Svendborg Brakes Hydraulic Brake Control Unit Installation and Maintenence Manual

Name: Date: Revision:

Installation and Maintenance Manual

HYDRAULIC BRAKE CONTROL UNIT 3000-0129-801 (1106-0006-803)

MEH-3000-0129-801 08.08.2010 A

Installation and Maintenance Manual – 3000-0129-801

Table of content TABLE OF CONTENT ..................................................................................................................................... 1 1.

GENERAL .......................................................................................................................................... 2

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8

Who to contact ............................................................................................................................... .... 2 Safety ................................................................................................................................................. ............................................... .................................................................................................. 2 Conventions used in this manual........................................................................................................ manual........................................................................................................ 2 Disclaimer ........................................................................................................................................... 3 Transportation .................................................................................................................................... 3 Lifting .................................................................................................................................................. 3 Storage ............................................................................................................................................... 4 How to order spare parts .................................................................................................................... 4

2.

MOUNTING AND COMMISSIONING ............................................................................................... 5

2.1 2.2 2.3

Mounting ............................................................................................................................................ 5 Connections ........................................................................................................................................ 5 Before starting the pump unit ............................................................................................................. ............. ................................................................................................ 5

3.

DESCRIPTION OF THE HYDRAULIC SYSTEM ............................................................................... 6

3.1 3.3

General ............................................................................................................................................... 6 Hydraulic diagram............................................................................................................................... 7

4.

MAINTENANCE ................................................................................................................................. 8

4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11

Inspection ........................................................................................................................................... 8 Adjustment .......................................................................................................................................... 8 Checks ................................................................................................................................................ 8 Function test ....................................................................................................................................... 9 Dismantling the power unit ................................................................................................................. 9 Changing the oil .................................................................................................................................. 9 Changing the oil and cleaning the reservoir ..................................................................................... 10 Changing the oil filter ........................................................................................................................ 10 Changing the air breather ................................................................................................................. 10 Measuring the gas pressure press ure ............................................................................................................. 10 Recharging the accumulator............................................................................................................. 11

5.

TROUBLE SHOOTING .................................................................................................................... 13

5.1 5.2 5.3 5.4

Failure intro ....................................................................................................................................... 13 Power unit does not release pressure .............................................................................................. 14 Power unit does not set / build pressure .......................................................................................... 15 Other failures .................................................................................................................................... 16

APPENDIX A - DIMENSION DIM ENSION DRAWING ....................................................................................................... 17 APPENDIX B - DIMENSION DRAWING - FRAME ....................................................................................... 18 APPENDIX B - SPARE PARTS LIST - FRAME ............................................................................................ 19 APPENDIX C - SPARE PART DRAWING – TANK....................................................................................... T ANK....................................................................................... 20 APPENDIX C - SPARE PARTS LIST – TANK .............................................................................................. 21 APPENDIX D – SPARE PART DRAWING – MAIN BLOCK ......................................................................... 22 APPENDIX D - SPARE PARTS LIST - MAIN BLOCK.................................................................................. 23 APPENDIX E - SPARE PART DRAWING – DRAW WORKS BLOCK ......................................................... 24 APPENDIX E - SPARE PARTS LIST - DRAW WORKS BLOCK ................................................................. 25 APPENDIX F - HYDRAULIC SETTINGS SET TINGS ...................................................................................................... 26 APPENDIX G - ADJUSTING ......................................................................................................................... 27 APPENDIX H - ELECTRICAL DIAGRAM ..................................................................................................... 29 APPENDIX I - RECOMMENDED RECOMM ENDED FLUID ....................................................................................................... 31 APPENDIX J - RECOMMENDED SPARE PARTS ....................................................................................... 32

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1.

It is the customer’s responsibility that the air gap between brake pads and brake disc never exceeds the air gap recommended. Always use a torque wrench when refitting mounting bolts or valves in order to ensure the torque obtained is the torque described in this manual. There should be one manual available for the service / maintenance crew as a minimum.

General

•

Thank you for buying a Svendborg Brakes product. Before using the product please read this manual carefully.

1.1

•

Who to contact

•

In case you have any questions to this manual please contact your local representative or nearest Svendborg Brakes Office: Svendborg Brakes Offices:

Hydraulic power unit: Do not operate the hydraulic power unit before correctly filling the reservoir / oil tank with oil. Do not adjust valves or pressure switches to higher operating pressure than specified in the manual. Do not change the size or type of components. Do not use hydraulic fluids not recommended in this manual. •

•

Denmark: Jernbanevej 9, DK-5882 Vejstrup Tel +45 63 255 255 E-Mail: [email protected]

•

•

Germany: Kirchnerstrasse 42, DE-32257 Bünde Tel +49 522 368 540-0 E-Mail: [email protected]

Brakes: Do not operate the brake before removing the air from the hydraulic system by bleeding and then re-filling with oil. Do not use higher operating pressures than specified on the nameplate of the brake / or in the manual. Do not change the size or type of spring pack. Do not use the brake pads when they are worn to the minimum thickness as shown in the manual. Do not operate the brake if there is dirt or corrosion protection on disc or brake pads. •

Spain: C/ San Benito 24, 1ºB, ES-42001 Soria Tel: +34 975 233 655 E-Mail: [email protected]

•

USA: 100 Fillmore Street, 5th Floor, Denver, CO 80206 Tel: +1 303 285 1271 E-Mail: [email protected]

.

