Sehnsen industries Itd 8500 River Road, Richmond BC Canada V6X 1¥4. Tel (604) 273 3737 - Fax (604) 273 9654 USER’S MANUAL Conveyor Brake System (Revision 2) SHIP DATE: CUSTOMER NAME: PURCHASE ORDER No: JLL. JOB NO: INSTALLED LOCATION: EQUIPMENT: January 1999 Krupp Ganada LPL 9.2 519 3859 Los Pelambres Overland Conveyor Chile Conveyor 120-CV-05 2 - 20S2040A Caliper Brakes 3 - 2DS2040B Caliper Brakes 5 - 2438 X 65 mm Brake Discs 2 - QSM32 Quick Set Modules 1 - HU057CPD Hydraulic Power Unit Conveyor 120-CV-06 2 - 2DS2040A Caliper Brakes 3 - 2DS2040B Caliper Brakes 5 - 2438 X 65 mm Brake Discs 2 - QSM32 Quick Set Modules 1 - HUOS7CPD Hydraulic Power Unit Conveyor 120-CV-07 1 - 2DS2040A Caliper Brake 1 - 2DS2040B Caliper Brake 1 - DS2040B Caliper Brake 3 - 2438 X 65 mm Brake Discs 2 - QSM32 Quick Set Modules 1 - HU057CPD Hydraulic Power Unit Johnson Industries Ltd. Vancouver, B.C. rrmepbaesait oanore> 2.0 3.0 4.0 5.0 6.0 7.0 Sohn sem industries Itd 8500 River Road, Richmond BC Canada V6X 1¥4 Tel (604) 273 3737 - Fax (604) 273 9654 INDEX JOHNSON DS2040 CALIPER BRAKE Page DESCRIPTION ... 2.020... . eee cece eee eee eres 1 11 Caliper... 2.2... Bee eee eee 1 INSTALLATION... 2.26 cece 1 2.1 Preparation . 2.2 Mounting 23 Piping... : 24 Electrical.......... 3.1. Linings 32 Disc... 33 AirGap.. 3.4 Actuator 3.5 Instrumentation . TROUBLE SHOOTING ...... 12.0.2 2.2 e eee eee cee eee eee eee 4.1 Brake Will Not Set or Release 4.2 Brake Slips . 4.3 Brake Rubbing 4.4 Rapid or Uneven Lining Wear EGG 3G 1e) Gop poapeqcecuncodun sucooundGUconsdoonodne G00 6.1 Warranty . . 62 Service... DRAWINGS AND SERVICE DATA (As Required)Seohmson industries Itd D9 8500 River Road, Richmond BC Canada V6X 1Y4 Tel (604) 2733737 - Fax (604) 273 9654 USER’S MANUAL 1.0 DESCRIPTION 1.1 Caliper The DS2040 caliper brake is a direct acting type of brake utilizing two spring set, hydraulically released actuators acting directly onto the brake shoe. The calipers are mounted in a frame, either singly or two per frame, via two bearing pins. The bearing pins and teffon slide bearings in the caliper allows the caliper to float laterally and articulate to a small degree, thus compensating for axial runouts or angular misalignment of the brake disc. The DS2040 caliper brake also features sintered metalic linings capable of withstanding high temperatures, high temperature teflon seals in the actuator plus lining temperature switches, ‘release indicating proximity switch and a lining wear proximity switch. The critical features, specifications, controls, and dimensions are summarized on specification drawings which are included as part of this manual 2.0 INSTALLATION 1 Preparation Prior to placement of the brakes the disc must be mounted and the conveyor belt fully tensioned. Tension in the conveyor belt produces deflection in the pulley shaft causing angular deflection at the brake disc. Tensioning the belt to its normal operating level prior to mounting the brakes will ensure that the brakes will be aligned with the disc. Verify that the disc runout is within tolerance and the mounting bolts are properly torqued (Refer to drawing B3859-44). To properly mount the disc, the disc and coupling mating surfaces must be degreased. Then, insert the bolts and pre-load to 100 KN in diametrically opposing pairs using a calibrated torque wrench. Do not hammer or grind the botts in attempts to insert the bolts through the disc or coupling. Afterall the botts are properly pre-loaded, fasten the lock nuts and pre-load to 200 KN. After the disc has been mounted, the rust inhibitor that was applied for shipping must be removed with a non oil based solvent. After commissioning, the locknuts must be removed, the hex nuts re-torqued and the locknuts re-applied using loctite. 2.2 Mounting To facilitate positioning of the brake frame, one caliper will have to be removed for the secondary drive and bend pulley brakes. To remove a caliper from the brake frame, remove the pin retainers and pull out the bearing pins while supporting the weight of the calipers with a hoist. With one caliper removed, lift or pull the brake assembly into place, leading with the removed caliper end. Once the brake assembly is in place, loosely fasten the mounting bots to secure the brakes. The removed caliper can then be lowered into place using a hoist and re~ installed. It will be necessary to use a second hoist to re-install the caliper for the secondary drive pulley. This will facilitate aligning the bearing pin journals to allow installation of the pins and retainers. For the bend pulley, lower the caliper into place from the top and install the bottom bearing pin first. Continue lowering the hoist to align the top bearing pin journals. rnesazanekhmsen industries lid w 8500 River Road, Richmond BC Canada V6X 1Y4 Tel (604) 2733737 - Fax (604) 273 9654 USER’S MANUAL 1.0 DESCRIPTION 1.1 Caliper ‘The DS2040 caliper brake is a direct acting type of brake utilizing two spring set, hydraulically released actuators acting directly onto the brake shoe. The calipers are mounted in a frame, either singly or two per frame, via two bearing pins. The bearing pins and teflon slide bearings in the caliper allows the caliper to float laterally and articulate to a small degree, thus ‘compensating for axial runouts or angular misalignment of the brake disc. ‘The DS2040 caliper brake also features sintered metalic linings capable of withstanding high ‘temperatures, high temperature teflon seals in the actuator plus lining temperature switches, release indicating proximity switch and a lining wear proximity switch. The critical features, specifications, controls, and dimensions are summarized on specification drawings which are included as part of this manual 2.0 INSTALLATION 2.1 Preparation Prior to placement of the brakes the disc must be mounted and the conveyor belt fully tensioned. ‘Tension in the conveyor belt produces deflection in the pulley shaft causing angular deflection at the brake disc. Tensioning the belt to its normal operating level prior to mounting the brakes will ensure that the brakes will be aligned with the disc. Verify that the disc runout is within tolerance and the mounting bolts are properly torqued (Refer to drawing B3859-44). To properly mount the diso, the disc and coupling mating surtaces must be degreased. Then, insert the bolls and pre-load to 100 kN jin diametrically opposing pairs using a calibrated torque wrench. Do not hammer or grind the bolts in attempts to insert the bolts through the disc or coupling. Afterall the bolts are properly pre-loaded, fasten the lock nuts and pre-load to 200 kN. After the disc has been mounted, the rust inhibitor that was applied for shipping must be removed with a non oil based solvent. After commissioning, the locknuts must be removed, the hex nuts re-torqued and the locknuts re-applied using loctite. 2.2 Mounting To facilitate positioning of the brake frame, one caliper will have to be removed for the secondary drive and bend pulley brakes. To remove a caliper from the brake frame, remove the pin retainers and pull out the beating pins while supporting the weight of the calipers with a hoist. With one caliper removed, lift or pull the brake assembly into place, leading with the removed caliper end. Once the brake assembly is in place, loosely fasten the mounting bolts to secure the brakes. The removed caliper can then be lowered into place using a hoist and re- installed. It will be necessary to use a second hoist to re-install the caliper for the secondary rive pulley. This will facilitate aligning the bearing pin journals to allow installation of the pins and retainers. For the bend pulley, lower the caliper into place from the top and install the bottom bearing pin first. Continue lowering the hoist to align the top bearing pin journals. oes2.2 Mounting Cont'd Before tightening the brake frame mounting bolts, set the caliper to clamp the disc. This procedure will require removal of the actuator caging rings. To remove the caging ring, apply 8 release pressure of 138 bars to the actuator. With the actuator pressurized, remove the cover and unscrew the caging ring. Flip the caging ring around to mount the ring in the stowed position and re-mount the cover plate. Refer to the actuator instruction sheet at the back of this fnanual, The auxiliary hydraulic power used to manually release the brakes must be limited to ‘a maximum pressure of 200 bars. The oil must be fitered to a 10 micron absolute (ISO 18/15) cleanliness level. WARNING: Over pressurization or contaminated oil will damage the actuators. verify that the brake frame is square with the disc and that isc. Verify that the caliper has adequate float on both sides. itis preferable to have 3 mm more float on the actuator side of the caliper to compensate for the decrease of lateral float as the linings wear. Once the brake frame is bolted in place, release the caliper and ensure that the disc to shoe clearance is roughly equal on both sides and that the caliper floats freely. It is critical that the brakes have adequate radial clearance between the disc outer diameter and the caliper center plate. This clearance must be checked and verified to be a minimum of 4.5 mm. if adjustment is necessary, the entire pulley assembly must be repositioned. Reter to procedure in conveyor manual to locate pulley assembly. After repositioning the pulley, the brake mounting must be re-verified and adjusted if necessary. ‘Once the caliper is set on the disc, the linings are fully seated on the di WARNING: Failure to mount the brakes to allow sufficient float, articulation or radial clearance may result in catastrophic failure. 2.3 Piping In cases, such as the Los Pelambres Coarse Ore Conveyor, where a long piping run from the brakes to the hydraulic control unit is required, a quick set module is equipped with the brake system, The quick set module must be mounted close to the brakes and the runs to each brake assembly should be of equal lengths for best performance. The brake system must be plumbed with adequately sized piping and leak tested using water at a pressure of 200 bars. After leak testing, flush to a 10 micron absolute (ISO 18/18) cleanliness level before connecting to the brakes.3.0 2.4 Electrical ‘The brake ‘assemblies are supplied with a DIN connected wiring harness which is pre-wired to a NEMA 4 electrical enclosure. For the secondary drive and bend pulley, the electrical box must be field mounted and the leads connected to the appropriate instruments.. Ensure that the box ig mounted in a visible place and that the conduits do not interfere with existing machinery. Verify that the wing leads are connected to the correct instruments by testing the inputs from each instrument. Refer to the electrical wiring diagrams enclosed in this manual. INSPECTION AND MAINTENANCE 3.4 Linings Friction linings carry only the manufacturer's warranty and must be adequately tested by the user in his particular application to verify performance | characteristics. New linings must be thoroughly bumished and seated on the disc. Rated torque is obtained when linings are fully bedded. Contaminated or burt linings must be discarded. The stopping capacity of a spring applied caliper brake is dependent on the actuator extension. The brake stopping capacity will decrease as the linings wear. The lining’s condition and thickness, as well as the brake actuation, should be carefully monitored at least monthly to ensure proper brake performance. ickness wears to 5.0 mm (6.25 mm with backing plate). nt to four trips of the lining wear proximity switch. To compensate for lining wear, the "DS" caliper tends to shift towards the actuator side thereby decreasing the available float. Itis critical that he lining wear and i's effect on the lateral float ‘are monitored regularly. To check the available float, shift the caliper so that the fixed shoe presses against the disc. If the gap between caliper and brake frame on the actuator side is inadequate, replace the linings. Required float will depend on axial runout of the disc, thermal growth of the pulley system as well as angular deflections of the shaft. yeous to carry a spare set of brake shoes which may ichinery. Replacement linings must be as originally specified. Before removing the shoe plates to service the linings, the temperature switches must be removed. When replacing the friction linings, ensure that MICA insulators are used between the shoe plate and the pads on the actuator side. The friction linings on the non-actuator side must not have MICA insulators. This arrangement is required to deflect heat away from the actuators and into the bulk of the calipers. Linings must be replaced when the thi This extent of lining wear is equivale ‘n critical applications, it will be advantags be relined without tying up operating ma ‘As the friction linings wear, the spring stroke will increase, decreasing applied brake force. If there is still usable lining, when the actuator rod extension becomes excessive, the extension can be reduced by increasing the effective spindle length. See service drawings. 3.2 Disc ‘The disc face should have a surface finish of Ra = 1.6 micrometers. If the surface finish ‘exceeds Ra - 3.2, then the disc must be reconditioned or replaced. The disc faces should be fat and parallel to within 0.025 mm per 300 mm of diameter and lateral runout should not exceed 0.025 mm per 300 mm of diameter.v 32 isc Cont'd {Allowing the brake lining rivets to contact the disc may cause scoring. A new lining will wear and ‘conform to minor disc scratches. If after bumishing and testing, the brake application is not ‘acceptably smooth, the scored disc must be removed and re-machined, removing no more that 0.5 mm from each face. ‘The heat dissipation capacity of the disc must not be exceeded. Disc deformation or mounting bolt failure may oocur at operating temperatures above 500°C. If maximum torque of the caliper when used under dynamic conditions exceeds the energy dissipating capacity of the disc, the torque must be limited. In back to back braking applications, a sufficiently long cooling off period must be allowed so that subsequent braking operations do not cause excessive heating. CAUTION: Never apply water to a hot disc. “The disc must be periodically inspected for heat checking and to ensure disc mounting botts are properly secured. 3 Air Gap 3.4 ‘The air gap must be inspected after every braking application and adjusted if necessary to compensate for wear. If the air gap is greater than 4 mm, then the actuator spindle must be extended. Begin by removing the back cover and spindle retainer, loosen the jam nut. Apply release pressure to brake and insert a 2.5 mm shim between the disc and the actuator side brake pad. Ensure that the caliper is shifted over so that all of the air gap is on the actuator side of the caliper. Screw in the adjustment spindles evenly until pads contact the shim (one full tun changes the air gap by 1.6 mm). Tighten the jam nut, replace the spindle retainer and back cover and remove shim. Cycle the brakes and verify the air gap. After adjusting the air gap the release and lining wear indicating switches must be re-adjusted (See Section 3.5).. Refer to air ‘gap adjustment procedures in the back of this manual. ‘When adjusting the air gap, ensure that the caliper floats freely laterally. It will be necessary, ona regular basis, to remove bearing pins and clean both pins and slide bearings in the caliper. This should be done whenever the brakes are serviced or the calipers are difficult to move laterally. Although lubricating the bearing pins and caliper slide bearings will reduce the sliding friction, this practise should be avoided if possible. The lubricant will atract dust and therefore necessitate more frequent maintenance intervals. The presence of dust in the bearings will also reduce their life. Actuator "DS" actuators are spring set and hydraulic release. During installation, the springs can be held released with the caging ring. After installing the brakes, pressurize the actuator to unscrew ‘the Caging ring and reverse if for stowage between the actuator body and cover plate for future use. With loss of release pressure, the brake can be released by removing the actuator assembly botts.g 3.4 Actuator Cont'd WARNING Spring actuators store energy and can be dangerous. Refer to actuator instructions. Extending the adjustable actuator reduces the brake air gap and increases actuator and brake applied force. See customer and service drawings for actuator information and instructions. To disassemble the actuator for servicing, remove the spindle and compress the springs. Unscrew the spring from the piston and slowly release the springs. When replacing seals, ensure that they are installed correctly and are not damaged. Care must be taken not to allow the actuator interior to become contaminated or the seal surfaces to be scored. Refer to the actuator instruction sheet at the back of this manual. After servicing, apply pressure to verify actuator performance. The actuator plunger should be totally retracted at release pressure, (137 bars) and begin to extend at hold-off pressure (130 bars). The observed pressure should be within +/-10% of the specified pressure. 3.5 Instrumentation “The "DS" brake system for the Los Pelambres Coarse Ore Conveyor features two temperature switches, a release indicating proximity switch and ai lining wear proximity switch. All three switches are DIN connected and easily replaced. The temperature switch is intended to limit the back to back stopping frequency. Itis factory set to re-close at 170°C during the cooling down period after a stop. Do not attempt to adjust the switch setting to increase stopping frequency. Verify the switch settings periodically to ensure set points remain fixed. ‘The release indicating proximity switch is set to indicate actuator retraction within 1.5 mm of full retraction. Ensure that the switch resets before pads touch the disc. The release switch is adjusted by removing the connector, loosening the jam nut and turning the switch housing clockwise or counter-clockwise, depending on desired adjustment. ‘The lining wear switch is sot to limit the air gap to a maximum value of 4 mm. Maintaining the air gap within the specified limits is critical to overall performance of the brake; an excessive air ‘gap results in insufficient braking torque. It is important that the switch is properly adjusted whenever the air gap is adjusted. To adjust the lining wear switch, release the brakes and sorew in the switch housing unti it contacts the shoe plate. From that position, retract the switch back a 1/4 turn and secure the setting with the jam nuts. ‘The proximity switches must be adjusted whenever the brake linings are changed or actuators are adjusted for wear. Fallure to adjust switches will result in improper indication of pad wear and brake release. Vnee0897nSehnsen wg 4.0 TROUBLE SHOOTING Symptom 44 Brake will not release or set. 42 Brake slips. 43 Brake rubbing. rngs8s0 ren Possible Cause a) Actuators caged out. b) Inadequate pressure ‘supply. ©) One or more actuators caged out. 2) Inadequate actuator spring force. @) Excessive air gap. 4) Linings contaminated. 9) Poor lining contact. h) Linings wrong friction grade. ) Brake demand increased. J) Inadequate float. a) Inadequate air gap. b) Inadequate pressure supply. ©) Excessive dise runout 4) Restrained caliper float. Action Apply release pressure and remove caging rings. Verify supply pressure is 198 to 200 bars. Apply release pressure and remove caging ring. Verity hold-off and release, pressure. Replace actuator if pressure are lower than specified. Re-adjust air gap to 2.5 mm. Replace linings, eliminate source of contamination. Burnish linings. Replace linings with specified grade. Check that rated brake torque is adequate. Check brake mounting and correct if necessary. Inspect lining wear and replace if necessary. Re-adjust air gap to 2.5 mm. Verify pressure supply is 138 to 200 bars. Check disc mounting and correct if required. Ensure caliper floats freely on pins. Check condition of pins and bearings, verity caliper assembly bolts are tight, verify that bearing pins slide easily in and out of frame.4,0 TROUBLE SHOOTING CONT'D. ‘Symptom Possible Cause Action 44 Rapid or uneven a) Brake shoe rubbing. Seo 4.3. lining wear. b) Excassive operating Verity temperature does not temperature. exceed 500°C. ©) Disc surface finish Recondition disc surface or exceeds Ra = 3.2 replace disc. micrometers. <¢) Improper lining grade. Replace linings with specified ‘grade. ) Caliper mis-aligned. Reposition caliper. Ensure adequate articulation. 5.0 SPARE PARTS The number and nature of spare parts which the user should carry will be a matter of user judgement and will depend on the severity of service, frequency of cycling, and the functional criticality of the caliper brakes. The parts which may require replacement during the normal life of the brake are: a) Actuator Seal Kit b) Friction Linings c/w Rivets and Insulators ©) Actuator d) Pad Wear Proximity Switch e) Brake Release Proximity Switch 4) Lining Temperature Switches ) Brake Shoe Set c/w Linings ‘When ordering spare parts, always specify job number, serial number, item number, and quantity required. \vnesit859manBoo ws RRANTY AND SERVICE 6.1 Warranty We warrant our calipers and discs to be of the quality specified in our Quotations. We guarantee our materials and workmanship for a period of twelve months from date of delivery to the end user. Disc and lining performance as regards wear, coefficient of friction, and energy dissipation depend on the severity and condition of the brake service. Therefore, the Purchaser shall verify through adequate testing that all linings, calipers and discs perform satisfactorily in his particular application, any warranty concerning such performance being expressly excluded herefrom, Our liability in respect of any failure of the goods supplied by us or any loss, injury or damage attributed thereto, shall be limited to making good the repair by replacing and refitting free of charge any goods or parts thereof which are shown to our satisfaction to have been proved, Under their intended use, defective in materials and workmanship within the twelve month guarantee period, provided that such defective parts are prompily returned as directed by us, transportation charges being paid by the Purchaser, and provided further that no burning or welding has been done on any such defective goods or parts. In every case, the customer shall be charged for replacement parts on a pro rata basis for the elapsed portion of the warranty period. In the case of friction linings, products and components manufactured by others, we extend to the Purchaser the warranties of the manufacturer only. Deterioration, damage, or malfunction caused by inadequate storage or handling prior to or after sale to the end user are not covered by this warranty. We reserve the right to make changes and add improvements at any time without incurring any obligation to make such changes and improvements on products ‘already produced. This warranty and guarantee is in lieu of all warranties, conditions, or by law or expressed by statute. 