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ZPMC

SBB series Safety Disc Brake

Operators Manual

ZPMC FENGCHENG BRAKE Co., LTD.

Version No 2.0 Copyright reserved Date 2006/8/1


Contents

1. Important Information 1

1.1 Safety Precautions 1

1.2 Limited Warranty 2

2. General 2

3. Installation and Adjustment 3

3.1 Lifting and transportation 3

3.2 Preparation before installation 3

3.3 Installation5

3.4Adjustment 5

4. Operation and Maintenance 8

4.1 Operation 8

4.2 Maintenance 8

5. Spare Parts List 9


1. Important Information
1.1 Safety Precautions
SBB series safety Disc Brake (short form: the brake) is used for deceleration and
stop/braking of rotating machinery by exerting pressure on friction linings on the
brake disc. At the same time, the mechanical energy of moving parts is absorbed and
transformed into heat energy at the frictional surfaces and then is emitted by heat
flow.
The necessary conditions for the brake normal operating are: 1. The mechanism of
exerting pressure on the linings on the brake disc is normally actuated, 2. The contact
pressure, the frictional coefficient between linings and brake disc are within design
values.
If any condition is absent, the brake wont work normally; as a result of the
malfunctions include free-control of the machinery, free falling-down of load,
and body injury or loss of life.
In order to confirm the brake function normally, avoid accident and ensure the safety
for life, the designers who will select the brake and operators must understand
following principles and requirements (not limited to these) and strictly adhere to:
a. The braking torque of new brake can be 50% rated value or less until the friction
lining and brake disc are ran-in;
b.The braking torque of the brake used in the hoist mechanism or similar must be
double more than actual load torque on the brake shaft;
c. Read and understand the manual thoroughly and obey it before installing, operating
and maintenance;
d.Prohibit optionally releasing the braking spring, ensure the torque must comply with
the value designed;
e. Prohibit sticking or spraying any oil, paint, grease and other contaminations on the
friction surface of the brake disc and brake lining;
f. Prohibit touching the brake disc, brake lining and adjoining parts so as to avoid
skins burnt by the heat of braking, even if the machinery stop; do not drop any
object on the rotating disc because centrifugal force of rotating disc will project the
object then damage somebody; equip cover for all disc and coupling or hub as
possible;
g.Prohibit releasing the brake by hand release lever when the brake work normally
(see section 4.2);
h.Do not enter or near the area under the lifting cargo to avoid hurt for body or death
due to the load falling down resulting from the brake sudden malfunction;
i. Only use the spares and parts from our company or approbated by it;
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j. Do not cover the nameplate and warning marks due to the painting and other
contaminations.
1.2 Limited Warranty
Our company warrants that the product will be free from defects in design, produce,
materials and workmanship for one year from the date on which the product is
delivered to the purchaser. Within the warranty period, our companys responsibility
is to replace or restore the brake that has been confirmed which is defective after test
in our company, but the original purchasers must keep the brake is intact and carry it
to our company or to our companys authorized service stations. Except as stated in
this limited warranty our company does not make and disclaims all express or implied
warranties, including (but not limited to) its fitness for a particular purpose, its design,
condition or workmanship.
Our company will not be liable for any special, indirect, incidental damages,
including without limitation: transportation costs, loss of profits, property
damage, lost production, loss of life or body injury. Our companys maximum
liability under any circumstances will be the purchase price of the product paid
by the original purchaser.
If the product is damaged due to installing and maintaining not complying with the
manual, misuse or incorrect operation and accident, our warranty will not be valid.
Only maintain or operate the brake after read and understand thoroughly the manual
and warning on the brake warning marks. However, such warning information cant
ensure to forecast all possible mishaps or accidents, so the user is obligated to try to
find out dangerous state under the brake work normally on the base of understanding
the chapter 1.1, and to maintain or care correctly.
2. General
SBB series safety disc brake (hereinafter briefly called brake) is mainly used as
emergency brake at low speed shaft (driving output shaft) for various large and
middle crane at main hoist and boom hoist mechanism and cable, ropeway crane at
driving mechanism, or service and emergency brake for mine winder lifter,
obliquitous belt conveyor at driving mechanism.
The brake is applied by disc spring and released by hydraulic pressure oilwhich
structure is shown as Fig.1, and the principle of operation is following: When the
hydraulic fluid flows into cylinder under solenoid valve controlling, the hydraulic
fluid push the piston rod move and farther press the disc spring and open the arms,
then braking torque is eliminated; when the solenoid valve is powered off, the
pressure oil will return to oil tank by the spring force acting, simultaneously the
spring force through the piston rod and the arms acts on the disc, and then the rated
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torque is established.