•

•

•

or visit us at: www.svendborg-brakes.com

1.2

Safety The Svendborg Brakes brake line of products are designed to be mounted on a rotating brake disc for use in conjunction with parking brake applications, service brake applications or emergency brake applications only.

Personal safety Do not work on the brake/ system before: The manual has been read and understood. The brake disc is locked and not able to rotate before adjusting the brake and / or air gap. Locking / securing the brake piston by using the air gap bolt / air gap nut if working on a spring applied brake. Being sure there is no pressure on the hydraulic power unit or circuit. Being sure the oil pressure in the accumulator(s) has been relieved / removed. The control signals has been shut off and blocked before working on the system. The electrical power has been shut off • •

•

•

Note:

Always make sure that you consult Svendborg Brakes A/S before using tools or any other equipment not recommended / specified in this manual. In order to maintain the guarantee always use original spare parts from Svendborg Brakes A/S.

•

•

•

•

•

1.3 It is the customer’s responsibility that the brake and hydraulic aggregate are always clean, and free from dirt, grease or oil.

•

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Conventions used in this manual To make sure that you perform certain tasks properly, please take note on the following symbols used throughout this manual.


WARNING: Information to prevent personal injury when trying to complete a task.

1.5

Transportation When leaving the factory the hydraulic power unit is always packed / wrapped to ensure maximum security for the product during transport.

CAUTION: Information to prevent damage to the components when trying to complete a task.

CAUTION If the hydraulic power unit has been sent by air freight - please note that the gas (N2) pressure has been released / removed from the accumulator(s). A label (see figure 1.1) is then attached to the accumulator.

WARNING: Electrical shock hazard

IMPORTANT: Information that you MUST follow to complete a task.

FIGURE 1.1

NOTE: Tips and additional information to aid in completing a task. Figures within brackets ( ) relate to position number and appendix number i.e. (15-C) refers to position number 15 in appendix C on both drawing and bill of material (parts list).

1.4

If the accumulator is not pre-charged it must be recharged before usage. See section 4.10 – “Recharging the accumulator” for details

Disclaimer

Normally there is no hydraulic oil in the unit. A warning label is attached to it.

Svendborg Brakes A/S reserves the right to revise this document without prior notification. These documents have been proofread for errors in translation and accuracy. Despite this, technical and typographical deviations can sometimes occur.

WARNING FOR TRANSPORT REASONS THE PUMP IS SHIPPED WITHOUT OIL FILL WITH RECOMMENDED OIL BEFORE STARTING REFER TO MANUAL

This document is updated on a regular basis; changes will be published in future printings. Improvements and/or changes to the described products or manual can be implemented at any time without preceding notice. In no event shall Svendborg Brakes A/S be liable for any special, incidental, consequential or punitive damages. This includes, but is not limited to: damage to other property or person, inconvenience, loss of goodwill, lost profits or revenue, loss of use of this product or any associated equipment, cost of substitutive equipment, downtime costs or claims of any party such damages, resulting from any misspellings or inaccurate information in this users guide.

The hydraulic power unit must be filled with oil according to appendix I of this manual before usage. If running dry the pump will be destroyed.

1.6

This document or parts hereof may in no event be copied, reproduced, changed or translated to other languages without explicit written permission from Svendborg Brakes A/S.

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Lifting The hydraulic power unit weighs app. 375 kg (825 lbs). If it is necessary to use a lifting harness, under no circumstance place it around valves, gauges or accumulators. See below how to lift. If not mounted in cabinet the hydraulic power unit may be lifted in the motor – see figure 1.3.


1.7

FIGURE 1.3

Storage Hydraulic power units must be stored indoor in a clean, dry area. They must be stored in such a way that it can’t be damaged by passing or falling objects. For indoor storage for up to 3 month the hydraulic power unit does not need any surface treatment. For longer periods you should cover it with plastic / a canvas cover to protect it against dirt

1.8

How to order spare parts When ordering spare parts for your hydraulic power unit please refer to the specific item number in the parts list – see appendices.

CORRECT WAY TO LIFT

CAUTION Do not lift the hydraulic power unit in the valves etc. – see figure 1.4

For full identification of the hydraulic power unit please note the ID-number labelled on the manifold or on the tank.