6.2 Service \mesbiasso men Johnson ‘Industries otters field service, supervision, and assistance, during installation, maintenance, and testing, at a nominal per diem rate plus disbursements at cost. Under no circumstances are field services of any kind allowed for in the invoiced price of our hydraulic power units unless specifically agreed to in wating,BRAKE SHOE REPLACEMENT PROCEDURE | Shoes should be removed and re-lined whenever the linings show excessive weer | (<5 mm thickness.) or damage. Never sllow friction lining rivets to contoct the disc Replacement linings are much less expensive thon replacing or re-machining scored disc | 1 Ensure that the conveyor drive is locked out ond that the conveyor is dogged or held by onother brake while the adjustments are being made, | Fully release broke and cage actuators, remove temperature. switches; Retract actuator spindles per drawing OSPSS-01 and switches per drawing DSSA-01; | Secure broke shoes with hoist rings @); Remove shoe guide pins) and return springs @on octuator side; | Remove broke shoes, relie and reinstall or replace with newly lined shoes; Replace shoe guide pins (being sure to install return springs @)on ectustor side, Insure that shoe pins ore fully threaded into sho Adjust actuator spindles per drawing DSPSS—01 and switches per drowing DSSA~O1; Return the broke to its set condition and remove any dogging means employed to secure the Conveyor while the shoe replacement was mode ©2 Nowaun ‘OS’ SERIES GRAKE SHOE REPLACEMENT | ndustriesyelevan ja PROCEDURE | ‘Figyrend 86 Sonata vox te BY! _oca | DATE: “950622 _[ OWG. NO. | 2 oS A = a _oral oP Neen STAN Sea aa has/Sasease | OSPR—-01.2)GAP ADJUSTMENT PROCEDURE The cir gop must be adjusted whenever the gap is less thon 2.0 mm or more than 4.0 mm. Ensure thot the conveyor drive is locked out ond that the conveyor is dogged or held by “angther brake while the Remove back covers (D to access With brake set (0 bors counter-pr Apply full release pressure to the Blace 9 2.5 mm shim @ between Screw the adjustment’ spindies Dump the release pressure so thi Tighten the jam nuts G) with the Testroined from turning by Apply full release pressure again 9. Replace the octuator covers 1. Return the brake to its set co Conveyor while the gap adju: ond reset releose and wei ndition the gop adjustment spindies @ essure), loosen jam nuts @) on actuator adjustment spindles @ ; i eer Coe atl O° SS EE contact the. shine © an the shims @ond-dee @): at the pads 6) bear fully release pressure ot O bors and the adjustment spindles @) friction; ‘ond remove the shims @; ‘or proximity switches per drewing DSSA-O1 logging means employed to secure the ‘ond remove ony di istment was made, wi industrieselevan | J ea BY! NAJ DATE: 940930 _| DWG. NO. SoA SS BFE ES SP SE St: Rev. 950011 INSpS__O1.3 S00 Ress, eazy, Sommeet Engng Tas shu PATH: _dbe/hsp/S85Sdsgpaqj cae ‘DS’ SERIES BRAKE AIR GAP ADJUSTMENT PROCEDURESHOWN GEFORE ADJUSTER Sow comRECTLY ADJUSTED BRAKE RELEASE AND PAD WEAR LIMIT SWITCH ADJUSTMENT PROCEDURE Switches should be adjusted whenever broke linings ore chonged or actuators odjusted for wear, Feilure to odjust switches as indicated will result in improper indication of pad wear ond brake release Ensure that the conveyor drive is locked out ond that the conveyor is dogged or held by ‘onother broke while the adjustments ore being mode: Remove electrical connectors @) from rear of switches: 2 3. Leosen jom nuts @ on. switch body @): 4 Rotete auitch body G) counterclockwise until switch nose @is recessed in brake bose © 5. Apply full release pressure to brake; 8. Serew ‘the ‘switch body @ in unti-switch nose @ contacts cear of brake shoe © 7. Back switch housing out 1/4 turn and tighten jom nuts Q ; 8. Replace electrical connectors Os 9. Return the broke to its set condition and remove any doggin means employed to secure the hoist while the switch adjustment. was mode WARNING, Before removing brake shoe © for lining replacement recess switch nose fully Impact to switch nose will damage switch. WARNING: The position of the switch inside the housing@ is foctory set. DO NOT ADJUST. ['Ds' SERIES BRAKE RELEASE AND WEAR LIMIT SWITCH: ADJUSTMENT PROCEDURE ure ms dustr svelevan, jo 8500. feve, Pees, Behmone, BC ,.conade Sx 4 By: OCA DATE: 950622 DWG. NO. TE ee ee ee ore ae Ban ies, Some Sse eSi ™ _[eati aa /nn/sessamemeal [OSSActuators two ports to allow flow through control. o! Port size Caging Ring shown in stowed To cage o cover plote and caging ring. Pressurize actuator to extend crew on caging ring, he caging ring’ will how held the piston in position with release of pressure. eon e mm » WARNING © Spring broke actuators store energy and can be dangerous Handle with caution. Follow proper procedure. Always loosen assembly bolts uniformly. To properly remove trapped air, on air bleeder must be located at highest position. ¢ hydroult oil With the air bleeder open, fill the #8 SAE ORE, ctuator under low pressure, Allow oil to escope until clear of ir or foam. Cycle actuctor several times ond repeat Actuator lines must be bled whenever © hydraulic line hes been opened, 7 ba -@ | ‘re equipped with ae broke moy be released by removing the actuctor attachment bolts. Loosen attachment bolts uniformly to allow safe spring expansion. When servicing actuators, re~pack springs using high pressure molybdenum grease. (Petro—Caneco Barimol Heavy or equivolent). Orientation of spring stack must be mointcined ot re—assembly, l el With toss of release pressure, the fh Position, g ‘ctuator, remove piston and Actuator disassembly tool To check integrity of spring pack, verify release ond hold—off pressures are os follows Releose: 137 bars Hold—off: 130 bors ata ACTUATOR DIS—ASSEMBLY INSTRUCTIONS: Remove the caged actustor from the broke base: Pressurize actuator and remove cover piote and caging ring; De-pressurize actuator ond remove spindle reteiner ond spindle: Measure dimension "A" = spring guide to piston recess; record for octuetor assembly: Compress springs in press with allowance to access spring guide ot actuator bose end. Unscrew spring guide opproximately 12 mm using actuator disassembly tool ~See ports list; Slowly release the press, allowing the springs to sofely release to their free height; Upon assembly, reverse cbove procedures. Verify dimension “A” is 40.5 mm, hold off pressure is 130 bers, release pressure is 137 bors and. stroke is 17.5 mm "DS" SERIES BRAKE ACTUATOR INSTRUCTIONS ehmseom |, er ces INDUSTRIES LTD. 8500 RIVER RO, RICHMOND Bc, canapa vex ive | SC: : REV._ 971008 1 DSAS—01.3 TEL (604) 273 3737 ax (604) 273 9654 [PATH a /in078s8argcone L eeTy -65.0040.25 M30 1S.0. METRIC COARSE THREAD X 55 DP ‘Imm CHAMFER eee BOTH SIDES 1 1.6 36 HOLES (REF B3859-44.0)) 1.5mm CHAMFER BOTH SIDES —l HOLE CIRCLE 1455 1200.00*8 20 ! ~—___ +0.00 1287.80 9-99 Za \ 2 ren CHMF THIS SIDE 6.5mm CHMF OPPOSITE SIDE | FOR MATING TO HUB SPECIFICATIONS MATERIAL: QT100 STEEL ASTM - A514 e ~B24semm X 6Smm THICK BRAKE DISC | LOS PELOMBRES CONVEYORS 120-CV-05,06, & 07 Wekhmsem industries /elevania : BUPP CANADA e — = By By OATE: 981210 | OWS. 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SeTUNURETEL ‘ sounssiud vo TREN S30W04 Onan IHNEN une 255 = oF © OMG ssa00801 "inc Sid gzivia anoxic Ha srs ONUNNON % sonneae us caLYOWEN=735 “INaRUSHrOY % BOLVMIOY ONRSINID /9 BEAM ONUVOLS O3EVINIE ATWOMMNGAN "LIS ONES BSE = SNOMVOETOIESSTI=6SRSa [_RaRA MRI Wa] J ATINd BAY ABVONODIS BOR poner sn | ATANSSY BIVYE Y3drVO Borozsaz | m zit sows ouamna amino | ww 295 = ovo © amu ssanoloy" yan 1 Solin SmaGD A/D Blarwo SANE OSE ATNONMAO TS He BOSS — SNOUVOOIESPSISSSBEe LS TERERTINT are on ona mad von emo 2o-to-021 ¥OKGANOD SBUANFTRE SOT AagTind dn-avL ABNISSY BAVYE Y3dIVO BovOZSA BlueAg|a / Sel\SNpul nosunon — CES Zines ano Oe 14 959 01 51109 YOHONY ovor=aua Oe ‘aayiemon sou a8 Bowen Wa 3 uroge ae 201 ‘vogue 30H8 GaN TONS NOB BOLT SONS {04 "Ws aingy09 "ZY MISIS "Zo0-nO-S92Cz ‘SSSA ONE OBIZBNNOD NAG LHON YOWYOION H/2 ‘Gannon dau = Na» WON EST X OE 3UuNSOIONG rTM OL GAMA TH SAMOS BUMUNASANCL ONAN ONY ‘SMOLMS AUTUHOMG OWYOOM 3SVTTEN " OMLZILI BYSN SHOS/ MENT ume ONE TONS ¥ OL ORIBHY "MEIN GRBINS HOIKL Wa :NouYoUDads anna sunsonoa Now ‘Nouwannuisis ‘SowNN NouDaa | awnon aera | ssronssaia wow wan suO4 oNtanVO "wn wre 192 = oo © omc ssanoto. ant now HU aI OW -Somaae wows caivawam-as ‘wamisnrar HIND WYO HBO ONINOTS GISVITG ATWOWIAOAH LS Suse BONES — SNOMVOTSIOSES:41 5VAC Ls2 9 10 Ls3 np oT o_o — — — —[innaswenTedestairgap }— - NEUTRAL, — [ining Temperate OK -- Lining Temperature 0.K}- — — —[— Brake Released P— SETINGS ° TS1, 1S2, TS3, TS4: 170°C FALLING US, US3: FULLY RETRACTED ts2, US4: 4mm EXTENDING ELECTRICAL SCHEMATIC industries / elevanja "8500 River Roos, Richmond 86 Conado VEX 14 tel 604 973. 3757 So Fox 608 278 9034, Bath Rood, Bcdgater Somerset, England Tas «NU a enFe Beis SOE Gare zo00s 20S2040A & 20S2040B CALIPER BRAKES |___ CONVEYORS 120-Cv-005, ~006, & -007 x dj ATE: 98/06/02 _[ OWG. NO. SC: REV. _| 18-2.3 PATH: _Ipilipenvrs/ip385918a aS bee —15VAC st SETINGS TS1, TS2: 170°C FALLING tsi FULLY RETRACTED Us2) 4mm EXTENDING NEUTRAL — — — {iking Temperate —}- — + Linings are worn + Mehmsom industries /elevanja am Sen industries “elevanja : SO ee emma [ DATE: 98/0602 _[ OWG. NO ie Pek Renee e Some? eee = = | Ba eg aaeay SE eTS [pant —pliponmarpaessiea | A385918-1.3 ELECTRICAL WIRING DIAGRAM 0S20408 CALIPER BRAKE TAKE-UP PULLEY, CONVEYOR 120-Cv—007ITEM PART NO. QTY DESCRIPTION él 20520404 1 BRAKE FRAME 2 DS2040Z 2 CALIPER BRAKE 3 BBP2040H 4 BEARING PIN ~ HEAVY 4 8KB2040H 8 RETAINER BAR ~ HEAVY 5 F12C28HS 16 KEEPER BOLT 6 €E22040A 1 ELECTRICAL ENCLOSURE. 7 BMB3859A 2 MOUNTING BRACKET. RIGHT HAND SHOWN (LEFT HAND OPPOSITE) "2082040A CALIPER GRAKE ASSEMBLY PRIMARY DRIVE BRAKE Mat > en mm SE OD Bay | 2s oS 00-07 esr. RUPP cae 7pit/ipconvrs/ip38591 1] mnoustmics (70 a (04) 273 5737 2800 even Roao, mcwuowo ac fax. (604) 273 96s [J/N S/O JAN 99 eels cannon von 110 nx oeasrsse [SigITEM PART NO. QTY DESCRIPTION 1 20820408 1 BRAKE FRAME 2 0S2040Z 2 CALIPER BRAKE 3 8BP2040H 4 BEARING PIN — HEAVY 4 BKB2040H 8 RETAINER BAR — HEAVY 5 FI2C28H5 16 KEEPER BOLT 6 £E22040B 1 ELECTRICAL ENCLOSURE LEFT HAND SHOWN (RIGHT HAND OPPOSITE) 7pit/ipcorvrs /ipSBS012 lcust. (FIELD MOUNTED) 20820408 CALIPER BRAKE ASSEMBLY SECONDARY DRIVE & TAKE-UP PULLEYS LOS PELAMBRES CONVEYORS 120-Cv-05, & -08 _| KRUPP CANADA, TEL (604) 273.3757 ‘8500 miveR ROAD, RICHMOND GC” FAK, (604) 273 9684 JI/N 3859 DWE. NO. S/D_vAN 99 cannon ver 114 noe o-ss7sse Le jageg A3859-P2ITEM PART NO 20820408 0S20402 BBP2040 8KB2040 F82C16HS £€20408 ary i 1 2 2 4 Ouauns ELECTRICAL enctos eer URE. SHIP Gm ConNECTED WING Hi Tiiheconn7oeaai Loose c/w DESCRIPTION BRAKE FRAME CALIPER BRAKE BEARING PIN RETAINER BAR KEEPER BOLT ELECTRICAL ENCLOSURE 520408 CALIPER BRAKE ASSEMBLY TAKE-UP PULLEY LOS PELAMBRES CONVEYOR 120-CV-O7 [CUST. _KRUPP CANADA he, (604) 273 9854 ly/N_3859 DWG._NO: S/0_JAN 99) smoustnes 9. TEL, (404) 273 5757 8500 IVER ROAD, RICHMOND BC 39785 IS/N’s_ A3859-P3PART NO. BAHTO40FV BBFL3859 8BFC3859 BBFR385¢ 8S2030 BFS3859 SPG3859 8SRS2030 BS82040 F22C248H5, F22C5N FI8c56s8 BMBLE3859 BPS3040_ BLTS3859 BRPS3040 BwPS3040 BHH3859 Figrad F8OP32 BIL3859 FERI7 RECOMMENDED. SPARE_eAgTS TEM PART NO. DESCRPTION 1 BAHIO4OEY ACTUATOR ~ © a SOBIAAGR UBT GOCPNMR UN =F = RNNew— ary DESCRIPTION 2 ACTUATOR ASSEMBLY 1 ACTUATOR PLATE. 1 CENTER PLATE 1 CALIPER PLATE, 2 SHOE PLATE 30 FRICTION. LINING 4 SHOE GUIDE PIN 2 SHOE RETURN SPRING — 4 SLIDE_BEARING “———~ 6 CALIPER ASSEMBLY Bt 6 CALIPER ASSEMBLY NUT. 8 2 4 2 1 1 2 4 ACTUATOR MOUNTING BOLT CALIPER UFTING EYE SHOE UFTING EYE LINING TEPERATURE SWITCH BRAKE RELEASE SWITCH LINING WEAR SWITCH FLOW-THRU LINE HOSE PROX SWITCH LOCK NUT DOWELL PIN 15 MICA LINING INSULATORS 90 LINING’ RIVETS Flow THRU 1A BARAOVSKT SEAL KIT ~ HIGH TEMP 5 BFS3859°FRICTON UNINGS 9 8582060 SUDE BEARING 15 GLTS38S9 UNING TEMPERATURE SWITCH 6 7 2 56 BRPSIOO BRAKE RELEASE PROXIMITY” SWITCH BBWPS30s0 UNING WEAR PROXIMITY SWITCH 883060 BEARING PI 8S38595 BRAKE SHOE PalR C/W UNINGS @ Mehn industries / elevanja 18500 River Road. Richmond OC Conage VOX IY Ta! G04 399 S797 oo Fon 608 suse Bath Rose, Bacgrote, Somerset Enind TAS OU KRUPP. CANADA / LOS PELAMBRES DS2040 CALIPER BRAKE ASSEMBLY By. HE OATE:JuLY 30/98 [ OWG. NO. ES REY, PATH: pit/Incnves/ 385923 “JA3859—P35.1 Tel 626. WSeati =<" or ond ss0aesASSEMBLY NOTES Ts ACTUATOR ASSEMBLY: ‘5 ASSEWELE ACTUATOR HOUSNG, PISTON, SPRINGS, WASHER & SPRING GUIDE WITH SPRINGS AT FREE HEIGHT. G. PRESS SPaING BASE UNL SPRINGS ARE FULLY COMPRESSED. TURN SPRING GUIDE WITH THE PISTON FIXED, ‘uNne Tent WARNING! 00 NOT TURN PISTON? TURNING PISTON WILL "SCORE THE CHLNDER BORE C. VERIFY SPRING GUIDE FULLY THREADED INTO PISTON BY MEASURING BETWEEN THE SPRING GUDE AND BOTTOM ‘OF PISTON RETANER RECESS. 1.220 1. PRESSURE TEST ACTUATOR PER OA’ SHEET ACTUATOR HOUSING ‘SPINDLE ACUTATOR BASE SPRING GUIDE DISC SPRING PISTON CAGING RING END COVER SCREW END COVER SPINOLE RETAINER SCREW SPINDLE RETAINER SPINOLE JAM NUT SPRING WASHER 1A BAPHIO40F 1B BAPPR1040 iC BAPCB1040 10 BAPSG1040 1E BAPSH1040— I iF BAPPN1040 1G BAPCR1040 1H -FSTO4C24S5 J BAPCV1040 1K FSTO4CO6SS 1L BAPTR1040 iM FSTIGCJHB IN BAPSWI040 iP BAPOP1040V PISTON SEAL 1Q BAPOR1040V ROD SEAL. 1R BAPWRIO40V ROD WIPER 1S BAPWB1040V BASE WIPER Beane RL 1T — BAPPG4 BLEEDER PORT PLUG pit/Ipenvrs/385923) BAH1O40FV ACTUATOR ASSEMBLY @ LOS PELAMBRES COARSE ORE CONVEYORS at © Bn mm SS im 2282865 conse one convevons— (8500 RIVER ROAD, MICKWOND ac Fax, (604) 273 9454 [J/N 3954 S/O JAN 99 Ows. (NO. wv =~ Seana as {'A3859-P6FENWAL THERMOSWITCH® Temperature Controller Installation Instructions To ensure safe and proper performance, read these instructions carefully before attempting to install or operate this Fenwal product. Please retain for future reference. The shell of each THERMOSWITCH® Controller contains the catalog number, the current rating, the temperature range, and the contact arrangement. Controllers that are component recognized or listed by Underwriter’s Laboratories or certified by the Canadian ‘Standards Association (CSA) will also bear the symbol of the approving agency. In addition, UL component recog nized units with temperature ranges up to S00°F will have a4” as the first digit of the Catalog Number. The fitth digit of the catalog number describes whether con- tacts open or close on temperature rise. If contacts open ‘on temperature rise, the fith digit of the number is an even number (17000, 17002, etc.). If contacts close on temper- ature rise, the fith digit is an odd number (17021, 17023, etc.). It the fourth digit is "2" or “7” (0.g., 17021, 170771), the con- troller is compression operated. Compression units that close on temperature rise are recommended if overranging is anticipated. Low temperature units [- 100 to +400°F (~78 to +204°C)] can be overranged to 500°F (260°C) and high temperature units [-100 to, +600°F (~73 to +316°C)] overranged to 700*F for intervals not exceeding one hour. INSTALLATION MOUNTING ‘THERMOSWITCH Controllers are supplied in five basic head configurations - Cartridge, Block Head, Hex Head, Coupling Head and Circular Flange. See Figure 1 To avoid restricting shell expansion when making installa- tions in solid metal blocks, a 0.625 in diameter reamed hole for 5/8 in standard units or a 0.812 in diameter reamed hole for 13/16 in heavy duty units is recommended. See the fol- lowing specitic controller style listing for additional installa- tion instructions, Cartridge (Style 1) ~ Hole should have a short spline t. receive the 0.125 in diameter locating pin. This prevent: the unit from rotating when the adjusting sleeve is turned ‘The cartridge style may be used for surface control if in serted into a Fenwal surface mounting well (Cat. Ne 1100-2). Block Head (Style 2) ~ Mounted in a similar manner t: the cartridge type. Ifthe unit is to be inserted into a reame: hole, mount two short pins on either side of the hole. Th: pins should rest against the sides of the block head to pre vent rotation of the unit Hex and Coupling Head (Styles 3 and 4) ~ Installed liki any pipe fiting. if installed in a pipe tee, the tee should br large enough to allow adequate circulation of the flui: ‘around the temperature-sensitive section of the controlle: See Table 1 for maximum torque values.INSTALLATION (Continued) A\CAUTION Excessive torque applied to units may change temperature set- ‘ings. Table 1 THERMOSWITGH Controller Max. Torque ‘Standard (5/8 in dia) Ee Heavy Duty (13/16 n dia) mand “4 fib (6.4 Nem) when Teflon tape lubricant Is used. **8 tub (10.8 Nem) when Teflon tape lubricant is used. Circular Flange (Style 5) - Three holes in flange allow easy mounting on any flat surface. [CAUTIONS] Tension Operated Controllers Tension operated THERMOSWITCH controllers are iden- tified by having a number other than 2 or 7 as the fourth digit of their Catalog Number. Applying excess tension on the element of a tension operated controller may permanently warp the element, and in extreme cases, tear the anchor pin loose. To avoid over-tension, pay close attention to the following cautions: 1. Do not expose controller to temperatures above its upper range limit, 2, Do not expose controller to more than 100F* (65C") ‘above its calibration point. Therefore, preset controller to approximate required elevated temperature before in- serting it into the process. Preset by tuming adjusting sleeve in direction of arrow on head of controller. See Table 3 3, If necessary to decrease temperature of a tension oper- ated controller in a heated system, it may be necessary to do this in several increments. Do not turn adjusting sleeve to achieve more than 100F* (55°C) temperature drop at a time. Wait until controller stabilizes (begins to cycle). Then repeat until desired setting is reached. ‘Compression Operated Controllers Compression operated THERMOSWITCH controllers are identified by having a 2 or 7 as the fourth digit of their Catalog Number. Applying excess compression on the ele- ment of a compression operated controller may result in warping or crushing it. To avoid over-compression, pay close attention to the following cautions: 1. When rotating adjusting sleeve, do not exceed upper range limit of controller. 2, When removing controller from a heated system, never plunge it into a colder medium or use an air blast for rapid cooling. Tension or Compression Operated Controllers 1. Certain gases or liquids (including water at elevated temperature) could be corrosive and/or cause electro- Iytic action which could severely shorten life of contro ler. Rate of corrosion or electrolysis is influenced by many system parameters such as chemical makeup, temperature of solution, stray electrical currents, etc. Consult supplier of your chemicals or Fenwal for appli cation suggestions. Also, note that Fenwal offers vari- ous platings and Type $21 Stainless steel, heliarc welded thermowells for added protection. 2. Be sure that there is sutticient but not excessive room for the installed controller to expand in diameter and length. 3. Insulate head of controller when large ambient temper- ature variations may occur. This precaution is not necessary on junction box type controllers (Series 17800). 4, DO NOT immerse controller into liquids or gases un- less it was specified for that job. 5. DO NOT seal controller head with silicone materials. 6. DONOT thermally shield controller from medium being controlled. 7. DO NOT remove adjusting sleeve or turn it in farther than necessary for desired operation. This action may permanently damage controller. 8, DO NOT oil controller. Oil around adjusting sleeve will flow inside controller, contaminating contacts. 9. DO NOT handle unit with pliers or force it into position either by hand or with tools. 10. DO NOT subject shell of controller to deformation. WIRING Connect controller leads in series with the load and power supply. AXCAUTION DO NOT exceed the ratings indicated on the controller shell. Capacitors are not required under average conditions. However, for smoother control at small loads or to prevent contact bounce due to vibration, the capacitance listed in Table 2 is recommended. Wire capacitors in parallel with controller lead connections. Use capacitors fated for a minimum of 600 VDC with 120 VAG circuits and a minimum of 1000 VDC for 240 VAC circuits.Table 2 ° Capacitance (uF) Vottag Service ‘Tonpearty 420 VAG Resistance | None Required 240, VAC Resistance o1 120VAC Relays 0.001 100.01 240 VAC Relays 0.001 00.01 15-25 VAC, Relays 0.02 120 VAC. Motor Use Relay 240 VAC Motor Use Relay TESTING AND ADJUSTMENT The arrow on the head of the controller indicates the direc- tion to turn the adjusting screw to increase the temperature setting. Each full turn of the adjusting sleeve will change the temperature the approximate amount shown in Table 3. After the controller has been installed, allow the controller to operate for several cycles to permit the controlled system to stabilize. Then adjust to the desired temperature. Check the setting by cooling the system to ambient temperature, teheating it, and rechecking the temperature. Where ex- tremely accurate control is desired, several adjustments may be necessary. However, once adjusted, the accuracy of the setting will be maintained. TESTING TEMPERATURE SET POINT ‘The set point temperature is the temperature at which the contacts on a THERMOSWITCH Controller just “make (close). All controllers are set at room temperature [75 18°F (24 +8°C)] unless ordered with a specific factory setting (MOD 3). Testing the temperature set point in an application, unde: conditions where the heat source is remotely located fror the controller, or when ambient temperature conditions are far below or above 75°F (24°C), may give misleading re- sults. in some cases, this has led to rejection of controller that were within proper setting tolerance. If you require tem perature set point testing, Fenwal recommends the Mode 8001-0 Test Kit. If you choose to build your own tes. equipment, we recommend that you contact your Fenwa representative for guidance in setting up a good therma test system. ‘Tension Operated ‘Compression Operated “Approx. F' ‘Approx. Catalog Per Full Catalog Per Full Number Tum of Number Turn of Adj Sleeve Adj Sleeve 15050 to 16051 | 165 = = 17000 to 17382) 80-115 | 17021 to 17323] 70-100 17800 126 17821 75 17802 160 17823 90 18000 to 18002| 80-100 | 18021 to 18023] 75-901.0 2.0 3.0 40 5.0 6.0 7.0 Sehnsen industries Itd D 8500 River Road, Richmond BC Canada V6X 1Y4 Tel (604) 2733737 - Fax (604) 273 9654 INDEX HU057CPD HYDRAULIC POWER UNIT DESCRIPTION . SHOP PREPARATION ..... 24. Assembly . 22 Testing ..... 23 © Shipment .... 1 INSTALLATION . 3.1 Location and Mounting og 3.2 Hydraulic Connections : 1 33 Electrical Connections . 2 3.4 Priming the System . 2 2 OPERATION .... 4.1 General Operation . 42 Specific Operation . 43 Calibration . 43.1 Relief Valve : 43.2 Pressure Switches... 43.3. Accumulator Precharge 43.4 Sequence Valves : 43.5 Flow Control and Pressure Reducing Valves . ... 43.6 Proportional Control Valve .......-- 2224+ MAINTENANCE pee eee 5.1 Prevention ....... 2-5 - 56 5.2 Hydraulic Oil Features fierce 6 53 Hydraulic Oil Service .. . 6 6 TROUBLE SHOOTING 6.1 Noisy Pump .. 62 Low or Erratic Pressure .. 63 No Pressure . 6.4 Actuator Fails to 8.5 “Slow or Erratic Actuation 66 Erratic Pump Operation .. WARRANTY AND SERVICE pag oe 8 7.4 Warranty . 8 72 Service oe 8 7.3 Recommended Spare Parts 8 74 — Ordering Spare Parts .... 8nekhnson industries ltd D 8500 River Road, Richmond BC Canada V6X 1Y4 Tel (604) 273 3737 - Fax (604) 273 9654 USER’S MANUAL B. HUOS7CPD HYDRAULIC POWER UNIT 4.0 DESCRIPTION ‘The Johnson HUOS7CPD hydraulic power unit is designed for controlling spring set - hydraulically released caliper brakes. The system consists of two identical redundant circuits all enclosed within a lockable cabinet. Each circuit consists of a pump mounted directly to a motor, pressure and return filters, pressure switches and gauges, a circuit block with flow control and sequence valves, accumulators plus other devices. The reservoir is sealed and is provided with an immersion heater, bladder with breather, a vent and sight gauge. ‘The power unit is equipped with foot mount brackets. 