling point to prevent ground pollution. Special attention should be paid to timely maintenance after oil leakage occurs to reduce leakage. Oil pollution on the ground should be removed in time. Waste acid and waste oil shall be recovered in time and shall not be scattered on the ground or poured into sewers to prevent pollution to soil and water quality.

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.

3.4.5wastewater

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.

3.4.6Handling of Dangerous 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.

electric locomotive is composed of frame device, walking device, rubber damping device, braking device, sand spreading device, ceiling device, buffer device, seat device and other parts.

4.1Frame device

Frame device made of steel plate(30mmthick) welded into a box-shaped skeleton structure, is the main component of the electric locomotive. It is divided into three chambers by the partition, and the front and rear chambers and the ceiling form the driver's cab at both ends. There are driver operation facilities such as driver controller in the cab. In the middle of the mechanical room, installed with running devices, braking devices, sand and some electrical equipment, such as traction motors.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.

4.2walking device

is mainly composed of traction motor, elastic boom, elastic coupling, motor bracket, gear box, wheel set and axle box assembly, etc. The torque of the motor is transmitted to the wheel set after two-stage reduction by the bevel spur gear.diagram3, its transmission system is shown indiagram4.

4.3rubber damping device

rubber damping device is4is composed of a rubber spring.Department4point support device, each group of springs are placed on an axle box, except for the wheel set and reduction box, the weight of the whole vehicle is on the spring.

4.4braking device

systemThe locomotive powered by the dynamic system is decelerated and stopped. This motor locomotive is equippedspineswheel braking and electric braking.

spineswheelbraking means that the driver operateson the ratchetBrakingPull RodImplement braking and relief of electric locomotives (Pull rod upis braking,Pull rod downward pressurefor mitigation.). WhenWhen pulling up the pull rod,rod drives the linkage mechanism to move, thereby driving the brake rod and the brake lever to move,causes the brake shoe to generate pressure on the wheel, so that the friction braking force is generated between the wheel and the brake shoe, thereby slowing down or stopping the electric locomotive. Foundation brakingSame sidetwoblock brake shoe balances the pressure between the brake shoes through the coupling between the brake levers, so that the electric locomotive'stwoblock brake shoe is basically the same. At the same time, the coupler is used to adjust the gap between the brake shoe and the wheel to ensure the reliable operation of the foundation brake.brake device Referdiagram5.

4.5Sanding device

Sanding system seediagram6, the sand box should be filled with dry sand, when necessarypullSandingPull Rod, sandpull rod drives sand box to swing and vibratethe sand grainsDispersionfalls on the rail surface in front of the locomotive to improve the adhesion coefficient between the rail wheels.

4.6Ceiling device

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, both sides of the driver's cab are respectively providedwith chainpushpulldoor, endand righthas larger glass to widen the driver's field of vision.

4.7Buffer device

Buffer Seediagram7. 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.

4.8seat

steel plateandrubbercompositionwith backrestcushion,SuspensioninBody Partition,The operator can adjust the position according to the comfort of his operation,the seat position when working for the driver.

The electrical part of the electric locomotive consists of a power supply device,frequency conversionspeed control device, traction motor, DC power converter, lighting signal lamp, master switch,electricity meterand connecting wires, etc.

5.1For the model and specification of main electrical equipment, seetable3shown.

For electrical schematic diagram, seediagram8Electrical wiring diagram seediagram9

table3Models and specifications of main electrical equipment

Serial Number	type	Namesaid	Quantity	Gaugegrid
1	YBVF-22Q(140)	flameproof DC traction motor	2	Rated voltage:140V, rated power:22kW
2	KBPT-44/192Z	battery electric locomotive flameproof frequency converter	2	Rated voltage:192V, rated power:44 kW
3	DXB2-10/24/192	Mine Flameproof DC Power Converter	1	input voltage:192V, output voltage:24V
4	DXT-192	Explosion-proof special power supply device	1	Rated voltage:192V, rated capacity;560Ah
5	YBZ1-300	mine flameproof typeelectricity meter	2	Range:0-300V
6	DGY36/24BX(A)	Mine Flameproof Locomotive Lightingsignallamp	2	Rated voltage:24V, rated power:36W
7	KBM-3/110	Mine Flameproof Master Switch	2	Rated voltage:110V, rated current:3A
8	DCB-350/380	Mine Flameproof Pin Connector	4	Rated voltage:380V, rated current:350A

5.2Electrical Principle

5.2.1control mode

electric locomotive adopts direct torque 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.