FIGURE 1.4 FIGURE 1.6

PU: 3000-0129-801 ID: 1-500032588

WRONG WAY TO LIFT

If the hydraulic power unit is mounted in a cabinet the unit can be lifted by using the lifting point in the supporting frame. FIGURE 1.5

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2. 2.1

2.3.2

Mounting and commissioning

WARNING Connect the valves (19, 20, 20.1, 22.1, 23.1, 23.2), the motors (4A, 4B), the pressure transmitters (40, 42, B1, B2, B3, B4), the thermo switch (5e) and the level switch (5c) to the voltage described in Appendix E.

Mounting In the bottom of the frame there are 4 holes Ø14 for floor mounting.

2.2

Connections

CAUTION

Hydraulic pressure ports out of the manifold are size 12 JIC metric male according to DIN 20 078 N

2.3

2.3.3

Before starting the pump unit Check accumulator before starting – if the accumulator has a warning sign telling that the accumulator has NOT been pre-charged (in case of air freight – see section 1.5). Charge the accumulator before usage – see section 4.9 for details.

FIGURE 2.1

2.3.1

Electrical connections

Fill up the tank on the pump unit with oil of the recommended quality (see appendix I). The oil volume is approx. 105 litres. Fill up the tank as described in section 4.6.4 & 4.6.5 FIGURE 2.2

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Start the electric motor. Check that the rotation of the electric motor is correct as indicated on the motor – i.e. clockwise viewed from the fan end.


3.

Description of the hydraulic system

3.1

General The hydraulic unit 1106-0006-803 has been developed to use together with failsafe brake callipers from Svendborg Brakes. The pump can be connected to one or more brakes.

3.1.2

Function (See diagram 1106-0006-603) The following describes function of the system.

3.1.2.1 System energy Stand by. In the hydraulic system an electro motor (4) and a pump (2) converts electrical power into oil pressure and oil flow. The pressure transmitter (40) will indicate that there is no pressure in the accumulator. This should lead to that valve (19) gets signal and goes on. The pressure rises and when the set value is reached valve (19) should open again. Then the oil flows through valve (17) to the filter (15) and back to tank through valve (19). Note for service people: In case of any failure, the pressure in the accumulator can be released through the accumulator dump valve (52), which during normal operation is closed, and the ACCUdump ball valve. 3.1.2.2 Releasing the brakes. When signal to open the brakes is given, valve (19, 20, 22.1, 23.1 & 23.2) goes on, and oil will flow through valve valves (20.1 to 20.2) to the brakes. The pressure at each brake channel can be monitored at each pressure transmitter (B1 to B2). When the brakes are lifted some oil will be used from the accumulator, and the pressure will drop. This will be indicated from the transmitter (40), valve (19) will close and the pump will refill the accumulator.

3.1.2.4 Emergency braking. In case of emergency braking or in case of power failure the brakes will be applied by deactivating valves (20 and 22.1), and the brakes will be applied with a limited force (set at valve (24.1)). Again this brake force is active for a programmed time, and after this time the valves (23.1, 23.2) goes off and applies full brake force. In this case an UPS has to ensure power for this operation (19 Watt each coil). In case of failure in the UPS all valves will go off, and 100 % braking force will be applied without delay. 3.1.2.5 Opening one brake channel. If a signal is given to one of the valves (20.1 or 20.2) each brake channel may be isolated in the actual position (energized coils) the valves are operated, also valve 22.1, 23.1, 23.2 are closed (energized). Pressure at each brake channel may be monitored by the pressure transducers (B1 to B2). 3.1.2.6 Bedding in. When signal is given to the brakes the valves (20) and (22.1) goes off and the oil is dropped to tank through and to the pre-set value of valve (24.1), valve (20, 23.1& 23.2) must be on when bedding in. The achieved force will apply the brakes with a reduced torque that is sufficient to bed the brake pads in – in order to get the right coefficient of friction. See separate information packed with the brake pads.

3.2.

3.1.2.3 Normal braking, 2 stage. When signal is given to the brakes the valves (20) and (22.1) goes off and the oil is dropped to tank through and to the pre-set value of valve (24.1) after a certain time, valve (23.2) is opened (off) and the oil is dumped to the tank – the brakes are applied.

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Monitoring Pressure transmitter (42) monitors the system pressure (see 3.2.1). When there is need for re-boosting the system pressure it must have the motor started and give signal to valve (19). Pressure transmitter (42) monitors the pressure before the filter. If the measured pressure difference over the filter (15) exceeds 5 bar this transmitter has to indicate a warning signal. The signal from pressure transmitter (42) must be compared with the signal from pressure transmitter (40) when the brakes are in operation. The signal from pressure transmitter (42) must be < 5 bar when valve (19) is open and the oil is circulated through the pump, filter and valve 19. If the pressure is above 5 bar the filter element must be replaced. Transmitter (5c) monitors the oil level in the tank. Transmitter (5e) monitors the oil temperature in the tank.


