Technical data sheet Nº: 53.550 I Edited by: Unitzer Bilbao Tested by: Sales Department Delivery date : May 1.999 Date Rev.5. November 2.005 Date Rev.6. July 2.007 Date Rev.7. October 2007 Aplicación Nuevas Tecnologías, ANTEC S.A. Ramón y Cajal, 74 48.920 Portugalete (Bizkaia) Tel.: 34.94.496.50.11 Fax: 34.94.496.53.37 Dep. Postventa: sales@antecsa.com Pág.1-36
1. INTRODUCTION. Pag.3. 1.1. WHO SHOULD READ THIS MANUAL Pag.3. 1.2. SECURITY INSTRUCTIONS. Pag.3. 1.3. GENERAL ASPECTS. Pag.5. 2. STATE OF SHIPMENT AND STORAGE Pag.13. 2.1. STATE OF SHIPMENT Pag.13. 2.2. DISC AND ASSEMBLY SURFACE. Pag.14. 2.3. INSTALLATION PROCEDURE Pag.14. 3. BRAKE MAINTENANCE Pag.18. 4. BRAKE GAP ADJUSTMENT Pag.18. 5. DETECTORS ADJUSTMENT. Pag.21. 6. REPLACEMENT OF THE LINNINGS. Pag.26. 7. REPLACEMENT OF THE SPRING PACKAGE Pag.29. 8. REPLACEMENT OF THE SEALS Pag.33. 9. SPARES. Pag.35. 10. CONTINUOUS IMPROVEMENT Pag.35. 11. APENDIX I. Pag.36. Page 2-36
1. INTRODUCTION. 1.1. WHO SHOULD READ THIS MANUAL. This manual has been prepared to simplify as much as possible the installation, operation and maintenance of the brake. It will be of help for not only the workers who are going to manipulate the brake but also for the technicians and maintenance service, therefore it is advisable to have it at the complete disposal for those that are going to work with these brakes and to make sure that they fulfil the instructions described. This Manual tries to clarify any constructive doubts as well as the basics of the brake, and we believe that it will be very helpful for workers and technicians using it as material for information and consults. NOTE In case of any eventuality, or any doubt, please fill free to contact ANTEC s after sales service, indicating the type and the serial number of the brake. NOTE Due to continuous improvements in the design of our brakes, minor differences may exist between the brake in your possession and the one shown on this manual, ANTEC reserves the right to modification without any special notice. 1.2. SECURITY INSTRUCTIONS. Throughout this Manual different symbols may appear that emphasize the importance of the section in which they are located, in general somewhat referring to security, therefore it is recommended to put even more attention in these points. Warning: This symbol will be placed in the points or paragraphs that require a reading with greater attention. They will generally talk about some kind of operation that need to be taken with special care. Page 3-36
Danger of death: This symbol will be placed in the points or paragraphs that need a reading with greater attention. They will generally talk about some operation that can involve a deathly danger. High temperatures: This symbol will be placed in the points or paragraphs that need a reading with greater attention. They will generally talk about some operation that can involve a danger of high temperatures. NOTE This symbol will be placed in the points or paragraphs where some important data or observations are indicated For the manipulation of the Antec brakes it will be necessary to consider the following security procedures: 1-. Any worker or technician must get dressed suitably to manipulate the brake (clothes, boots, helmet, security glasses, ). 2-.Keep always in good state the warning signals (if there are) of the brake and respect them. In the case of repair or maintenance place a signal that informs to other workers that in that machine some work is being done to the Antec brake, and in if necessary that the voltage is disconnected. 3-. Get the complete specifications about the used fluids in order to avoid health problems and for a safer manipulation 4-. Assure an appropriate isolation of the electrical elements (if any) to avoid electrical shocks. 5-. Observe the limit values indicated for each element of the brake and for the brake itself. 6-. Before starting up the machine with the Antec brakes, ensure that the brake is correctly placed and secured with the necessary torque. Page 4-36
