Name: MEB-0300-050

Date: 11.02.2015
Revision: K

Installation and Maintenance

Manual

HYDRAULIC FAIL-SAFE
MONO SPRING
DISC BRAKE
BSFI 300-MSxxS-200

RELEASED
343 by helle.vestergaard
344
Installation and Maintenance Manual BSFI 300-MSxxS-200

Table of Contents
TABLE OF CONTENTS .......................................................................................................... 1
1. GENERAL ...................................................................................................................... 3
1.1 Intro ................................................................................................................................ 3
1.2 Safety ............................................................................................................................. 3
1.3 Conventions used in this manual .................................................................................... 4
1.4 Disclaimer ....................................................................................................................... 4
1.5 Nameplate / Serial-numbers ........................................................................................... 4
1.6 Conversion factors .......................................................................................................... 5
1.7 Lubrication ...................................................................................................................... 5
1.8 Before starting ................................................................................................................ 5
1.9 Disposal .......................................................................................................................... 6
2. INSTALLATION ............................................................................................................. 7
2.1 Lifting and handling the brake ......................................................................................... 7
2.2 Cleaning the brake disc .................................................................................................. 7
2.3 Cleaning of the mounting surfaces .................................................................................. 7
2.4 Mounting the brake ......................................................................................................... 8
2.5 Inspecting the alignment of the brake ............................................................................. 8
2.6 Connecting the hydraulics ............................................................................................... 9
2.7 Bleeding the brake .......................................................................................................... 9
2.8 Mounting the brake pads ................................................................................................ 9
2.9 Bedding in of the brake pads .......................................................................................... 10
2.10 Adjusting the brake ......................................................................................................... 11
2.11 Before using the brake .................................................................................................... 11
2.12 Removing the brake ........................................................................................................ 12
3. MAINTENANCE ............................................................................................................. 13
3.1 Replacing the brake pads ............................................................................................... 13
3.2 Checking the spring package .......................................................................................... 13
3.3 Replacing the spring package ......................................................................................... 14
3.4 Dismantling the active caliper ......................................................................................... 14
3.5 Lubrication ...................................................................................................................... 16
3.6 Storage ........................................................................................................................... 16
4. TROUBLE SHOOTING .................................................................................................. 17
APPENDIX A - DIMENSION DRAWING ................................................................................. 18
APPENDIX B - MOUNTING DRAWING .................................................................................. 19
APPENDIX C - SPARE PARTS DRAWING, CALIPER HALF................................................. 20
APPENDIX C - SPARE PARTS LIST, CALIPER HALF .......................................................... 21
APPENDIX D - SPARE PARTS DRAWING, PASSIVE CALIPER ........................................... 22
APPENDIX D - SPARE PARTS LIST, PASSIVE CALIPER .................................................... 22
APPENDIX E - SPARE PARTS DRAWING, BASE PLATE .................................................... 23
APPENDIX E - SPARE PARTS LIST, BASE PLATE .............................................................. 23
APPENDIX F - POSITIONING SYSTEM ................................................................................. 24
APPENDIX G - INDICATORS.................................................................................................. 25
APPENDIX H - TECHNICAL DATA......................................................................................... 26
APPENDIX I - RECOMMENDED FLUID ................................................................................. 27
APPENDIX J - RECOMMENDED SPARE PARTS .................................................................. 28

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1. General x There should be one manual available for

the service/maintenance crew as a
1.1 Intro minimum.
x Do not perform any work on the products
Svendborg Brakes’ range of high-integrity
before the manual has been read and
brakes offers a brake designer a system of
understood.
braking that meets the highest requirements
for safety and reliability for large braking
Hydraulic aggregate / hydraulic power
applications and multifunctional service
unit:
braking.
Svendborg Brakes is able to deliver to you x Do not operate the hydraulic aggregate
complete solutions including brakes, before correctly filling the reservoir/oil tank
hydraulic power units and electronic SOBO
® with oil.
brake-controls. x Do not adjust valves or pressure switches
to higher operating pressure than
In case you have any questions to this specified in the manual.
manual please contact your local x Do not change the size or type of
representative or nearest Svendborg Brakes components.
office. x Do not use hydraulic fluids not
recommended in this manual.
Svendborg Brakes offices:
Brakes:
Denmark: x Do not operate the brake before removing
Phone: +45 63 255 255 the air from the hydraulic system by
Fax: +45 62 281 058 bleeding and then re-filling with oil.
E-mail: [email protected] x Do not use higher operating pressures
than specified on the nameplate of the
For current contact information, brake/or in the manual.
please reference
x Do not change the size or type of spring
www.svendborg-brakes.com.
pack.
x Do not use the brake pads when they are
1.2 Safety worn to the minimum thickness as shown
The Svendborg Brakes brake line of in the manual.
products are designed to be mounted on a x Do not operate the brake if there is dirt or
rotating brake disc for use in conjunction corrosion on brake disc or on brake pads.
with parking brake applications and or x Do not try to adjust the brake or remove it,
service brake applications only. before securing the brake disc from
rotating.
Note: x Do not work on a spring applied brake
x Always make sure that you consult without locking/securing the piston by
Svendborg Brakes before using tools or using the air gab bolt/nut.
any other equipment not recommended in
this manual
x Always use original spare parts from
Svendborg Brakes.
x It is the customer’s responsibility that the
brake and hydraulic aggregate are always
clean, and free from dirt, grease or oil.
x It is the customer’s responsibility that the
air gap between brake pads and brake
disc never exceeds the air gap
recommended.
x Always use a torque wrench when refitting
mounting bolts or valves in order to ensure
the torque obtained is the torque
described in this manual.
x Always be sure that the brake disc is
locked and not able to rotate before
adjusting the air gap.

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1.3 Conventions used in this manual resulting from any misspellings or inaccurate
information in this users guide.
To make sure that you perform certain tasks
properly, please take note on the following
This document or parts hereof may in no
symbols used throughout this manual.
event be copied, reproduced, changed or
translated to other languages without
WARNING: Information to prevent injury to
express written permission from Svendborg
yourself when trying to complete a task.
Brakes.

CAUTION: Information to prevent damage 1.5 Nameplate / Serial-numbers

to the components when trying to complete Before contacting Svendborg Brakes or your
a task. local reseller please record the serial
number of the product.
IMPORTANT: Information that you MUST This will ease the process of identifying the
follow to complete a task. actual product supplied and will help in
locating eventual problems.

NOTE: Tips and additional information to Brakes - reading the sign / nameplate
aid in completing a task. The sign is located on the brake and should
look like this:
1.4 Disclaimer
Product
In no event shall Svendborg Brakes be liable
for special, incidental, consequential or
punitive damages, including, without
limitation, damage to other property or
person caused by any defect in this product,
inconvenience, loss of goodwill, lost profits
or revenue, loss of use of this product or any
associated equipment, cost of substitutive 1-100035848 490-2831-806
equipment, downtime costs or claims of any
party dealing with purchaser for such
damages, resulting from the use of this
Naming of the brake:
product.
“TYPE”
The type is the description (name) of the
Manual
brake.
Svendborg Brakes reserves the right to
revise this document without prior
Serial number:
notification. These documents have been
The serial number is located on the
proofread for errors in translation and
nameplate / sign at the label named
accuracy. Despite this, technical and
“SERIAL NO.”.
typographical deviations can sometimes
occur.
The serial number is a unique number,
This document is updated on a regular
which identifies the brake / spring pack.
basis; changes will be published in future
printings. Improvements and/or changes to
Other information on the nameplate / sign
the described products or manual can be
“ITEM NO”
implemented at any time without preceding
This shows the item number of the brake
notice.
including the version number.
In no event shall Svendborg Brakes be liable
for any special, incidental, consequential or
“CLAMPING FORCE” and “OPERATING
punitive damages.
PRESSURE”
This includes, but is not limited to: damage
to other property or person, inconvenience,
The performance of the brake is shown by
loss of goodwill, lost profits or revenue, loss
the clamping force provided.
of use of this product or any associated
The operating pressure has to ensure
equipment, cost of substitutive equipment,
correct use of the brake.
downtime costs or claims of any party
dealing with purchaser for such damages,

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Brakes with a spring pack Molykote is produced by Dow Corning.

Spring applied fail safe brakes are marked Hydraulic oil can be synthetic or mineral oil
with the minimum clamping force (nominal) as per recommended oil types.
provided and the minimum operating Molybdenum Disulfide (MoS2) can be in
pressure (oil pressure) to ensure that the various forms; either spray, fluid or solid
brake is lifted. state.