3.3

Hydraulic diagram

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4.

4.3

Maintenance

By remaining alert and paying close attention to detail it is possible to detect faults in their early stages and so prevent them from developing into more serious malfunctions. This is particular true during the early stages, but also remains true throughout the service life of the pump unit.

Maintenance is important for the ability of the hydraulic power unit to control the brakes at any time. Maintenance consists of inspection and service.

4.1

Inspection At initial commissioning inspection is done to check if adjustment of the pump unit is necessary. Later inspection is done on a regular basis.

4.2

A constant look out should be kept for: External leaks Dirt Damage, especially to hoses and pipes Unusual noises from pump, electrical motor, valves etc. Proper functioning of instruments • • • •

Adjustment A number of components demands the right setting or charging in order to make the braking system work properly. The correct setting and how to adjust it can be found in Appendix D. All of these components in a pump unit are pre-set to the right pressure from the factory. They may need adjustment during initial commissioning.

Inspection plan Function Test of each valve Hydraulic oil Level of oil If not using the level and termo switch 3 litre tank Temperature Oil condition (sample) Oil change Filters Oil filter cleaning (change if necessary) Air filter change Accumulators Gas pressure

•

See Initial commissioning and chapter installation

External leaks Dirt Damage Noises Instruments / electrical connections 324911-sbdk_MEH-3000-0129-801_A.doc

Service intervals periods after commissioning. Whatever comes first of:

Before first real operation

6 months / 1000 h

Continuous

Monthly / 160 h

Continuous

Weekly / 40 h

Continuous

Monthly / 160 h 6 months / 1000 h 2 years / 4000 h

After one week

6 months / 1000 h 6 months / 1000 h

Daily

6 months / 1000 h According to legal requirements

Continuous

6 months / 1000 h

Other checks Adjustments Valves etc. Checks

Checks

Continuous Continuous

Monthly / 160 h or if decresing oil level Monthly / 160 h Monthly / 160 h Monthly / 160 h

Continuous

6 months / 1000 h

Daily

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4.4

Function test

Testing component position (see hydraulic diagram)

Component Before action

19

Action 4A, 4B: on 4A, 4B: off.

2A, 4A, 2B, 4B, 16, 19, 20, 40, 42, A1 Testpoint: P

4: off 19:on

20, 20.1, A1, B1 Testpoint: P0

4A: on 20: on 4B: off 22.1, 22.2, 23.1, 23.2: on 20.1: on 4A: off 20.1:off

22.1 Testpoint: P0

20:on 20.1: off

22.1:off

23.1 Testpoint: P0 23.2 Testpoint: P0

22.1: off 23.1: on 22.2: on

23.1: off

4.5

Explantion

4A, 4B: on

23.2: off

Motors should start and recirculate the oil through the filter back to the tank. After test stops the motors. Motors should start and stop at the preset pressure signal from 42. For a period of 10 minutes motor should not re-start proving all connections and the valves 19, 20 are tight Opening the valve 20 should let the oil from accumulator A1 to the brakes through connection P2, P3 and P4. This can be monitored at each transmitter B2 ... B4 CAUTION: Brakes P2, P3 & P4 will be released during this test. Disconnect the motor 4A Opening of valve 20.1 (off) will let the oil into the brake connectet to P1 from the accumulator. B1 shall change value. CAUTION: Brake P1 will be released during this test. Opening of valve 22.1 shall lower the pressure to level preset by valve 24.1 oil is dumped to tank. CAUTION: Brakes will be applied to reduced torque during this test. Opening the valve 23.1 will dump the oil back to tank. Opening the valve 23.2 will dump the oil back to tank. CAUTION: Brakes will be applied during this test

Dismantling the power unit This should only be carried out in an authorised hydraulic workshop. Ask for separate information.

4.6 4.6.1

4.6.2

Make sure that the whole oil drains into a secondary container for proper disposal.

4.6.3

Close the drain valve and re-fit the end nut.

4.6.4

Refill the oil reservoir to the top level mark in the sight glass located on the reservoir sidewall.

Changing the oil WARNING: Disconnect all power to the hydraulic power unit and relieve all internal oil pressure in the system.

With the drain valve: Remove the end nut Open the valve. The location of the drain is on the side of the reservoir.

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CAUTION Use only filtered oil of the right viscosity for refilling (see appendix I).

4.6.5

Page 9

Connect the electrical power again and start the pump. Let the unit run 10 cycles (pressurising/de-pressurising). With system pressurised bleed the brakes. With system de-pressurised refill oil if necessary.