5.2.2battery current through pin connectorenters by reactanceL, isolated two-polepipeD1, electrolytic capacitorC1,C2. re-enter by sixonlyIGBTModule(T1-T6) composed of three-phase inverter circuit and by the system.movementIGBTModule(T7), freewheeling diode(D2), braking resistance(R5).DTCfrequency conversion control circuit generates a three-phase sine wave pulse width modulation signal, which drivesmovementT1-T6 IGBTthe modules to turn on or off in sequence. Output three-phase alternating current to drive three-phase asynchronous motors. When the locomotive speed exceeds the speed set by the driver's controller, the three-phase asynchronous motor exceeds the synchronous speed and enters the power generation state. PassoverIGBTmodule increases the DC bus voltage. Reach a certain value (rated powerpressure250V's locomotiveabout300V), chopper systemmovementIGBTconduction, thereby protecting.C1,C2,T1-T6.

5.2.3Battery power first through the pin connector, go to other electrical equipment. When the electric locomotive is overloaded or short-circuited, the protection circuit works to cut off the power supply to achieve the purpose of overload and short-circuit protection. Can be replaced after troubleshootingpin connector inner fuse body, make the locomotive enter the normal working state. The forward and reverse directions of the electric locomotive are changed by operating the direction handle of the driver controller.changeIGBTtrigger sequence realizes the positive and reverse direction operation of the electric locomotive.

5.2.4The starting, acceleration and braking of the electric locomotive are operated by the main handle of the driver controller.in0position, the electric locomotive is in braking state. When the main handle is in the low-speed position, the locomotive runs at low speed. As the handle moves in the high-speed direction, the running speed of the locomotive increases. When the handle reaches the high-speed position, the locomotive will accelerate to the highest running speed. When the handle moves in the opposite direction, the locomotive will quickly reduce the running speed under the action of electric braking. For example, when the locomotive is running at full speed, return the main handle.50%, the locomotive will slow down within a few seconds.50%.attention! This type of locomotive is not in the state of Sui,Therefore, when it is desired to slow down through a curve, it is only necessary to turn the main handle in the opposite direction as appropriate. Do not turn the main handle0bit. Main handle turn0position, the electric locomotive will stop quickly.

6electric locomotive

6.1Basic requirements for the use of electric locomotives

a.Drivers who operate electric locomotives must receive training and pass the examination before they can drive electric locomotives. Drivers who are not electric locomotives 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.

6.2Electric Locomotive

Check before using the motor car.

6.2.1Check the lubrication of moving parts and components, and ensure the oil quantity of gearbox.hold5kgaround(L-AN46full loss system oil), you can measure the oil rod oil mark height.(25mm) full immersion shall prevail.

6.2.2check whether the coupling pin of the power supply unit and the frame is firmly fixed.

6.2.3check whether the power supply unit plug connector is firmly inserted and whether the polarity is correct.

6.2.4check that the bolts of all removable parts are firm.

6.2.5tapping.

6.2.6Check whether the brake mechanism is flexible, between the brake shoe and the wheelgap2~3mm.

6.2.7shall regularly check the condition of the connecting wire of the electrical circuit. If the wire insulation is damaged, insulation aging and corrosion, it shall be handled or replaced in time to avoid short circuit and damage to electrical equipment.

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

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

6.2.10check whether the sand-spreading mechanism is flexible, the sand shall be screened and dried, and the sand shall be filled in sufficient quantity.

6.2.11check the foundation brake coupling, the lock nut must be tightened.

6.2.12After the battery is charged, check whether the voltage meets the regulations, 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 it can be put into 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.

6.3Shift

6.3.1The inspection of shift change is the same as that before using the motor car. In addition, the bearing temperature should be checked (not muchin95℃, the ambient temperature is+40℃). The driver shall clean the dust and dirt of the motor vehicle during the shift change.mud,Keep all parts of the electric locomotive clean. At the same time, the shift handover driver should inform the successor driver of the abnormal conditions and damage during use and fill in the shift handover record.

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

6.4electric 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)According to the driving direction, turn the reversing handle to the forward or backward position.

d)Check whether the brake is in good condition,It is strictly forbidden to operate the electric locomotive in case of system failure.

6.4.2Starting of electric locomotive

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

B)turns the main handle sequentially from the low-speed position to the high-speed position, the speed of the electric locomotive gradually increases.

c)is in the low-speed position and the electric locomotive does not move in place, 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 in any position, the handle must be turned back quickly"0"location.

6.4.3Stopping of 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: It is strictly prohibited to use reverse traction to stop the electric locomotive during operation.

c)In order to stop the locomotive, only the main handle needs to be moved."0"bit. 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 brake again. 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.

6.4.2Driver Operation Precautions:

a)When the power supply pin is connected:①reversing handle must be set to zero position,②pay attention to the positive and negative polarity of the power supply must not be inserted wrong.