7. - Antec will never be consider responsible of the use and maintenance of the tools that are used by the customer while assembling and manipulating the brakes. The failure to fulfil these norms may cause irreversible damages to the ANTEC brakes, and what is even more important, to the workers who are manipulating theme. These damages can cause the death of the worker. 1.3. GENERAL ASPECTS The use of the Antec brakes for unforeseen operations or a negligent use of them can cause serious damages to these as well as major injuries to the people who are in their area of influence. NHC-900 callipers are negative operation brakes (failsafe), braking with no pressure. The maximum working pressure is 21 Mpa, while the minimum pressure depends on the strength of the spring package. This minimum pressure can be seen in the attached picture. DESIGNATION NHC-910 NHC - 917 NHC - 925 NHC - 931 NHC - 937 NHC - 947 NHC - 956 Clamping force (1 mm. gap) N 10.000 17.000 25.000 31.000 37.000 47.000 56.000 Braking force (µ=0,4) N 8.000 13.600 20.000 24.800 29.600 37.600 44.000 Stroke mm 3.5 3,5 3,5 3,5 3,5 3,5 3,5 Life (Cycles) >2.000.000 > 2.000.000 > 2.000.000 > 2.000.000 1.750.000 950.000 800.000 Strength loss per mm Min opening preassure máx. % 4.82 5,10 8,50 7,00 8,32 11,57 10,50 Mpa 4 6 8 10 12 16 18 Preassure máx. Mpa 21 21 21 21 21 21 21 Page 5-36
Denominación Clamping force (1 mm. gap) Braking force (µ=0,4) NHC - 925 - E NHC - 931 E NHC - 937 - E NHC - 940 - E NHC - 942 - E NHC - 947 - E NHC - 956 - E NHC - 947- EE NHC - 956-EE N 25.000 31.000 37.000 40.000 42.000 47.000 57.000 47.000 57.000 N 20.000 24.800 29.600 32.000 33.600 37.600 45.600 37.600 45.600 Stroke mm 3,5 3,5 3,5 3.5 3.5 3,5 3,5 3,5 3,5 Life (Cycles) Strength loss per mm Min opening preassure máx. Preassure máx. > 2.000.000 > 2.000.000 > 2.000.000 1.000.000 800.000 > 2.000.000 > 2.000.000 > 2.000.000 > 2.000.00 0 % 4,19 3,60 4,09 3.52 3.38 5,67 4,81 3,75 3,25 Mpa 8 10 12 12 Mpa 21 21 21 21 12 16 18 16 18 21 21 21 21 21 The NHC brakes are self aligned callipers, acting in both sides of the braking disc with big enough linings that can be made of organic or sinter metal material. The brake has two entrances 3/8 G thread for the hydraulic connection, one in the upper part of the brake and another one in the lower part. It is recommended to use the upper connection, using the other one when the oil must flow through the clamp. Two connections 1/8 G. thread are available for draining the brake. The lower one should be used by connecting a transparent plastic tube with the purpose of gathering the possible oil leakages. IMPORTANT: Never introduce pressure through the drain valve. NOTE The fixing bolts, the washers, the power unit and the hydraulic connections are accessories not included with the supply of the brakes Page 6-36
Drain thread 1/8 G Hydraulic admission thread 3/8 G Upper Hydraulic admission thread 3/8 G Upper drain thread 1/8 G Lower drain thread 1/8 G Lower Hydraulic admission thread 3/8 G Page 7-36
BRAKE COMPONENTS Part Number Designation 1 MAIN BODY 2 FRAME 3 PISTON 4 BRAKE COVER 5 SPRING PACKAGE GUIDE 6 REGULATION BOLT 7 CALIPER BLOCKING PLATE 8 DETECTION PLATE 9 DETECTOR S COVER 10 DETECTOR S PLATE C.S.A. Y D.D. 11 SPRING PACKAGE 12 SPRING SUPPLEMENT 13 CALLIPER BASE 14 CALIPER SHAFT 15 CALIPER UNION PLATE 16 CALIPER SPRING 17 CALIPER SPACER 19 LINING 20 LOWER RETRACTION BOLT SPRING 21 UPPER RETRACTION BOLT SPRING 23 SEAL 24 SEAL 25 SCRAPER 26 SCRAPER 27 GUIDE RING 28 GUIDE RING 30 SCREW M- 20X100 31 WASHER 32 BUSH 34 PIN 35 O-RING 36 NUT M-27X2 37 SCREW M-12X45 38 SCREW M- 8X35 39 SCREW M- 8X100 40 WASHER 42 SCREW M- 8X14 43 SCREW M- 20X35 44 WASHER 50 C.S.A. & D.D. DETECTOR 51 SCREW M- 10X100 52 NUT M-10 56 SPACER 60 EYE BOLT 61 WASHER 65 SPACER Page 8-36
ASSEMBLY 9 60 4 15 1 14 2 DISC 50 51 17 56 52 37 40 13 6 16 36 8 7 10 21 39 61 65 30 31 Page 9-36
42 19 20 38 43 44 5 12 11 3 35 28 23 24 27 25 Page 10-36
ASSEMBLY EXPLOSION 9 30 26 60 15 50 31 17 10 7 6 5 36 8 4 12 11 16 56 1 14 37 3 40 21 39 61 65 19 42 52 13 51 2 44 20 38 43 Page 11-36