4.7

Changing the oil and cleaning the reservoir

4.7.1

Disconnect all power to the hydraulic power unit and relieve all internal oil pressure in the system. This procedure is recommended always to be carried out in a hydraulic workshop to ensure clean environment. Empty the reservoir as described in section 4.6.1 & 4.6.2

4.7.2

Remove the tank cover with the mounted assembly (95 – 105 kg without oil).

4.7.3

Clean the reservoir with a flock free rag.

4.7.4

Refit the tank cover with the mounted assembly onto the reservoir

4.7.5

Refit the screws and torque tightens to 20 to 25 Nm.

4.7.6

After connecting to power and brakes fill reservoir as described in chapter 4.6.4 & 4.6.5

4.8

Changing the oil filter

4.8.1

Disconnect all power to the hydraulic power unit and relieve all internal oil pressure in the system.

4.9.2

The air breather is connected to the reservoir by pressing it in. Remove the air breather along with the seals.

4.9.3

Mount a new complete air breather.

4.10

Measuring the gas pressure

CAUTION 4.10.1 Disconnect all power to the hydraulic power unit and relieve all internal oil pressure in the system.

Oil pressure must be zero to measure the gas pressure correctly. When working with a hydraulic power unit it is recommended to install two pressure gauges for measuring accumulator pressure and brake pressure. Unscrew the threaded cap on top of the accumulator FIGURE 4.16

The oil filter is placed in the filter housing. 4.8.2

4.8.3

Using an open end spanner, turn the filter housing counter clockwise until it is disconnected from the filter manifold. Remove the oil filter and clean the inside of the filter housing and cavity. Insert a new oil filter minding the orientation.

4.8.4

Clean the o-ring and Teflon-ring outside the filter housing. Renew o-ring and Teflon-ring if necessary.

4.8.5

Refit the filter housing.

4.9

Changing the air breather

4.9.1

Disconnect all power to the hydraulic power unit and relieve all internal oil pressure in the system. The air breather consists of two parts: A strainer inside the reservoir and A filter in the cap

324911-sbdk_MEH-3000-0129-801_A.doc

4.10.2 Using the 6mm Allen key turn the plug by turning it counter clockwise (¼ turn). The screw is now loose without loosing gas FIGURE 4.17

4.10.3 Mount the gas pressure gauge and close the side valve.

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FIGURE 4.18

4.11.1 Establish a filling line between the pressure valve and a gas tank. The accumulator charger kit contains pressure gauge and filling line. Remember that the adaptor from the and to the gas tank is country specific may need to be ordered separately.

gas gas line and

FIGURE 4.21

4.10.4 Open the top valve, measure the gas pressure and close the top valve again.

FIGURE 4.19

4.11.2 Open the gas tank valve and the top valve to fill gas into the accumulator. Close gas tank valve and wait several minutes for the new gas to decline to accumulator temperature. Measure the gas pressure. If the pressure is too low apply more gas. FIGURE 4.22

4.10.5 If the gas pressure does not meet the required value (see appendix C), the accumulator must be recharged.

4.11

Recharging the accumulator WARNING Recharging must be done according to local safety regulations for working with pressure tanks.

4.11.3 If the gas pressure is too high open the side valve to relieve gas. Close the top valve when the gas pressure is correct. FIGURE 4.23

FIGURE 4.20

4.11.4 Open the side valve, relieve the pressure completely and remove the gas pressure gauge.

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Installation and Maintenance Manual – 3000-0129-801 4.11.5 Tighten the plug (18 - 22Nm) using the 6mm Allen key (hexagonal) and mount the threaded end cap by use of hand

FIGURE 4.24

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5.

Trouble Shooting

5.1

Failure intro

Locate which part of the braking system that causes the failure and proceed to the corresponding section.

Failure

Brakes are failsafe

Brakes are active

Brakes will not close

Brakes will not open

Brakes are free of pressure NO See chapter 5.2 "PU doesn't release pressure"

Brakes will not open

Brakes and PU works but behave unexpected or unusual

Brakes will not close

Brakes have enough pressure (according to appendix D) NO YES See chapter 5.3 "PU doesn't set pressure"

See chapter 5.4 "Other PU failure

324911-sbdk_MEH-3000-0129-801_A.doc

PU is working OK. Failure is caused by the brakes.

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5.2

Power unit does not release pressure 5.2 PU doesn't release pressure

Valve between brakes and tank doesn't open

Failure in solenoid or it's power supply - Try manual override - if this releases the pressure failure is in the coil or its power supply. - Try disconnecting the electrical plug from the coil - if this releases pressure failure is in the power supply.

Defective or dirty (choked) valve or nozzle - Before unscrewing a valve or other component you must make sure that the pressure behind is released. If you have only one dump valve, you can release through a minimess hose.