2.0 SHOP PREPARATION 2.4 Assembh ‘The hydraulic power unit is assembled with attention to cleanliness and detail. The reservoir interior is glyptal coated. The system components are left with the original manufacturer's coatings. Brass, aluminium stainless steel, and rubber components are normally not painted. 2.2 Testing 10% | Solenoid [2.7 A/25 W ]3.7a/50 Ww i Power consumption | max 35 W max, 55 W. i ‘Current rating | max. 1.5 A [max 2.2 i Solencid opt pulse wid modulated bebe Im 227A | Ime = 3.7 A | ‘Setpoint Vy £0... + 10 V (z 10) } Differential OV 12) } input | | VwEo...+10¥ i Val On. + 10¥ ‘Signal source (Setpoint) | Potentiometer R= 1k @ + 10 V supply from b 32 (10 mA) or extemal source te | Actuabvaiue feedback | Oscib 26 [esp 2 98" 0811 405.095 10.2Vw7 8! 0...» 10V © 0811 405 096 10.2 Vw7.8 kHz | 0... + 10V. - 0811 405.0971 10.8 Vw7.SkHz 0... + 10V Boar 405 098, [10.2 Ve¥7.8kH2 | 0... +10V. 0811405089 | 108Vw7.8kHz | 0... + 10V Enabling, ouput stage | atz 16, V=85...40V; (eg. 10V trom = 2) I | _ LED (green) on front plate lights up Cable lengths and |” Solenoid cable: < 65 ft 18 AWG £180 fi: 14 AWG, cross-sections |. Botrenepeen mar 159 at 100 prim L Supply and capacitor 18 AWG: _ TED dips ‘green: enable Yellow: cable break _ fed: 24V powersupply low (<21V) | Fault indication 226: Switching output = Cable break No faut + 24 V (mat 100 mA) ae Fautov H = £5 stabization Shor-— gonae onare = fone) SoeeE er mess wa Seats a Sewanee aS Ssas ou paehomedy ia Stas uae aaa heag ean Saves tent suowoess nee 0H cnn sun cones ron eae rnd aaaDKB/U-U eoPak™ DK6/-U wire signal isolators 4.20049.107 2.304.107 heats agra coon Do enage _ sexo masse a = — i000. 31008 Sse ae ee bie :eiseedh N2evecs5h OUT = Sona RAN ora our Tone eS Ramee = are rater death aeserc = Fr ‘apie seiowe WEBBS sewwe) SenES xe re wa TS os se a 5 = Sire oe occa TOS Bet 85 ccs TRS ‘Zi-vana DS4or Bee nsoInstallation, Operation And Maintenance Of Reliance® Standard Industrial AC Induction Motors * 180 — 449 Frames (NEMA) ¢ 112 — 280 Frames (IEC) “Solutions AC MOTORS | ti" Instruction Manual B-3620-24 June, 1997 @ Rockwell Atension_ Reliance ElectricTable of Contents RECEIVING AND HANDLING . ACCEPTANCE EXTENDED STORAGE — AC MOTORS, DC MOTORS, GENERATORS AND SHIPBOARD MOTORS . 5 STORAGE CONDITIONS ~ SHORT TERM ... STORAGE PREPARATION ....... FOR STORAGE OF EXTENDED PERIODS OF TIME (GREATER THAN 18 MONTHS) ... UNPACKING . INSTALLATION INSPECTION LOCATION «0.2.2... LIFTING MEANS . MOUNTING 22.0... ..eeeeeeee MOUNTING OF 6 & 8 HOLE MOTOR FRAMES: RIVE : ‘i ROTATING PARTS : a SOME SATISFACTORY METHODS OF GUARDING GROUNDING STARTING : DRAIN PLUGS .... ROTATION en TEST FOR GENERAL CONDITION. INITIAL LUBRICATION OPERATION MAINTENANCE AND REPAIR DISASSEMBLY ..--.. 22... ecceeteceee REMOVING BRACKETS AND ROTOR... REMOVING AND REPLACING BALL BEARINGS REASSEMBLY LUBRICATION OF BEARINGS ..... GREASE LUBRICATED BEARINGS .. RECOMMENDED LUBRICANT .. BALL BEARING MOTORS ........ ROLLER BEARING MOTORS , LUBRICATION PROCEDURE .... LUBRICATION INSTRUCTIONS ... SERVICE CONDITIONS... LUBRICATION FREQUENCY LUBRICATION VOLUME .. REPLACEMENT BEARINGS ........ poooco GENERAL CROSS SECTION AND PARTS IDENTIFICATION DRAWING ‘TOTAL SERVICE PROGRAMS .. RENEWAL PARTS . ADDITIONAL LITERATURE . Fotance® is a vademart of lance Electic Inui Company ors subsidaries, 191997 Rocke Irtrrational Corporation|AR WITH THE CONSTRUCTION AND OPERATION OF HOULD INSTALL, ADJUST, OPERATE, AND/OR SER- THIS MANUAL IN ITS ENTIRETY BEFORE PROCEED. ULD RESULT IN SEVERE BODILY INJURY OR LOSS OF ONLY QUALIFIED ELECTRICAL PERSONNEL FAMILI THIS EQUIPMENT AND THE HAZARDS INVOLVED Si VICE THIS EQUIPMENT. READ AND UNDERSTAND ING, FAILURE TO OBSERVE THIS PRECAUTION Col LIFE. The products described in this manuel are manufactured by of for Reliance Electric Industrial Company. RECEIVING AND HANDLING ACCEPTANCE ‘Thoroughly inspect the equipment before accepting ship- menttrom the transportation company. Itany of the goods called for in the bill of lading or express receipt are dam- ‘agedor the quantity is short, do not accept them unti the {eight or express agent makes an appropriate notation ‘on your freight bill or express receipt. If any concealed loss or damage is discovered later, natity your freight or express agent at once and request him to make an in- spection. We will be very happy to assist you in collecting claims for joss or damage in shipment; however, this will ingness on our pan does not remove the transportation company’s responsibility in reimbursing you for collection of claims or replacement of material. Claims for loss or damage in shipment must not be deducted from the Reliance Electric invoice,nor should payment of the Reliance Electric invoice be withheld awaiting adjustment of such claims, as the carrier guarantees sate delivery. considerable damage has been incurred and the situa- tion is urgent, contact the nearest Reliance Electric Sales Office for assistance. Please keep a written record of all ‘communications. EXTENDED STORAGE ~ AC MOTORS considerable damage has been incurred and the situa- tion is urgent, contact the nearest Reliance Electric Sales Office for assistance, Please keep a written record of all communications. STORAGE CONDITIONS — T TERI The following storage requirements must be followed 1. Motors are to be kept in their original containers or Provided with equivalent protection and stored in a warehouse free from extremes in temperature, hu- mnidity, and corrosive atmosphere. 2, unusual vibrations exist at the storage location, the ‘motor should be protected with isolation pads. 3. All breathers and drains are to be operable while in storage and/or the moisture drain plugs removed. The motors must be stored so the drain is at the lowest point. STORAGE PREPARATION Improper storage of electric machines will result in seri- ously reduced reliability of that equipment, For example anelectric motor that does not experience regular usage while being exposed to normally humid atmospheric con- ditions is likely to cause the bearings to rust or ru Particles from surrounding surfaces to contaminate the bearings. The electrical insulation may absorb an exces- sive amount of moisture leading to the motor winding failing to ground. The following preparations should be followed: 1, Minimize condensation in and around the motor by use of desiccants or other humidity control methods, 2. Motor space heaters when specified are to be ener- gized where there is a possibility that the storage ambient conditions will reach the dew point. Space heaters are an option. 3. Coatall external machined surfaces with a material to Prevent corrosion, An acceptable product for this pur- pose is Exxon Rust Ban #392. 4. Measure and record the electrical resistance of the winding insulation with a megger or an insulation re- sistance meter. Minimum accepted Megohm level is the insulation kV rating +1 Megohm. Iflevels all below the above, contact the nearest Reliance sales otfce. The recorded data will be required when removing from storage.5, Some motors have a shioping brace attached to the shaft to prevent damage during transportation. The shipping brace, if provided, must be removed and stored for future use. The brace must be reinstalled to hold the shaft firmly in place against the bearing be- fore the motor is moved. 6. Upon placing the motor into extended storage (great- er than 3 months), the motors with regreasable bearings must be greased per Table 1 followed by the motor shaft being rotated a minimum of 15 times after greasing. Non-regreasable motors with “Do Not Lubri- cate" nameplate should also be rotated 15 times to redistribute grease within the bearing. 7. Remove the grease drain plug, if supplied, (opposite the grease fitting) on the bottom of each end bracket prior to lubricating the motor. Replace the plug after greasing. Table 1. Lubrication Volume (Storage) NEMA Vol. in Frame Size (IEC) Cubic In. (Cm) 182 thru 215 (112 - 132) 05 (8) 254 thru 266 (160 — 180) 1.016) 324 thru 365 (200 228) 15 (24) 404 thru 449 (250 ~ 260) 25 (40) 8. Regreasabie bearings are to be greased per Table 1 atthe time of being placed into extended storage. Mo- tor shafts are to be rotated at least 15 revolutions manually every 3 months end additional grease add- ed every nine months per Table 1 to each bearing. Bearings are to be greased atthe time of removal from storage. Non-regreasable motors should have their shaft tated 15 revolutions every 3 months. 8. All breather drains should be fully operable while in storage. The motors must be stored so the drain is at the lowest point. All breathers and automatic “T Grains must be operable to allow breathing at points other than through the bearing fits. 10.The space heaters when specified are to be con ected and operable while in storage. 11. Windings are to be meggered at the time equipmentis Put in storage. Reference Para. 4 on page 1. At the time of removal from storage, the insulation resis- tance reading must not have dropped more than 50% from the initial reading. Any drop below this point ne- Cessitates electrical or mechanical drying. Refer to ~ "Motor Drying Procedure.” 12.Where motors are not stored in the original contain- ers, but are removed and mounted on other pieces of ‘machinery, the mounting must be such that the drains and breathers and space heaters are fully operable. in this respect, the drains must be kept at the lowest point in the motor so that all condensation can auto- matically drain out. FOR STORAGE OF EXTENDED PERIODS OF TIME (GREATER THAN 18 MONTHS) All requirements of general preparation and short term storage apply with the following additional requirements. 1. Motoris tobe crated in a box similar to EXPORT BOX- ING but that the “shell” (sides & top of box) will be LAG-BOLTED to the wooden base (not nalled as ex- port boxes are), This design will allow for the opening and reclosing the box many times without destroying the "shel 2, The motor will be sealed in an airtight vapor barrier bag with desiccant inside. This airtight bag will give added protection during shipment of motor to the per- ‘manent storage area. 3. Alter the first “Inspection” for megger reading, tuning the shaft, etc., the vapor bag should be re-sealed by taping it closed with masking or similar tape. Also add ew desiccant inside bag before closing. The shell should then be placed over the motor and the lag bolts replaced. 4. If a “zipper-closing” type bag is used instead of the “heat-sealed” type bag, then rezipper the bag closed instead of taping it. 5. Be sure to add new desiccant inside bag after each Periodic inspection, 6. Minimize the accumulation of condensed waterin and around the machine, UNPACKING ter unpacking and inspection to see that all parts are in good condition, turn the Shaft by hand to be sure there are ‘no obstructions to free rotation. Equipment which has been in storage for some time should be tested and relu- bricated (regreasable type) prior to being putintoservice. Refer to "Test General Condition” and “Lubrication” for procedure to be performed after extended storage. Equipment with roller bearings is shipped with a shaft block. After removing the shaft block, be sure to replace ~any bolts used to hold the shaft block in place during ship- ‘ment that are required in service.Per oe RR ALIFIED ELECTRICAL PERSONNEL FAMILIAR WITH THE CONSTRUCTION AND OPERATION OF THIS EQUIPMENT AND THE HAZARDS INVOLVED SHOULD INSTALL, ADJUST, OPERATE, AND/OR Sem, NICE THis EQUIPMENT. READ AND UNDERSTAND THIS MANUAL IN ITS ENTIRETY BEFORE PROCEED. ING. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULTIN SEVERE BODILY INJURY OR Loss OF LIFE. INSTALLATION INSPECTION After the motoris unpacked, exarhine the nameplate data, to see thatit agrees with the power circuit to which itis to be connected. The motor will operate with frequency not ‘more than 5% and voltage not more than 10% above or below the nameplate data, or combined variation of voltage and frequency of not more than 10% above orbe- low nameplate data. Efficiency, power factor and current may vary fromnameplate data. Performance within these voltage and frequency variations will not necessarily bein ‘accordance with the standards established for operation at rated voltage and frequency. Typical Effect of Voltage and Frequency Variation on Induction Motor Characteristics Sone’ | Sane we | Petts — ae reese | Samy Seon sree felt ps | amar ee cst) eg | fotos ae vote [1 | ge " Show” OY (ee [oes** | Sipe fae |sseat forsee [cee [se Sine By fat fem fee ey ee feo amy |e semn sere [seme |ssmem Jose Some fame Pm” = = — cmos fo are fone dan Pere fee |e eee |e ne Sr |e [SE |e | |ithan [Behan [et [Set [me [ore fase dese |e eo a 7 [ie tape == ix atic 7 Bw [es [Bee | NOTE: This table shows general effects, which will ary somewhat for specific ratings.LOCATION The motor should be installed in a location compatible with the motor enclosure and specific ambient. Toallow adequate air low, the following clearances must be maintained between the motor and any obstruction: TEFC (100141) Enclosures - Fan Cover Air Intake - 180-210T Frame 1" 250-4497 Frame 4” IEC 112-132 2.5m IEC 160 ~ 280 10m ~ Envelope equal to the “P" dimension on the motor dimension sheet Exhaust Protected Enclosures ~ Bracket Intake ~ Same as TEFC ~ Exhaust out the sides-envelope a minimum of the "P" dimension Frame Exhaust plus 2” (Scr). Exhaust out the end-same as intake. LIFTING MEANS My warnina WHEN A LIFTING MEANS IS PROVIDED FOR HANDLING THE MOTOR, IT SHOULD NOT BE USED TO LIFT THE MOTOR PLUS ADDITIONAL EQUIPMENT SUCH AS GEARS, PUMPS, COM- PRESSORS, OR OTHER DRIVEN EQUIPMENT. FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN BODILY INJURY. In the case of assemblies on a common base, any iting means provided on the motor or generator should not be used tolift the assembly and base but, rather, the assem- bly should be litted by a sling around the base or by other, lifting means provided on the base. In all cases care should be taken to assure lifting in the direction intended in the design of the ling means. Likewise, precautions should be taken to prevent hazardous overloads due to deceleration, acceleration or shock forces. MOUNTING Mount the motor on a foundation sufficiently rigid to pre- vent excessive vibration. Roller bearing and ball-bearing ‘otors may be mounted with the shaft at any angle. Roll- +f bearing motors are not suitable for coupled duty applications. After carefully aligning the motor with the driven unit, bolt securely in place. When motors, which are normally mounted with the shaft in a horizontal position, are mounted vertically, it may be Necessary to provide additional guards to prevent foreign objects from falling into the motor openings and striking rotating parts. Such guards may be obtained at the time of purchase or from a local service repair center. Explosion proof motors aré shipped from the factory with the conduit box mounted. If the conduit box is re- moved or rotated, a minimum of five (5) ful threads of engagement on the motor pipe nipple must be main- tained for explosion proof integrity of the conduit box. ‘Some motors have standardized frames containing 6 or 8 ‘mounting holes. 6 hole frames are not suitable for field re- versal of mounting from F-1 to F-2, etc. The following diagram indicates the proper mounting holes to use. MOUNTING OF 6 & 8 HOLE MOTOR FRAMES ‘Not present on “é-hole frame” Notused on 8-hole rama” (Allows F-1'a F2 conversion View From Above onive SHAFT END Always use these holes hich ae closer shat, Ties: 1398, 164 02,213,254, 284,328, | doon, 28, 200s, 2o0s 364, 406, 443 (NEMA) (IEC) Use these holes for long frame designations 184, 215, 256, 286, 326, 365, 405, 245 (NEMA) (WEG) 1720, 132M, 160L, 2601, 225M, 250M, 280M Use these holes for shart frame designations DRIVE The pulley, sprocket, or gear used in the drive should be located on the shaft as close to the shaft shoulder as pos- sible, Heat to instal. Driving a unit on the shaft will damage the bearings. Belt Drive; Align the pulleys so that the belt will run true; lighten the belt just enough to prevent slippage, any tight er will cause premature bearing failure. If possible, the lower side of the belt should be the driving side. {Chain Drive: Mount the sprocket on the shaft as close to the bracket as possible. Align the sprockets so that the chain will run true. Avoid excessive chain tension, Gear Drive and Direct Connection: Accurate alignmentis essential. Secure the motor and driven unit rigily to the base. ROTATING PARTS. ROTATING PARTS, SUCH AS COUPLINGS, PUL- LEYS, EXTERNAL FANS, AND UNUSED SHAFT EXTENSIONS, SHOULD BE PERMANENTLY GUARDED AGAINST ACCIDENTAL CONTACT WITH HANDS OR CLOTHING. THIS IS PARTICU- LARLY IMPORTANT WHERE THE PARTS HAVE SURFACE IRREGULARITIES SUCH AS KEYS, KEYWAYS OR SET SCREWS. FAILURE TO OB- SERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY. SOME SATISFACTORY METHODS OF GUARDING ARE: 1. Covering the machine and asseciated rotating parts with structural or decorative parts of the driven equip- ment. 2. Providing covers for the rotating parts. Covers should be sufficiently rigid to maintain adequate guarding in normal service, THE USER IS RESPONSIBLE FOR CONFORM- ING WITH THE NATIONAL ELECTRICAL CODE AND ALL OTHER APPLICABLE LOCAL CODES. WIRING PRACTICES, GROUNDING DISCON- NECTS AND OVERCURRENT PROTECTION ARE OF PARTICULAR IMPORTANCE. FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE, 7 N= 3) SUBSEQUENT STEPS REQUIRE ROTATING PARTS AND/OR ELECTRICAL CIRCUITS TO BE EXPOSED. STAY CLEAR IF UNIT MUST BE RUN- NING OR DISCONNECT AND LOCKOUT OR TAG POWER SOURCE IF CONTACT MUST BE MADE, ‘Connect the motor to the power supply according to the diagram on the motor nameplate. For most 230/460 volt ‘motors, nine leads are brought out from the stator wind- ings so that the motor may be connected for either230 or 460 volts, GROUNDING In the USA consult the National Electrical Code, Article 430 for information on grounding of motors, Article 445 for grounding of generators, and Articie 250 for general in- formation on grounding. In making the ground connection, the installer should make certain that there is a solid and permanent metallic connection between the ground point, the motor or generator terminal housing, and the motor or generator frame. In non-USA locations consult the appropriate national or local code applicable, Motors with resilient cushion rings usually must be pro- vided with a bonding conductor across the resilient member. Some motors are supplied with the bonding conductor on the concealed side of the cushion ring to protect the bond from damage. Motors with bonded cush- jon rings should usually be grounded at the time of installation in accordance with the above recommenda- tions for making ground connections. When motors with bonded cushion rings are used in multimotor installations ‘employing group fusing or group protection, the bonding of the cushion ring should be checked to determine that it is adequate for the rating of the branch circuit overcurrent protective device being used. ‘There are applications where grounding the exteriorparts, of a motor or generator may result in greater hazard by increasing the possibility of a person in the area simulta- neously contacting ground and some other nearby live electrical parts of other ungrounded electrical equipment. Inportable equipment itis dificult to be sure that a posi- tive ground connection is maintained as the equipments moved, and providing a grounding conductor may lead to alfalse sense of security. The user must select a motor starter and overcurrent protection suitable for this motor and its application. Con- sult otor starter application data as well as the National Electric Code andior other applicable local codes.WHEN CAREFUL CONSIDERATION OF THE HAZARDS INVOLVED IN A PARTICULAR AP- PLICATION INDICATE THE MACHINE FRAMES SHOULD NOT BE GROUNDED OR WHEN UN- USUAL OPERATING CONDITIONS DICTATE ‘THAT A GROUNDED FRAME CANNOT BE USED, ‘THE INSTALLER SHOULD MAKE SURE THEMA- CHINE:IS PERMANENTLY AND EFFECTIVELY INSULATED FROM GROUND. IN THOSE INSTALLATIONS WHERE THE MACHINE FRAME IS INSULATED FROM GROUND, IT IS RECOMMENDED THAT APPROPRIATE WARN- ING LABELS OR SIGNS BE PLACED ON OR IN THE AREA OF THE EQUIPMENT BY THE IN- STALLER. FAILURE TO OBSERVE THESE PRE- CAUTIONS COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE. STARTING Ay warning BEFORE STARTING MOTOR, REMOVE ALL UN- USED SHAFT KEYS AND LOOSE ROTATING PARTS TO PREVENT THEM FROM FLYING OFF. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY. A. caution Check direction of motor rotation before cou- pling motor to load. Failure to observe this pre- caution could result in damage to or destruction of the equipment. Before starting the motor, check the following items: 1. The rotor should tum freely when disconnected from the load. 2. Driven machine should be unloaded when first start- ing the motor. The motor should run smoothly with litle noise. Ifthe mo- tor should failto start and produces a decided hum, it may be that the load is too great for the motor or that it has been connected improperly. Shutdown immediately and investigate for trouble, DRAIN PLUGS if motor is totally enclosed fan-cooled or non-venti- lated it Is recommended that condensation O——O— — — — —flinings wom Tadustai-gap }— —| 9 7 10 ss BRAKE #2 oo SET — > ise item ——- | -O— +}, 183 Ts4 o Ee ——0—- TO Lining Temperature OK] | 17 a 19 Gg 20 t ——— He OR Td L isa — o—o— — — — ——4 21 — — 22 A EXIINGS LEGEND 31, TS2, TS3, TS4: 170°C FALLING LS1,LS3 — BRAKE RELEASE INDICATING PROXIMITY SWITCH 31, LS3: FULLY RETRACTED —LS2,LS4 — AIR GAP/LINING WEAR INDICATING PROXIMITY SWITCH 32, LSa: 4mm EXTENDING TS1,...4 ~ DISC TEMPERATURE INTER LOCK SWITCH ELECTRICAL SCHEMATIC. 20S2040A & 20520408 CALIPER BRAKES. eae 120-CV-005, -005, & —007 DATE: 98/06/02 | OWG. NO. REV.AY.K. Jan soe 24 jonvrsir14/Ip385918a A3859 18-1 @M industries / elevanja WV e00 Wr nage Rares oe verge Te 1a Gey SSF eee oS Bain Reg, Bidgyaler, Somerset Eogend Tas aU 78 AaB Fon oF 8 aoaFARIS SNIS1 FT HAND SHOWN IGHT HAND OPPOSITE) ITEM oMaUNs PART NO. 2082040B 1 BBP2040H 4 ar 2 BKB2040H 8 F12C28H5 £E22040B i IY DESCRIPTION BRAKE FRAME CALIPER BRAKE BEARING PIN — HEAVY RETAINER BAR — HEAVY 16 KEEPER BOLT ELECTRICAL ENCLOSURE (FIELD MOUNTED) Wnoustnes: ~ pit/ipenvrs/14/ipS86912 Te. (604) 273 5737 at, (604) 273 9654 lcusT. 