1.6 Conversion factors 1.8 Before starting

All units in this manual are in metric units. 1.8.1 Please check that all the parts listed on the
order have been delivered.
If you have needs for conversion between
metric and imperial units the following
figures can be used.

Table 1.1
Conversion factors
Length:
1 Inch = 25.4 mm (millimetre)
mm
1 = 0.0394 inch
(millimetre)
Mass:
1 kg (kilogram) = 2.2046 lb (pound)
1 lb (pound) = 0.4536 kg (kilogram)
Force:
1 N (Newton) = 0.2248 lbf. (pound force)
kN (kilo-
1 = 224.8089 lbf. (pound force)
Newton) 1.8.2 A tool kit is needed to be able to install the
Pressure: brake correctly. If a such has been ordered it
1 Bar = 0.1
MPa (Mega should be included in the delivery. The same
Pascal) tool kit can be used for several brakes of the
PSI (pound per same type.
1 Bar = 14.5038
square inch)
Torque: 1.8.3 Any indicators that may have been ordered
Nm (Newton lbf.ft. (pound are not mounted on the brake but packed
1 = 0.7376
meter) foot) separately to avoid damage during
lbf.ft. (pound Nm (Newton
1 = 1.3557 transportation and mounting of the brake.
foot) meter)
1.8.4 The brake pads have also been packed
Example:
separately and should not be unpacked until
115 bar = 11.5 MPa = 1667.937 PSI
immediately before mounting them.
15 kNm = 11,064 lbf.ft.
1.8.5 All loose parts should be visually inspected
1.7 Lubrication to check they are intact after transport, and
they should be removed before the brake is
Different types of lubrication are used in
lifted from the transport crate.
different situations.
This can be either for lubrication of the seals
1.8.6 The brake is marked with a label, which
or disc springs during servicing or when
should be checked against the ordered
tightening bolts of a diameter above 16mm.
items. The nameplate contains information
on the type of brake, the serial number and
Some symbols are used on the drawing to
the necessary working pressure of the
indicate where lubrication is needed during
brake.
service:
1.8.7 If anything is missing from the delivery
Ì Grease - Molykote P74
according to the ordered items, or if anything
† Grease - Molykote B20
is damaged please contact the supplier
{ Hydraulic oil
immediately.
MoS2 Molybdenum Disulfide

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1.9 Disposal
General
The operator and / or user are responsible
for the proper disposal of the brake and the
associated components.
If any doubts about the correct disposal
please do not hesitate to contact Svendborg
Brakes or your local dealer or regional
disposal enterprises for further information.

Brake pads
The brake pads are made of a steel back
plate and some brake pad material / lining.
The brake pad material is either made of an
organic compound or of sintered metal.
Either type is asbestos free and free of lead.

The brake pads can be treated as metallic

waste.

Hydraulic oil
Hydraulic oil may not enter the environment
and must be professionally treated.
The oil must be removed from the brake and
from the hydraulic system / unit and stored
in proper containers until delivery to local
disposal enterprises.

Brake
The brake is in general made of cast iron or
machined steel.
Once the hydraulic oil has been removed
from the brake and the seals have been
removed - the brake can be treated as steel
waste/scrap.

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2. Installation WARNING
Solvent cleaners can be flammable,
2.1 Lifting and handling the brake
poisonous and can cause burns.
The Mono-spring BSFI 300 brake is
equipped with a top plate with holes and To avoid serious personal injury when you
should only be lifted by means of placing a use solvent cleaners, you must read the
hook through them. manufacturer’s instructions before using a
solvent cleaner, and then carefully follow
these instructions.

Also follow these procedures:

x Wear safe eye protection

x Wear clothing that protects your skin
x Work in a well-ventilated areas

All ways follow local rules and regulations for

/ when working with solvents.

2.3 Cleaning of the mounting surfaces

The mounting surface of the customer post /
gear box must comply with the relevant
arrangement drawings and mounting data
drawings.

If the mounting surface is not within the

CAUTION specification this can cause the base plate
Do not fit any hook or tie any rope, chain or to permanently distort and prevent the
strap around switches, valves, accumulator, caliper form sliding on the shafts / axles.
gauges etc. - this may damage the parts.
It is critical that the base plate is bolted to
The total weight of the caliper is approx. 72 the mounting surface in compliance with the
kilos. tolerance specified on the caliper mounting
drawing.
2.2 Cleaning the brake disc
IMPORTANT
Before installing the brake calipers the brake
The joint between the base plate and the
disc must be cleaned from any dirt or anti customer post / gear box is classified as a
corrosive protection.
friction joint.
The anti-corrosive protection can normally
Therefore NO lubricant or other compound
easily be removed in two steps:
shall be applied between the caliper and
mounting surfaces.
1) By using petroleum or diesel fuel for the
initial cleaning.
The mounting of the caliper does NOT rely
on the shear capacity of the mounting bolts
2) Using solvent cleaners to remove the
but of the friction joint. This friction joint is
remaining dirt completely.
created by the clean, dry lubricant free
surface machined to the correct surface
Use a cleaning solvent for the final cleaning.
finish and of the tension created by the
Solvent cleaners could be clear methylated
mounting bolts.
spirit or white spirit or isopropyl alcohol.
The mounting surfaces for the base plate
Any residual oil or anti-corrosion preparation
should be cleaned in a similar way as the
will reduce the coefficient of friction greatly.
brake disc - see section 2.2 - Cleaning the
brake disc.

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2.4.8 When the piston is completely lifted, screw

WARNING the flange nut into the end of the center bolt,
Solvent cleaners can be flammable, with the hand.
poisonous and can cause burns.
Please follow the manufacturer’s instructions 2.4.9 The hydraulic pressure can now be
and - see section 2.2 - Cleaning the brake released.
disc.
2.4.10 Remove the hand pump / hydraulic power
2.4 Mounting the brake unit and plug the pressure connection on the
2.4.1 Remove the indicator set, if fitted. caliper again.

2.4.2 When the brake is to be lifted for mounting,

mount an eye bolt on the back of the
passive caliper half.
The brake can be lifted using these eye
bolts.

2.4.11 Unscrew the adjusting screw approx. 2 turns

(anti-clockwise) with the spanner (adjusting
tool) to allow sufficient space between the
pads so the brake can later be swung up
round the brake disc.

IMPORTANT
Mount the brake pads so that the curved
CAUTION side of the pad is placed towards the caliper
Ensure that the mounting flange is cleaned and at the same time is parallel to the
of dirt and oil. periphery of the disc.

2.4.3 Lift the brake to the mounting flange and 2.4.12 Check the mounting flanges and disc for dirt
mount the lowest and innermost bolt without and grease.
tightening.
2.4.13 Tip the brake into its place and fit the 4 bolts
2.4.4 Tip the brake backwards. in the bottom plate. M20, grade 8.8 - Mv =
305 Nm.
2.4.5 Unscrew the cover on the adjusting screw.
2.4.14 The hydraulic power unit can now be
2.4.6 Remove the threaded plug in the upper mounted to the brake.
pressure connection and connect a hand
pump or hydraulic power unit. Check the 2.4.15 Check the position of the brake, continue to
position of the adjusting screw, (Xmax. = adjust the air gap
17mm).
2.5 Inspecting the alignment of the
2.4.7 Apply min. release pressure according to brake
Test Certificate or nameplate on brake, Max.
210bar. 2.5.1 Make sure that the piston is completely lifted
and the pads are not in contact with the disc.

2.5.2 Check that the pads can move freely.

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IMPORTANT
The axial movement of the brake disc must
not exceed 0.5mm.

2.6 Connecting the hydraulics

The brake is provided with two pressure
connections (17, 20-D) BSP 1/4”. The
connection at the lowest position shall
always be used as pressure connection
when connecting the brake to the hydraulic
system. The highest pressure connection 2.7 Bleeding the brake
can be used, depending on the design of the 2.7.1 The hydraulic system of the caliper must
hydraulic system, if through flushing is ALWAYS be bled in conjunction with
required. assembly or when making changes in the
system.

2.7.2 This bleeding should be repeated a few

times a year, since any air in the system will
impair the function - see section 2.6 -
Connecting the hydraulics.

2.8 Mounting the brake pads

NOTE
The brake pads are packet in sealed plastic
to protect them from contamination - please
keep the pads in the packet for as long as
possible.
CAUTION
CAUTION
The drain connections (18, 21) BSP 1/8”
Be careful to protect the pads from grease
must not be subjected to pressure UNDER
and oil which would significantly impair the
ANY CIRCUMSTANCES.
friction coefficient.