Page 12-36
2. STATE OF SHIPMENT AND ASSEMBLY 2.1. STATE OF SHIPMENT When the brakes are dispatched from ANTEC, they are dully packed in order to warranty the brake safety while transportation. The brakes NHCE are supplied completely assembled and in the maximum opening position and with the blocking plate installed. Caliper blocking plate ANTEC certifies that the brakes NHC have been tested in our test benches with the corresponding working oil. The inner parts of the brake remain lubricated so that the brake will not have any corrosion problem while it s transportation to the customer s facilities and assembly NOTE This film of oil that helps to avoid corrosion in the inner parts of the brake during the transportation and installation only lasts for a limited period of time. In case of storage of the brakes during long periods of time, the customer will supply oil pressure to the brake during at least 10 minutes once a month Caps are installed in all drain and pressure holes for transportation. Page 13-36
2.2. DISC AND ASSEMBLY SURFACE Before starting with the assembly, the perfect parallelism between the surface where the clamp will be installed and the faces of the disc must be verified, as well as the correct positioning considering the disc. 0.1 Disc 0.1 Both, the disc and the assembly surfaces of the machine and the brake will have to be cleaned thoroughly to leave them free of painting, oil, rust, etc. 2.3. INSTALLATION PROCEDURE For the installation of the brake proceed as follows: 2.3.1 Unpack the brake, remove all caps (hydraulic admission cap, drain cap). 2.3.2 Clean the disc where the NHC brake will be installed. Any remaining particle may damage the brake, and cause several malfunctions. 2.3.3 Clean the contact surface between the brake and the frame as well as the linings. The brakes after unpackaging and during transportation to the place where they will be installed may be contaminated, and therefore both contact surfaces must be cleaned. Page 14-36
2.3.4 Place the brake assembly on the disc sliding it, and verify that it is correctly centred and located. Disc 2.3.5 Place the washers and the bolts M-20 quality 10.9. Do not tighten them yet Screws M-20 quality 10.9 2.3.6 Verify the parallelism stated in point 2.2. Page 15-36
2.3.7 Fasten the brake to the structure frame tightening the bolts with the corresponding tightening torque. The use of quality 10.9 bolts is recommended. (See table at Appendix I). 2.3.8 Verify the tightening torque of the two bolts of the end-stops. (See table at Appendix I) 2.3.9 Set up the brake as stated in point 4. 2.3.10 Connect the brake to the hydraulic circuit through the oil entrance and install the drain as previously stated in point 1.3 of this technical notice Drain thread 1/8 G Hydraulic admisión thread 3/8 G As it has already been said, two drain connections 1/8 G. thread exists. In case of vertical installation of the brakes, the lower one should be used connecting a plastic transparent tube in order to gather any possible oil leakages. If the installation is horizontal, the drain can be connected to any of the two connections. Page 16-36
IMPORTANT: Never introduce pressure through the drain valve. NOTE When the brake is installed and connected to the hydraulic circuit please bleed the system in order to avoid any failure in the normal brake functioning Upper Hydraulic admission thread 3/8 G Upper drain thread 1/8 G Lower drain thread 1/8 G Lower hydraulic admisión thread 3/8 G Page 17-36