2DS2040B CALIPER BRAKE ASSEMBLY SECONDARY DRIVE & TAKE-UP PULLEYS LOS PELAMBRES CONVEYORS 12( KRUPP CANADA /N_ 3 so |TEM PART_NO, ary 1 BHAT040 2 2 BBFL3859 1 3 BBFC3859 1 4 BBFR3859 1 5 BS4978 2 6 BFS3859 20 a BFSGBK3 20 8 BILS3859 i 9 F6R17 100 10 BPSG3859 4 1 BSRS2050 2 12 8SB2040 4 13 F22C248H5 6 i4 F22C5N 6 15 F18C56S8 8 16 BMBLE16, 2 17 BMBLE6 4 18 BLTS3859 2 19 BRPS3040 1 20 BWPS3040 1 21 BHH3859 1 22 F8DP32 4 ASSEMBLY NOTES 2% ‘APPLY RUST INHIBITOR SANDBLAST AND APPLY FRICTION LININGS DESCRIPTION ACTUATOR ASSEMBLY ACTUATOR: PLATE CENTER PLATE CALIPER PLATE SHOE PLATE FRICTION LINING — 3 RIVET FRICTION LINING ~ 2 RIVET LINING INSULATER LINING RIVETS SHOE GUIDE PIN SHOE RETURN SPRING SLIDE_BEARING CALIPER ASSEMBLY BOLT CALIPER ASSEMBLY NUT ACTUATOR MOUNTING BOLT CALIPER LIFTING EYE SHOE LIFTING EYE LINING TEPERATURE SWITCH BRAKE RELEASE SWITCH LINING WEAR SWITCH FLOW-THRU LINE HOSE DOWELL PIN TO SURFACES OF CENTER PLATE (EM 3) BEFORE ASSEMBLY PRIMER BEFORE MOUNTING ACTUATORS (ITEM 6 & 7) RIVETED TO SHOE PLATES (ITEMS) APPLY NEVER SEIZE TO THREADS OF SHOE GUIDE PIN (ITEM 10) TORQUE ACTUATOR BOLTS (ITEM 15} TORQUE CALIPER ASSEMBLY NUTS Jo 580 FT-Las (TEM 14) TO 650 FT-LBS ALLIGN FLATS OF NUTS AND BOLTS WITH CURVATURE OF FRAME THERMAL INSULATOR APPLIED TO ACTUATOR SIDE. ONLY Kehnsen incusties / clevanja Yr wsoortver past Ramana te comer tr ‘Sormersel Englond TAG aN Batt Road, Bridgnot ea DH2040 CALIPER BRAKE PARTS LIST & ASSEMBLY DETAIL Wwe. NO. s__|A4978—-P6.d 6278 ‘on!DANGER! ACTUATOR CONTAINS COMPRESSED SPRINGS ITEM PART NO. QTY DESCRIPTION 1 BHAI040 1. ACTUATOR BODY 2 BANAP1050 71 ACTUATOR PISTON 3 BAHAST050 1 ADJUSTMENT SPINDLE 4 BASC1050 1 SPRING COLLAR 5S FKMFE14 = 7 LOCK NUT 6 — SHP455650 1 PISTON SEAL 7 SHR605300 1. ROD SEAL 8 SHRWD300 1 ROD WIPER PARIS Wis! YAOOO@ ITEM PART NO. QTY DESCRIPTION 9 SHRWJ650 1 ROD WIPER 10 sHW2654 WEAR STRIP 11 SSLI125 SHAFT SEAL 12 BARS1050 RETURN SPRING AIR BLEEDER SPINDLE RETAINER RETAINER SCREW PORT PLUG - SKT 14 BAPTRI025 15 Faci2cs8 1 1 fi 13 BAHBIS 7 1 ‘i 16 FHPSON-O4 4 m industries Jelevanja ltd) SS _ ndusinies /elevan cower BC Canada -~ Te: 604 273 3737 Fox: 604 275 9654 slo ON Conada ~~ Te: 416 213 9991 Fox: 416 215 9992 BHA1040 ACTUATOR | __PARTS _L ST ____ ara! [CUST. NINERA LOS PELANERES qrater SOM England ~~ Tel: 01278 456411 Fax: 01278 429949 J/N 4978 S/d FeO 06 We NO. dr ots asst /oha 4978 - PD, Gé { © e \ All Al2 Al3 Al4 AIS Al6 Al7 Al8 PARIS WISI | Al AS (A15) (13)(47) (A14) BAPH1140 1 BAPPR1040 1 BAPCB1040 1 BAPSG1140 1 BAPSH1050 18 BAPPN1040 1 BAPCR1040 1 FST04C24S5 4 BAPCV1040 1 FSTO4CO6S5 4 BAPTR1040. 1 BAEG1040 2 BAPSW1140. 1 BAPOP1040 1 BAPOR1040 1 BAPWR1040 1 BAPWB1040 1 BAPABO4 1 (416) (A17) ACTUATOR HOUSING SPINDLE ACUTATOR BASE SPRING GUIDE DISC SPRING PISTON CAGING RING END COVER SCREW END COVER SPINDLE RETAINER SCREW SPINDLE RETAINER END GASKET SPRING WASHER PISTON SEAL ROD SEAL ROD WIPER BASE WIPER AIR BLEEDER cower BC Conada onto ON Canada Igvater SOW Englon industries /elevanja Itd| dbrJact/ds_acirs/T0400sm ~~ Tek 604 275 3737 Fox: 604 273 9654|cUST._ ~~ Tek 416 213 9991 Fox; 416 213 9992] s/n 01278 45641 Fox: ( 01278 429949 AINERA LOS PELAMBRES. | IS/N's_ BAH1140 ACTUATOR. ASSEMBLY _ — _4978 $/DMar.20/06 | WG. NO. BAH1040-418806- 0 |A1040— p21 |Wt Effective: “aust 1997 FENWAL THERMOSWITCH® Temperature Controller Installation Instructions ATTENTION: To ensure safe and proper performance, read {these instructions carefully before attempting to install or operate this Fenwal product. Please retain for future reference. The shell of each THERMOSWITCH® Controller contains the catalog number, the current rating, the temperature range, and the contact arrangement. Controllers that are component recognized or listed by Underwriter’s Laboratories or certified by the Canadian Standards Association (CSA) will also bear the symbol of the approving agency. In addition, UL component recog- nized units with temperature ranges up to 500°F will have “4” as the first digit of the Catalog Number. The fitth digit of the catalog number describes whether con- tacts open or close on temperature rise. If contacts open on temperature rise, the fifth digit of the number is an even ‘umber (17000, 17002, etc.). f contacts close on temper- ature rise, the fifth digit is an odd number (17021, 17023, etc.) If the fourth digit is “2° or *7" e.g., 17021, 17071), the con. troller is compression operated. Compression units that close on temperature rise are recommended if overranging is anticipated. Low temperature units [- 100 to +400°F (~73 to +204°C)] can be overranged to 500°F (260°C) and high temperature units [~-100 to +600°F (—73 to + 316°C)] overranged to 700°F for intervals not exceeding one hour. INSTALLATION MOUNTING THERMOSWITCH Controllers are supplied in five basic head configurations ~ Cartridge, Block Head, Hex Head, Coupling Head and Circular Flange. See Figure 1. To avoid restricting shell expansion when making installa- tions in solid metal blocks, a 0.625 in diameter reamed hole for 5/8 in standard units or a 0.812 in diameter reamed hole for 13/16 in heavy duty units is recommended. See the fol owing specific controller style listing for additional installa. tion instructions. Tempero Aaesng Shed Const ons Figure 1 Cartridge (Style 1) ~ Hole should have a shor spline to receive the 0.125 in diameter locating pin. This prevents the unit from rotating when the adjusting sleeve is tured, The cartridge style may be used for surface control if in- serted into a Fenwal surface mounting well (Cat. No. 1110-2). Block Head (Style 2) ~ Mounted in a similar manner to the cartridge type. If the unit is to be inserted into areamed hole, mount two short pins on either side of the hole. The pins should rest against the sides of the block head to pre- vent rotation of the unit, Hex and Coupling Head (Styles 3 and 4) — Installed like any pipe fitting. If installed in a pipe tee, the tee should be large enough to allow adequate circulation of the fluid around the temperature-sensitive section of the controller. See Table 1 for maximum torque values.NSTALLATION (Continued) AXCAUTION | 2xcessive torque applied to units may change temperature st ings. Table 1 THERMOSWITCH Controller | Max. Torque 35 fib" _ Standard (6/8in cia) ara) 7O te Heavy Duty (13/16in dia) 24.aNen) 4 feb (6.4 Nem) when Teflon tape lubricants used. '8 ftlb (10.8 Nemn) when Teflon tape lubricant is used, ireular Flange (Style 5) — Three holes in flange allow sy mounting on any fat surface. [AscauTions) ension Operated Controllers ansion operated THERMOSWITCH controllers are iden- ied by having a number other than 2 or 7 as the fourth digit their Catalog Number. Applying excess tension on the ement of a tension operated controler may permanently arp the element, and in extreme cases, tear the anchor 1 loose. To avoid over-tension, pay close attention to the tlowing cautions: Do not expose controller to temperatures above its upper range limit, Do not expose controller to more than 100F* (55C*) above its calibration point. Therefore, preset controller to approximate required elevated temperature before in- Serting it into the process. Preset by turning adjusting sleeve in direction of arrow on head of controler. See Table 3. necessary to decrease temperature of a tension oper- ated controller in a heated system, it may be necessary to do this in several increments. Do not turn adjusting sleeve to achieve more than 100F° (65°C) temperature drop at a time. Wait until controller stabilizes (begins to cycle). Then repeat until desired ‘setting is reached. mpression Operated Controllers ‘nipression operated THERMOSWITCH controllers are atiled by having a 2 or 7 as the fourth digit of their alog Number. Applying excess compression on the ele- at of a compression operated controller may result in ing or crushing it. To avoid over-compression, pay s@ attention to the following cautions: ‘When rotating adjusting sleeve, do not exceed upper ange limit of controller. 2. When removing controller from a heated syste" "Never plunge it into a colder medium or use an air BS + for rapid cooling. Tension or Compression Operated Controllers 1. Certain gases or liquids (including water at ested temperature) could be corrosive and/or cause *tro- 'ytie action which could severely shorten life oO" €rol- ler. Rate of corrosion or electrolysis is influnaC® by ‘many system parameters such as chemical mixup, temperature of solution, stray electrical current, wet, Consult supplier of your chemicals or Fenwal ortpi- cation suggestions. Also, note that Fenwal oft ari- ous platings and Type 321 Stainless steol, M!® arc welded thermowells for added protection. 2. Be sure that there is sufficient but not excessite"om for the installed controller to expand in diametet Sand length. 3, Insulate head of controller when large ambienttenf> er- ature variations may ocour. This precaution & mot Necessary on junction box type controllers (Series 17800). 4. DO NOT immerse controller into liquids or gases less it was specitied for that job. 5. DO NOT seal controller head with silicone materials 6. DONOT thermally shield controller from medium teing controlled. 7. DO NOT remove adjusting sleeve or turn it in father than necessary for desired operation. This action may permanently damage controller. 8. DO NOT oil controller. Oil around adjusting sleeve will {low inside controller, contaminating contacts. 9. DO NOT handle unit with pliers or force it into postion either by hand or with tools. 10. DO NOT subject shell of controller to deformation, WIRING Connect controller leads in series with the load and power supply. [AcauTION 0 NOT exceed the ratings indicated on the controler shel. Capacitors are not required under average concitions. However, for smoother control at small loads or to prevent Contact bounce due to vibration, the capacitance listed in Table 2 is recommended. Wire capacitors in parallel with controller lead connections. Use capacitors rated for a ‘minimum of 600 VDC with 120 VAC circuits and a minimum of 1000 VDC for 240 VAC circuits.‘Capacitance (uF) (nonpolarized) Resistance | None Required Resistance o4 Relays 0.001 to0.01 240 VAC Relays 0.001 to0.01 15-25 VAC Relays 0.02) 120 VAC. Motor Use Relay 240 VAC Motor Use Relay TESTING AND ADJUSTMENT ‘The arrow on the head of the controller indicates the direo- tion to turn the adjusting screw to increase the temperatura getting. Each ull turn of the adjusting sleeve wil change the temperature the approximate amount shown in Table 3. After the controller has been installed, allow the controller {0 operate for several cycles to permit the controlled system {o stabilize. Then adjust to the desired temperature. Chock the setting by cooling the system to ambient temperature reheating it, and rechecking the temperature. Where ox: fremely accurate control is desired, several adjustments may be necessary. However, once adjusted, the accuracy of the setting will be maintained. TESTING TEMPERATURE SET POINT The set point temperature is the temperature 2¥ hich the contacts on @ THERMOSWITCH Controler jst “make” (close). All controllers are set at room temp aMyre (75 + 15°F (24 +8°C)] unless ordered with a spedicn factory setting (MOD 3) Testing the temperature set point in an apple, under Conditions where the heat source is remotely laleq from the controller, or when ambient temperature cont ons are far below or above 75°F (24°C), may give mista wing ro- ult. In some cases, this has led to rejection of wtroliors that were within proper setting tolerance. If you tL ire tom. erature set point testing, Fenwal recommends thes Model 80001-0 Test Kit. If you choose to build you Own test equipment, we recommend that you contact yair Fenwal representative for guidance in setting up a gotd thermal test system. Tension Operated 165 17000 to 17352} 80-115 | 17021 to 17323 17800 125 17821 17802 160 17823 18000 to 18002] 80-100 | 18021 to te0231.0 2.0 3.0 4.0 5.0 Western Office [Easter Office ‘8500 River Road 108 Skyway Avenue Richmond BC Toronto Ot Canada MQW 4Y9 Tel: 416213 9991 Fax: 416 213 9992 Canada V6X 1Y4 Tel: 604 273 3737 Fax: 604 273 9654 INDEX INSTALLATION 1.1 GENERAL. 1.2 MOUNTING. 1.3 PLUMBING........ 1.4 FLUSHING. INSPECTION AND MAINTENANCE 2 LININGS eee ere 2.2 BURNISHING... 23 DISC. 24. AIR GAP. 2.5 LUBRICATION. 2.6 LIMIT SWITCHE:! ACTUATORS 3. 32 INSPECTION AND MAINTENANCE, PRESSURE SUPPLY... = TROUBLE SHOOTING 44 4.2 43 44 45 BRAKES WILL NOT RELEASE. BRAKES WILL NOT SET. SLOW BRAKE RESPONSE, BRAKES SLIP... RAPID OR ERRATIC LINING WEAR... WARRANTY AND SERVICE 5A 5.2 53 RECOMMENDED SPARE PARTS... SERVICE. WARRANTY .sessscsossssnrneetsenen FidbgenereDS_manual wp DlEuropean Office Bath Road Bridgwater Somerset England TA6 4NU Tek: 01278 456 411 Fax: 01278 429 949 industries / elevanja ~4auee 9 10 10 .u u ul 12DS2040 CALIPER BRAKE10 INSTALLATION LL 12 GENERAL The Johnson Industries ‘DS’ series caliper brake is a direct acting type of brake utilizing spring set, hydraulically released actuators acting directly onto the brake shoe. The calipers are mounted in a frame via two bearing pins. Teflon slide bearings in the caliper allow the brake to float laterally on the bearing pins to compensate for axial movement of the disc or lining wear. The ‘DS' caliper brakes are available in a large range of clamping forces and can be selected with various types of friction grades. The brakes are available in either left or right hand orientation and three different styles of bases for horizontal, vertical or inclined mounting. Contact Johnson Industries for assistance in selecting a brake most suitable for the user’s application. MOUNTING Discs are normally installed prior to placement of the caliper. Discs are shipped with a rust inhibitor coating applied to the exposed surfaces. This coating will permanently damage the friction linings if allowed to come in contact-with the disc. It is imperative to thoroughly remove the rust inhibitor with a cleaning solyent prior to installation of the calipers, Most calipers are shipped in the released mode for ease of installation Before tightening caliper bolts, set the caliper to clamp on the disc. This is done by removing the caging ring from the actuators. To remove the caging ring, apply enough pressure to the actuator to fully release the brakes (sce the certified print at the back of this manual). With the actuator pressurized, remove the cover and unscrew the caging ring. Flip the caging ring around to mount the ring in the stowed position and re-install the cover plate. Refer to the actuator instruction sheet at the back of this manual. The hydraulic power pack used to manually release the brakes must be limited to a maximum pressure of 3000 psi and the oi] must be filtered to a 10 micron absolute GSO 18/15) cleanliness level. With the caliper clamped on the disc verify that the shoes are parallel with the disc and that the base sits flat. Correct with shims if necessary. Verify that the pads are fully seated on the disc and that the assembly is, Reposition the brakes or shim the base if required . centered with the dise. Once the caliper is properly positioned release the brakes and verify that the caliper has adequate float on both sides of the brake frame. After bolting the brake frame in place, release the caliper and ensure that the caliper floats freely. It is critical that the brakes, have adequate radial clearance between the disc outer diameter and the caliper center plate. This clearance must be checked and verified to be a minimum of 3/16 of an inch Once the positioning of the brakes is verified to be correct the brake mounting bolts Page |4 a t 13 14 must be tightened. Preload the mounting bolts to the value specified on the certified drawing or to a maximum of seventy-five percent of the bolt proof load. Use either Jock washers or jam nuts to ensure that the mounting bolts do not work loose. The brake pedestal must be designed to allow enough wrench clearance to properly tighten the mounting bolts. When operating temperatures exceed 300°F (150°C), oversized bolt holes should be used in both disc and hub. It is preferable to drill the disc/hub mounting holes together using the same set up. PLUMBING ‘The brake system must be plumbed with adequately sized piping or tubing, preferably stainless, suitably rated for the operating pressures. Generally, Y4 inch diameter JIC tubing and ¥4 inch diameter pipe is sufficient for most applications. The piping must be adequately supported with pipe clamps every 4 feet for 4 inch and 3/4 inch lines. The connection to the brake must be done with a flexible hose suitably rated for the operating pressure. Before connecting to the brakes, the plumbing must be purged to remove all the coarse contaminants. After connecting to the brakes and hydraulic unit, thoroughly flush all hydraulic systems to a 10 micron absolute (ISO 17/14) cleanliness level before applying full operating pressure When all connections have been made, air must be bled from all hydraulic actuators during initial pressurization. ‘The brakes must be cycled several times to get all the air out For hydraulically released brakes the system must be flushed prior to-commissioning the equipment to ensure proper and reliable operation of the equipment. This procedure must be done periodically or whenever the circuit has been broken to replace a component. For newly commissioned systems the piping and/or hoses must also be pre-flushed prior to connecting to the equipment to remove any coarse contaminants. After plumbing the complete system can be flushed by following the guidelines below. The oil should ideally be flushed to an 1.S.0. cleanliness level of 17/14. This cleanliness level can be achieved by using a ten micron (or finer) filter element with a beta rating of 75 (or higher). ‘The duration of flushing should be sufficient to allow all the oil in the reservoir and system to be circulated a minimum of four times through the filter. The set up for flushing should include a suitable filter, as specified above, in the retum line portion of the circuit to filter out contaminants before the oil reaches the reservoir. Page 2Itis undesirable to flush the contaminants into the reservoir as they will be picked up by the pump and possibly cause damage. Many hydraulic control units have a return line filter in which case it is only required that the element be suitably rated. For those cases that do not have a return line filter a spin-on filter can be temporarily added to the circuit for flushing. Many hydraulic brake systems have reciprocating flow type circuits whereas flushing requires circulatory flow. For these cases a suitably rated hose must be plumbed between the flushing filter and the second actuator port. For flow through type circuits a retum line will already be present. Flushing is best accomplished with turbulent flow to “blast” the contaminants out of the system. For those hydraulic control units which have a Brake Release Solenoid Valve turbulent flow is created by cycling the valve. The valve should be left de-energized long enough to charge up the system accumulator between cycles. If the H.P.U. does not have a Brake Release Solenoid Valve then a ball valve can be temporarily added up stream of the flushing filter. Do not add a shut off valve between the filter and reservoir as high pressure will burst the filter. Friction linings carry only the manufacturer’s warranty and must be adequately tested by the User in his particular application to verify performance characteristics, New linings must be thoroughly burnished and seated on the disc. Rated torque is obtained when the linings are fully bedded. Contaminated or burnt linings must be discarded Stopping capacity of a spring applied caliper brake is dependant on the actuator extension. Wear of the linings increases the air gap which results in an increase of the actuator extension. The lining condition and thickness, as well as the air gap must be monitored on a regular basis to ensure proper brake performance. See section 2.4 for adjusting the air gap. Allowing oil, grease, slurry etc. to contaminate the linings will have a severe detrimental, effect on the stopping capacity of the brakes. Ensure that there are no sources of contamination near the disc or brakes. Lightly contaminated linings can be cleaned with Page 3' i t 4 é 22 non oil based solvent and burnished. ‘When the lining thickness wears down to 0.28 inches the shoes must be removed and new linings installed. Allowing the linings to wear further will eventually result in the rivets contacting and scoring the disc. In dynamic applications, wearing of the linings beyond the bottom of the lining grooves or allowing the grooves to become packed with loose debris will have a detrimental effect on the stopping capacity of the brakes. When installing new linings ensure that the linings are bonded as well as riveted and that the rivets are all snug. In critical applications it is advantageous to carry a spare set of lined brakes shoes to avoid down time of operating machinery, Replacement linings must be as originally specified. BURNISHING Burnishing of friction linings is done to provide good, clean contact between the linings and disc. The procedure removes minor contamination on the disc or Jinings as well as any minor high spots or misalignment of the linings. New linings require burnishing to fully embed the linings on the disc and periodically over the life of the linings to remove any light contamination or oxide film from the swept face of the dise. Before burnishing, ensure that the disc and linings are free from contamination. If cleaning is required, use a non oil based solvent. If the swept face of the disc has a heavy oxide layer then initial burnishing is required to remove it. This stage should be done at a lower temperature and clamping force. After the rust is removed inspect the linings and verify that the lining grooves have not become packed with loose debris. Clean out the grooves if necessary. Heavily contaminated or burnt linings must be discarded, In addition to preparing the linings and disc for bumishing, any safety interlocks of the drive mechanism from the brake system should be bridged to allow the disc to be driven through the brakes, To bumish, the clamping force of the brake shoes and disc speed should selected so that the frictional power generated is in the range of 0.15 to 4.5 horsepower per square inch of lining area. The clamping force of the brake shoes can be adjusted by controlling the pressure in the actuators. It is preferable to bumish at the high end of the range to reduce the burnishing time but ultimately the brake torque while bumishing will be limited by the torque capacity of the drive. Insufficient lining pressure during burnishing can polish the lining material, resulting in a reduction of the friction coefficient. If this has happened the linings must be removed and sanded manually to scuff the Page 4w 23 surface. ‘The temperature must be monitored through out the bumnishing process. The temperature of the disc should be maintained between 250°F (120°) and 450°F (230°C), When the upper temperature limit is reached pause burnishing until the disc has cooled to the lower limit. Never allow the disc temperature to exceed 500°F (260°C). Permanent damage to the lining material will result, Burnish until a minimum of seventy-five percent lining contact and a bright disc surface is achieved. To measure the degree of contact, set the brakes and use a 002" feeler gauge to probe the perimeter of cach brake shoe. If the amount the feeler gauge was able to probe exceeds twenty-five percent of the lining area then further burnishing is required. The adequacy of burnishing must also be verified with load tests or stopping time measurements. If the actual brake torque does not meet the rated brake torque then further bumnishing is required CAUTION Do not put equipment into service if rated brake torque cannot be developed. Consult Johnson Industries for assistance BRAKE DISC For standard applications the disc should be manufactured from ASTM A588 or ‘equivalent material. The disc must be suitably dimensioned for the brake application The O.D. must be selected to provide the desired torque, the LD. must allow enough radial clearance to remove the shoes during liner replacement and the thickness must be chosen to safely absorb the brake energy input. Refer to the certified drawing at the back of this manual for critical dimensions. For bolted connections the locating, diameter of the disc should be machined to a H8 tolerance class. The disc should be balanced to ISO 1940/1 grade G40 for tow speed applications and G6.3 for high speed applications. The swept path of the disc should have a surface finish within 32 to 64 rms micro inches. Surface finishes in excess of the maximum will result in rough braking action and rapid lining wear. Scored or rough discs must be reconditioned, Page 524 removing no more than 0.02 inches per inch of thickness. Faces should be flat and parallel within 0.004 inches across the swept face. Lateral and radial run-out should not exceed 0.001 inches and 0.002 inches per 12 inches of diameter respectively. The heat dissipating capacity of the disc must not be exceeded. If the brake energy input of the caliper, when used under dynamic conditions of continuous application or a high duty cycle, exceeds the energy dissipating capacity of the disc then the torque must be limited or the duty cycle reduced. For high duty cycle applications ASTM ASI4 or equivalent must be specified for the disc material and special attention must be paid to the thermal and braking stresses on the disc/hub assembly. Consult Johnson Industries for such applications. WARNIN¢ NEVER APPLY WATER TO A HOT DISC Permanent damage in the form of heat checking and ‘warping will result AIR GAP The air gap must be inspected on a regular basis and adjusted if necessary for lining ixcessive air gap will result in excessive actuator extension and a significant loss wear of braking torque. An excessive air gap and actuator extension; 1, reduces the clamping force and therefore the braking torque beca the loss of spring force associated with actuator extension. 