Oil too cold

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At very high viscosity an active brake cannot press back oil to tank through the system

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5.3

Power unit does not set / build pressure 5.3 PU doesn't give (enough) pressure

Tank level very low and/or oil contamination outside the baking system

If leakage point isn't obvious you must refill the tank and start the pump watching for leaking oil or bubbles. Be carefull: Oil jets can be hazardous and oil contamination is harmfull to the environment

Motor isn't running

- Power supply failure or motor wrongly connected - Defective motor - Oil level too low or oil too hot (cut off by level/thermo switch) - Defective pressure switch

Motor is running the wrong direction

Phases in the motor junction box are wrongly connected (swapped)

Motor is running but speed decreases before system has reached the right pressure.

- Power supply has too low voltage - Defective motor

Motor is running but no pressure is generated

- Coupling between motor and pump is broken - Defective pump - Defective safety releif valve

Motor is running but runs backwards after it stops

Defective check valve

Pressure is generated but not sufficient

- Safety relief valve out of adjustment or defective - Pressure switch setting too low - Defective pump - Leaking valves

Pressure is generated but isn't transferred to brakes on command

Valve between pump and brakes doesn't open when it should

Try manual override - if this solves the problem the coil or its power supply fails. If not the valve is defective.

Pressure is generated but is transferred to tank when it should have been to the brakes

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Valve(s) between brakes and tank doesn't close when it should

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5.4

Other failures

5.4 Other failures

Failure in instrumentation

Do you get the right signals from - level/thermo switch - pressure switches or transmitters in the pump line - pressure switches or transmitters in the brake line - pressure switches or transmitters for accumulator monitoring

Insufficient braking torque

Failure in brake pad or brake pad not bedded in? Brake pad or disc oiled or greased? Air gab adjustment overdue? Failsafe brake line not fully unloaded? Active brake pressure too low? Failure in brake caliber? Valves not operational due to too high viscosity (low oil temperature)?

Slow brake

Air in the braking system? Valves not working correctly due to oil contamination? Orifices too small for viscosity (low oil temperature)?

Too fast braking

Viscosity too low due to too high oil temperature? Precharged pressure in the accumulators are wrong?

Excessive operating temperature

Ambient temperature too high? Pump running continously (due to leaky valves, external leaks or wrong component adjustment?

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Appendix A - Dimension drawing

S E K A R B G R O B D N E V S

L A I T N E D I F N O C

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Appendix B - Dimension drawing - Frame



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Appendix B - Spare parts list - Frame For brake control unit 3000-0129-801 according to Spare Part Drawing and Hydraulic Diagram (section 3.3)

Pos

Qty

A1

1 1 1 1

Description

SB item no

ACCU 6,00L 330BAR CABINET COVER PLATES FOR. CABINET BRACKET FOR BLOCK

4860-0024-001 9893-9000-006 9893-0003-801 9806-0000-013

Rec. Mounting Adjustment spare torque method parts qty. [Nm] (see apx. (note 1) (note 2) C & D) 90

Notes 1) It is highly recommended to have the spare parts of the marked type in stock as this may reduce downtime in case of failure. The quantity stated is the minimum quantity recommended. 2) Mounting torque (Nm) (lb/ft = value x 0.74) for each component or bolt fixing the component. 3) Turn in to bottom and out ¼ revolutions.

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Appendix C - Spare part drawing – tank



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Appendix C - Spare parts list – tank For brake control unit 3000-0129-801 according to Spare Part Drawing and Hydraulic Diagram (section 3.3)

Pos

Qty

2A

1

GEAR PUMP 3,2 CCM

0305-1117-002

17

3A 3A

1 1

9803-2070-002 9803-1047-001

65 24

4A

1

5160-0999-001

65

5

1

BELL HOUSE COUPLING MOTOR 3X600V 60HZ 2,2 KW TANK 110 L

5a

1

5b

1

5b

1

5c

1

5d

1

5e

1

5e

1

5f 5f 5g VD ACC-D

1 1 1 4 1

Description

LEVEL GLASS AIR BREATHER W/MOIST ABSO ADAPTOR FOR AIR BREATHER PRES TRANSMITTER 0,1BAR 4-20MA TANK COVER F/ 110 LTR TEMP TRANS. -10/+150 DEGR PROTECTIVE TUBE FOR TA3431 BALL VALVE 1" HYDR PLUG 1" BSP HEATING ELEM 500W VIBRATION DAMPER HYDR BALL VALVE 1/4"

SB item no

Rec. Mounting Adjustment spare torque method parts qty. [Nm] (see apx. (note 1) (note 2) C & D)

1211-1000-002 WITH TERMOMETER

1231-3024-002

1

2 MICRON

1712-0024-002

1

17

1712-9024-001 4080-0999-002

1

20

9510-0036-001

1

20

9510-0036-002

1

20

9622-8999-090 9004-1010-090 5101-0099-006 9820-3074-009 2280-1999-040

1

1221-1100-003

35 1


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Appendix D – Spare part drawing – Main block