3. BRAKE MAINTENANCE For the NHC brake maintenance please verify systematically the following aspects of the brake: - Lining wear off. Anytime the thickness of the organic material of the lining is below 2 mm in the lowest point, proceed with the replacement of the lining. - Verify the correct tightening torque of the end-stops bolts and of the fixing bolts. - Verify that there are no leakages through the hydraulic connections. - Check the brake draining 4. BRAKE GAP ADJUSTMENT. 4.1. Supply the minimum pressure to the calliper to achieve the brake release 4.2. With the calliper connected to the hydraulic pressure, screw the regulation screw until the total gap or distance, between lining and disc, will be of 1 mm. Once reached this gap tighten the nut to block the regulation screw The gap can be measured using a 1 mm pattern, moving the calliper until you have contact between one pad and one side of the disc and 1 mm in the opposite side. (See last drawing in this section). Remove the 1 mm pattern once the gap has been verified. Continue with the gap regulation using the brake support screws. Tighten the support screws until the gap between the disc and the linings is 0.5 mm on each side. Page 18-36
Nut Regulation screw A Support screws Ensure this distance tightening the regulation screw Use a 1 mm pattern. While this operation is taking place the pressure supplied will be the minimum brake release pressure 1mm Page 19-36
0.5 mm 0.5 mm Regulation of the gap with the brake support screws Page 20-36
4.3 The bigger the gap is, the smaller the clamping force will be and the shorter the spring package s life will be. 4.4 The gap will NEVER be bigger than 3.5 mm, in other words, the linings wear off will never be more than 1,25 mm per lining. This gap can be measured as dimension A from the figure. With new linings (No wear off) and a gap of 1 mm to one side of the disc the dimension A will be of 14 mm therefore for the maximum allowed gap of 3,5 mm the dimension A should be of 11,5 mm. 4.5 For the readjustment of the gap, when this one reaches 3.5 mm, untight the nut in order to release the regulation screw (6). After this operation please follow with the instructions indicated in the paragraph 4.1 4.6 The gap adjustment have to be done EVERYTIME the brake is installed or the linings changed. 4.7 Remove pressure from the brake In this moment the calliper will brake by the action of the brake spring package 5. DETECTORS ADJUSTMENT. Whenever the brake has installed the pad wear and the open switch detectors (C.S.A & D.D.), they will have to be installed on the cover as it is indicated in the figure D.D C.S.A. Page 21-36
The two switches installed on the brake have the following porpoises: 1. Pad wear indicator (D.D): This switch indicates when the pad has worn off 2 mm of material. In order to understand how to adjust this type of detectors, find enclosed some technical information about it. TECHNICAL DATA. - Detector`s length: 46.5+13 mm - Minimum working length: 2 mm - Maximum working length: 6 mm - Range of Temperatures: -5+70 Cº - Protection rate: IP66 - Tension: 5 a 250 V - Thermical current: 12 A - Wires ID: 1: Black (common) 2: Brown (NC) 4: Blue (NO) How to adjust the pad wear indicator? The switch detects continuously the detection plate (8) no matter the brake is opened or closed, This plate (8) moves in common with the piston (3). When the detector produces a signal then the brake operator must know that the lining has worn off 2 mm. As a consequence of this pad wear off the brake loses clamping force, so the brake must be readjusted following what stated in point 4 of this manual. Page 22-36
a) b) 41,5 mm 44.5 mm 8 NOTE Important: Before making any adjustment to the pad wear indicator the brake must have been regulated as stated on point 4 of this manual. The first step before adjusting the pad wear indicator is to open the brake by giving pressure to it. Adjust the pad wear indicator to 41.5 mm as stated in figure a). The nominal length of the detector is 46.5, so this means to compress the switch to 41.5 mm. Page 23-36
The 5 mm compressed correspond to the following: When the lining has worn of 2 mm of material, the switch will go from 41.5 mm to 44.5 = 41.5+1+2 mm tas shon on figure b) se that the detector will not detect the detection plate any longer. NOTE Important: The 44.5 mm will be measured with the brake closed. Anytime the pad wear indicator is adjusted the state of the lining will be revised 2. The open switch indicator (C.S.A): This detector indicates when the brake is opened (with pressure). If the switch does not detect the brake is closed (without pressure). The switch is the same as the one used for the pad wear off with the same technical features. How to adjust the open switch indicator (C.S.A.)? The first step before adjusting the pad wear indicator is to open the brake by giving pressure to it. Page 24-36