A pipe with a length of approx. 10-20cm can Organic brake pads are very sensitive to
be connected to the lowest drainage grease and oil and cannot be cleaned. They
connection. A plastic hose which discharges must be discarded and be replaced if
into a vessel or similar can be connected to exposed to this.
the free end of the pipe so as to check, if Brake pads of sintered metal are less
any leakage occurs from the piston seals. sensitive to oil and can be cleaned with
solvent and re-used.
CAUTION
Check that the pressure connection which is WARNING
not used is sufficiently tight to eliminate any Solvent cleaners can be flammable,
risk of leakage and that the adjusting screw poisonous and can cause burns.
is screwed sufficiently far into the yoke. Please follow the manufacturer’s instructions
and - see section 2.2 - Cleaning the brake
CAUTION disc.
Never apply hydraulic pressure to the caliper
There are two possibilities to mount the
before you have checked that X d 17mm.
pads:
1) Small hub diameter (i.e. when the hub
diameter is smaller than disc
diameter - 480mm). Remove the allen
screws from the inside of the brake pad.
The brake pad can now be mounted by

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sliding it from the centre of the brake

disc towards the caliper. Tight the allen
screws of the pad and mount the pad-
retraction springs.

2) Large hub diameter (i.e. when the hub

diameter is larger than disc diameter
- 480 mm). Remove the mounting
screws and the brake pad holder. The
brake pad can be mounted by sliding it
sideways in. Bring the pad holder back
in position and tight the mounting
screws with the right torque. Mount the
pad-retractions springs.

2.9 Bedding in of the brake pads

To obtain the rated coefficient of friction
between the brake pad and the brake disc,
and to ensure the pad surface is aligned to
the disc, it is essential that the pads are
bedded to the disc surface.

The coefficient of friction may drop by

approx. 20% when not bedded in.
IMPORTANT
The pads should be inserted with the This can be done by making a series of
rounded edge orientated so that it follows load-tests with increasing load or speed until
the curvature of the disc. sufficient coefficient of friction is achieved.
Re-fit the two screws and tighten them as If the brake disc is new the time of bedding
specified. in will be longer because the disc also has to
be bedded in. Always use new pads with a
new disc. Never use used pads with a new
disc.

Organic pads:
Organic pads can normally be bedded in by
driving the disc through the pads with a
minimum of 25% of the rated clamping force
applied, or if that is not possible by making a
series of activations with increased load or
increased speed.

Sinter-metal pads:
The bedding in process for sinter-metal pads
is the same as for organic pads, but with a
slightly higher clamping force when bedding
in - approx. 40% of the rated clamping force
applied.

During the process of “bedding in”, the disc

temperature should be monitored to ensure
that the disc does not overheat.

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Instruction for the bedding in process is 2.10.5 Check by measuring with, for example, a
packed together with the pads. 1mm feeler gauge that the air gap between
the disc and the pad is exactly 1mm. If the
2.10 Adjusting the brake positioning system is mounted, the 1mm air
gap must be adjusted to 0.5mm air gap on
The air gap is the space between the brake each side of the brake disc, see data sheet.
pads and the brake disc, when the piston is
completely lifted back against the adjusting
screw.

2.10.6 Apply release pressure to the caliper, see

Test Certificate or nameplate.

CAUTION 2.10.7 Remove the flange nut.

This total air gap must be adjusted to 1mm
at installation and must NEVER exceed 2.10.8 Re-mount the cover and O-ring.
3mm, i.e. 1mm wear on each pad. When the
air gap is >3mm the caliper must be 2.10.9 Re-fit the indicator (if fitted).
adjusted.
2.11 Before using the brake
2.10.1 Remove the indicator set, if fitted. Please check that the disc has been blocked
mechanically while the following points are
2.10.2 Check the position of the adjusting screw, checked:
Xmax. d 17mm, and apply release pressure
to the caliper, see test certificate or 1) That the disc and the pads are clean,
nameplate. containing no dirt after mounting.
2) That bolts and hydraulic connections
have been tightened using the right
torque.
3) That the electrical installations have
been connected correctly.
4) That the brake set for the correct air
gab.
5) That the brake opens and closes
correctly, and with the right reaction
times.
2.10.3 Mount the flange nut and release the oil
6) That the indicators function correctly.
pressure.
Please make sure the brake is closed and
2.10.4 Turn the adjusting screw clockwise using the
that the hydraulic pressure has been
spanner (adjusting tool) until both pads are
removed.
in contact with the disc. Then turn the
adjusting screw a half turn backwards (180°
Free the disc from the mechanical blocking.
anti-clockwise).There will now be 1mm air
gap (the thread of the adjusting screw has a
The brake is now ready for use. Please note
pitch of 2mm).
that the pads need to be bedded in for a

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while before the full effect of the brake is

obtained.

2.12 Removing the brake

2.12.1 Apply hydraulic pressure, see Test
Certificate or nameplate.

2.12.2 Remove the cover, and mount the flange nut

- see section 2.4 - Mounting the brake.

2.12.3 Relieve the pressure.

2.12.4 Remove 3 of the bolts in the ground plate

and loosen the 4th.

2.12.5 The brake can now be turned around the 4th

bolt and the brake pads be removed.

2.12.6 Apply hydraulic pressure again, remove the

flange nut and re-fit the cover.

2.12.7 Remove hose and pipe connections. The

brake can be removed safely from the
mounting place by removing the 4th bolt.

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towards the centre of the brake disc.

3. Maintenance Mounting is done in reverse order.
3.1 Replacing the brake pads
The brake pads must be replaced when
each pad has been worn 5mm.

All brake pads for the brake consist of a

steel back plate and a friction material. The
brake pad has a total thickness of 24mm,
i.e. all brake pads must be replaced at the
latest when the thickness of friction material
+ back plate is minimum 19mm.

3.1.1 Unscrew the cover.

3.1.2 Check the position of the adjusting screw

(Xmax = 17mm). Apply max. release
pressure to the caliper (see Test certificate
or nameplate).

If the hub diameter is large (i.e. larger than

disc diameter - 480mm) you have to remove
the mounting screws, and the brake pad
holder. The brake pad can be removed by
sliding it sideways out of the brake.
Mounting is done in reverse order.

3.1.8 Re-connect the hydraulic power unit to the

brake.

CAUTION
All pipes and hoses shall be undamaged
and thoroughly free of dirt see section 2.6 -
Connecting the hydraulics.

3.1.9 Adjust the air gap between the new brake

pads and the brake disc.
Follow the section 2.10 - Adjusting the
brake.

CAUTION
3.1.3 When the piston is fully lifted, mount the Remember the bedding in of brake pads.
flange nut on the center bolt.
3.2 Checking the spring package
3.1.4 Release the oil pressure. If you want to check the spring pack visually
before it has reached its calculated service
3.1.5 Turn the adjusting screw anti-clockwise life, it can be carried out as follows:
using the spanner (adjusting tool), as far out
as possible, i.e. until the adjusting screw 3.2.1 Remove the spring pack - see section 3.4 -
comes into contact with the O-ring. Dismantling the active caliper.

3.1.6 Remove the brake pad retraction spring set IMPORTANT

(if fitted).
The positioning of each individual cup spring
in relation to each other is very important
3.1.7 If the hub diameter is small (i.e. smaller than
and must be carefully checked.
disc diameter - 480mm) you have the
Distance shims, if any, must be placed
possibility of replacing the brake pad by
towards the adjusting screw.
removing the allen screws from the inside of
the brake pad and then slide the brake pad

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CAUTION CAUTION
A spring package must NEVER be mounted A spring package must NEVER be mounted
and must be discarded when: and must be discarded when:

1) There is any doubt as to the positioning 1) There is any doubt as to the positioning
of the cup springs. of the cup springs.
2) A single cup spring is broken or 2) A single cup spring is broken or
scratched. scratched.

3.4 Dismantling the active caliper

General
The greatest possible cleanliness must be
observed when working on a hydraulic
system of any type.
Each part must be washed in solvent
(paraffin, white spirit) and dried before being
lubricated and fitted.

WARNING
Solvent cleaners can be flammable,
poisonous and can cause burns.
Please follow the manufacturer’s instructions
and - see section 2.2 - Cleaning the brake
disc.