Fig.1
1.Lock nut 2. Adjusting bolt of clearance balancing 3. Braking arm A 4.Release
indicating switch 5. Adjustment nut 6. Lining wear indicating limit switch
7.Braking arm B 8. Lifting bolt 9. Exhaust and pressure gauge connector
10. Hydraulic cylinder 11. Piston 12. Disc spring group 13. Monitoring window
14. Installing center adjustment nut 15. Shoes aligning device 16. Frame 17. Shoes
18. brake lining

SBB series technical data see to table 1


Table 1

Release pressure Release oil Clamping Each side released


Type
(rated/Max) volume force clearance
SBB365 (8/10) MPa 270mL 365kN 12mm
SBB425 (9.5/10) MPa 270mL 425kN 12mm
3. Installation and adjustment
3.1 Lifting and transportation
The brake must be lifted carefully in order to avoid damage, and must be lifted by
using crane and lifting rope for its 710kg weight. The lifting position show as fig-2.
Prohibit from using other parts except lifting bolt to lift
3.2 Preparation before installation
The brake must be installed correctly; otherwise, it will affect the design
performance. So the users must comply with the manual strictly during installing. If
need helps, please contact with our sales department.
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Fig.2
3.2.1 check disc and brake
a. Check if the nameplate parameters comply with requirement;
b. Check if have all parts
c. If there is any corrosion and jamming at every pivot point;
d. Check if the lining surfaces have oil (grease) and other impurity that affect the
performance;
e. Check if the disc surface has rust, oil (grease) and damage due to welding,
unevenness and other defects. Prohibit from using disc with crack or other serious
defects.
If found abnormal situation, please install after dealing with it.
3.2.2 Check brake and foundation
a. The foundation must be fixed and evenness;
b. The tolerance and surface roughness of the foundation refer to Fig.3.

Fig.3
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3.3 Installation of the brake
3.3.1 Installation of the brake
a. Clear the oil and dirt on the brake lining and surface of foundation, and then lift the
brake onto the foundation by crane.
b.Release adjustment nut (part 5, Fig.1), rotate clockwise the lock nut (part 1, Fig.1.)
to open the arms, and ensure the average distance between two linings is bigger 3mm
than the thickness of disc. Remove the opened brake to installing position, put on the
connecting bolt(not screw down temporarily) , adjust the position of the brake and
make the edge of the lining retract about 3~5mm relative to outside diameter of the
disc (refer to Fig.4), after in the right position, screw down the connecting bolt.

Fig.4
c. Connect the limit switch cable (signal indication). The specification of the limit
switch cable entry stuffing is Pg13.5(31.5)(note: The connection must be firm in
order to avoid get loose due to cable loose ).
3.3.2 Hydraulic pipeline connection and exhausting
a. Installing and adjusting hydraulic power unit well before installing the brake
(please refer to the operators manual of hydraulic power unit), install and arrange the
hydraulic pipeline well. The oil entry thread of the brake cylinder is M18X1.5 (refer
to Fig.1), the inside diameter of the pipeline must be over or equal to10mm, and the
inlet oil volume is 270mL when shoe clearance of the brake is 2mm.
b. Exhaust air in the cylinder before operating and adjusting the brake, the method is:
on the top of the cylinder there is exhaust and pressure gauge connector (part 9 in
Fig.1). The thread of the connector is M16. When testing pressure, remove the cover
and connect the pressure gauge accessory; when exhausting, remove the protection
cover ring for anti-falling, screw the cover tightly (refer to Fig.5). After exhausting,
replace the connector as delivery state.
3.4 Adjustment
3.4.1 All adjustment must be operated before first installing and after changing new
lining. At first installing, please according to following steps:
a. The adjustment of clamping force and total shoe clearance(two sides clearance
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Fig.5
adds): clamping force of the brake is relative to the length of total shoe clearance or
piston rod( no screw thread section ) shown out from cylinder head (refer to fig1), so
only adjust dimension L and make it conform to regulation of table 2. The method to
adjust: release the brake by electric control or manual-operated pump (refer to
operators manual of hydraulic power unit), release the lock nut (part 1, Fig.1), and
rotate the adjustment nut (part 5, Fig.1) for a certain distance toward the arms
direction, and then close the brake, observe the length of piston rod ( no screw thread
section) shown out from cylinder head (refer to Fig.1) if it conforms to regulation of
fig2, after adjustment, then stop rotating the adjustment nut (part 5, Fig.1) and tighten
the lock nut (part 1, Fig.1);
Table 2
Total Clamping When closed, overhang length
type note
clearance(mm) force(KN) L(mm) of piston rod