2. increases the brake reaction time because of the larger volume of oil to be discharged. 3. reduces the allowable lining wear as the actuators have a limited amount of stroke 4, could result in loss of actuator force due to inadequate stroke. eof The air gap must be adjusted back within specifications whenever it has grown out of tolerance, The air gap is adjusted by extending the actuator spindle. Begin by removing the back cover and spindle retainer. Apply release pressure to the actuators and insert a shim of equivalent thickness as the desired air gap between the disc and the actuator side brake pad. Ensure that the caliper is shifted over o that all the air gap is on the actuator side of the caliper. Screw in the adjustment spindles until the pads contact the shim and all the spindles contact the back of the shoe. One fall turn on the adjustment spindles closes the air gap by 1/16 of an inch, Ensure that the spindle retainer lines up with its mounting holes. After lining up the spindle retainer holes install the retainer and back cover then remove the shim. Cycle the brakes and recheck the Page 625 2.6 air gap. After adjusting the air gap the release and wear switches must be adjusted also (see section 3.5). The air gap is measured by pushing one shoe against the disc while measuring the distance between the lining and disc on the other shoe. Refer to the air gap adjustment procedures (drawing DSPS-01) at the back of this manual WARNIL Adjusting the air gap without release pressure in the actuator will result in damage to the actuator spindle, For applications that require a faster response time of the brakes, the air gap can be reduced. In these cases close attention must be paid to the axial run-out of the disc and for possible dragging of the shoes. In applications with high axial run-out of the disc the air gap can be increased to compensate. For these cases consult Johnson Industries as the lateral float capability of the brakes is critic: LUBRICATION When adjusting the air gap, ensure that the caliper floats freely. It will be necessary, on a regular basis, to remove the bearing pins and clean both pins and slide bearings in the caliper. Although lubricating the slide bearings will reduce the sliding friction, this practice should be avoided if possible. The lubricant will attract dust and therefore require more frequent maintenance intervals and possible reduce the life of the bearings When replacing linings ensure that the threads of the shoe pins have sufficient anti galling compound applied and that pins on the actuator side also has an EP grease applied to the shank. LIMIT SWITCHES Brake release and lining wear proximity switches are available as an option. The switches are supplied pre wired to DIN 43650 spade terminals. If present, both switches must be adjusted whenever the air gap is adjusted. Failure to adjust the switches will result in improper indication of pad wear and brake release. Switch actuation of the brake release proximity switch must occur within 1/16 of an inch of full actuator retraction. Ensure that the switch resets before the pads contact the disc. The position of the switch in the caliper must be adjusted whenever the air gap has been adjusted, This procedure is done by releasing the brakes, removing the connector, loosening the jam nut and turning the switch housing clockwise. Advance Page 73.0 ACTUATO) 3 the switch housing until it contacts the shoe plate then retract it one quatter tur, Secure the setting by tightening the jam nut to 25 foot-pounds. The lining wear limit switch is set to trip at a maximum air gap value of 3/16 of an inch (4.5 mm). Maintaining the air gap within specified limits is critical to the overall performance of the brake; an excessive air gap results in insufficient braking torque. It is important that the wear switch is properly adjusted whenever the air gap is adjusted. ‘The wear switch set point is adjusted in the exact same manner as the release switch. When replacing linings fully retract both switches to avoid damaging switches. Refer to the switch adjustment procedures at the back of this manual. INSPECTION AND MAINTENANCE If the actuator needs to be removed, release the caliper and mechanically cage the springs. Refer to the actuator instruction sheet at the back of this manual for actuator caging technique. DANGER Spring actuators contain compressed springs and are dangerous. Refer to actuator instruction sheet before servicing. Seals can be safely replaced using the disassembly procedure outlined in actuator instruction sheet. Actuators should be retuned to Johnson Industries Ltd. for routine inspection and reconditioning on a 24 month basis or more frequently for extreme operating conditions. When replacing seals, ensure that they are installed correctly and are not damaged. Care must be taken not to allow the actuator interior to become contaminated or the seal surfaces to become scratched. Recondition or change the cylinder if the surface finish exceeds 16 rms micro inches. Reconditioning of hydraulic actuator sealing surfaces are permitted so long as the resultant radial clearance after honing does not exceed 0.004 inches. After servicing apply pressure to measure hold-off and release pressures and verity actuator performance. Use a dial indicator on the actuator piston and a valve that allows accurate pressure control to measure hold-off and release pressures. The actuator rod should be totally retracted at the specified release pressure and begin extending at the specified hold-off pressure. Refer to the certified print at the back of Page 8w i Mekhnsen : op this manual for the specified release and hold-off pressures. The measured values must be within plus or minus ten percent of the specified pressure 3.2 : A hydraulic control system should supply well filtered, high quality, petroleum based fluid having good lubricity and oxidation resistance. An ISO VG32 hydraulic oil having a 4 viscosity index greater then 200 is recommended. ‘The viscosity must not exceed é 1000 cSt (4500 SUS) at the minimum ambient temperature. Bleed air from actuator and lines after installation or servicing. Failure to bleed air from hydraulic lines and actuator will result in slow and erratic actuation and can damage the seals. Page 94.0 TROUBLE SHOOTIN service temperature ©. Inadequately sized} Verify flow rating of valves valves SYMPTOM CAUSE DIAGNOSIS RECTIFICATION 4d a, Control valve failure} Energize valve and verify valv¢ Replace or repair Brakes will actuation control valve not release b. System pressure too | Verify system pressure greater| Adjust pressure settings low than specified release pressure ¢. Actuator seized | Verify actuator response to. | Replace actuator release pressure 42 a. Control valve failure] De-energize valve and verify | Replace or repair Brakes valve actuation. Verify contro} defective valve. Open not set valve is fail safe design. Verify all valves blocking no other valves closed pressure at actuator. b. Actuators caged out } Verify caging ring in stowed position Apply release pressure and remove caging rings ¢. Actuator spring failure Verify hold-off pressure with if Replace actuator specification d. Insufficient actuator stroke Verify actuator stroke sufficierft Adjust air gap or to close air gap replace linings if necessary. Remove actuator jam nuts and release actuator. 43 a. Aerated oil Verify no air in oil Bleed actuators Slow brake response | b. High oil viscosity | Verify oil specification and | Replace oil Replace valves with properly sized valves Page 1044 a, Contaminated lining Verify linings and disc dry and] Clean with solvent and Brakes slip | or disc free from oil bumish. Check for oil leaks, b. Poor lining contact | Verify 75% minimum contact.| Clean grooves if Verify grooves not plugged. | necessary. Burnish linings. Verify hold-off pressure withi c. Failed actuator specification Replace actuator springs Verify air gap within tolerance| 4d. Excessive air gap Adjust air gap to Verify grade of linings specification e.Incorrect linings | Verify caliper does not contact] Replace linings brake frame when brakes set Check brake mounting and cortect if necessary. Replace linings if worn. Inadequate float 45 a. Both shoes dragging] Verify brake release pressure. } Adjust system pressure Rapid or | on flange erratic lining wear |b. One shoe dragging | Verify brakes centered on disc | Reposition brakes, on flange Verify adequate float Verify bearing condition Recondition swept face ¢. Rough disc surface | Verify surface finish within | of disc finish specifications Reposition and/or shim e. Linings not fully | Verify brakes properly brakes to fully seat seated on dise positioned and mounted. linings Correct disc run-out if f. High axial run-out | Measure axial run-out. Verify] possible. Adjust air gap] adequate air gap and lateral — | to accommodate dise. float, Limit duty eycle of brakes g. Excessive dise Verify maximum disc temperature temperature not exceeded. Page 15.3 meohnseon 9 The number and nature of spare parts that should be carried will depend on severity of service, frequency of cycling and functional criticality of the brakes. Parts which may require replacement due to normal wear are: 1. Friction Finings (clw rivets) 2. Actuator seals 3. Release & wear switches 4, Slide bearings For critical applications with high duty cycle it may be advantageous to carry a set of lined shoes, actuator assemblies and caliper pins to reduce down time. When ordering spare parts, specify caliper model and serial number, and part number and quantity of spare parts. VICE Johnson Industries offers field service, supervision, and assistance, during installation, maintenance, and tests, at a nominal per diem rate plus disbursements at cost plus a handling fee. Under no circumstances are field services of any kind or'commissioning allowed for in the prices of our brakes unless expressly so stated in writing on our quotations. Johnson Industries also offers shop services to recondition or repair worn brake assemblies or components, Contact a Johnson Industries representative for an estimate of the work desired, WARRANTY Johnson Industries warrants their calipers and dises to be of the quality specified in our quotations. We guarantee our materials and workmanship for a period of ninety days from date of delivery to the end user. Disc and lining performance in regards to wear, friction coefficient, and energy dissipation depend on severity and condition of the brake crvice. Therefore, the purchaser shall verify through adequate testing that all linings, calipers and dises perform satisfactorily in his particular application, any warranty concerning such performance being expressly excluded here from. Our liability in respect of any failure of goods supplied by us or any loss, injury or damage attributed thereto, shall be limited to making good the repair by replacing and refitting free of charge-any Page 12g00ds or parts thereof which are shown to our satisfaction to have been proved, under their intended use, defective in materials and workmanship within the ninety day guarantee period, provided that such defective parts are promptly returned as directed by us, transportation charges being paid by the purchaser, and provided further that no burning or welding or any modifications of any sort has been done on any such defective goods or parts. In every case, the customer shall be charged for replacement parts on a pro rata basis for the elapsed portion of the warranty period. In the case of friction linings, products and components manufactured by others, we extend to the Purchaser the warranties of the manufacturer only, Deterioration, damage, or malfunction caused by inadequate storage or handling prior to or after sale to the end user are not covered by this warranty. We reserve the right to make changes and add improvements at any lime without incurring any obligation to make such changes and improvements on products already produced. This warranty and guarantee is in lieu of all warranties, conditions, or liabilities implied by law or expressed by statuteOption 1 GAP ADJUSTMENT PROCEDURE Ensure that the hoist drive is locked out ond that the hoist drum is dogged or held by onother brake while the adjustments ore_being made; Remove back covers (and retaining plate@ to access ‘the air gap adjustment spindles @ Apply full release pressure to the brake to open it to its maximum air gap; Option 1 A. Place appropriate shims @) between the disc ©) and brake pads © to provide the desired air gap, Total thickness of shims to be equal to desired air gap: 8. Screw thé adjustment spindles (2 in evenly, using the flats@, until the pads © contact the shim @. Do not force spindle against shims such that Shims cannot be removed C. Ensure thot screw holes on spindle retainer ©) line up. Adjust if necessary Option 2: A. Mount @ dial indicator ® on the caliper to sense the disc. Push caliper over so that opposite shoe contacts “disc ond zero dial indicotor. Push caliper back so that near shoe contacts disc and read displacement from dial indicator Screw the adjustment spindles @) in evenly, using the flats (2), to correct air gap if sary. (spindles have a .076" per quarter turn adjustment resolution) For brakes with two or more actuators per side ensure thal linings are parallel to the disc after adjustment, C. Ensure thot screw holes on spindle retainer @ line up. If screw holes do not line up, release brakes, readjust B. nece Note: Adjust if necessary Reinstall spindle retainers @ and remeasure. Stow caging ring@@ and reinstall adjustment access covers Return the brake to its set condition and remove any dogging means employed to secure the hoist while the gap adjustment was made. e | AIR GAP ADJUSTMENT PROCEDURE Mehnseon industries /elevanja |____——_0S" SERIES CALIPER BRAKE 500 Fives Pang, gyrers Be Conate Yar TV ONG. NO. i DSPS—01.6 Bah Roa x, Somerset Engiond Tas @NO hEBRAKE SHOE REPLACEMENT PROCEDURE Shoes should be removed ond re~lined whenever the linings show excessive wear (<5 mm thickness.) or damage. Never allow friction lining rivets to contact the disc. Replocement linings are much less expensive than replacing or re-machining a scored disc 1. Ensure that the conveyor drive is locked out and that the conveyor is dogged or held by another brake while the adjustments are being made; 2. Fully release brake and cage actuators, remove temperature switches; 3. Retract actuator spindles per drawing OSPSS-01 and switches per drawing DSSA~01; 4 Secure brake shoes with hoist rings G); 5. Remove shoe guide pins (1) ond return springs @ on actuator sid 6. Remove brake shoes, reline and reinstall or replace with newly lined shoes; 7. Replace shoe guide pins @) being sure to install return springs @ on actuator side, Insure thot shoe pins are fully threaded into shoe: 8. Adjust actuator spindles’ per drawing DSPSS-O1 ond switches per drawing DSSA-O1; 9. Return the brake to its set condition and remove any dogging means employed to secure the conveyor while the shoe replecement was made. REPLACEMENT. ‘DS’ SERIES BRAKE SHOE PROCEDURE industries / elevanja ~~ iver oe, Reyrora Cocoa vee | DATE: _950622 Ye EF 3S SST e oe oT oe Se REV. 950911 Both Reed, Sadgaater, Somerset Eeglong Te 4NU rrVLV—-SL6 7 QL __=esers /enoayiie eT ae couse 4OD~A9-021 NOASANOD NSNPU BOSaqOm e NA 5% OL S1N08 OMONY ovoT=3ue or AaTINd d-hv oma) ATENISSY 3YVYE ¥dII¥D aorozse | B/UBNBO / Sel SSAGOTNE WORLORTS sai eooNSE OaEUNDUE S ose imenassy \ 8B O9tT are. 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Al BAH1140 2 BBFL3B59 3 BBFC3859 4 BBFR3859 AS Bs4978 6 BFS5859 as BPSC3859 8 BSRS2030 9 BSB2040 10 22C24BH5 1 2C5N 12 F1BC56S8 13 BMBLE3B59 14 BPS3040 15 BLTS3859 16 BRPS3040 7 BWPS3040 18 BHH3859 19 FI6F2J 20 FeDP32 21 BILS3859 22 FORI7 As BFSGBKS 180 Conada vex 14 SLAP REY HT a Th aS DESCRIPTION ACTUATOR ASSEMBLY ACTUATOR PLATE, CENTER PLATE CALIPER PLATE SHOE PLATE FRICTION LINING — SHOE GUIDE PIN SHOE RETURN SPRING SLIDE_BEARING CALIPER ASSEMBLY BOLT CALIPER ASSEMBLY NUT ACTUATOR MOUNTING BOLT CALIPER LIFTING EYE SHOE LIFTING EYE LINING TEPERATURE SWITCH BRAKE RELEASE SWITCH LINING WEAR SWITCH FLOW-THRU LINE HOSE PROX SWITCH LOCK NUT DOWELL PIN LINING INSULATOR LINING RIVETS FRICTION LINING No 2 3 RIVET 8 N®ODEANANNO ao Rosansas Mgtee Ne 8 2 RIVET DS2040 CALIPER BRAKE ASSEMBLY KRUPP CANADA / LOS PELAMBRES [By HE BATE'JULY 30/08 [ OWEN. = |#12 JIC PRESSURE CONNECTION TO BRAKE #8 JIC RETURN LINE FROM BRAKE QUICK APPLY MODULI ELECTRICAL BOX a ~8 JIC PRESSURE AND —12 JIC RETURN CONNECTIONS TO POWER UNT A 230 cu.in_ BLADDER — ACCUMULATOR oa | SPECIFICATIONS & SETTINGS QUICK APPLY —~ | | MANIFOLD. | SOLENOID VALVES: 115VAC/SOHZ/19w ACCUMULATOR PRECHARGE: 103 ‘BARS "PRVQ’ OUTPUT PRESSURE: 117 BARS 'PSQA’ PRESSURE SWITCH: 110 BARS QUANTITY: TWO. TAG NUMBERS 120-CV-005~23¢02 120-CV-006-23C02 4 MOUNTING HOLES ba gy 012.7 [1/2"] | a DIMENSIONS: mm} e QUICK APPLY MODULE Mehnson industries / elevanja (OS PELAERES COMEYORS 120-7-05 & 06 “BOTT net tae GT | Se Crote Wet PP CANADAaa RiGee i | st, 2 SH eas Baas, SURE SWITCH PSQA: PRESSURE REDUCING VALVE PRVOQ: ACCUMULATOR ACQA: sva 100 MILLISECONDS AFTER TO Ri 8 EASE BRAKES ALL SOLENOID VALVES NEED TO RAKE LINE PRESSURE SWITCH - HI = 110 BAR (RISING) 117 BARS 103 BARS ‘82 & SVB3-BRAKE APPLY SOLENOID VALVES APPLY BRAKES ENERGIZE SVB3 FOLL ED BY SVBI & SvB2 BE DE-ENERGIZED BRAKES FULLY APPLIED ehasen industries / elevanja | ELECTRICAL & HYDRAULIC SCHEMATIC. QUICK APPLY MODULES CONVEYS 120=¢Vv~005, & GOS one: NOV OS, STV. ANOS “2. JANOS 134978.94PART_NO. ENC4978 EBP4978, HoB4978 HVSV3C10 HVSV3010 HSVC115D HCV—CXEB HAC2308 HACC172 HACB120 HCV=XFAB HSP35HED HRV-PBHB HPG300BL £EQ4978 1 1 2 1 QTY DESCRIPTION QUICK APPLY ENCLOSURE BACK PAN CIRCUIT BLOCK SOLENOID VALVE (SVRB1&2) SOLENOID VALVE (SvsB) SOLENOID COIL CHECK VALVE ACCUMULATOR ACCUMULATOR CLAMP ACCUMULATOR BASE CHECK VALVE PRESSURE SWITCH PRESSURE REDUCING VALVE PRESSURE GAUGE ELECTRICAL ENCLOSURE Mehnsen industries / elevanja sens Reknand 80 Cones aE Ne Te Se TNT eT Bites Soman tne Te a OO ET QUICK APPLY MODULE ASSEMBLY DRAWING HE owe FEB O68 [man Soke aK ca 4978—P1. ean pit/Iperves/r14/ipB859Zza g, ith 2 ke SPECIFICATIONS NLET PORT MODEL No.: HARS2562 SPRING ACCUMULATOR APPLICATION: 1000 psi - 100 psi LINEAR RAMP VOLUME: 244 cu. in OPERATING PRESSURES RETRACTION: 1150 psi MAX DESIGN: 3006 psi DESIGN LIFE: 10,000 CYCLES ASSEMBLY WEIGHT: 85 Ibs MOUNTING: BOLTED BRACKETS (SUPPLIED) @m industries /elevanja Itd| 1900 psi RAMP ACCUMULATOR — | y SaceneeetiaeE SPECIFICATION DRAWING Yorenr 8 Conodn —~ Tb 606275 157 Fo: 60 218 9884 [ayctLEpKens “| oaTE-Oct 1 (6. WO : Terao OM Conado, Tek 416-713 991 For 416 215 9982 [=> Arigvoler SOM Enclond ~~ Tet 01278 456411 Fox: 01278 479849. |= A2562-01.0ITEM GTY PART NO. DESCRIFTION PSI_RAMP_ACCUMULATOR LY DRAWING P/N HARS2562 one: AUG O4FRENO DE CALIBRE DH2040#682508 Industries / elevanja 2.0 40 ‘f° Wester office © Eastern Office £500 Dennett Place 108 Skyway Averve Detta BC. Toronto ON Canada Vac 1N4 Canada Maw av “Tol: 604 940 4555, Tok: 416.213 9991 Fax: 604 940 4565 Fax: 416 213 9902 ‘www jbrakes.com wow. brakes.ca INDICE INSTALACION 1.1 GENERAL... 12 MONTAJE 1.3 PLOMERIA . 1.4 DESCARGA INSPECCION Y MANTENIMIENTO 2.1 LINEAJE .... 2.2 BRUNIMIENTO 23 DISCOS ... 24 ESPACIO DE 2.5 LUBRICACION ...... 