3.3 Replacing the spring package Parts must be stored in, and assembly work
The spring pack must ALWAYS be replaced must be carried out in a clean and dust free
after: environment. Dirt shortens the service life of
the seals considerably and may also
Brake type Operations damage the active caliper.
BSFI 304 to BSFI 340 2.000.000
The surface of the piston and the yoke
BSFI 345 320.000 which works against the seals is highly
BSFI 350 and BSFI 355 2.000.000 polished. Check that they are not damaged
BSFI 360 530.000 and handle them carefully to avoid
BSFI 365 270.000 damaging the surface in any way. A
BSFI 370 70.000 damaged piston will immediately ruin the
seals.
Replacing the spring pack - see section 3.4 -
Dismantling the active caliper. 3.4.1 Apply release pressure (see Test certificate
or nameplate) to the caliper and mount the
IMPORTANT flange nut.
The positioning of each individual cup spring
3.4.2 Release the oil pressure.
in relation to each other is very important
and must therefore be carefully checked.
3.4.3 Turn the adjusting screw anti-clockwise
Distance shims, if any, must be placed
using the spanner (adjusting tool), until X =
towards the adjusting screw.
17mm.
Lubricate the springs and the adjusting 3.4.4 Loosen the mounting bolts in the bottom
screw thoroughly when fitting. plate of the Monospring brake and tip the
brake backwards around the lowest and
innermost bolt.

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3.4.13 Remove the spring pack.

3.4.14 Push the piston including center bolt

backwards.

3.4.15 Remove the wiper and the seals.

3.4.16 Wash the parts thoroughly, dry and lubricate

them.

3.4.17 Our sealing solution has changed over time.

However they are chosen with ‘form, fit and
function’ which means that they are fully
3.4.5 Remove the pads, and tip the brake back interchangeable.
into place.
The current seal kit uses a mix / combination
3.4.6 Apply release pressure (see “Test certificate of the U-cup and the Stepseal type seals but
or nameplate) to the caliper and remove the older brakes can be with either U-cups or
flange nut. Stepseal.
When replacing the seal kit the mixed set is
3.4.7 Release the oil pressure. preferred.
3.4.8 Dismantle and plug the hydraulic Mount the new seals and the wiper as
connections. indicated in the figure.
3.4.9 Store the flange nut together with the
spanner as part of the tool kit.

3.4.10 Remove the 2 allen screws and the top

plate.

The piston seal (12) for the Stepseal

consists of an O-ring (12A-C) and a sealing
ring (12-C).
The wiper (16) also consists of an O-ring
(16A-C) together with the wiper (16-C).
Place the O-ring in the groove first. Then
form the sealing ring in a U-form and place
3.4.11 Remove the 4 mounting bolts and remove them in the groove with the O-ring. Squeeze
the whole caliper half. The caliper half must out any kink.
be taken to a workshop prepared for The u-cup seal (15-C) should be mounted in
hydraulic work. the groove as indicated in the figure.

3.4.12 Remove the adjusting screw from the yoke.

WARNING
Before removing the adjusting screw, be
sure there is no pressure on the caliper.

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Old style U-cup seal kit (not used

anymore) CAUTION
Use your fingers only. Be very careful with
the edges on the piston rod seals - even a
tiny scratch can ruin the seals.

3.4.18 Push the piston as far into the yoke as

possible. The adjusting screw can be used
as a tool.

3.4.19 Fit the spring pack. - see section 3.3 -

Replacing the spring package.

3.4.20 Turn the adjusting screw clockwise, using

the spanner, until it is max. 17mm out of the
yoke.

3.4.21 The caliper is ready for re-installation and

Both the u-cup seal and wiper are single adjustment - see section 2.4 - Mounting the
parts. Form the sealing ring in a U-form and brake.
place them in the groove - squeeze out any
kink. 3.5 Lubrication
Lubrication is required only when dismantling
Old style Stepseal seal kit (not used the active caliper - see section 3.4 -
anymore) Dismantling the active caliper and when
replacing the spring pack - see section 3.3 -
Replacing the spring package.

Seal-surfaces lubricated with hydraulic oil.

Springs, threads etc. lubricated with MoS2.

3.6 Storage
The brake is externally treated before delivery
with an anti-corrosion film which is sufficient
for indoor storage for 12 months.

If the caliper is to be stored for periods

longer than 12 months, it must be worked 20
times at full stroke each 12 months.

IMPORTANT
The piston seals for the step seal version The anti-corrosion protection must be re-
consist of a sealing ring and O-ring. The applied as necessary after transport and
wiper consists of an O-ring together with the handling if stored for more than 12 months.
wiper. Any kind of work carried out on the brake,
which are not mentioned in this manual
For both seal and wiper: Place the O-ring in
should be regarded as repair. In such cases
the groove first. Then form the sealing ring
please contact your local Svendborg Brakes
in a U-form and place them in the groove
supplier.
with the O-ring. Squeeze out any kink.

IMPORTANT
Be careful orienting the seals correctly when
mounting - wrongly oriented seals will result
in leakage.

Lubricate the seals and yoke according to

the lubrication note in the Appendix C -
Spare parts drawing.

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4. Trouble shooting
Fault Cause Action

The brake applies slowly Air in the hydraulic Bleed system at highest point and
at brake

Air gap between brake pad and Adjust air gap

disc too large

Abnormal throttling in the hydraulic Check that all valves are in the
system / valve in wrong position correct position

Abnormal throttling in the hoses Clean and check pipes hoses and
and valves valves

Oil in lines between brake and Check that the oil is the
tank has too high viscosity (too recommended grade
thick and not too cold

Long braking time or Load too heavy or speed too high Check the braking distance, load
insufficient braking force and speed values

Air gap too large Adjust the air gap

Oil, paint or grease on brake disc Clean the disc with solvent.
or pad Replace pad. Check that the brake
does not leak

All brakes not connected Check valves where applicable

Incorrect or damaged spring Replace whole spring pack not

individual cup springs

Leakage Worn seals or sealing surfaces Replace seals. Check sealing

surfaces

Uneven wear on pad The brake is incorrectly aligned Check the alignment o the brake
and bracket

Excessive disc throw or shaft Replace the brake disc and check
deflection the shaft deflection

Abnormally heavy wear on Increased brake utilization Check that the load, speed and
brake pad frequency do not exceed
permissible values

Insufficient air gap Adjust the air gap

The brake does not lift properly Check the oil pressure

Check the movements of pads

and pistons and the position of
cup springs and guides

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Appendix A - Dimension drawing

SVENDBORG BRAKES

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Appendix B - Mounting Drawing

ed
eas
Rel

SVENDBORG BRAKES

CONFIDENTIAL

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Appendix C - Spare parts drawing, Caliper half

SVENDBORG BRAKES

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Appendix C - Spare parts list, Caliper half

BSFI 300 MSxxS -200

Pos. Qty Item number Item name

1 1 pcs 490-1977-001 ADJUSTING SCREW BSFI300-X-200
2 1 pcs 490-1923-001 YOKE BSFI300-S-XXX
3 1 pcs 490-1942-001 PISTON BSFI300-S-XXX
5 1 pcs 490-0284-001 CENTER BOLT

6 1 pcs 490-xxxx-xxx SPRING PACK BSFX3XX-X-2XX E

For item numbers on specific spring-pack size -
see Recommended Spare Parts

7 2 pcs 490-1925-001 PAD HOLDER BSFI300-X-XXX

8 4 pcs 4490-0633-009 BOLT M12X50 10.9
9 4 pcs 478-0870-001 WASHER Ø13X24X2

13 1 pcs 2522-2111-113 HYDR PLUG 1/2" BSP W/SEAL

14 1 pcs 4490-0101-001 FLANGE NUT M24 8
17 1 pcs 2522-2111-110 HYDR PLUG 1/4" BSP W/SEAL
18 1 pcs 2522-2111-109 HYDR PLUG 1/8" BSP W/SEAL
20 1 pcs 2522-2111-110 HYDR PLUG 1/4" BSP W/SEAL
21 1 pcs 2522-4502-109 HYDR PLUG 1/8" BSP PLASTIC
22 1 pcs 490-0285-001 COVER JACK DAW GF35
23 1 pcs 478-0815-003 NAMEPLATE W/4 HOLES
24 4 pcs 4490-0676-001 BLIND RIVET Ø2,4X6 RH

478-2768-823 SEAL KIT BSFI 300-MS

11 1 pcs 6490-0044-003 O-RING Ø124,3X5,7 MM NBR-70
12 1 pcs 6490-0023-015 ROD SEAL Ø130X6,3 - STEPSEAL K, PTFE
12a 1 pcs 6490-0024-007 O-RING Ø135,89X5,33 MM NBR-70
15 1 pcs 6490-0051-001 ROD SEAL Ø90X6,3 U-CUP , PU
16 1 pcs 6490-0048-001 WIPER Ø90X6 - EXCLUDER 2, PTFE
16a 1 pcs 6490-0024-009 O-RING Ø94,84X3,53 MM NBR-70

For ordering spare parts:

Please refer to the manual number MEB-0300-050, position number and item number.