Adjust the switch to 44 mm as stated in figure. The nominal length of the detector is 46.5, so this means to compress the switch to 44 mm. This detector will indicate us when the brake is opened. Once made the first adjustment of the open switch indicator (C.S.A) and as long as the brake is not disassembled, the operator will not need to readjust it anymore. 44 mm The 2.5 mm corresponding to the difference between the 46.5 of the nominal switch length and the 44 mm belong to the following: Page 25-36
After adjusting the brake and the detectors, if installed, it is time to start up the brake. It I important to consider the following information: NOTE When the brake is installed and connected to the hydraulic circuit please bleed the system in order to avoid any failure in the normal brake functioning 6. REPLACEMENT OF THE LINNINGS. The linings are made of a steel plate and the friction material, it s total thickness is 25 mm per lining. Anytime the total thickness of one of them has been reduced to 17 mm at any point, this is, 8 mm have been worn off, they will have to be replaced 25 mm 8mm 17 mm Page 26-36
In order to change of the linings the following instructions must be considered: 6.1. Give pressure to the clamp, at least the minimum pressure that appears in the attached table in point 1.3. Hydraulic admisión thread 3/8 G 6.2. Once the calliper is opened and maintaining the hydraulic pressure, remove the first cover that covers the detectors, if there are any installed. After this, unscrew whatever is necessary the regulation screw in order to place the blocking plate in the blocking position. Once we have placed blocking plate, tighten the regulation screw in order to block the brake. After this the hydraulic pressure can be removed. 1.Remove the cover 3. Introduce the blocking plate 2.Unscrew as much as necessary 4.Tighten the screw Page 27-36
6.3 In order to change the linings, remove the retraction screws with their springs, and after that remove the lining external screws Make sure that the blocking plate indicated in paragraph 6.2 is correctly located. Be especially careful, while changing the linings with the springs of the retraction screws. LOWER BODY LINING. Lining external screws Lining Retraction screws and springs Page 28-36
UPPER BODY LINING. Lining external screws Retraction screws and springs Lining 6.4. Place the new linings. 6.5. Proceed. in an inverse way as stated in point 6.3 (Insert the retraction screws and the lining external screws). After this, give pressure to the brake and proceed again as stated in point 4 (Brake gap adjustment). In case of the disassemble of the brake, please proceed as indicated in point 2.3 before proceeding with what indicated in point 4 (Installation procedure). 6.6. Notice that when the brake is installed and connected to the hydraulic circuit, the system must be bled in order to avoid any failure in the normal brake functioning NOTE In order to warranty the friction coefficient it is recommended to consider a bedding period whenever new linings are installed 7. REPLACEMENT OF THE SPRING PACKAGE. The procedure for replacing the spring package is a dangerous procedure for the person in charge of it, Therefore ANTEC warns about this danger and advices to the customer of the importance of creating a specific prevention of risk protocol for this point. Page 29-36