2.6 SUICHES DE LIMITE ACCIONADORES INSPECCION Y MANTENIMIE PROVEEDOR DE PRESION SOLUCION DE PROBLEMAS 4.1 FRENOS NO SE SUELTAN 4.2 FRENOS NO SE APLICAN 4.3 REACCION LENTA DE FRE! 4.4 DESLIZAMIENTO 4.5 USO RAPIDO 0 IRRE! GARANTIAS Y SERVICIOS 5.1 PIEZAS DE REPUESTO RECOMENDA 5.2 SERVICIO 3 GARANTIA © European office Bath Road Bridgwater Somerset England TAG 4¥Q Tel: 01278 456 411 Fax: 01278 429 949 www olevanja.com e@nan eoonas1.0 INSTALACION 1 1.2 GENERAL EI freno del calibre de la serie ‘DH’ de Johnson Industries es un tipo de freno de accién directa utilizando accionadores aplicados hidraulicamente que acta directamente en el zapato del freno. Los calibres estén montados en un marco por via de dos clavijas de soporte. Los soporte de deslice teflon en el calibre le permite al freno flotar lateralmente en las clavijas de soporte para compensar el movimiento axial de el disco o de la usura del lineaje. Los frenos de! calibre ‘DH’ son disponibles en una gran variedad de fuerza de apriete y puede ser seleccionada con varios tipos de grados de friccién. Los frenos son disponibles con accionadores ya sea en el lado derecho 0 izquierdo o ambos lados y en tres diferentes estilos de bases para montaje ya sea horizontal, vertical o inclinado. Contacte a Johnson Industries para asistirle en la seleccién de freno mas adeouada para la aplicacion del usuario, MONTAJE Los discos son normalmente instalados antes de la colocacién del calibre. Los discos son mandados con una capa de inhibidor de sarto aplicadas a las superficies expuestas. Esta capa dafiara permanentemente el lineaje de friccién si esta es permitica llegar en contacto con el disco, Es indispensable el remover totalmente el inhibidor de sarro con un solvente para limpieza antes de la instalacién de los calibres. La mayoria de calibres son enviados dle modo sueltos para facilitar la instalacién. dis Antes de apretar los peros del calibre, sujete el calibre en « Esto es hecho al aplicar 1000 psi de presion hidrdulica a los accionadores. EI paquete de poder hidrdulico usado para disparar los trenos manualmente tienen que estar limitado a una presién maxima de 2000 psi y el aceite tiene que ser filtrado a un absolurto nivel de limpieza de 10 micrén (ISO 18/15). Con el calibre sujetado en el disco verifique que los zapatos estén paralelos con el disco y que fa base este planamente sentada. Corrija con chapas de relleno si es nocesario. Verifique que las almohadillas quopan completamente en el disco y que el ensamblaje este centrado con el disco, Recoloque los frenos 0 suplemente con calzo la base si lo es requerido,1.4 presionizacién. Los frenos tienen que ser ciclados varias veces para sacar todo el aire. DESCARGA Para frenos disparados hidrdulicamente el sistema tiene que ser descargado antes de comisionar el equipo para asegurar una apropiada y confiable operacién del equipo. Este procedimiento tiene que hacerse periédicamente o cuando el circuito se haya quebrado y haya que remplazar un componente. Para un sistema nuevamente comisionado las pipas y las mangueras también tienen que ser pre-descargadas antes de ser conectadas al equipo para remover cualquier contaminacién aspera. Después de plomear el sistema completo puede ser descargado ai hacer lo siguiente. El aceite tieno que ser idealmente descargado a un nivel de limpieza 8.0. de 17/14. Este nivel de limpieza puede lograrse al usar un 10 micrén (0 mas fino) un elemento filtrante con un beta considerable de 75 (o mas alto). La duracién del descargue tiene que ser suficiente para permitir todo el aceite dentro del embalse y el sisterna que sea circulado a un minimo de cuatro veces por el filtro. El estabiecimiento tiene que incluir un filtro apropiado, como especificado arriba, en la porcién de linea retornable del circuit para filtrar los contaminantes antes que lleguen al embalso. indeseable el descargar los contaminantes dentro del embalse porquo pueden ser recogidos por la bomba y posibblemente cause dafio. Muchas unidades de control hidrdulicas tienen una linea de filtro retornable por lo cual en este caso solamente se requiere que el elemento sea apropiadamente valorado. Para esos casos que no tienen una linea de filtro retornable un filtro girador puede ser lemporaneamente agregado al circuito para descarga. Muchos sistemas hidraulicos tienen tipos de circuitos de flujo alternativo mientras que el descargar se requiere un flujo circulalive. Para estos casos una manguera apropiadamente considerada tiene que ser plomeada entre el filtro descargador y el segundo conducto accionader. Para flujo por medio de tipo de circuitos una linea rotornable estar presente, Descargamiento es mejor logrado con un flujo turbulent para “derribar” los contaminantes del sistema. Para esas unidades de2.2 Cuando se instale nuevos lineajes asesdrese que los lineajes estén unidos y también remachados y que todos los remaches estén cémodos. En aplicaciones criticas es de ventaja el cargar un juego de repuestos de zapatos de frenos alineados para prevenir el apagar las maquinas operadoras. Lineajes reemplazadores tienen que ser como lo es especificado originalmente. BRUNIMIENTO El brufiimiento de lineajes de friccién esta hecho para proveer un buen contacto limpio entre los lineajes y el disco. El procedimiento remueve contaminaciones menores en el disco 0 lineajes también como cualquier mancha alta menores 0 mal alineamiento de los lineajes. Nuevos lineajes requieren bruiimiento para colocar totalmente los lineajes en el disco y periédicamente sobre la vida de los lineajes para remover cualquier contaminacién de luz o pelicula de oxido de la careta entlechada del disco. Antes del bruimiento, aseguirese que el disco y lineajes estén libres de contaminacién. Si se requiere el limpiar, use un solvente de base sin aceite. Sila careta enflechada del disco tiene una capa pesada de sarro entonces el brunimiento inicial es requerido para removerlo ta etapa tiene que ser hecha a una baja temperatura y fuerza de apriete. Después que el sarro ha sido removido inspeccione los lineajes y verifique que las ranuras de lineajes no se han llenado de escombros sueltos. Limpie las ranuras si el necesario. Lineajes contaminados grandemente o quemados tienen que ser descartados. Ademas de preparar los lineajes y discos para el brufimiento. Cualquier enganche de seguridad del mecanismo de propulsién de sistema de frenos debieran de ser enpuentados para permitirle ai disco el ser manejado por los frenos. Para bruni, aplique una presion de 500 a 750 psi a lo accionadores y propulsionelo a los frenos a una velocidad de 100 a 150 fpm del disco. La fuerza de apriete de los zapatos de ireno puede ser ajustado al controlar la presién en los accionadores. Fs preferible brufir con el maximo alcance para reducir el tiempo « brunimiento pero finalmente la torsidn del freno mientras se brufe da por la capacidad da la torsion de la propulsion, el lineaje durante el brufimiento pue A limi rsuficiante presién ¢2.3 DISCO DE FRENO Para aplicaciones estandar ol disco debe de ser manufacturado de ASTM A588 0 un material equivalente a este. EI disco debe de ser apropiadamente dimensionado para la aplicacién del freno. El. D. debe ser seleccionado para proveer la torsion deseada, el |. D. debe de permitir suficiente espacio radial para remover los zapatos durante el remplazamiento lineador y la densidad debe de ser escogida para absorber cuidadosamente la entrada de energia del freno. Refiérase al dibujo certificado en lo de atras de este manual para dimensiones criticas. Para las conexiones empernadas el didmetro localizante del disco debe de ser maquinado a una clase de lolerancia de H8. El disco debe de ser balanceado a ISO 1940/1 grado G40 para aplicaciones de baja velocidad y G6.3 para aplicacién de alta velocidad. La careta en flecha del disco debe de tener una superficie terminada dentro de 32 a 64 rms micro pulgadas. Una superficie terminada excediendo lo maximo resultara quebrandose bruscamente y desgaste rapido del lineaje. Discos rayados 0 dsperos tienen que ser reacondicionados, removiendo no mas de 0.02 pulgadas por pulgada de densidad. Caretas deben de estar planas y paralelas dentro de 0.004 pulgadas a través de la careta en flecha. Vencimiento radial y lateral no deben de excederse de 0.001 pulgadas y 0.002 pulgadas por 12 pulgada tespectivamente en diametros, se. Si La capacidad de calor disipada dei disco no debe de exceder la energia absorbida en el freno del calibre, cuando usada bajo condiciones dinamicas de aplicaciones continua a un ciclo de alte unci6n, excede la capacidad de la energia disipada del disco entonces la torsién debe de ser limitada 0 reducir la funcién del Para aplicaciones de alta funcién ASTM A514 0 equivalente debi ser especificado para el material del disco y una atencién especial debe de ser puesta a la tensién quebranies y lermal en el ensamblaje del disco/manija, Consulte a Johnson Indus tales aplicaciones por NUNCA APLIQUE AGUA A UN DISCO CALIENTE i Dafio permanente en forma de una corriente de c imiento serd el resultado,2.6 Cuando ajustando el espacio de aire, asegtirese que el calibre flote libremente. Serd necesario, en base regular, el remover las clavijas de soporte y el limpiar ambas clavijas y el soportes de deslice en el calibre. Aunque lubricando el soporte de deslice reduciria la friccién del deslice, esta practica debe de evitarse si es posible. El lubricante atraera polvo y por eso requerird mas frecuentes intervalos de mantenimiento y posiblemente reducira la vida de los soportes. Cuando remplazando los lineajes asegurese que los filetes de las clavijas del zapato tengan suficiente compuesto de ante irritante aplicado y que una grasa EP también sea aplicada al vastago. SUICHES DE LIMITE Los suiches de proximidad del disparador de frenos y del desgaste de lineaje son disponibles como una opcién. Los suiches son suplidos ya precableados a unas terminales de azada de DIN 43650. Si se presenta, ambos suiches deben de ser ajustados cada vez que el espacio de aire es ajustado. El no ajustar los suiches resultaria en una indicacién inadecuada de desgaste en las almohadilias y disparo de frenos EI mando del suiche de! suiche de proximidad del disparacior de frenos debe de ocurrir dentro de 4/16 de una pulgada de plena retracci6n del accionador. Asegtirese que el suiche se ponga a cero antes que las almohadillas contacten el disco. La posiciéri de! suiche en el calibre debe de ajustarse cada vez que el espacio de aire es ajustado. Este procedimiento es llevado a cabo al disparar {os frenos, removiendo el conector, aflojando la contratuerca dandole vuelta al bastidor del suiche de izquierda a derecha Avance el bastidor del suiche hasta que contacte la placa de! zapato y luego retrdigalo un cuarto de vuelta. Asegure las regulaciones apretando fa contratuerca a 25 fibras por pie. El suiche de limite del desgaste de lineaje es listo para ponerse en marcha a un maximo valor del espacio de aire de 2/16 de una pulgada (4.5mm). Manteniendo el espacio de aire dentro de sus limites ospecificados es critico al total cumplimaiento de! freno.4.0 SOLUCION DE PROBLEMAS SINTOMA CAUSA DIAGNOSTICO RECTIFICACION 4A a. Fallaenlavalvula Verificar que no haya Remplazar o reparar la Frenos no de control presion en elaccionador —_valvula de control se sueltan b. Lasclavijas del —_Verificar que las clavijas._—_Lubricarse Zapato estan del zapato estén libres atascadas ©. Accionador Verifique que el Remplazar el accionador atascado accionador responda a la presion 42 a. Falla enla valvula Verificar que la valvula —- Remplazaro reparar la de contro! presuriza al accionador _valvula defectuosa Frenosno bh insuficiente Verificar que halla Ajustar el espacio de aire se aplican carrera del suficiente carrera en el © remplazar los lineajes accionador accionador para que cierre_si es necesario el espacio de aire 43 a. Aceite aireado —_Verificar que no haya aire Exudar los accionadores Reaccion en elaceite lenta de frenos b. Alla viscosidad —_Verificar a especificacién_-Remplazar aceite y servicio de la temperatura del ac Verificar la evaiuacion del Remplazar valvul: ©. Valvulas inadecuadament fiuido de fas vélvulas valvulas apropiadar e medidas medidas a. Espacio de aire —_Verificar el espacio de aire Ajustar ef espacio de aire excesivo que este dentro de especificaciones5.2 IEZAS DE REPUESTO RECOMENDADAS El numero y naturaleza de las piezas de repuesto que se deben de llevar dependerd en la severidad del servicio, frecuencia del ciclado y la criticalidad funcional de los frenos, Piezas cuales pueden requerir reemplazo debido al uso normal son Lineajes de friccién (c/w remaches) Sells del accionador Suiches de disparo y uso . Cojinetes de deslice epe Para aplicaciones criticas con ciclo de funcién alta puede ser de ventaja el mantener un par de zapatos alineados, montajes de accionadores, y clavijas del calibre para el reducir perdida de tiempo. Cuando ordene piezas de repuesto, especifique los modelos del calibre y nimero de serie, niimero de pieza y la cantidad de piezas de repuesto. SERVICIO Johnson industries ofrece servicio del campo, supervisién, y asistencia durante | instalaci6n, mantenimiento, y pruebas, en una tarifa diaria nominal m: desembolsos al costo mas e! honorario de direccién. Bajo ninguna circunstancias los cargos de servicio de campo de cualquier forma o comisién &s permitido en los precios de nuestros frenos al menos que esto sea expresadamente dicho por escrito en nuestras cotizaciones. Jonson Industrie también ofrece servicios de taller para reponer o reparar fajes de frenos usados 0 sus componentes. Contacte a ios representan! de Johnson industries para un estimado det trabajo que usted desee Johnson Industries garantiza que sus calibres y discos son de la calidad especificada en nuestras cotizaciones. Nosotros garantizamos nuestros materiales y trabajo por un periodo de noventa cias desde la fecha de mando a usador. El funcionamiento de los linajes y discos en relacién al desgaste, Coeficiente de friccién y disipacién de energia dependen de la severidad y Condiciones del servicio de frenos. Por io tanto, el usuario dehera de verificar mediante pruebas adecuadas que todos los lineajes, calibres y discos funcionen900 ® 'S00-A9—021 szuOGHLuOd: YSOQYSN3dNOd VIIOd 3488VO 30 ONIX B0r0zHG + WON vonsoms | ‘so gO era2 bk fap veep vce] eet SS SOL PSP VY VION 30 SONNE Sov aouW to 6 ©) Comusonsg ov ross norm a _ ng 5 gna USER oP anors so Bs \ 3B ie suais09 ovr 2 we tins “eas: ovoid Sorina MONI VIIa 1 30. rear SOVGHLNYD “5: ‘wooideasua oovaerid Sho WOT 1 WIND OF2. (zoamvor exo 730 ond @ os 2) 9910 2a AL oe} Ho soaHoesrt 4 SfOTSEL HOTWAOKSHYEL —-aoaNO-IOY 3a oraNeY WEAN aMVANOM / Sau; 9 "S00 Bate “so oa) ° Sorevasia aiuOssy /"confesart Cavatoy 5 ‘SNvios Sua RONTPsistema de frenos debieran de ser enpuentados para permitirle al disco el ser manejado por los frenos. Para brufir, la fuerza apretadora de los zapatos y disco del freno debe de ser seleccionada para que el poder friccional generado este en el rango de 0.15 a 4.5 caballos de fuerza por la pulgada cuadrada del érea del lineaje. La fuerza de apriete de los zapatos de freno puede ser ajustado al controlar la presion en los accionadores. Es preferible bruiir con el maximo alcance para educir el tiempo del brunimiento pero finalmente la torsién del freno mientras se brufe seré limitada por la capacidad de la torsién de la Propulsion. Insuficiente presién en el lineaje durante el brufiimiento puede pullir el material del lineaje, resultando en una reducci6n de la friccién coeficiente. Si esto ya ha pasado los lineajes deben de ser removidos y lijados manualmente para frotar la superficie. La temperatura tiene que ser controlada durante el proceso del brufiimiento. La temperatura del disco tiene que ser mantenida entre 250°F (120%) y 450°F (230%). Cuando se alcance el limite superior de la temperatura ponga pausa al brufimiento hasta que el disco se haya entriado al limite mas bajo. {Nunca permita que la temperatura del disco excedal 1500°F (260°). Dafio permanente al lineaje del materia Brufia hasta que un minimo de setenta y cinco por ciento del contacto del lineaje y una superficie luminosa en el disco ser adquirida. Para medir el grado de contacto, ajuste los frenos y use una galga palpadora de .002" para sondear el perimetro de cada zapato del freno. Sila cantidad que la galga palpadora haya podido sondear excede el veinte y cinco por ciento del area del lineaje entonces mas. brufiimiento es requerido. La suficiencia del bruhimiento también debe de ser verificada con pruebas de carga o con medidas de paro del tiempo. Si a torsién verdadera del freno no cruza con el régimen de torsion del freno entonces mas brufimiento debe de ser requerido, {CUIDADO INo ponga el equipo en servicio si el régimen de la} ftorsin del freno no es desarrollado. Consulte a }2.4 ESPACIO DE AIRE El espacio de aire debe de ser inspeccionado en base regular y ajustado si es necesario por desgaste del lineaje. Un excesivo espacio de aire resultaria en una extensién excesiva del accionador y una perdida significante de la torsién dol freno. Un-excesivo espacio de aire y extensién del accionador; 1. reduce la fuerza de la abrazadera y por eso la torsion del freno por la perdida de la fuerza del resorte asociada con la extensién del accionador. 2. incrementa el tiempo de reaccién del freno por la gran cantidad de volumen de aceite que sera cargado. 3. reduce el uso permisible del lineaje mientras los accionadores tienen una cantidad limitada de carrera. 4. puede resultar en una perdida de fuerza del accionador debido a una carrera inadecuada, El espacio de aire debe de ser ajustado nuevamente dentro de sus especificaciones cada vez que se haya salido de su tolerancia. El espacio de aire es ajustado al extender el eje del accionador. Empiece por el remover la cubierta trasera y el contenedor del eje. Aplique presion libre a los accionadores e inserte una chapa de relleno de equivalente densidad como la del espacio de aire entre el disco y las almohadillas del freno del lado del accionador. Asegure de que el calibre sea excedente cambiado de puesto de modo que todo el espacio de aire este en el lado del accionador del calibre. Atornille los husos de ajuste hasta que las almohadillas hagan contacto con el relleno y todos los husos contacten la parte posterior del zapato. Una vuelta completa en el ajustamiento de los husos cierra el espacio de aire por 1/16 de una pulgada. Asegure que el retenedor del huso se alinee con sus agujeros de montaje. Después de alinear los agujeros del detenedor de huso instale el detenedor y cubierta trasera luego quite la chapa de relleno. Roté los frenos y vuelva a chequear el espacio de aire. Después de ajustar el espacio de aire los suiches de disparo y desgaste si son suplidos tienen que ser también ajustados (mirar seccién 3.5). El espacio de aire es medido al empujar un zapato contra el disco mientras se mide la distancia entre el lineaje y el disco en el otro zapato. Referirse al procedimiento de ajustamiento del espacio de aire (dibujo DSPS- 01) en la parte posterior de este manual. 9antes que las almohadillas contacten el disco. La posicién del suiche en el calibre debe de ajustarse cada vez que el espacio de aire es ajustado. Este procedimiento es llevado a cabo al disparar los frenos, removiendo el conector, aflojando la contratuerca y dandole vuelta al basticor de! suiche de izquierda a derecha. Avance el bastidor del suiche hasta que contacte la placa del zapato y luego retrdigalo un cuarto de vuelta. Asegure las regulaciones apretando la contratuerca a 25 libras por pie El suiche de limite del desgaste de lineaje es listo para ponerse en marcha a un maximo valor del espacio de aire de 3/16 de una pulgada (4.5mm). Manteniendo el espacio de aire dentro de sus limites especificados es critico al total cumplimiento del freno; un excesivo espacio de aire resulta en una insuficiente torsién del freno. Es importante que el suiche de desgaste sea apropiadamente ajustado cada vez que el espacio de aire es ajustado. El punto de regulacién del suiche de desgaste es ajustado de la manera exacta que el suiche de disparo. Cuando remplazando los lineajes retraiga completamente ambos interruptores para evitar el dario de los suiches. Referirse al procedimiento del ajustamiento de suiche en lo de alras de este manual. 3.0 ACCIONADORES 34 Siel accionador necesite ser movido, suelte al calibre y enjaule mecanicamente los resortes. Referirse a la hoja de instrucciones del accionador en la parte posterior de este manual para la técnica enjauladora del accionador. PELIGRO jAccionadores de resorte contienen resortes t komprimidos y son peligrosos. Referirse ala hojalde finstruccién del accionador antes de darle prantenimiento. Sellos pueden ser remplazados con seguridad usando el procedimiento del desmontaje trazado en la hoja de instruccién del4.0 SINTOMA 4d Frenos no se sueltan 42 Frenos no se aplican SOLUCION DE PROBLEMAS CAUSA Falla de la valvula de control La presion del sistema esta muy bajo Accionador atorado Falla en la valvula de control. Accionadores enjaulados hacia fuera Falla en el resorte del accionador Insuficiente corridas del accionador DIAGNOSTICO Energice fa valvula y verifique el accionador de {a valvula Verificar que el sistema de presién sea mayor que la presién de disparo especificada Verificar que el accionador responda a la presién disparada De energizar la valvula y verificar la actuacién de la valvula. Verificar la valvula de control esta disefiada contra fallas. Verificar que otras valvulas no estén cerradas, Verificar que el anillo enjaulador este en Posicién guardada. Verificar que la presion de paro este dentro de sus especificaciones Verificar que haya suficientes corridas del accionador para cerrar el espacio de aire. B RECTIFICACION Remplazar o reparar la valvula de control Ajuste las regulaciones de presion Remplazar accionador Remplazar o reparar la valvula defectuosa. Abra todas las valvulas bloqueando Ia presién al accionador. Aplicar presion soltante y quite los anillos enjauladores. Remplazar el accionador. Ajustar el espacio de aire © remplazar los lineajes si es necesario. Quitar la contratuerca del accionador y disparar el accionador,45 Uso rapido e irregular del lineaje Ambos zapatos se _Verificar la presién del arrastran en el lanzamiento del freno reborde Un zapato se arrastra_ Verificar frenos estén en el reborde. centrados en el disco. Verificar adecuado flotador. La superficie Verificar que la superficie terminada del disco terminada del disco este es aspera. en sus especificaciones. Lineajes no Verificar que los frenos asentados estén colocados y completamente en montados correctamente. disco Alto agotamiento Mida el agotamiento axial axial. Verifique el espacio de aire adecuado y flotador y lateral. ~ Temperatura Verificar que la maxima excesiva del disco. temperatura del disco no se exceda. 5.0 GARANTIA Y SERVICIO 51 PIEZAS DE REPUESTO RECOMENDADAS Ajustar la presion del sistema a su especificacién Recolocar frenos. Verificar la condicién del cojinete, Reparar la careta en flecha del disco Coloque y/o calee los frenos de nuevo para asentar completamente los linoajes. Cortija el agotamiento del disco si es posible Ajuste el espacio de aire para acomodar el disco. Limita el deber del ciclo de los frenos. El numero y naturaleza de las piezas de repuesto que se deben de llevar dependera en la severidad del servicio, frecuencia del ciclado y la criticalidad funcional de los frenos. Piezas cuales pueden requerir reemplazo debido al uso normal son: Lineajes de friccién (c/w remaches) Sellos del accionador Suiches de disparo y uso Cojinetes de deslice Pena Para aplicaciones criticas con ciclo de funcidn alta puede ser de ventaja eldeterioro, dafo y el malfuncionamiento causado por el almacenaje inadecuado 0 manejo antes de o después de venta al usuario final no estan cubiertos por esta garantia. Nos reservamos el derecho de realizar cambios y mejorias a cualquier hora sin incurrir en ninguna obligaci6n de llevar a cabo tales cambios y mejorias en los productos ya producidos. Esta garantia se expide en lugar de todas las demas garantias, condiciones o responsabilidades implicitas por ley o expresadas por estatutos. 7PRECAUCION ] Los accionadores de freno de muelles almacenan energia y pueden ser | peligrosos. Manejese con precaucion. Siga los procedimientos debidos. Afloje siempre de manera uniforme los tornillos del dispositivo. Para disipar correctamente el oire atrapado debe contarse con dos abertures que permiten el tun purgador de aire en lo parte mas alto. Cone! purgador control del fluido higraulce, de cire abierto, llene el accionader @ baja presion. ‘Permite Tomano de la aberture: #8. ORB que el fluido salga hosta que no quede cire ni espumo. Cicle el accionador varios veces ¥y repita’ el procedimiento. Las luberias del accionador deben purgase coda vez que se haya abierto uno lineo hidraulico Los Accionadores cuentan con UI = Con Ia perdida de presion de desembrague el freno puede solterse retirando los toinillos de conexion de ‘occionador. Afloje los tornillos de manera uniforme para permitir que los muelles se expandan de forma segura. Al dar servicio a los accionadores, compacte de nuevo los muelies usando grasa de molibdeno de alto presion. Mantengase {a orientacion del grupo des muelles al volver 0 ensamblor. Le argolla de enjualado aporece en posicion de olmacenaje. " Para enjaular el accionador, quite la placa cobertora y la argolla de enjaulado. Presurice el ‘accionador para extender el piston y atornille la. argolla, La argolta sujetara el piston en su sitio ol liberarse la. presion Herramienta especial para desmontaje del accionader. NOTA; Pora vetwvicar que el paquete Ge" melon fundiona. cortectmente, ercloreoe’ de’ Tgue tas: presones de felenelon’y desenganche sean’ los INSTRUCTIVO DE DESMONTAJE DEL ACCIONADOR: siguientes: Retire et acsionader enjusiado de lo bose del freno; Resenganche: 137, boras Prosurzor el acelcnoser'y reliror le poee caper 7'ta crools ce enfsclod Bespresirizr el geslonodor y quiter el sujetodor del eje y el ej: Tome la medida "A" - quia’ del eje a la hendiduro de! piston; archivor para el montaje del Comprima’ los mueles en ta prensa dejondo un margen de occeso a la guia de los muelles an el extrem do lo bose del accionador Dastorlie a cuig cel mete Seco ner eae ‘2mm ‘utizando la herromiente copestl para’ deamontoje wer Gesonnaes Men ee esement piocas de ropucate 6. Eitere ia’prenso lentomente, permitendo que los muciles desengonchen de monera segura hasta olednzor au alors here 7. Al montor el aparato, invierta los procedimientos de orribo. Verifique que la medida *, sea 40.5 mm, que lo presion de fetencion ‘seo de 130 bras qos fy Sesion he ooh brague sea de: 137 barbs y'eP golpe. Sea Ser") Seow w INSTRUCTIVO DEL ACCIONADOR DEL FREN( e@ DE SERIE 'DS’ meohnseon a INDUSTRIES LTD. —— 8500 RIVER RD, RICHMOND BC, CANADA vex tra | SCR DSAS-—01.3 TeL (604) 278 3707 ere lranntess Yanai inns4 PROCEDIMIENTO DE AJUSTE DEL ESPACIO DE AIRE El espacio de cire debe ajustarse cuando el espacio sea menor a 2.0 mm o mayor a 4.0 mm. y que el transportador 1. Cerciorese de que el mecanismo de arrastre del transportador este bloqueado stes; se encuentre sujetado 0 afianzade por otro freno mientras se reclizon los aye 2. Retire las topos traseras () para tener acceso a las varillas de ajuste del espacio de aire @; we abra a su moximo espacio de aire; Aplique presion total de desembrague al freno para y lo pastilla del freno del lado del Coloque ‘un espaciador de 2.5 mm(@) entre el disco accionador ©): Atornille uniformemente las varillag de ajuste @, utilizando los filos plonos@ hoste que las pastilas 6 toquen el espaciador Vacie lo presion de desembrague para que las pastilas @descansen totalmente sobre el espaciader @y el disco 6); SS BS 9. Aplique de nuevo presion de desembrague total y retire los espactadores @: 10. Coloque las tapas del accionador () y reconecte los interruptores de proximidad de desembrague y, de desgaste conforme al dibujo DSSA—01; 11. Ponga otra vez el freno en posicion fija y retire todos los medios que hays utilizado para ofionzar ¥ ‘Sujetor el transportador mientras reclizaba los ajustes al espacio de aire PROCEDIMENTO DE AJUSTE DEL ESPACIO DE AIRE ; ; ; DEL FRENO SERIE ‘OS" industries / elevanja 3500 i Ranh Fayre Se Gone yet a ee 2s 3 rae zat Sc, REV 950911 SPs — Bath Ree, Seale, Sevgee Emgend aS a aga ncn Ter ieee TD SPS—O1 DATE: 940930 _| OWG. NO. BY way Tne: 9PMSUKI.0 X 95 DP >] [65.004 0.25 PARA EL OJO DE ELEVACION ‘mm CHAFLAN /- ANBOS LADOS (36) 042.0 ESPACIADO 10° A +9.00 —0.20 287.80, i ANILLO DE PERNO | 1455 | 3 L. 1200 00+ 9-29 2mm CHAFLAN ESTE LADO 6.5mm CHAFLAN LADO OPUESTO PARA ACOPLARSE AL CUBO whe 45.04 0.2 NSTALAR PERNOS POR EL LADO DEL DISCO. PRECARGAR PERNOS A 750 KN-M~ TORCIONE LA COTRATUERCA A 1500 N-M A UM_DE ETIQUETS CAN. ORIGINAL CANT. DEP 20-CV-005. 