For easing the whole procedure please write down the type number and serial-number from the nameplate -
pos. 23.

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Appendix D - Spare parts drawing, Passive Caliper

Drawing is valid for 490-1899-801 / 802 / 803

SVENDBORG BRAKES

Appendix D - Spare parts list, Passive Caliper

Passive caliper - 490-1899-801

Pos. Qty Item number Item name

1 1 pcs 490-1899-001 PAS. CALIPER GGG50 W/BEAR.
2 4 pcs 7490-0001-004 SLIDE BEARING Ø55X50X40
3 2 pcs 490-1926-001 PAD HOLDER BSFI300-MS
4 4 pcs 4490-0633-009 BOLT M12X50 10.9
5 4 pcs 478-0870-001 WASHER Ø13X24X2

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Appendix E - Spare parts drawing, Base plate

SVENDBORG BRAKES

Appendix E - Spare parts list, Base plate

Base plate - 490-0419-801

Pos. Qty Item number Item name

1 2 pcs 490-0553-001 SHAFT Ø50
2 2 pcs 4490-0607-006 SPRING PIN SLOTTED Ø6X20
3 2 pcs 4490-0607-007 SPRING PIN SLOTTED Ø4X20
4 1 pcs 490-0419-002 BASE PLATE

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Appendix F - Positioning system

Name: DEB-0300-027

DATA SHEET Date: 17.02.2011

Revision: C

Positioning system for BSFI 300-MSXXX

Standard (S) and offshore (R) versions

Adjusting
1) Adjust the brake to the desired air gap (standard is 1mm)
2) Mount the spacers (5) and the springs (4) on both shafts (if not done already)
3) Mount the nut (2) on bolt (1). Nut must be at the head of the bolt (1)
4) Mount the bolts (1) with nuts (2) and washer (3) in both threaded holes in passive calliper
5) Adjust the calliper to an air gap of 0.5mm (half of the air gap) on each side of the disc,
by turning the bolts (1) - secure the bolt with nut (2). Repeat for both bolts.

Spareparts
490 2122-801 (Standard version)

Item Qt Parts no. Description

1 2 4490 0613-013 Bolt M10x160
2 2 4490 0614-001 Nut, M10
3 2 2151 2022-173 Washer
4 2 3490 0032-001 Spring
5 2 490 0515-001 Spacer

490 2122-803 (Offshore version)

Item Qt Parts no. Description

1 2 4490 0641-015 Bolt M10x160 A4
2 2 4490 0666-090 Nut, M10 A4
3 2 2151 2022-172 Washer A4
4 2 3490 0032-001 Spring
5 2 490 0515-001 Spacer

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Appendix G - Indicators

Name: DEB-INDI-014

DATA SHEET Date: 21.03.2013

Revision: B

BRAKE SWITCH - “BRAKE RELEASED” & “PAD WEAR”

Spring applied failsafe brakes
Function 30V Connections 125V Connections
Two micro-switches are mounted inside the housing of
the switch. The plunger detects the piston movement
through extender pins (if applicable) touching the brake
piston through the adjusting screw.

The “Brake Release” switch triggers when the brake is

released / activated (On/Off). The switch is closed from
fully lifted brake to approx. 0.4mm of piston movement ON/OFF PAD WEAR ON/OFF PAD WEAR
signal signal signal signal
The “Pad Wear” switch triggers when the brake pad is COLOR CODE:
worn to the allowed limit (1, 2, 3 or 4mm wear), and the BK = BLACK, BN = BROWN, WH = WHITE, GY = GREY, BU = BLUE
brake needs adjustment. INDICATOR NOT MOUNTED 30VDC 125VAC
Brake ON / OFF switch (1-4) ON / OFF
Brake ON / OFF switch is OPEN signal
The actual switch points vary according to the specific
brake type / switch and are not adjustable. PAD WEAR switch (3-2-5)
PAD WEAR switch OPEN (2-3) PAD WEAR
signal
The brake switch is available for 2 voltages: 30 VDC or
125 VAC / 30 VDC (high current) and with different cable
BRAKE "OFF", NO "PAD WEAR" **)
options. The cable is connected to the switch by a Indicator mounted & brake is OFF ON / OFF
standard M12 connector (angled). Brake "Lifted" - Contact is made signal
Brake ON / OFF switch is CLOSED (1-4)

Fail Safe operation PAD WEAR contact is made PAD WEAR

signal
PAD WEAR switch is CLOSED (2-3)
For fail-safe operations the switch should be wired to
have a signal/connection when everything is ok (i.e.
closing a normally open switch (NO)). BRAKE "ON", NO "PAD WEAR" *)
ON / OFF
The connection should disappear when switching i.e. Indicator mounted & brake is activated
Brake released - Contact is broken signal
applying the brake, having wear or in case of faults like Brake ON / OFF switch is OPEN (1-4)
broken cable, poor connections etc. PAD WEAR contact is made PAD WEAR
signal
NOTE - The indication for “Pad Wear” is only active PAD WEAR switch is CLOSED (2-3)
during braking and disappears when the brake is lifted.
BRAKE "ON", "PAD WEAR" *)
Indicator mounted & brake is activated ON / OFF
Mounting Brake released - Contact is broken signal
1. Mount the brake and brake pads - refer to manual. Brake ON / OFF switch is OPEN (1-4)
2. Remove the plug (1/2” BSP) from the adjusting screw. PAD WEAR contact is broken PAD WEAR
signal
3. Mount the indicator (figure C) into the threaded hole or PAD WEAR switch is OPEN (2-3)
mount the adaptor (BSFI 200 / BSFH 300-S) on the
indicator before mouting (figure D). BRAKE "OFF", "PAD WEAR" **)
ON / OFF
4. Mount the M12 connector on the switch – for electrical Indicator mounted & brake is OFF signal
Brake "Lifted" - Contact is made
connection see connection diagram. Brake ON / OFF switch is CLOSED (1-4)

PAD WEAR switch is CLOSED (2-3) PAD WEAR

because NO indication for PAD WEAR signal
when brake is lifted

*) = Brake “ON” = NO hydraulic pressure / brake released / activated

**) = Brake “OFF” = MAX. hydraulic pressure = brake “lifted”

Technical data 30 VDC

0 0
125 VAC
0 0
64
+min 15mm to remove plug
Fig.C
Operating temperature : -40 C to +85 C -40 C to +85 C
Max. Voltage / Current : 30 VDC / 100 mA 125 VAC / 3 A Ø40
45 (75 with adaptor)

30 VDC / 2 A B
Switching tolerance : +/- 0.2mm +/- 0.2mm
Max. Stroke : 16mm 16mm
Protection grade : IP 65 (mounted) IP 65 (mounted)
Max. Tightening torque 1/2” BSP : 20 Nm - A) 20 Nm - A)
Max. Tightening torque M12 : finger tight - B) finger tight - B) Fig.D
Min. no. of operations : 1 million 1 million
Cable length : 5, 10 or 15meters 5, 10 or 15meters
A
Cable type/material : PUR PUR
2 2
Cable dimension : 5 x 0.34mm 4 x 0.34mm
Thread size - A) : 1/2” BSP (G 1/2”) 1/2” BSP (G 1/2”)
Spanner size (SW) - A) : 36mm 36mm

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Appendix H - Technical Data

Name: DEB-0300-016

DATA SHEET Date: 20.11.2012

Revision: G

TECHNICAL DATA AND CALCULATION FUNDAMENTALS FOR

DISC BRAKE BSFI 300 - “E”
1) 1)
Caliper Clamping force Braking Loss of Operating Balancing pressure Piston Max. Pad surface
2) 3) 4) 6)
type [N] force force per pressure travel air pressure
[MPa] 3)
1mm gap
MIN MAX [N] [%] [MPa] MIN MAX [mm] [mm] [N/mm²]