The spring package must be replaced, the latest, when the number of cycles stated in the table at section 1.3. has been reached. When the retirement and substitution of the spring package is required the indications below must be followed: 7.1. With the brake removed from the machine, remove the cover of the detectors and the detector s plate, if any. Detector s cover Detectors Detector s plate 7.2. Connect pressure to the brake in order to remove the nut, the detection plate, the blocking plate, in case it is installed, and finally the regulation screw. Regulation screw Nut Detection plate Blocking plate 7.3.Remove pressure. Without hydraulic pressure, untighten the bolts that fix the brake cover, removing this one, as well as the spring package guide, the supplement if installed and finally the spring package. Page 30-36
Regulation screw Cover bolts Brake cover Suplement Spring package 7.4. Introduce the spring package guide in it s housing carefully Spring package guide Page 31-36
7.5. Introduce the new spring package through the spring package guide lubricating it abundantly, with green consistent grease (Sopral Super-grass 792/2 or equivalent). Special care must be taken to install the washers in the correct position, as shown in the attached drawing. Also install the spring supplement if any. Spring package 7.6. Put the cover, in which we will have installed a new scraper (Part nº 26), noticing that the pin must be housed in the piston. Proceed with the installation of the blocking plate, in the blocking position, as well as the detection plate, the nut and the regulation screw. Finally screw the cover fixing bolts with a tightening torque of 84 Nm Regulation screw Nut Detection plate Blocking plate Scraper part nº 26 Cover Page 32-36
7.7. Give pressure to the brake and tighten the nut, with the blocking plate installed, in order to leave the brake blocked. 7.8. Install the detectors plate, the detectors if any, and the detector s cover 7.9.Continue with the assembly following points 2.3, 4 and 5. 8. REPLACEMENT OF THE SEALS The change of the seals will take place in an area as clean as possible, in order to avoid the contamination by abrasive particles of the inner pieces of the calliper. NOTE The manipulation of the parts and seals will be done with maximum care, with the purpose of avoiding superficial damages that could cause oil leakages The correct superficial state of the parts must be verified, before the assembly of new seals. Steps to follow for the replacement of the seals: 8.1. Remove the spring package according to points7-1, 7-2 and 7-3. 8.2. Remove the piston. Piston Page 33-36
8.3. Remove used guides and seals. 35 28 23 24 27 25 Part number DESIGNATION 35 O-ring. Several NHC models don t have this O-ring. 28 Guide ring 23 Seal. 24 Seal 27 Guide ring. 25 Scraper 26 Scraper assembled in it s position (see point 6.6.) Page 34-36
8.4.Put the new seals with great care in order not to deteriorate them. Keep in mind that any damage to the lips of the seals may lead to a leakage 8.5.Introduce carefully the piston, after having verified that it s state is correct 7.9. 8.6. Continue with the assembly following the points 7-4, 7-5, 7-6,7-7, 7-8 and 9. SPARES. ANTEC recommends to have several spare parts prepared for a possible failure. Antec recommends as spare parts the following elements. Part number Designation Quantity 11 Spring package 1 23 Seal 1 24 Seal 1 25 Scraper 1 26 Scraper 1 27 Guide ring 1 28 Guide ring 1 35 O-ring 1 19 Lining 2 For further information please do not hesitate to contact ANTEC s after sales service indicating the type and the serial number of the brake. 10. CONTINUOUS IMPROVEMENT Antec S.A. will be pleased, in it s continuous improvement process, to receive any suggestion or advice in order to improve this manual. Please send any comments to the sales department s e-mail: sales@antecsa.com. Page 35-36
11. APENDIX I TIGHTENING TORQUE Ma (N.m) NOT LUBRICATED QUALITY 8.8 QUALITY 10.9 M6 10 14 M8 25 34 M10 48 68 M12 84 118 M14 132 186 M16 206 289 M18 284 397 M20 402 569 M22 540 765 M24 697 981 M27 1030 1472 M30 1422 1962 TIGHTENING TORQUE Ma (N.m) LUBRICATED WITH OIL QUALITY 8.8 QUALITY10.9 M6 9 13 M8 21 31 M10 42 61 M12 72 106 M14 115 168 M16 174 256 M18 247 357 M20 350 498 M22 470 688 M24 603 858 M27 889 1266 M30 1207 1720 Page 36-36