120-Gy-0n6 120-CV-007 usl0is eS] 5 5 DISCOS SUPLIDOS VIENEN COMPLETOS CON | FSPECIFICACIONES 5 Bi M39.X 175 PARA PERNOS A. DIN 931, MATERIAL: QT100 ECERO/ ASTM - A514 CLASE 10.9 Y DIN 934, CLASE 10 PESO: 1790 KG 139401 LBS] TUER —_ : @2438mm X 65mm DISCO GRUESO DEL FRENO TRANSPORTADORES 120-CV-005, 006, & 007 Thyssen Krupp / Minera Los Pelambres BF be 981210 | NWG. NO. SOM industries / el os A3859-20.6{PELIGRO! PARTS LIST ACCIONADOR CONTIENE 3) OOM) GEC RESORTES COMPRIMIDOS 13 4 aw HALOS BAHAP1050 BAAS) 050 BASC 1050 FRMFET4 6 SHP455650 SHR605300 8 SHRWD300 1 aSeR i Vancouver BC Gonads Taranto ON Conada Bridgwater SOM England NUM,_DE_PIEZAS CANT, (@ DESCRIP CUERPO DEL ACCIONADOR PISTON BE ACCIONADOR HUSO DE AJUSTAMIENTO COLLAR DEL RESORTE CONTRATUERCA SELLO DEL PISTON SELLO DE BARRA UMPIADOR DE BARRA TEM PART. No, SHRWI650 SHW2654 SSL1125 BARS1050 BAHBSS @ QTY DESCRIPTION 1 1 1 LSTA DE Tel: 604 273 3737 Fox: 604 273 985¢{CUST. WINERA LOS PELANBR Tol: 416 215 9991 Fox 416 213 99925710 47 S ~O LINPIADOR DE BARRA BANDA DE DESGASTE SELLO DE EVE RESORTE DE RETORNO EVACUADOR DE AIRE DETENEDOR DEL HUSO TORNILLO OL DETENEDOR ENCHUFE PORTUARIO.FRENO DE CALIBRE DS20403.0 4.0 5.0 ehusenm industries / elevanja {Western Office 5 £6500 Dennett Place Delta BC Canada VG 1Na Tel: 604 940 4555 Fx; 604 940 4565, ‘wor jbrakes.com INSTALACION 1.1 GENERAL 1.2. MONTAJE 1.3 PLOMERIA . 1.4 DESCARGA Eastern Office 108 Skyway Avenue Toronto ON. Canada MaW 49 Tol: 416 213 9991 Fax: 416 213 9992 www.brakes.ca INDICE INSPECCION Y MANTENIMIENTO 2.4 LINEAJE ..... 2.2 BRUNIMIENTO 2.3 DISCOS 2.4 ESPACIO DE AIRE. 2.5 LUBRICACION . 2.6 SUICHES DE LIMITE .. ACCIONADORES 3.1 INSPECCION Y MANTENIMIENTO 3.2 PROVEEDOR DE PRESION SOLUCION DE PROBLEMAS 4.1 FRENOS NO SE SUELTAN ... 4.2 FRENOS NO SE APLICAN..... 4.3 REACCION LENTA DE FRENOS . . 4.4 DESLIZAMIENTO DE 4.5 USO RAPIDO O IRREGULAR DEL GARANTIAS Y SERVICIOS 5.1 PIEZAS DE REPUESTO RECOMENDADAS 5.2 SERVICIO. 5.3. GARANTIA . FRENOS . AJE 1 European Office Bath Road Bridgwater Somerset England TAS 4YQ) Tel: 01278 456.411 Fax: 01278 429 949 ‘worn. elevania.com kone 15 16 16He@hmsem industries / elevanja 1.0 ‘Bf Western office 1 Eastern Office 1 European ottice 8500 Demet Pace 108 Skyway Avenue Bath Road Deta ac Toronto ON Bridgwater Somerset Canada VAG 194 Canada MSW 4v9 England TAS 4¥Q Tel 604 940 4555 Tet: 416213 9991 Tel, 01278 456 411 Fax: 604 940 4565, Fax: 416 213 9962 Fax 01278 429 049 woe rakes com worw.brakes.ca wwe elevania.com INSTALACION 1.4 GENERAL 1.2 Elfreno de! calibre de la serie ‘DS' de Johnson Industries es un tipo de freno de accién directa utilizando un equipo de resortes, accionadores disparados hidraulicamente actuando directamente en el zapato del freno. Los calibres estén montados en un marco por via de dos clavijas de soporte. Los soporte de deslice teflon en el calibre le permite al freno flotar lateralmente en las clavijas de Soporte para compensar el movimiento axial de el disco o de la usura del lineaje. Los frenos del calibre ‘DS’ son disponibles en una gran variedad de fuerza de apriete y puede ser seleccionada con varios tipos de grados de friccién. Los frenos son disponibles ya sea en una orientacién de mano derecha 0 izquierda y de tres diferentes estilos de bases para montaje horizontal, vertical o inclinado. Contacte a Johnson Industries para asistirle en la seleccidn de freno mas adecuada para la aplicacién del usuario. MONTAJE Los discos son normaimente instalados antes de la colocacién del calibre. Los discos son mandados con una capa de inhibidor de sarfo aplicadas a las superficies expuestas. Esta capa dafiara permanentemente el lineaje de friccién si esta es permitida llegar en Contacto con el disco. Es indispensable el remover totalmente el inhibidor de sarro con un solvente para limpieza antes de la instalacién de los calibres. La mayoria de calibres son enviados de modo suettos para facilitar la instalacién, Antes de apretar los pernos del calibre, sujete el calibre en el disco. Esto es hecho al remover el anillo enjaulador de los accionadores. Para remover el anillo enjaulador, aplique suficiente presion al accionador para dispara completamente los frenos (mire la impresion certificada en la parte posterior de este manual). Con el accionador presurizado, quite la cubierta y desatornille el anillo enjaulador. Déle vuelta al anillo enjaulador al otro lado para montar el anillo en la posicion guardada y reinstale la tapadera. Refiérase a la hoja de instruccion del accionador en la parte posterior de este manual. El uso del equipo de poder hidrdulico del disparar los frenos1.3 manualmente debe de ser limitado a una maxima presién de 3000 psi y el aceite debe de ser filtrado a un nivel absoluto de limpieza de 10 micrones (ISO 18/15). Con el calibre sujetado en el disco verifique que los zapatos estén paralelos con el disco y que la base esta planamente sentada. Corrija con chapas de relleno si es necesario. Verifique que las almohadillas quepan completamente en el disco y que el ensamblaje este centrado con el disco. Recoloque los frenos o suplemente con calzo la base silo es requerido. Cuando el calibre este apropiadamente colocado suelte los frenos y verifique que el calibre tenga un flote adecuado en ambos lados de el marco del freno. Después de empernar el marco del freno en su lugar, suelte el calibre y asegurese que el calibre flote libremente. Es ctitico de que los frenos tengan un despojo radial entre el diametro extemo del disco y el plato céntrico del calibre. Este despojo tiene que ser chequeado y verificado ser un minimo de 3/16 de una pulgada. Cuando la posicién de los frenos haya sido verificada el estar correcta los pernos de montaje del freno tienen que apretarse, Procarge los pernos de montaje al valor especificado en el dibujo certificado 0 a un maximo de setenta y cinco por ciento de la prueba de carga de los pernos. Use ya sea una arandela de presion o una contratuerca para asegurar que los pemnos de montaje no se aflojen. El pedestal del freno tiene que ser disefiado a que le permita suficiente espacio a la llave de apriote para apretar los pernos de montaje. Cuando las temperaturas operadoras excedan 300°F (150°C), los. agujeros de perno grandes deben de ser usados en ambos disco y cubo. Es preferible el taladrar junto los agujeros de montaje cel discofcubo usando el mismo ajuste. PLOMERIA La plomeria del sistema de freno tiene que ser con pipas 0 tubos de medida adecuada, preferiblemente inoxidable, apropiadamente considerada para el operar con presiones. Generalmente una tuberia de ¥% pulgada de didémetro JIC y una pipa de ¥% pulgada de didmetro es suficiente para la mayoria de las aplicaciones. Las. pipas tienen que ser adecuadamente sostenidas con abrazaderas do pipa cada 4 pies para % pulgada y lineas de % pulgada. La conexién del freno tiene que ser hecha con una manguera flexible apropiadamente considerada para el operar con presion. Antes dew 14 Conectarse a los frenos, la plomeria tiene que ser limpiada para remover todos los asperos contaminantes. Después de haberse conectado a la unidad de frenos e hidraulicas descargue totalmente todo sistema hidrdulico a un absoluto nivel de limpieza de 10 micrén (ISO 17/14) antes de aplicar una plena presién operativa. Cuando todas las conexiones estén hechas, el aire tiene que ser extraido de todos los accionadores hidraulicos durante la inicial presionizacién. Los frenos tienen que ser ciclados varias veces para sacar todo el aire DESCARGA Para frenos disparados hidrdulicamente el sistema tiene que ser descargado antes de comisionar el equipo para asegurar una apropiada y confiable operacién del equipo. Este procedimiento tiene que hacerse periédicamente o cuando el circuito se haya quebrado y haya que remplazar un componente. Para un sistema Nuevamente comisionado las pipas y las mangueras también tienen que ser pre-descargadas antes de ser conectadas al equipo para remover cualquier contaminacién aspera. Después de plomoar el sistema completo puede ser descargado al hacer lo siguiente. El aceite tiene que ser idealmente descargado a un nivel de limpieza 1.8.0. de 17/14. Este nivel de limpieza puede lograrse al usar un 10 micr6n (0 mas fino) un elemento filtrante con un beta considerable de 75 (0 mas alto). La duracién del descargue tiene que ser suficiente Para permitir todo el aceite dentro del embalse y el sistema que sea circulado a un minimo de cuatro veces por el filtro. Elestablecimiento tiene que incluir un filtro apropiado, como especificado arriba, en la porcién de linea retornable del circuito para filrar los contaminantes antes que lleguen al embalse. Es indeseable el descargar los contaminantes dentro del embalse porque pueden ser recogidos por la bomba y posiblemente cause dafio. Muchas unidades de contro! hidrdulicas tienen una linea de filtro retornable por fo cual en este caso solamente se requiere que el elemento sea apropiadamente valorado. Para esos casos que no tienen una linea de filtro retornable un filtro girador puede ser temporaneamente agregado al circuito para descarga. Muchos sistemas hidrdulicos tienen tipos de circuitos de flujo alternativo mientras que el descargar se requiere un flujo circulativo.2.0 INSPE 24 Para estos casos una manguera apropiadamente considerada tiene que ser plomeada entre el filtro descargador y el segundo conducto accionador. Para flujo por medio de tipo de circuitos una linea retomable estard presente. Descargamiento és mejor logrado con un flujo turbulento para “derribar’ los contaminantes del sistema. Para esas unidades de controles hidrdulicas cuales tienen una Valvula de Solenoide con Frenos Sueltos un flujo turbulento es creado al ciclar la valvula. La valvula debe de dejarse amortiguar el suficiente tiempo para que cargue el sistema acumulador entre ciclos, Sila H.P.U. no tiene una Valvula de Solenoide con Frenos Sueltos entonces una valvula de bola puede ser afiadida temporalmente hacia lo de arriba del filtro de descarga DVERTENCIA! jo agregue una vilvula de cierre entreel filtro y el embalsel porque la presién alta reventara el filtro. ION Y MANTENIMIENTO LINEAJE Lineaje de friccién tiene solo la garantia del manifacturador y tiene que ser adecuadamente probada por el Usuario en su particular aplicacién para verificar las caracteristicas de cumplimiento. La torsién nominal es obtenida cuando los lineajes estén totalmente fundados. Lineajes quemados 0 contaminados deben de ser descartados La capacidad de paro de un resorte aplicado en el freno del calibrador es dependiente en la extensién del accionador. El desgaste de los lineajes incrementa el espacio de aire el cual resulla en él incremento de la extensién del accionador. La condicién y densidad, tanto como el espacio de aire deben de ser monitoreados a base regular para asegurar el funcionamiento apropiado del freno. Ver seccién 2.4 para el ajustamiento del espacio de aire. Permitir aceite, grasa, manchas, etc. para contaminar el lineaje tendra un efecto perjudicial severo en la capacidad de paro del freno Asegtirese de que no haya ningun tipo de contaminacién cerca del2.2 disco 0 frenos. Lineajes contaminados un poquito pueden ser limpiados con un solvente basado sin aceite y bruitidos. ‘Cuando la densidad del lineaje se vaya gastando al llegar a 0.28 pulgadas el zapato tiene que ser removido y nuevos lineajes instalados. Permitir que los lineajes se desgasten aun mas alla resultara en que los remaches hagan contacto y desgasten el disco. En aplicaciones dindmica, gastamiento de los lineajes mas alla debajo de la ranura del lineaje o permitirles a las ranuras que se llenen con escombros sueltos tendré un efecto perjudicial en la capacidad de paro en los frenos. Cuandbo se instale nuevos lineajes asesérese que los lineajes estén unidos y también remachados y que todos los remaches estén cémodos. En aplicaciones criticas es de ventaja el cargar un juego de repuestos de zapatos de frenos alineados para prevenir el apagar las maquinas operadoras. Lineajes reemplazadores tienen que ser como lo es especificado originalmente. BRUNIMIENTO El brufimiento de lineajes de friccién esta hecho para proveer un buen contacto limpio entre los lineajes y el disco. El procedimiento remueve contaminaciones menores en el disco o lineajes también como cualquier mancha alta menores o mal alineamiento de los lineajes. Nuevos lineajes requieren brufimiento para colocar totalmente los lineajes en el disco y periédicamente sobre la vida de los lineajes para remover cualquier contaminacion de luz o pelicula de oxido de la careta enflechada del disco. Antes del bruitimiento, asegtirese que el disco y lineajes estén libres de contaminacién. Si se requiere el impiar, use un solvente de base sin aceite. Sila careta enflechada del disco tiene una capa pesada de sarro entonces el brufiimiento inicial es requerido para removerlo. Esta etapa tiene que ser hecha a una baja temperatura y fuerza de apriete. Después que el sarro ha sido removido inspeccione los lineajes y verifique que las ranuras de lineajes no se han llenado de escombros sueltos. Limpie las ranuras si el necesario. Lineajes contaminados grandemente o quemados tienen que ser descartados. Ademas de preparar los lineajes y discos para el brufimiento Cualquier enganche de seguridad del mecanismo de propulsion del23 DISCO DE FRENO Para aplicaciones estandar el disco debe de ser manufacturado de ASTM A588 0 un material equivalente a este. El disco debe de ser apropiadamente dimensionado para la aplicacion del freno. ElO. D. debe ser seleccionado para proveer la torsion deseada, el |. D. debe de permitir suficiente espacio radial para remover los zapatos durante el remplazamiento lineador y la densidad debe de ser escogida para absorber cuidadosamente la entrada de energia del freno. Refiérase al dibujo certificado en lo de alrés de este manual para dimensiones criticas. Para las conexiones empernadas el didmetro localizante del disco debe de ser maquinado a una clase de tolerancia de HB. El disco debe de ser balanceado a ISO 1940/1 grado G40 para aplicaciones de baja velocidad y G6.3 para aplicacién de alta velocidad. La careta en flecha del disco debe de tener una superficie terminada dentro de 32 a 64 rms micro pulgadas. Una superficie terminada excediendo lo maximo resultara quebrandose bruscamente y desgaste rapido del lineaje. Discos rayados o Asperos tienen que ser reacondicionados, removiendo no mas de 0.02 pulgadas por pulgada de densidad. Caretas deben de estar planas y paralelas dentro de 0.004 pulgadas a través de la careta en flecha. Vencimiento radial y lateral no deben de excederse de 0.001 pulgadas y 0.002 pulgadas por 12 pulgada respectivamente en didmetros. La capacidad de calor disipada del disco no debe de excederse. Si la energia absorbida en el freno del calibre, cuando usada bajo condiciones dinamicas de aplicaciones continua a un ciclo de alta funcién, excede la capacidad de la energia disipada del disco entonces la torsion debe de ser limitada o reducir la funcidn del ciclo. Para aplicaciones de alta funcién ASTM A514 0 equivalente debe de ser especificado para el material del disco y una atencién especial debe de ser puesta a la tension quebrantes y termal en el ensamblaje del disco/manija. Consulte a Johnson Industries por tales aplicaciones. INUNCA APLIQUE AGUA A UN DISCO CALIENTE {Daiio permanente en forma de una corriente de calor y25 26 j PELIGRO [Elajustar el espacio de aire sin soltar la presiént j enel accionador puede resultar dafiando el | huso del accionador. Para aplicaciones que requieren una reaccién de tiempo mas rapida en los frenos, el espacio de aire puede ser reducido. En estos casos se debe de prestar mucha atencién al desgaste axial del disco y por el posible arrastre de los zapatos. En aplicaciones con un alto desgaste axial en el disco el espacio de aire puede ser aumentado para compensar. Para estos casos consulte a Johnson Industries porque la capacidad lateral flotante de los frenos es critica LUBRICACION Cuando ajustando el espacio de aire, asegtirese que el calibre flote libremente. Sera necesario, en base regular, el remover las clavijas de soporte y el limpiar ambas clavijas y el soportes de deslice en el calibre. Aunque lubricando e! soporte de deslice reducitia la friccion del destice, esta practica debe de evitarse si es posible. El lubricante atraerd polvo y por eso requeriré mas frecuentes intervalos de mantenimiento y posiblemente reducird la vida de los soportes. Cuando remplazando los lineajes aseguirese que los filetes de las clavijas del zapato tengan suficiente compuesto de ante irritante aplicado y que las clavijas al lado del accionador también tengan una grasa EP aplicada al vastago. SUICHES DE LIMITE Los suiches de proximidad del disparador de frenos y del desgaste de lineaje son disponibles como una opcién. Los suiches son suplidos ya precableados a unas terminales de azada de DIN 43650. Si se presenta, ambos suiches deben de ser ajustados cada vez que el espacio de aire es ajustado. Elno ajustar los suiches resultaria en una indicaci6n inadecuada de desgaste en las almohadillas y disparo de frenos. El mando del suiche del suiche de proximidad del disparador de frenos debe de ocurrir dentro de 1/16 de una pulgada de plena retraccién del accionador. Aseguirese que el suiche se ponga a cero to3.2 mohnseon wv accionador. Los accionadores deben de ser regresado a Johnson Industries Ltd. para una inspeccién y reparo rutinaria en base de 24 meses 0 con mas frecuencia para condiciones operativas extremas. Cando remplazando sellos, asegure que estén instalados correctamente y que no estén dafiados. Se debe de tomar cuidado de no permitir que el interior del accionador sea contaminado 0 de que la superficie de los sellos se raye. Repare o cambio el cilindro si la superficie terminada excede 16 rms micro pulgadas. Reparaci6n de la superficie selladora del accionador hidraulico es permitido tanto y como la separaci6n radial resultante después de esmerilar no exceda de 0.004 pulgadas. Después del mantenimiento aplique presin para medir el paro y disparo de las presiones y verificar el funcionamiento del accionador. Use un indicador de dial en el pistén de accionador y una valvula que permite un control preciso de presin para medir el paro y disparo de presiones. La barra del accionador debe de estar totalmente retraida al disparo de presién especificado y empezar a extenderse en la presién de paro especificada. Referirse a al impresion certificada en la parte posterior del manual para las presiones de paro y disparo especificadas. Los valores de medida tienen que estar dentro del diez por ciento mas o menos de las presiones especificadas. PROVEEDOR DE PRESION Un sistema de control hidraulico debe de suplir un buen fluido de base de petréleo filtrado, de alta calidad teniendo buena lubricidad y resistente a la oxidacién. Un aceite hidraulico SO VG32 teniendo un indice de viscosidad mas 0 menos de 200 es recomendado. La viscosidad no debe de excederse de 1000 cSt (4500 SUS) a la minima temperatura de ambiente. Extraiga aire del accionador y lineas después de la instalacién o servicio. Fracaso de no extraer aire de las lineas hidraulicas y accionador puede resultar en un mando lento e irregular y puede dajiar los sellos.mohnsen wg 4.3 Reaccién lenta de frenos 44 Deslizamie nto del freno Aceite aireado Alta viscosidad del aceite Valvulas inadecuadamente medidas Espacio.de aire excesivo Lineajes o discos contaminados. Pobre contacto del lineaje Resortes del accionador fallan Espacio de aire excesivo Lineajes incorrectos. Flotador inadecuado. Verificar que no haya aire en el aceite Verificar la especificacion y servicio de la temperatura Verificar la evaluacién del fluido de las valvulas Verificar el espacio de aire que este dentro de especificaciones Verificar que lineajes y disco estén secos y libres de aceite Verificar un contacto minimo de-75%. Verificar que las ranuras no estén enchufadas. Verificar la presion de Paro dentro de sus especificaciones Verificar que el espacio de aire este dentro de su tolerancia Verificar grado del lineaje Vorificar que el calibre no contacte el marco del freno cuando los frenos sean ajustados, Exudar los accionadores Remplazar aceite Remplazar valvulas con valvulas apropiadamente medidas Ajustar el espacio de aire Limpiar con un soivente sin base de aceite y brufiir. Revisar por goteras de aceite. Cambiar ranuras si es necesario. Bruftir los lineajes, Remplazar accionador Ajustar el espacio de aire a su especificacién Remplazar lineajes Revisar el montaje del freno y corregirio si es necesario. Remplazar los lineajes si estan desgastados,5.2 5.3 mantener un par de zapatos alineados, montajes de accionadores, y clavijas de! calibre para el reducir perdida de tiempo. Cuando ordene piezas de repuesto, especifique los modelos del calibre y numero de serie, ntimero de pieza y la cantidad de piezas de repuesto. SERVICIO Johnson industries ofrece servicio de! campo, supervisién, y asistencia durante | instalacién, mantenimiento, y pruebas, en una tarifa diaria nominal mas desembolsos al costo mas el honorario de direccién. Bajo ninguna circunstancias los cargos de servicio de campo dé cualquier forma o comisién le €s permitido en los precios de nuestros frenos al menos que esto sea expresadamente dicho por escrito en nuestras cotizaciones. Jonson Industrie también ofrece servicios de taller para reponer o reparar montajes de frenos usados 0 sus componentes. Contacte a los representante: de Johnson Industries para un estimado del