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Appendix D - Spare parts list - Main block For brake control unit 3000-0129-801 according to Spare Part Drawing and Hydraulic Diagram (section 3.3)

Description

SB item no


Pos

Qty

15

1

FILTER HOUSING HIGH PRES

1701-1024-015

15

1

FILTER ELEMENT HIGH PRES

1701-2024-004

15

1

FILTER INDICATOR VISUAL

1720-1024-003

50

16

1

RELIEFVALVE MAX 350BAR

9103-5043-002

50

180 1

17.1, 17.2 18.1, 18.2 19, 20

3

CHECK VALVE

6010-1043-005

1

50

2

BLOCK FOR STANDARD VALVE P-A

2243-9999-802

1

5

19

1

2222-1024-801

1

5

20

1

DIR POPPET VALVE 2/2 NO W/ OVR DIR POPPET VALVE 2/2 NC W/ OVR

2222-0024-801

1

5

19, 20

2

COIL 24 VDC - UL

2224-0024-002

1

5

19, 20

2

PLUG DIN 43650 240V

5105-0999-001

1

5

40 42

1 1

PRESSURE TRANSMITTER PRESSURE TRANSMITTER

4080-0024-010 4080-0024-001

1 1

20 20

41

2

TEST POINT NIPPLE

9009-1010-040

1

30

P, P0 52

1 1

PRES GAUGE THROTTLE VALVE ADJ

4012-5999-001 6001-2024-002

1 1

30 50


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Appendix E - Spare part drawing – Draw works block



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Appendix E - Spare parts list - Draw works block For brake control unit 3000-0129-801 according to Spare Part Drawing and Hydraulic Diagram (section 3.3)

Pos


Description

SB item no

20.1, 20.2 BLOCK FOR STANDARD 22.1, VALVE P-A 23.1, 23.2

2243-9999-802

1

5

20.1, 20.2 DIR POPPET VALVE 2/2 NO 22.1, W/ OVR 23.1, 23.2

2222-1024-801

1

5

20.1, 20.2 COIL 24 VDC - UL 22.1, 23.1, 23.2

2224-0024-002

1

5

20.1, 20.2 PLUG DIN 43650 240V 22.1, 23.1, 23.2

5105-0999-001

1

5

9102-1043-002

1

50

4080-0024-010

1

20

9009-1010-040

1

30

24.1

RELIEFVALVE MAX 350BAR

B1. B2

PRESSURE TRANSMITTER

M1, M2

TEST POINT NIPPLE

12-28 VDC 4-20 MA


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Appendix F - Hydraulic settings Extract from production settings report:

Customer: Customer O/No.: Our O/Ack. No.:

POWER UNIT

Item No.: 1106-0006-803 Serial No: Settings for brake: BSFI 3120-S-200 (6x)

Test

Test point System relief valve Accumulator Burnish pressure

No leaks at full pressure

Setting 230  155 100 

300

Setting Tolerance +/-10 +/-3

Position Unit bar bar bar

sec

Settings approved:

J.E.Andersen Initials 26.07.2010 Date For actual information on how to adjust the settings see Appendix B – Spare parts and Appendix D - Adjustment

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16 A1 24.1


Appendix G - Adjusting Choose method according to Appendix B “Spare parts list” Adjustment method

Item type

Item drawing/Photo

Description

The pressure switches have fixed hysteresis. Precise adjustment of set point to actuate on increasing pressure 1. Lower system pressure to 0 bar. 2. Increase pressure slowly and check if micro switch is actuated at desired switch pressure. 3. If necessary, readjust by turning the adjustment screw 4. Repeat step 1 - 3 until micro switch operates at desired switch pressure.

1

Pressure switch

Precise adjustment of set point to actuate on decreasing pressure 1. Increase pressure up to a point clearly above the desired switch pressure (at least, switch pressure plus max. hysteresis; not above max. operating pressure). 2. Lower pressure slowly and check if micro switch is actuated at desired switch pressure. 3. If necessary, readjust by turning the adjustment screw. 4. Repeat step 1 - 3 until micro switch operates at desired switch pressure. Tamper proof cap Adjustment screw

2

Relief valve or Counter pressure valve (same item)

324911-sbdk_MEH-3000-0129-801_A.doc

Lock nut

The system safety valve (Pos. 16 – relief valve) is preset at the factory to the correct pressure / setting. Do not adjust this valve. If the tamper proof cap is broken or missing the power unit is no longer covered by Svendborg Brakes warranty. For other relief valves if adjustment is needed, remove the tamper proof cap, loosen the lock nut and screw out (counter-clockwise) to decrease max. pressure setting. Screw in (clockwise) to increase max. pressure. Remember to re-tighten the lock nut.