2 405 55
3 385 57.5
SBB365 4 365 60 Rated value
5 340 62.5
6 315 65
2 462 55
3 442 57.5
SBB425 4 425 60 Rated value
5 397 62.5
6 375 65
Note: when actual release pressure of oil cylinder exceeds rated release pressure, shoe
clearance will increase, and maximum can be 1mm bigger than setting-up value. If
actual release pressure is over 10MPa, it may damage disc spring.
b. Adjustment of the clearance balancing: open the brake and observe clearance of the
both sides between shoe and disc are the same, if not, please adjust it to be the same
according to the following: first release lock nut( two sides) of adjusting bolt (part2,
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Fig1) of clearance balancing, screw in adjusting bolt of the side which clearance is
larger (note: there should be clearance between adjusting bolt and base jamb when the
other side clearance is smaller, if not, should screw out this smaller side adjusting bolt
to have enough clearance) until the two sides clearance is basically equal (eyeballing),
then screw out the clearance 0.1~0.2mm between smaller side adjusting bolt and base
jamb, finally tighten the lock nut of two sides.
Note: Adjustment of the clearance balancing is generally done in the non-work
state of mechanism, if mechanism works, it may bring deformation due to
mechanisms load action so that two sides shoe clearance of the brake in the
work state appears unequal. When the brake appears unequal in the work state,
as long as friction linings do not stick to the disc, it will not affect the mechanism
and brakes performance; when it appears to stick to the disc, total clearance
should be kept steady, adjust the clearance sticking to the one side disc bigger
(the other side adjust smaller) properly, assure that brake linings do not stick to
the disc.
c. Adjustment of shoe aligning: the brake with spring aligning device (part 15, Fig.1)
on two shoes can ensure that the shoes completely deviate from the disc while the
brake is opening (refer to Fig.1). when adjust, firstly unscrew the bolts on the aligning
device and make steel wire loose; After make the brake be closed normally, screw
down two bolts using hexagon ring spanner. After adjustment, you commonly need
not adjust during operation (If bolts loosen because of vibration, need adjust).
3.4.2 Adjustment of the limit switch
The brake equips a release limit (indication) switch (part 4 in Fig.1) and a lining
wear limit (indication) switch (part 6.fig1). Switch has DC type (when power supply
is DC 12300V, current capacity of the connectors are 3300mA.) and AC type
( when power supply is AC 20250V 50/60Hz, current capacity of the connectors are
3400mA). When wiring, you should pay attention to requirements in order and
switchs instruction, dont connect power supply in error.
The adjustment of limit switch is to adjust its relative position, make dimensions
X and Y (refer to Fig.6) comply with the value listed at following table 3(after
adjustment, then tighten the fasten bolt on the limit switch).