trabajo que usted dese. GARANTIA Johnson Industries garantiza que sus calibres y discos son de la calidad especificada en nuestras cotizaciones. Nosotros garantizamos nuestros materiales y trabajo por un periodo de noventa dias desde la fecha de mando al usador. El funcionamiento de los linajes y discos en relacién al desgasto, Coeficiente de friccién y disipacién de energia dependen de la severidad y Condiciones del servicio de frenos. Por lo tanto, el usuario deber de verificar mediante pruebas adecuadas que todos los lineajes, calibres y discos funcionen satisfactoriamente en la aplicacién particular, cualquier garantia referente a tal funcionamiento expreso de que es excluido aqui. Nuestra responsabilidad respecto a cualquier falta de las mercancias provistas por nosotros o cualquier perdida, lesiones o dafios ademis atribuidos, se limitara a cumplir con realizar la reparaci6n substituyendo y reinstalando gratuitamente cualquier mercancia o piezas de las cuales se demuestren a nuestra satisfaccién el haber sido comprobadas, bajo su uso previsto, defectuoso en materiales y la ejecucién del Periodo de los noventa dias de garantia, a condicién de que tales piezas defectuosas se devuelvan puntualmente segun lo dirigido por nosotros, cargas de transporte seran pagadas por el comprador, y siempre y cuando no se haya uemado, soldado ni modificado ninguno de los productos o piezas defectuosas. En todo caso, el cliente serd cargado por el reemplazo de las piezas a base de prorrateo por la porcién transcurrida del periodo de la garantia. En el caso de los lineajes de friccién, productos y componentes manufacturados por terceros, extendemos al Comprador las garantias de los fabricantes solamente. El 16Po bun eon PROCEDIMIENTO DE AJUSTE DEL INTERRUPTOR LIMITADOR DE DESEMBRAGUE Y DESGASTE DE PASTILLAS DEL FRENO Los interruptores deben ajustarse cuando se reemplocen los forros del freno 6 cuando fos accionadores se ajusten por degaste. El no ajustar los interruptores como se indica resultara en malo indicacion del desgoste de postillas y del desembrague de! freno Cerciorese de que el mecanismo de arrastre del transportador este bloqueodo y que el transportador se encuentre sujetado o afianzado por otro freno mientras se realizan los ajustes; Retire los conectores electricos (de Ia parte posterior de los interruptores: Afloje las contratuercas @ del cuerpo_del interruptor @) ; Haga irar el cuerpo. del interruotor @) en direccion contraria o lag manecillas del reloj hasta que lo punta del interruptor @ encoje en la base del treno ©): Aplique al freno presion total de dsembrague; Atornille el cuerpo del interruptor @) hasta que Ja punto del interruptor @ haga contacto con la porte posterior de la zapata del freno Haga retroceder la caja de distribucion 1/4 de giro y apriete las contratuercos @ ; Reinstale los. conectores electricos (1) Pongo el treno y retire los medios que haya utilizedo pora afianzar el malacate mientras se realizaba el ajuste de interruptores, PRECAUCION: Antes de quitor la zapata del freno©® para cambiar los forros emportre totalmente la punta del interruptor @). Los impactos contra la punto del interruptor pueden danar el interruptor. PRECAUGION: Lo posicion del interruptor dentro de su cojo Gesta dispuesta de fabrica, "NO AJUSTAR PROCEDIMIENTO DE AJUSTE DEL INTERRUPTORLIMITADC. DE DESEMBRAGUE Y DESGASTE DEL FRENO SERIE 'DS 1500 fia Fane enon ee coats VX Wa DATE: “950622 _| DWG. NO. SS Fehon Be me /OSSA-01.2 aon eat Seat em eae AY PATH: dbr/hs0/R14/3A59danencaat industries / elevanjaMN oor ww » Mehmsen industries /elevana| qa PROCEDIMIENTO PARA RECAMBIO DE LA ZAPATA DEL FRENO Las zapatos deben quitarse y volver a forrarse cuando los forros muestren desgaste excesivo ( Jou arvinon /"SaueI9o S00 auenva Tao coum -¢ | ovevasi@ OoninwGH /Bikossy oovonuy Notow! z SINVIO™ SuBriv BOFOESS 2usrwa 730 0 SINOMVISIOSaST(A1 0} @- @2 AT ) ee) thot CAL POEUN TD NS (A15) (A16) Al BAPH1140 1 CUBIERTA DEL ACCIONADOR A2 BAPPR1040 1 HUSO A3 BAPCB1040 1 BASE DEL AC INADOR A4 BAPSG1140. 1 GUIA: DEL RESORTE AS. BAPSH1050 18 RESORTE DEL DISCO AG BAPPN1040 1 PISTON AZ BAPCR1040 1 ANILLO ENJAULADOR A&8 ~-FSTO4C24S5 4 TORNILLO DE LA CUBIERTA DE EXTREMO Ag BAPCV1040 1 CUBIERTA DE EXTREMO. A1O FSTO4CO6S5 4 TORNILLO DEL DETENEDOR All BAPTR1040 1 DETENEDOR DEL HUSO Al2 BAEG1040 2 GUARNICON DEL EXTREMO. AIS BAPSW1 140 1 ARANDELA DE RESORTE Al4 BAPOP 1040 1 SELLO DEL PISTON A1S BAPOR1040 1 SELLO DE BARRA Al6 BAPWR1040, i LIMPIADOR DE BARRA Al7 BAPWB1040 1 LIMPIADOR DE BASE A18 BAHB4S 1 EVACUADOR DE AIRE dbrJaci/as_ccirs/10400sm e om industri i BAH1140° ACCIONADOR amsem industries /elevania ltd OU ENSAMBLAJE. zal anesurer BC Canada =~ Tek: 604 275 3757 Fox: 604 275 9654{CUST. MINERA LOS PELAMBRES wronla ON Canada =~ Tak: 416 213 9991 Foxe 416 213 9992[y 71 498904 — [s/oMar.20/06 | OWS. No. idgeater SOW England ~ Tel 01278 456411 Fox: 01278 429949 A1040-P2.1 | Is/n's _BAH1040-498904—#12 JIC CONEXION DE PRESION A FRENOS Ay #8 SIC LINEA DE REGRESSO DE FRENOS CONEXION DE -8 JIC PRESION Y -12 vic RETORNO A UNIDAD DE PODER | ESPECIFICACIONES Y AJUSTES VALVULAS DE SOLENOIDE: 115VAC/SOHZ/19W | - PRECARGA DE ACUMULADORES: 103 BARS. "PRVQ’ PRESION DE SALIDA: BARS 'PSQK’ SUICHE DE PRESION: 110 BARS 5 CANTIDAD: TWO PESO: 75 Kg A NUMERO DE ETIQUETA 120-CV-005-23¢02 120-CV~006-23C02 DIMENSIONES: mm een PLICACION RAPIDA DEL. MODULO TRANSPORTADOR, 120-CV-05 & 06 | cs smnces] OJ owe: 980430 [rae | rey DHE. sw.140 BAR (CRECIENDO) 147 BARS 103 BARS VALVULA REDUCTORA DE PRESION PRVQ: ACUMULADOR ACOA: LEYENDA SvB1, SVB2 & SVB3: FRENO PARA ALICAR VALVULA DE SOLENOIDE ~ PARA APLICAR FRENOS ENERGISE SVB3 SEGUIDA POR SV81 & SVBZ 100 MILLISEGUNDOS DESPUES — PARA OISPARAR LOS FRENOS TODAS LAS VALVULAS DE SOLENOIDE NECESITAN ESTAR DESENERGIZADAS PSQA: SUICHE DE PRESION DE LA LINEA DE FRENO ALTOSFRENOS PLENAMENTE APLICADOS eeHE ane NOVOS T ] SQUEMATICO ELF “TRICO Y HIDRAULICO MODULO DE LICACIONCANT, DESCRIPCION ENC4978 7 ENCIERRE DE APLICAR RAPIDO EBP4978 1 CACEROLA TRASERA HCB4978 1 BLOQUE DE CIRCUITO HVSVSC10 2 VALVULA DE SOLENOIDE (SvB142) HVSV3010 1 VALVULA DE SOLENOIDE (5va3) HSVC115D 3. BOBINA DE_SOLENOIDE HCV~CXEB 7 VALVULA DE _-CHEQUEADORA HAC230B 1 ACUMULADOR HACC 172 1 AMBRAZADERA DEL ACUMULADOR HACB120 1 BASE DEL ACUMULADOR HCV-XFAB 1 VALVULA_ CHEQUEADORA HSP3SHED 1 SUICHE DE_PRESION HRV=PBHB 1 VALVULA_REDUCTORA DE PRESIO: HPG300BL 2 GALGA DE PRESION EEO4878 1 ENCIERRE ELECTRICO @ : ; : | Mekm=on industries / elevanja (80 Ber ho. ccinwe Be oN Nee eT Te | MODULO DE APLICACION RAPIDA|/* memes]: AE one FEB_O8 [rw 2 mes ae | SOME: DIBUJO D ENSAMBLAJE om xe se [oe Dh.NUMERO DE ENTRADA: HARG2562 ACUMULADOR DE RESOR IF APLICACION: 1000 psi - 100 psi RAMPA LINEAR VOLUMEN: 244 cu. in. PRESIONES OPERADORAS RETRACCION: 1150 psi DISENO MAXIMO: 3006 pei VIDA DISENADA: 10,000 CICLOS PESO ENSAMBLADO: 85 lbs MONTAJE: SOPORTE EMPERNADOS ) lamsen industries /elevanja itd) 1000 psi RAMP ACCUMULATOR a SPECIFICATION RAWIN( a 3 9854 Toronto ON Conada Yok: 416 215 9991 Tax: 416 265 9992 f Voncower BC Cones ~~ Te: 604 278 3787 Fox: 604 2 S4TF Fox: OF7T8 4549 Buidgnatr SOM Engh? —~ ek: 0RAMPA ACUMULADOR DE 1000 PS) DIBUJO DE ENSAMBLAJE P/t \RS2562HORESOR industries / elevanja DF venemonce Ess offce TD European Oftce Septet ace Ser ene oma eeeoe ee eaeasemen ence eas 470 eee ene Sarto eee oe ai gtnene ts rea es feaimetscen Paneeies ey eters eeee eee MANUAL DEL USUARIO FRENO DEL CALIBRE JOHNSON FECHA: FEBRERO, 2006 NOMBRE DEL CLIENTE: Thyssen Krupp Robbins NUMERO DE ORDEN DE 0601 002 6018 COMPRA: NUMERO DE TRABAJO 4978 JOHNSON IND.: SITIO: Chile del calibre EQUIPO: (2) 2DH2040B Fre (1) 20820408 Freno ce! calibre (2) 96 Discos de Freno en dia (2) QAM80 Médulos de Rapida Aplicacion (8) HARS2562 Acumuladores cle Resorte JOHNSON INDUSTRIES LTD. DELTA, B.C, - CANADAm@OhBSeOm w 13 Cuando el calibre este apropiadamente colocado suelte los frenos y verifique que el calibre tenga un flote adecuado en ambos lados de el marco del freno. Después de empemar el marco del freno en su lugar, suelte el calibre y asegurese que el calibre flote libremente. Es ctitico de que los frenos tengan un despojo radial entre el diametro extemo del disco y el plato céntrico del calibre. Este despojo tiene que ser chequeado y verificado ser un minimo de 3/16 de una Pulgada. Cuando la posicién de los frenos haya sido verificada el estar correcta los pernos de montaje del freno tienen que apretarse. Precarge los pernos de montaje al valor especificado en el dibujo certificado 0 a un maximo de setenta y cinco por ciento de la prueba de carga de los pernos. Use ya sea una arandela de presién o una Contratuerca para asegurar que los pernos de montaje no se aflojen. El pedestal del freno tiene que ser disefiado a que le permita suficiente espacio a la llave de apriete para apretar los pernos de montaje. Cuando las temperaturas operadoras excedan 300° (150°C), los agujeros de pemo grandes deben de ser usados en ambos disco y Cubo. Es preferible el taladrar junto los agujeros de montaje de! disco/cubo usando el mismo ajuste. La plomeria det sistema de freno tiene que ser con pipas o tabor medida adecuada, preferiblemente inoxidable, apropiadamenie considerada para el operar con presiones. Generalmente una tuberia de % pulgada de diémetro JIC y una pipa de % pulgada de didmetro es suficiente para la mayoria de las aplicaciones. Las pipas tienen que ser adecuadamente sostenidas con abrazaderas de pipa cada 4 pies. La conexién del freno tiene que ser hecha con una manguera flexible de 3/8 pulgadas en diametro apropiadamente considerada para el operar con presién, Antes de conectarse a los frenos, la plomerta tiene que ser limpiada para remover todos los Asperos contaminantes. Después de haberse conectado a la unidad de frenos @ hidrdulicas descargue totalmente todo sistema hidraulico @ un absoluto nivel de limpieza de 10 micrén (ISO 17/14) antes de aplicar una plena presi6n operativa Cuando todas las conexiones estén he | aire tiene que extraido de todos los accionadores hidraulicos durante {a inicialControles hidraulicas cuales tienen una Valvula de Solenoide con Frenos Sueltos un flujo turbulento es creado al ciclar la valvula. La valvula debe de dejarse amortiguar el suficiente tiempo para que cargue el sistema acumulador entre ciclos. Sila H.P.U. no tiene una Valvula de Solenoide con Frenos Sueltos entonces una valvula de bola puede ser afiadida temporaimente hacia lo de arriba del filtro de descarga. iADVERTENCIA? No agregue una vélvulade cietre entree filtro yelembals: 1a presién alta reventara el filtro. Lid 2.0 INSPECCION Y MANTENIMIENTO. 24 Lineaje de friccién tiene solo la garantia cel manifacturador y tiene que ser adecuadamente probada por el Usuario en su particular aplicacién para verificar las caracteristicas de cumplimiento. La torsién nominal es obtenida cuando los lineajes estén totalmente fundados. Lineajes quemadios 0 contaminados deben de set descartados, Permitir aceite, grasa, manchas, ete. para contaminar ol lineaje tendra un efecto perjudicial severo on la capacidad de paro del fren Asegiirese de quo ne haya ningtin tipo de contaminacién cerca do! disco 0 frenos. Lineajes contaminados un poquito pueden ser limpiados con un solvente basado sin aceite y brunidos Cuando ia densidad del lineaje se vaya gastando al llegar a 6.2% pulgadas el zapato tiene que ser removido y nuevos lineajes instalados. Permitir que los lineajes se desgastan aun ma: fesultara en que los remaches hagan contacto y desgasten ol di En aplicaciones dinamica, gastamiento de los lineajes mas alld debajo de la ranura del lineaje o permitiries a las ranuras que se Nenen con escombros sueltos tendré un efecto perjudicial en la jad de paro en los frenosmwohnsen w material del lineaje, resultando en una reduccién de la friccién coeficiente. Si esto ya ha pasado los lineajes deben de ser removidos y lijados manualmente para frotar la superticie. La temperatura tiene que ser controlada durante el proceso del brufiimiento. La temperatura del disco tiene que ser mantenida entre 250°F (120°) y 450°F (230%) para obtener el mejor resultado. Cuando el limite superior de la temperatura haya sido alcanzada pause el brufiimiento hasta que el disco se haya enfriado a su limite mas bajo. Pueda ser necesario el apagar el fluido refrigerante por los discos enfriados en agua. icuIDADO H Nunca permita que la temperatura del disco exceda { {500°F (260°). Daiio permanente al lineaje del materjal {puede ser ocasionado, H Brufa hasta que un minimo de setenta y cinco por ciento del contacto del lineaje y una superficie juminosa en el disco ser adquirida, Para medi el grado de contacto, ajuste los frenos y use una gaiga palpadora de .002" para sondear el perimetro de cada zapato de! freno. Sila cantidad que la galga palpadora haya podido sondear excede el veinte y cinco por ciento del area del lineaje entonces mas brufiimiento es requerido. La suficiencia del bruftimiento también debe de ser verificada con pruebas de carga o con medidas de paro del tiempo. Si la torsion verdadera del freno no cruza con ef régimer de torsién del freno entonces mas brufiimiento debe de ser requerido, icUIDADO INo ponga el equipo en servicio si el régimen de la ftorsidn del freno no es desarrollado. Consulte a Hohnson Industries por asistencia,24 ESPACIO DE AIRE El espacio de aire debe de ser inspeccionado en base regular y ajustado si es necesario por desgaste del lineaje. Un espacio de aire y extension del accionador excesiva; 1. incrementa el tiempo de reaccién del freno por la gran cantidad de volumen de aceite que sera cargado. 2. reduce el uso permisible del lineaje mientras los accionadores tienen una cantidad limitada de carrera. 3. puede resultar en una perdida de fuerza del accionador debido a una carrera inadecuada. El espacio de aire debe de ser ajustado nuevamente dentro de sus especificaciones cada vez que se haya salido de su tolerancia. El espacio de aire es ajustado al extender el eje del accionador. Empiece por el remover la barra de enganche y el contenedor del gje. Inserte una chapa de relleno de equivalente densidad hasta que encuentre el espacio de aire deseado entre el disco y la almohadilla del freno en ambos lados del disco. Atormille los ejes de ajuste hasta que las almohadillas contacten la chapa de relleno y todos los ejes Contacien lo de atras de los zapatos. Una media vuelta en los ejes de ajuste cierra ef espacio de aire una 0.04 pulgadas. Asegiirese de que el contenedor del eje este alineado con sus agujeros de montaje para instalar el contenedor y reinstalar la barra de enganche. Roié {os frenos y vuelva a chequear el espacio de aire. Después de ajustar el espacio de aire los suiches de disparo y desgaste si sor suplidos tienen que ser también ajustados (mirar seccién 3.5). El espacio de aire es medido al empujar un zapato contra el disco mientras se mide la distancia entre el lineaje y el disco en el otro zapato, Para aplicaciones que requieren una reaccién de tiempo mas rApida en los frenos, el espacio de aire puede ser reducido. En estos casos se debe de prestar mucha atencion al desgaste axial de! disco y por el posible arrastre de los zapatos. En aplicaciones con un allo desgaste axial en el disco el espacio de aire puede ser aumentado para compensar. Para estos casos consulte a Jol Industries porque la capacidad lateral flotante de los frenos es orttiimportante que el suiche de desgaste sea apropiadamente ajustado cada vez que el espacio de aire es ajustado. El punto de regulacién del suiche de desgaste es ajustado de la manera exacta que el suiche de disparo. Cuando remplazandb los lineajes retraiga completamente ambos interruptores para evitar el dato de los suiches. Referirse al procedimiento del ajustamiento de suiche en lo de atras de este manual. 3.0 ACCIONADORES 3. i INSPECCION Y MANTENIMIENTO Sellos pueden ser remplazados con toda seguridad al remover la tuerca almenada en la barra del pist6n y desarmando el accionador. Accionadores deben de ser regresados a Johnson Industries Ltd Para una inspeccion rutinaria y_reparacién en una base de 24 meses con mas frecuencia por si hay extremas condiciones operativas. Cuando se remplacen los sellos, asegurese que estén instalados correctamente y no estén dafiados. Se debe de tomar el cuidado de No permitir que el interior del accionador sea contaminado o que las superficies del sello se rayen. Repare o cambie el cilindro si el término de la superficie excede un 16:ms de micro pulgadas. La reparacién de las superficies selladoras del accionador hidrdulico son permitidas con tal que el despeje radial resultante después de set esmerilado no se exceda de 0.004 pulgadas. SION Un sistema de control hidraulico debe de suplir un buen fluido de base de petréieo filtrado, de alta calidad teniendo buena lubricidad y resistente a la oxidacién. Un aceile hidraulico ISO VG32 teniende un indice de viscosidad mas 0 menos de 200 es recomendado. Le viscosidad no debe cle excederse de 1000 cSt (4500 SUS) ala minima temperatura de ambiente. Extraiga aire del accionador y lineas después de la instalacion 0 servicio. Fracaso de no extract aire de las Imeas hidrdulicas y accionador puede resultar en un mando lento e irregular y puede dafar los sellos.44 Deslizamien to de frenos 45 Uso rapido e irregular del lineaje Discos 0 lineajes contaminados Pobre contacto del lineaje Lineajes incorrecto Flotador inadecuado Ambos zapatos se arrastran en el disco Zapato se arrastra en la mordaza La superficie terminada del disco es aspera Lineajes no asentados completamente en disco Alto agotamiento axial Temperatura excesiva del disco Verificar que lineajes y disco estén secos y libres de aceite Verificar un contacto minimo de 75%. Vetificar que las ranuras no estén enchutadas. Verificar el grado de los lineajes Verificar que el calibre no haga contacto con el marco del freno cuando los frenos sean ajustados, Verificar que no haya presi6n atrapada Verificar frenos esté centrado en el disco. Verificar adecuado flotador Verificar que la superficie terminada este dentro de sus especificaciones Verifique que los frenos estén colocados y montados correctamente Mida el agotamiento axial Verifique ef espacio de aire adecuado y tlotador lateral Verifique que la maxima temperatura del disco no este excedida, Limpiar con un solvente sin base de aceite y brufir. Revisar por goteras de aceite, Cambiar ranuras si es necesario. Brufir los lineajes. Remplazar lineajes Revisar el montaje del freno y corrijalos sien necesario Remplazar o corregir valvulas de control Recolocar frenos. Reparar la careta en flecha det disco Coloque y/o calce Io: frenos de nuevo para asentar comp! los lingajes Corrija ef agotamiento del disco si es posible. Ajuste el espacio de aire isco. para acomodar Limita el deber « de los frenos,satisfactoriamente en la aplicacién particular, cualquier garantia referente a tal funcionamiento expreso de que es excluido aqui. Nuestra responsabilidad Tespecto a cualquier falta de las mercancias provistas por nosotros o cualquier perdida, lesiones 0 dafios ademas atribuidos, se limitara a cumplir con realizar la Teparacién substituyendo y reinstalando gratuitamente cualquier mercancia o piezas de las cuales se demuestren a nuestra satisfaccién el haber sido comprobadas, bajo su uso previsto, defectuoso en materiales y la ejecucién del Periodo de los noventa dias de garantia, a condicién de que tales piezas. defectuosas se devuelvan puntualmente segtin lo dirigido por nosotros, cargas de transporte seran pagadas por el comprador, y siempre y cuando no se haya quemado, soldado ni modificado ninguno de los productos o piezas defectuosas. En todo caso, el cliente serd cargado por el reemplazo de las piezas a base de Prorrateo por la porcién transcurrida del period de la garantia, En el caso de los lineajes de friccion, productos y componentes manufacturados por terceros, extendemos al Comprador las garantias de los fabricantes solamente. El deterioro, dafio y el malfuncionamiento causado por el almacenaje inadecuado o manejo antes de o después de venta al usuario final no estén cubiertos por esta garantia, Nos reservamos el derecho de realizar cambios y mejorias a cualquier hora sin ineurrir en ninguna obligacién de llevar a cabo tales cambios y mejorias en los productos ya producidos. Esta garantia se expide en lugar de todas las demas garantias, condiciones o responsabilidades implicitas por ley 0 expresadas por estatutos.ART. NUM. DE PIEZA CANT. Al BAH1140 2 2 BBFL3859 i 3 BBFC3859 1 4 BBFR3859 1 As BS4978 2 AG BFS3859 20 7 BPSG3859 4 8 BSRS2050 2 9 BSB2040 4 10 F22C248H5 6 " F22C5N 6 12 F18C56s8 8 13 BMBLE16 2 14 BMBLES 4 15 BLTS3859 2 16 BRPS3040 i 17 BWPS3040 1 18 BHH3a59 1 19 FI6F2J 2 20 FE0P32 4 24 BILS3859 i 22 FERI7 100 Ad BFSGBK3 20 DESCRIPCION ENSAMBLAJE DEL ACCIONADOR PLACA DEL ACCIONADOR PLACA DEL CENTRO PLACA DEL CALIBRE PLACA DEL ZAPATO LINEAJE DE FRICCION = 3 REMACHES. CLAVIA DE GUIA DEL ZAPATO RESORTE REGESADOR DEL ZAPATO COJINETE DESLIZADOR PERNO ENSAMBLADOR DEL CALIBRE TUERCA ENSAMBLADORA DEL CALIBRE PERNOS DE MONTAJE DEL ACCIONADOR. OJO DE ELEVACION DEL CALIBRE QJO DE ELEVACION DEL ZAPATO SUICHE DE TEMPERATURA DEL LINEAJE SUICHE DE DISPARO DEL FRENO SUICHE DE DESGASTE DEL LINEAJE FLUJO—POR LA LINEA DE LA MANGUERA CONTRATUERCA CABILLA AISLADOR_DE_LINEAJE REMACHES DEL LINEAJE LINEAJE DE FRICCION — 2 REMACHES . Meohmsen industries / elevanja oS Both Road, Brdanoter Sn ba7e 28e0) nd 8 Consde VEX TY« Fox 5048 279 9654 eas eames ie DS2040 FRENO DE LINEAJE KRUPP CANADA / LOS PELANBRES DATE: JuLy 30798] OG. NO. REY.PARTS LIST ACCIONADOR CONTIENE RESORTES COMPRIMIDOS SSL LLL, SSN x is Vas WA aN a aN N LON yy \ SANA ONS (s Spo — G / SNA fof % f \ / & @ ® ART. NUM, DE PIEZAS CANT, DESCRIPCION ITEM PART NO, QTY DESCRIPTION 1 BHAIOAT CUERPO DEL ACCIONADOR ? SHRWWJ650 1 LIMPIADOR DE BARRA 2 BAHAP1050 1 PISTON DEL ACCIONADOR iO SHW2654 1 BANDA DE DESGASTE ; 3 BAHAS 1050 1 HUSO DE AJUSTAMIENTO 41 SSL1125 1 SELLO DE EJE 4 BASC 1050 7 COLLAR DEL RESORTE 12 BARS1050 ‘1 RESORTE DE RETORNO | 5 FKMFE1 4 1 CONTRATUERCA 13 BAHB4S 1 EVACUADOR DE AIRE | 6 SHP455650 PISTON 14 BAPTRIO: FENEDOR DEL HUSG i 7? SHR6OS3O0. LO DE BARRA 15 FAK LO DEL DETENEDGR | 8 SHRWDSOO 1 UMPIADOR DE BARRA 15 FHPSON-04 4 — ENCHUFE PORTUARIO. ~ BHAT040 ACCIONADOR ___USTA DE_PIEZAS , industries /elevanja Itd ae. cusities /elevan/a ltd Voncowwer BC Cunado Tels 604 273 3737 Fax: 604 273 S654] Toronto ON Canoda wv Tek 416 213 9991 Fox: 416 213 9992] 5 Bridgwater SOM England Tek 01278 AS6411 Fox: 01778 42994 A4978-P2.0PARTS LIST ARI Ip | 1 MARCO DEL FRENO | 2 2 FRENO DEL CALIBRE | 3 4 CLAVIJA DE SOPORTE — PESADO | 4 8 BARRA DE RETENC PESADO | | : 16 PERNO. DE_MANTENEDC i 6 1 CAJA. ELECTRICA | MANO IZQUI (MANO DERECHA 2020408 ENSAMBLAJE DEL FRENO DEL CALIBRE IMPULSION SECUNDARIA & POLEAS COMPENSADORAS | OS PELANBRES TRANSPORTADORES 120-C¥~-05, & =06 | FL (608) 275 937 oxo (604) 275-9858 h coun115VAC NEUTRAL ° 9 FRENO #1 FRENO DISPARADO Ts1 TEMP. DEL LINEAJE OK, Lsz O_O 05 — — — ESPACIO DE IRE NOR 9 10 Ls3 Eee eee | ———— O-——O-— —~ —— — —{__ FRENO DISPARADO}-— —— " ~ 2G I eeEeEeeeEereew 8 Z 183 184 PO “OE w sew Ey fy 7 ise —— Oren OO a So B i AJUSTES ‘LEYENDA TS, 182, 185, TS4 170 AL CAER LSt.Ls3 = 0 DEL PREM INOICANDO FL ' | LS1, LS3: CONTRAIDO TOTALMENTE 182,184 — ESPACIO OL AIRE / DESGASTE OF. LINEA. ! j 32, ese 4mm AL EXTENDER EL SUICHE DE PROXIMIDAD | TStit ~ SUICHE OE LA INTERCONEXION DE LA TEMPERATURA DEL oIsco . ae oo |. SCHEMATIGA DE ELECTRICA 20S2040A & 20520408 FRENOS DE CALIBRE. wi industries / elevanj IRANSPORTADORES 120~CV-005, 006, & —007_ 0 OWE. NO, 18500 Rivur Rood, Richmond BC Canada VEX’ Te Tel 604 27S 3157 Fan 008 SIS obs REV-4VK Jane Atipconslp3B50183 mersel Bath Roa, Bugler Sore on Aaa Beaty AS38591.