BSFI 306 6.000 6.600 3.200 6,0 2.3 0.87 0.95 1,0 3 0,15 - 0,33
BSFI 308 8.000 8.800 6.400 7,0 2.5 1.16 1.27 1,0 3 0,30 - 0,44
BSFI 310 10.000 11.000 8.000 4,5 3.5 1.45 1.59 1,0 3 0,38 - 0,55
BSFI 315 15.000 16.500 12.000 5,0 4.0 2.20 2.38 1,0 3 0,57 - 0,83
BSFI 317 17.000 19.000 13.600 4,0 4.2 2.46 2.74 1,0 3 0,66 - 0,95
BSFI 318 18.000 19.500 14.400 5,0 4.2 2.61 2.82 1,0 3 0,67 - 0,98
BSFI 320 20.000 22.200 16.000 3,0 4.5 2.90 3.21 1,0 3 0,77 - 1,11
BSFI 322 22.000 24.500 17.600 3,0 5.0 3.19 3.54 1,0 3 0,84 - 1,23
BSFI 325 25.000 27.800 20.000 12,0 5.5 3.62 4.02 1,0 3 0,96 - 1,39
BSFI 330 30.000 33.100 24.000 10,0 7.0 4.35 4.78 1,0 3 1,14 - 1,66
BSFI 332 32.000 35.200 25.600 9,0 7.0 4.63 5.09 1,0 3 1,21 - 1,76
BSFI 335 35.000 38.300 28.000 8,0 7.5 5.07 5.54 1,0 3 1,32 - 1,92
BSFI 340 40.000 43.600 32.000 7,0 8.5 5.79 6.30 1,0 3 1,50 - 2,18
BSFI 345 45.000 48.800 36.000 6,0 9.5 6.52 7.06 1,0 3 1,68 – 2,44
BSFI 350 50.000 54.000 40.000 11,0 10.5 7.24 7.81 1,0 3 1,86 - 2,70
BSFI 355 55.000 59.300 44.000 10,0 12.0 7.96 8.57 1,0 3 2,04 – 2,97
BSFI 360 60.000 64.400 48.000 9,0 13.0 8.69 9.31 1,0 3 2,22 - 3,22
BSFI 370 70.000 74.800 56.000 11,0 15.0 10.13 10.82 1,0 3 2,58 - 3,74
1)
All figures are based on 1mm air gap (Dual spring: Each side – Monospring: Total)
2)
Braking force (FB) is based on min. clamping force (FC), nominal coefficient of friction μ = 0.4 and 2 brake surfaces.
3)
The operating pressure is the minimum needed for operating the brake
4)
The piston travel at which the pressure limits is measured – the nominal pressure limits is identical to balancing pressure values
5)
Maximum recommended air gap depending on wear
6)
Pad pressure for organic / sintered pads respectively (based on max. clamping force).

BRAKING TORQUE
( D0  0,13)
The braking torque MB is calculated from following formula where: MB a ˜ FB ˜ [ Nm]
a is the number of calipers acting on the disc, FB is the braking force 2
according to table above [N] or is calculated from formula for FB, D0 is
the disc outer diameter and μ is the coeffiecient of friction
FB FC ˜ 2 ˜ P [ N ]
The actual braking torque may vary depending on adjustment of brake
and friction coefficient present

CALCULATION FUNDAMENTALS Dual Spring Mono Spring

Weight of caliper incl pads/bolts-no bracket): Approx. 65 kg. Approx. 85 kg
Overall dimensions (20mm disc) 326 x 316 x 379mm 279 x 420 x 299mm
Overall dimensions with indicators: 326 x 316 x 539mm 279 x 420 x 379mm
Pad width: 130mm 130mm
2 2
Pad area: (organic) 29.000mm (*) 29.000mm (*)
Max. wear of pad: (organic) 10mm (*) (=14 mm thick) 5mm (*) (= 19mm thick)
2 2
Pad area: (sintered) 20.000mm (*) 20.000mm (*)
Max. wear of pad: (sintered) 7mm (*) (=17 mm thick) 5mm (*) (= 19mm thick)
Nominal coefficient of friction: P = 0.4 P = 0.4
2 2
Total piston area - each caliper half: 69,1 cm 69,1cm
2 2
Total piston area - each caliper: 138,2 cm 69,1cm
3 3
Volume for each caliper at 1mm stroke: 13,8 cm 6,9cm
3 3
Volume for each caliper at 3mm stroke: 41,4 cm 20,7cm
Actuating time (guide value for calculation): 0.3 sec. 0.3sec
Pressure connection/port: 1/4" BSP 1/4" BSP
Drain connection port: 1/8" BSP 1/8" BSP
Recommended pipe size: 10/8mm 10/8mm
Maximum operating pressure 23.0 MPa 23.0 MPa
Operating temperature range -20 to +70 °C -20 to +70 °C

(For temperatures outside this range contact Svendborg Brakes)

(*) On each brake pad

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Appendix I - Recommended fluid

Name: DEB-DIVE-005

DATA SHEET Date: 19.05.2014

Revision: I

RECOMMENDED FLUID FOR DISC BRAKES & HYDRAULICS

PRESSURE FLUIDS / OIL TYPES
The following oil types are recommended by Svendborg Brakes – other types corresponding to these can be used.

The general temperature range for our standard ranges of products using hydraulic oil are -20°C to +60°C (-4°F to
+140°F) however the BSAK and BSAB brake series are generally approved for lower temperatures.
These are approved for usage at -40°C in wind turbines and for -30°C in other applications.

When quick brake reaction times are critical and operating at temperatures below 0°C (+32°F) it is recommended to use
the oil types listed in the Cold section as these types provides the most constant reaction times.
Extreme temperature applications may require special options. Please contact Svendborg Brakes.

Cold / special option Standard Special option

-40°C - +60°C -20°C - +40°C +10°C - +60°C +30°C - +70°C
Mineral oil
-40°F - +140°F -4°F - +104°F +50°F - +140°F +86°F - +158°F
Shell Tellus S4 VX 32 Tellus S2 V32 Tellus S2 V46 Tellus S2 V68
Mobil /
- DTE 10 Excel 32 DTE 10 Exel 46 DTE 10 Exel 68
EXXON
Texaco Rando Ashless 8401 Rando HDZ32 Rando HDZ46 Rando HDZ68
Valvoline - Ultramax HVLP32 Ultramax HVLP46 Ultramax HVLP68
-40°C - +50°C -20°C - +40°C +10°C - +60°C +30°C - +70°C
Synthetic oil
-40°F - +122°F -4°F - +104°F +50°F - +140°F +86°F - +158°F
Mobil - SHC 524 SHC 525 SHC 526
(1)
Bio Oil -40°C - +50°C -20°C - +30°C +10°C - +60°C +30°C - +70°C
(Ester or Colza oil)-40°F - +122°F -4°F - +86°F +50°F - +140°F +86°F - +158°F
Shell - Naturelle HF-E15 Naturelle HF-E32 Naturelle HF-E46
General: Mineral Pressure Fluids according to DIN 51524 Part 3
(1) There must be less than <200PPM water in the oil, due to the seals.

Viscosity
Recommended viscosity range: 20-200 cSt at working temperature. Generally Svendborg Brakes systems are designed
to allow higher viscosity in short periods.

Filtration
The oil in a hydraulic system and the oil added to the hydraulic system must always be filtered. The level of cleanliness
in a hydraulic system is an important factor to the lifetime of the system.
When refilling the hydraulic tank, it is stipulated that the oil added to the system is filtered through a 10-micron purity off-
line filter unit to the classes listed below.

The hydraulic system, supplied by Svendborg Brakes, has a build-in oil filter with a standard 10-micron purity filter. To
maintain a reliable system it is recommend that only hydraulic oil of the following classes of purity is used: NAS 1638,
Class 8, or ISO 4406, Class 19/17/14.
It is recommended that the filter is changed at a minimum, once every six months or more often depending on the level
of exposure to contamination.

Service life of pressure fluids

Mineral oil: 8.000 Hours or at least once a year.
Other fluids: 2.000 Hours or at least once a year.

Change of pressure fluid

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

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

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Appendix J - Recommended spare parts

Recommended spare parts for one brake

Item Item number

Spring pack
Spring pack BSFI 306 490-2966-801
Spring pack BSFI 308 490-3957-801
Spring pack BSFI 310 490-0357-801
Spring pack BSFI 315 490-0404-801
Spring pack BSFI 317 490-0355-801
Spring pack BSFI 318 490-0355-802
Spring pack BSFI 320 490-0324-801
Spring pack BSFI 322 490-0963-801
Spring pack BSFI 325 490-0833-801
Spring pack BSFI 327 490-0833-802
Spring pack BSFI 330 490-0335-801
Spring pack BSFI 332 490-3752-801 Check the nameplate for size
Spring pack BSFI 335 490-0336-801 - section 1.6.1
Spring pack BSFI 340 490-0337-801
Spring pack BSFI 345 490-1402-801
Spring pack BSFI 350 490-0298-801
Spring pack BSFI 355 490-1162-801
Spring pack BSFI 360 490-1731-801
Spring pack BSFI 370 490-0714-801

Brake pad set

Sinter metal MD550 490-0402-803
Organic BE3521 490-2047-801
Organic IP160 378-1313-801
Organic SB1001 491-0001-801