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

c)locomotive is running, it must be stopped before it can be carried out. Otherwise, the locomotive will brake reversely, causing damage to the motor..d)finds that the mechanical braking is abnormal and cannot be reliably braked, it should be stopped to check all parts of the braking system and eliminate it in time, therefore

obstacle and brake system failure.

7Maintenance and repair of electric locomotive

7.1bearing housing and adjustment of roller bearings

Remove the axle housing cover, whether the grease is dirty, generaleach6months (calcium-sodium-based lubricationgreaseZGN-2). Whether the bearing clearance is too small, the clearance can be maintained by adjusting the shimin0.15~0.20mmrange. 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.

7.2Wheelset Device

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

7.2.2The wear of the outer circle and rim of the wheel should be checked regularly every month. When the wheel tread is deepin3mm, grow up.in5mmthe dent, the wheelset should be removed and rotated on the lathe. When the thickness of the tire is worn25mm, the tyre 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 gap 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, if found wear or fatigue phenomenon to replace the new bearing;

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

7.3brake system (seediagram6)

7.3.1Always check whether the working condition of the brake system is normal. If it is found that there are parts with excessive wear, it must be replaced, and the adjustment screw under the connecting rod should be adjusted according to the degree of wear of the brake pad.Rod"6"the distance between the brake pad and the wheel is reached2~3mm, regulating screwnail"9"Borrow Bombsspring"8"makes the brake pad and the wheel concentric.

7.3.2Note: If you find that the thickness of the brake pad is worn to a smallin10mm, it must be replaced with a new one. When replacing, it only needs to be inclined.Pin"4"Pull up, remove the brake block, replace the brake shoe,6.5.4.1adjustment.

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

7.4Power Supply Unit

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

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

7.4.3power 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.

7.5electrical and mechanical products is shown in their respective product manuals.

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

7.7The locomotive can only be overhauled in the garage and other places without gas explosion, and the electrical equipment can only be overhauled when the driver control handle is set at zero position.

7.8Electric Locomotive

The electric locomotive shall betable3.

table3Lubrication System Table

Serial Number	lubrication part	lubrication cycle	RunSlidingagent	addition amount
1	connector pin	once a week	calcium-sodium base grease3	5g
2	Brake Lever Support Pin	once a week	calcium-sodium base grease3	5g
3	Brake shoe support pin	once a week	calcium-sodium base grease3	5g
3	Brake lever pin	once a week	calcium-sodium base grease3	5g
Note: Oil with similar performance is allowed, but mixed use is not allowed.

8Product spare parts, data with the vehicle.

8.1spare 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.

8.1.2For spare parts of motor and electrical equipment, see the instruction manual of motor and electrical equipment respectively.

8.2Product Documentation

a.Electric locomotive qualifiedcertificate1copies

B.electric locomotivebook1copies

c.flameproof frequency conversion devicebook1copies

d.mine flameproof variable frequency traction motorbook1copies

e.power supply unitbook1copies

f.packingList1copies

9Ordering Instructions

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

Example: Purchasebuy12t600raildistance, double cab explosion-proof special type variable frequency speed control battery motorcar10vehicles, please write according to this formula:

CTL 12/6 GP 192V,10vehicle

10Drawings

diagram2electric locomotive

1wheelright2decelerationbox3coupling

4HolderRack5bombspring6motor

diagram3Running Device Diagram

1cylindrical roller shaftBearingNU3052tapered roller shaftBearing322183tapered roller shaftBearing32211

4coupling5large bevel toothwheel6small spur gear

7large orthodontewheel8deep groove ball shaftBearing62219small bevel gear

10wheelright11traction motor

diagram4transmission system diagram

1hand.wheel2special snailmother3brake wireRod4cross arm

5Brakingcylinder6regulating screwRod7gatetile8bombspring

9regulating screwnail10tapered roller shaftBearing11transmission gear

diagram5Brake Schematic

1sandbox2connectedHead3Snailmother4union

5Snailmother6sprayHead7plugchild8Sand pipe

diagram6Sanding device

1outsideshell2bombspring3shell4Towbar

diagram7buffer device

Serial Number	Code	Name	Model	Quantity
1	M1 M2	Flameproof Variable Frequency Traction Motor	YBVF-22Q	2
2	SK BPB	Variable frequency speed regulating device	KBPT-44/192ZPB5-36/314X	2
3	ZB	Flameproof DC power converter	DXB2-10/24/192	1
4	1XC 2XC	power supply unit	DXT-192	2
5	V1V2	electricity meter	YBZ1-300	2
6	CL1 CL2	latch connector	DCB-350/380	4
7	1K 2K	master switch	KBM-3/110	2
8	ZD1-2XD1-2	lighting signal lamp	DGY36/24BX(A)	2