Fig.6
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Table 3
Lining wear limit Brake released limit( indication)
Each Brake closed Brake released Brake close Brake release
side shoe
Distance X (mm) Distance Y (mm)
clearance
1~2mm About 7.5 About12.5~ 17.5 About 14~9 About 4
X listed at above table is a detected distance that will cause switch to act when the
each side brake lining is worn 0.5mm.
4. Operation and maintenance
4.1 Operation
4.1.1 Check before running in:
a. Check if installation complies with requirement;
b. Check if the adjustment is up to the regulation requirements;
c. Check if the surfaces of the disc and lining have oil (grease) or other
contaminations;
If all checks are ok, the brake can be run-in.
4.1.2 Running-in the brake
Before operating, the brake must be run-in according following steps:
a. Operate about 10~20 times in normal state without load (drive motor runs together
with disc, the same requirement hereinafter), if have abnormal, dealing with it and run
again till operating normally.
b.Operate about 10~20 times with 50% rated load, observe if the braking state is stead,
if so, the brake can run about 3~5 times with rated load.
c. During running-in, following items should be checked: 1.The lining fit to the disc
when braking; 2. the temperature of the disc ( less than 350); 3. Whether the screw
joint is released; 4. If the limited switch is released; 5. If the sound of braking and
running is normal; 6. If the hydraulic system has leakage.
The brake can be operated only after running-in is normal.
4.2 Maintenance
4.2.1 Check following every 3~7 days:
a. Check if the surfaces of the disc and lining are polluted;
b. Check if the disc worn is no more than 1mm, otherwise, the disc should be
changed;
c. Check the lining, if the friction material thickness is less than 5mm, the lining
must be changed;
d. Check if the screw thread joint is released;
e. Check if the hydraulic system has leakage and pressure is normal;
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f. Check if the limited switch is released;
g. Check if the clearance is varied;
If abnormal situation is found, please stop operating the brake and deal with the
fault or adjust brake again.
4.2.2 Change the lining
When friction material of lining thickness is less than 5mm, the lining must be
changed (total thickness of lining is 20mm, and steel base thickness is 11mm), the
changing method is following (refer to Fig.7):

Fig.7
a. Switch on hydraulic power unit, release the bake, if the distance between lining
and disc is not enough, you can increase pressure of hydraulic power unit to open the
brake further.
Caution: The Max pressure cant be beyond 10Mpa, otherwise the disc spring
will be damaged;
b. Dismantle the shoes (part 17 in Fig.1)from brakeand release lock bolt of the
lining, then remove the lining;
c. Check new lining, observe if have oil and distortion on the surface, if so, please
clean it or change a new one;
d. Set the new brake lining key way engage with the linking key.
e. Screw down the lock bolt tightly, assembly shoes back, switch off the hydraulic
power unit to close the brake.
After installing new lining, Adjust according to section 2.4, checking and
running-in according to section 3.1. Only all are ok, the brake can be operated.
Caution: 1.Ensure that the braked shaft is free from any load and cannot
occur accident rotation when replacing the lining. 2. As the brake lining has
certain weight, please care about hurt for body due to fall down when changing it.
3. Please ensure brake is opened and it is no possible to suddenly close while
changing lining.
5. Spare Parts List
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Spare Parts List refers to table 4:
Table 4
Piece Piece Spare parts
specification Qty. note
No. appellation appellation
Release limit Proximity E2E2-X5Y1
4 1 OMRON
switch switch
Lining wear
Proximity
6 indicating E2E2-X5Y1 1 OMRON
switch
limit switch
Miniature high
PPT-3 M141.5 1 Wenzhou LiMin
Exhaust pressure joint
9
pressure joint Assembly
14 1 JB982-77
sealing ring
Dust ring WD1700700-N9 1 Busak+Shamban
Guiding ring F3 224/202.5 W5140 1 PARKER
Guiding ring F3 224/202.5 W5140 1 PARKER
Hydraulic U sealing ring B3 7085 P5008 2 PARKER
10
cylinder U sealing ring BS L025 P5008 1 PARKER
O sealing ring 190(inside dia.)5.3 1 GB3452.1
O sealing ring 70(inside dia.)4 2 GB3452.1
O sealing ring 200(outside dia.)3.1 1 GB1235
Disk spring
12 Disk spring 20010113.2518.2 23
assembly
Shoe aligning
15 Aligning spring SW365A-2 2 Attached drawing
device
Brake lining A ZW975.2 2 Attached drawing
18 Brake lining
Brake lining B ZW975.3 2 Attached drawing
Attached drawing:

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ZPMC FENGCHEN BRAKE Co., Ltd.

Marketing and After-sale service Department:


Tel: 0086-795-6201884 6203474 6201939
Fax: 0086-795-6201896 E-mail: ZPMC@hua-wu.com
Web site: www.hua-wu.com
Technology Department:
Tel: 0086-795-6203464 6201004

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