Brake pad retraction springs

Pad retraction spring set 490-0666-804

Seal kit
Seal Kit BSFI 300-MS 478-2768-823

Positioning system
Pos. system 490-2122-801

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Item Item number

Indicators
Mechanical indicators are as standard
with a 5meter cable, other options
available on request

30 VDC
Brake release & 1mm Pad Wear 490-3371-805
Brake release & 2mm Pad Wear 490-3372-805
Brake release & 3mm Pad Wear 490-3373-805

125 VAC
Brake release & 1mm Pad Wear 490-3381-805
Brake release & 2mm Pad Wear 490-3372-805
Brake release & 3mm Pad Wear 490-3373-805

Tools - part 1 Used for adjusting the brake (mandatory – 1 per brake)

Tools
Tool Kit BSFH/I 300-MS 490-0109-804

Tools - part 2 Used for manually lifting the brake piston (hydraulically)

Hand pump with 800mm test point 0350-1019-801

hose

Test point connectors (Mini mess)

Test point male 1/8 BSP (drain) 9009-1010-020
Test point male 1/4 BSP (pressure) 9009-1010-040
Test point male 1/2 BSP 9009-1010-080

Test point hose 800mm 9009-3010-008

Tools - part 3 Used for during maintenance / overhaul (optional)

Tool for lifting the adjusting screw out

of the yoke (M36) 490-3456-003

Tool for lifting piston out of the yoke 490-3456-004

(M24)

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Other parts

Drain kit

Drain bottle with tubing and fittings -

Drain bottle 0,5L plastic 9640-0999-001

Drain bottle 1,0L plastic 9640-0999-002

Converters (BSP on brake)

Male BSP to male NPT

1/8 BSP to 1/8 NPT (drain) 9040-1200-018
1/4 BSP to 1/4 NPT (pressure) 9040-1200-014
1/4 BSP to 3/8 NPT (pressure) 9040-1200-048

For purchasing and further information, please contact your local Svendborg Brakes supplier.

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 Name: MEH-3000-0278-805
Date: 19.05.2015
Revision: -

Installation and Maintenance

Manual

HYDRAULIC
BRAKE CONTROL UNIT
3000-0278-805
(1013-0128-836)

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Installation and Maintenance Manual – 3000-0278-805

Table of content
TABLE OF CONTENT ............................................................................................................. 1
1. GENERAL .................................................................................................................... 2
1.1 Who to contact ............................................................................................................. 2
1.2 Safety ........................................................................................................................... 2
1.3 Symbols used in this manual ........................................................................................ 3
1.4 Disclaimer ..................................................................................................................... 3
1.5  Transportation .............................................................................................................. 3
1.6 Lifting ............................................................................................................................ 4
1.7 Storage ......................................................................................................................... 4
1.8 How to order spare parts .............................................................................................. 4
2. INSTALLATION AND COMMISSIONING ................................................................... 5
2.1 Mounting....................................................................................................................... 5
2.2 Connections ................................................................................................................. 5
2.3 Before starting the pump unit ....................................................................................... 5
3. DESCRIPTION OF THE HYDRAULIC SYSTEM ......................................................... 7
3.1 General......................................................................................................................... 7
3.2 Function........................................................................................................................ 7
3.3 Hydraulic diagram ........................................................................................................ 9
4. MAINTENANCE ......................................................................................................... 10
4.1 Inspection ................................................................................................................... 10
4.2 Adjustment ................................................................................................................. 10
4.3 Checks ....................................................................................................................... 10
4.4 Function test ............................................................................................................... 12
4.5 Dismantling the power unit ......................................................................................... 12
4.6 Changing the oil ......................................................................................................... 12
4.7 Changing the oil and cleaning the reservoir ............................................................... 13
4.8 Changing the oil filter.................................................................................................. 14
4.9 Changing the air breather ........................................................................................... 15
4.10 Measuring the gas pressure ....................................................................................... 16
4.11 Recharging the accumulator ...................................................................................... 17
5. TROUBLE SHOOTING .............................................................................................. 18
5.1 Failure intro ................................................................................................................ 18
5.2 Power unit does not release pressure ........................................................................ 19
5.3 Power unit does not set / build pressure .................................................................... 20
5.4 Other failures .............................................................................................................. 21
APPENDIX A - DIMENSION DRAWING ............................................................................... 23
APPENDIX B - SPARE PART DRAWING ............................................................................ 24
APPENDIX B - SPARE PARTS LIST.................................................................................... 25
APPENDIX C - HYDRAULIC SETTINGS .............................................................................. 26
APPENDIX D - ADJUSTING ................................................................................................. 27
APPENDIX E - ELECTRICAL DIAGRAM ............................................................................. 28
APPENDIX F - RECOMMENDED FLUID .............................................................................. 29
APPENDIX G - RECOMMENDED SPARE PARTS .............................................................. 30

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Hydraulic power unit:

1. General x Do not operate the hydraulic power unit
Thank you for buying a Svendborg Brakes before correctly filling the reservoir / oil tank
product. with oil.
Before using the product please read this x Do not adjust valves or pressure switches to
manual carefully. higher operating pressure than specified in
the manual.
1.1 Who to contact x Do not change the size or type of
In case you have any questions to this components.
manual please contact your local x Do not use hydraulic fluids not
representative or nearest Svendborg Brakes recommended in this manual.
Office:
Brakes:
Head Office: x Do not operate the brake before removing
the air from the hydraulic system by
Svendborg Brakes - Denmark: bleeding and then re-filling with oil.
Phone: +45 63 255 255 x Do not use higher operating pressures than
Fax: +45 62 281 058 specified on the nameplate of the brake / or
E-mail: [email protected] in the manual.
x Do not change the size or type of spring
For local offices/current contact information, pack.
please refer to www.svendborg-brakes.com x Do not use the brake pads when they are
worn to the minimum thickness as shown in
1.2 Safety the manual.
The Svendborg Brakes brake line of x Do not operate the brake if there is dirt or
products are designed to be mounted on a corrosion protection on disc or brake pads.
rotating brake disc for use in conjunction
with parking brake applications, service Personal safety
brake applications or emergency brake Do not work on the brake/ system before:
applications only. x The manual has been read and understood.
x The brake disc is locked and not able to
NOTE rotate before adjusting the brake and / or air
x Always make sure that you consult gap.
Svendborg Brakes before using tools or any x Locking / securing the brake piston by using
other equipment not recommended / the air gap bolt / air gap nut if working on a
specified in this manual. spring applied brake.
x In order to maintain the warranty always use x Being sure there is no pressure on the
original spare parts from Svendborg Brakes. hydraulic power unit or circuit.
x Customer is responsible for always keeping x Being sure the oil pressure in the
the brake and hydraulic aggregate clean, accumulator(s) has been relieved /
and free from dirt, grease or oil. removed.
x Customer is responsible for the air gap x The control signals has been shut off and
between brake pads and brake disc never blocked before working on the system.
exceeds the air gap recommended. x The electrical power has been shut off.
x Always use a torque wrench when refitting
mounting bolts or valves in order to ensure
the torque obtained is the torque described
in this manual.
x There should be one manual available for
the service / maintenance crew as a
minimum.

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This document or parts hereof may in no

1.3 Symbols used in this manual
event be copied, reproduced, changed or
To make sure you perform certain tasks translated to other languages without explicit
properly, please take note on the following written permission from Svendborg Brakes.
symbols used throughout this manual.

WARNING 1.5 Transportation

Information to prevent personal injury when When leaving the factory the hydraulic
trying to complete a task. power unit is always packed / wrapped to
ensure maximum security for the product
CAUTION during transport.
Information to prevent damage to the
components when trying to complete a task. CAUTION
If the hydraulic power unit has been sent by
WARNING air freight - please note that the gas (N2)
Electrical shock hazard pressure may have been released /
removed from the accumulator(s).
IMPORTANT
Information you MUST follow to complete a A label (see figure 1.1) is then attached to
task. the accumulator.

NOTE FIGURE 1.1

Tips and additional information to aid in
completing a task.

Figures within brackets ( ) relate to

position number and Appendix number
i.e. (15-B) refers to position number 15 in
If the accumulator is not pre-charged it must
Appendix B on both drawing and bill of
be recharged before usage. See section
material (parts list).
4.11 – “Recharging the accumulator” for
details
1.4 Disclaimer
Svendborg Brakes reserves the right to Normally there is no hydraulic oil in the unit.
revise this document without prior A warning label is attached to it.
notification. These documents have been
proofread for errors in translation and
accuracy. Despite this, technical and WARNING
typographical deviations can sometimes FIGURE 1.2
occur.