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Installation and Maintenance Manual – 3000-0129-801 Adjustment method

Item type

Item drawing/Photo

Description

Display and setting keys:

The settings are locked from factory. To unlock you must hold down both arrow keys for 3 sec.

Display of measuring units 4 digit display

3

Pressure switch

LED display for active switching points Setting keys

4

5

Accumulator

Pressure switch

See section 4.8 & 4.9

Reset value

Set value

Lock ring

324911-sbdk_MEH-3000-0129-801_A.doc

Display shows for 2 sec. “oP6” and then “FrEE”. Now you can change the settings for upper switch point and/or hysteresis by selecting mode. Changes are made by using the arrow keys. After the changes you press both arrows again for 3 sec. Display will show “Loc” for a moment and the new settings are saved. Afterwards display will again show the measured pressure.

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To protect the pressure switch it is mounted with a cover. To demount this cover you must unplug the electrical plug and pull the cover off. The settings of the pressure switch are changed like this: 1) Unlock the lock ring 2) Change the set and reset values 3) Lock the lock ring 4) Remount the protection cover 5) Remount the electrical plug


Appendix H - Electrical diagram

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Appendix I - Recommended Fluid DEB-DIVE-005 Name: 27.08.2009 Date: Revision: C

DATA SHEET

RECOMMENDED FLUID FOR DISC BRAKES & HYDRAULICS PRESSURE FLUIDS / OIL TYPES The following oil types are recommended by Svendborg Brakes – other types corresponding to these can be used. The general temperat ure range for our standard ranges of products using hydraulic oil are -20°C to +60°C (-4°F to +140°F) however the BSAK and BSAB brake series are generally approved for lower temperatures. These are approved for usage at -40°C in wind turbines and for - 30°C in other applications. Extreme temperature applications may require special options. Please contact Svendborg Brakes.

Mineral Oil Shell Mobil Hydro Texaco Valvoline Syntethic Oil

Mobil Bio Oil

(1)

(Ester or Colza oil)

Shell

Special option -40°C - +20°C -40°F - +68°F Tellus Arctic -40°C - +20°C -40°F - +68°F -40°C - +20°C -40°F - +68°F -

Standard -20°C - +40°C +10°C - +60°C -4°F - +104°F +50°F - +140°F Tellus TX32 Tellus TX46 DTE 13M DTE 15M Rando HDZ32 Rando HDZ46 Ultramax HVLP32 Ultramax HVLP46

-20°C - +40°C -4°F - +104°F SHC 524 -20°C - +30°C -4°F - +86°F Naturelle HF-E15

Special option +30°C - +70° C +86°F - +15 8°F Tellus TX68 DTE 16M Rando HDZ68 Ultramax HVLP68

+10°C - +60°C +50°F - +140°F SHC 525

+30°C - +70° C +86°F - +15 8°F SHC 526

+10°C - +60°C +50°F - +140°F Naturelle HF-E32

+30°C - +70° C +86°F - +158 °F Naturelle HF-E46

General: Mineral Pressure Fluids according to DI N 51524 Part 3 (1) There must be less than <200PPM water in the oil, due to the seals.

Viscosity Recommended viscosity range: 20-200 cSt at working temperature.

Filtration The oil in a hydraulic system and the oil added to the hydraulic system must always be filtered. The level of cleanliness in a hydraulic system is an important factor to the lifetime of the system. When refilling the hydraulic tank, it is stipulated that the oil added to the system is filtered through a 10-micron purity offline filter unit to the classes listed below. The hydraulic system, supplied by Svendborg Brakes, has a build-in oil filter with a standard 10-micron purity filter. To maintain a reliable system it is recommend that only hydraulic oil of the following classes of purity is used: NAS 1638, Class 8, or ISO 4406, Class 19/17/14. It is recommended that the filter be changed at a minimum, once every six months or more often depending on the level of exposure to contamination.

Service life of pressure fluids Mineral oil: Other fluids:

8.000 Hours or at least once a year. 2.000 Hours or at least once a year.

Change of pressure fluid Note: The mixing or blending of different brands or types of pressure fluid can cause unintended chemical reactions, such as sludging, gumming etc. The complete hydraulic system should be thoroughly flushed prior to changing from one oil type to another. The respective manufactures should be contacted prior to changing from one pressure fluid to another.

Seal material Brakes from Svendborg Brakes A/S are normally s upplied with PUR-seals (PolyURethane) PTFE (PolyTetraFlourEthylene) seals can be delivered on request for most of the brake types. Note: the BSFG 400 brake series are supplied with NBR rubber fabric seals (acrylNitrile Butadiene Rubber).

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Svendborg Brakes Hydraulic Brake Control Unit Installation and Maintenence Manual

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