This document is updated on a regular WARNING

basis; changes will be published in future FOR TRANSPORT REASONS
printings. Improvements and/or changes to THE PUMP IS SHIPPED
the described products or manual can be
implemented at any time without preceding WITHOUT OIL
notice. FILL WITH RECOMMENDED OIL
BEFORE STARTING
In no event should Svendborg Brakes be REFER TO MANUAL
liable for any special, incidental,
consequential or punitive damages. This The hydraulic power unit must be filled with
includes, but is not limited to: damage to oil according to Appendix F of this manual
other property or person, inconvenience, before usage. If running dry the pump will be
loss of goodwill, lost profits or revenue, loss destroyed.
of use of this product or any associated
equipment, cost of substitutive equipment,
downtime costs or claims of any party such
damages, resulting from any misspellings or
inaccurate information in this users guide.

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1.6 Lifting FIGURE 1.5

The hydraulic power unit weighs app. 150 kg

(330 lbs). If it is necessary to use a lifting
harness, under no circumstance place it
around valves, gauges or accumulators.

See below how to lift.

If not mounted in cabinet the hydraulic

power unit may be lifted in the motor – see
figure 1.3

FIGURE 1.3

CORRECT WAY TO LIFT

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

CAUTION 1.8 How to order spare parts

Do not lift the hydraulic power unit in the When ordering spare parts for your hydraulic
valves etc. – see figure 1.4 power unit please refer to the specific item
number in the parts list – see appendices.
FIGURE 1.4
For full identification of the hydraulic power
unit please note the ID-number labelled on
the manifold or on the tank.

FIGURE 1.6

PU: 3000-0278-805

ID: 1-5000xxxxx
WRONG WAY TO LIFT

If the hydraulic power unit is mounted in a

cabinet the unit can be lifted by using the
lifting point in the supporting frame.

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2. Installation and The oil volume is approx. 6 litres.

Remove the air breather (5b), and add
commissioning filtered oil.

2.1 Mounting FIGURE 2.2

With the cabinet support bracket comes 4
smaller angular brackets for floor or wall
mounting. In each of these small brackets is
an Ø13 mm hole for bolting to the surface.

In the bottom of the tank there are 4

threaded M8 x 12 mm holes for floor
mounting.

In the back of the manifold there are 2

threaded M10 x 15 mm holes for wall 2.3.2 Fill the oil reservoir to the top level mark in
mounting. the sight glass located on the reservoir
sidewall.
See (Appendix A).
CAUTION
2.2 Connections Use only filtered oil of the right viscosity for
refilling (see Appendix F).
Hydraulic pressure ports out of the cabinet
or on the manifold are size 10L metric male
according to DIN 20 078 N. FIGURE 2.3

All pipes, hoses, fittings etc. mounted to the

total system, shall be flushed so it can meet
the demands in NAS 1638 Class 8 or ISO
4406 Class 19/17/14.

2.3 Before starting the pump unit

The power unit may have been sent without
nitrogen gas (N2) in the accumulator,
depending on global or local regulations for
transport of pressurized equipment. If the
unit has been sent without pressure, a label NOTE:
(see figure 2.1) is attached to the x Oil quantities are stated above but are to
accumulator. be checked for correct fill level by sight
glass in the tank.
x Greater oil volume will be required for
FIGURE 2.1 bleeding
x Oil must be filtered through a 10-micron
nominal filter.
x For more details see Appendix F.

2.3.3 Connect the electrical power. Check that the

If the accumulator is not pre-charged it must rotation of the electric motor is correct as
be charged before usage. See section 4.11 indicated on the motor – i.e. Counter
– “Recharging the accumulator”. clockwise viewed from the fan end.
After recharging you should remove the
label. WARNING
External electrical cables must be connected
If the accumulator is pre-charged – proceed to the junction box according to the electrical
to section 2.3.1 wiring, diagrams see Appendix E, or
separate documentation supplied along with
2.3.1 Fill up the tank with oil of the recommended the equipment.
quality (see Appendix F).
The unit must only be connected by a skilled
electrician.

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Customer is responsible to ensure all Air in the system could also destroy the
electrical connections are made according sealing (diesel effect) within the hydraulic
to national and international regulations for system.
the installation of electrical equipment.
Make a function check of the system by
The device must be supplied from an checking the pressure, and the hydraulic
isolated source and protected by an over settings list (Appendix C).
current device to ensure the limited voltage
circuit requirements according to national
and international standards.

No warranty will be considered if this is not

completed accordingly.

2.3.4 Start the electric motor and let the unit run
10 cycles (pressurising/de-pressurising):
x With system pressurised bleed the
brakes.
x With system de-pressurised refill oil
if necessary.

2.3.5 Bleeding and flushing the hydraulic

power unit.
To meet the demands in NAS 1638 Class 8
or ISO 4406 Class 19/17/14 the hydraulic
power units supplied from Svendborg
Brakes has been flushed before leaving the
factory.

But despite above, the hydraulic system

must always be flushed and bled again
before taking the system into full usage.

Flushing of the system will remove minor

particles and potential dirt in the system and
prevent damages to the system.

After flushing - the hydraulic power unit must

be bled in order to remove any air in the
system.

If the hydraulic power unit is not properly

bled potential damages to the sealing may
occur.

The hydraulic power unit must always be

bled in conjunction with assembly, repairs or
when making changes in the system.

Failure to bleed the hydraulic system will

allow air to remain in the brake system.

This could prevent the hydraulic pressure in

the brake system from reacting fast enough.

A possible result from this could be that the

brake pads will remain on the brake disc and
heating of the brake pads and brake disc
could occur.

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3. Description of the The accumulator (A1) serves as pressure

back-up preventing the motor from often
hydraulic system restarts. These accumulators also have
capacity to open the brakes without starting
the pump.
3.1 General
The hydraulic unit has been developed to be 3.2.2 Releasing the brakes:
used together with active/failsafe brake Power is connected to the electrical motor
calliper from Svendborg Brakes. The pump (4) and the solenoid valves (20, 26 and 27)
can be connected to one or more brakes. are energized, and the pressure will release
the brake.
The hydraulic power unit 3000-0278-805 The valves (20, 26 and 27) are kept
consists of 3 main items: energized at all time when the brakes are
released.
x Cabinet 9893-0001-912
x Power unit 1013-0128-836 NOTE
x Junction box 1013-0128-336 As long as there is a healthy system with full
power available valve (27) is energized.
Except for the dimension drawing and
mounting/handling instructions this manual 3.2.3 Applying the brakes – SOBO®.
holds no further information about the The parts active in the SOBO® braking
cabinet. system are:
x A main accumulator (A1).
The power unit is described in details x The directional valves (20, 22 and
including functionality, assembling/mounting, 26).
pressure settings, spare parts, description of x The throttle valves (20.1 and 26.1).
main parts, maintenance, trouble shooting, x The relief valve (22.1).
choice and handling of hydraulic medium x A small SOBO® accumulator (34).
etc.
The 2-stage accumulator (33) has no
The junction box is only described by an function for the SOBO® braking.
electrical diagram (see Appendix E). It holds
no active part and is only installed in order to Option UPS:
make logical and well-arranged electrical If the system is supplied with an UPS
connections. (Uninterrupted Power Supply), the main
accumulator can secure enough oil to feed
the braking sequence also in case of a grid
3.2 Function
fall out.
(See the hydraulic diagram section 3.3)
Valves (20 and 26), the throttle valves (20.1
3.2.1 System energy and 26.1), the relief valve (22.1) and the
In the hydraulic system an electro motor (4) small accumulator (34) are the heart of the
®
and a pump (2) converts electrical power SOBO system.
into oil pressure and oil flow.
During the whole SOBO®-braking valve (22)
Pressure is limited by: will be energised in the open position to
x The pressure switch (40) that turns secure contact between disc and pads.
off the motor when the pre-set
pressure is reached. By switching the valves (20 and 26) on and
x A safety relief valve (16). off with flow in and out through the throttle
valves, the pressure in the brakes can be
Pressure is monitored by a pressure switch controlled.
(40). If pressure drops below the pre-set
value the motor will restart boosting the The small accumulator (34) is used to make
pressure. the controlled oil volume larger, thus
increasing the oil flow response time, with
The check valve (17) prevents pressure the same size of throttle.
from going back to tank, when motor stops.

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This is very important because it makes it

possible to make the throttle area a little
bigger, which both makes it less sensitive to
dirt and temperature changes in the oil.

The working method in the basic version is

that the SOBO® controller measures the rpm
of the controlled system. In the program a
ramp defines the desired rpm as a function
of time.

During the braking sequence, - if the actual

rpm is above the ramp, the pressure in the
brake is relieved over the throttle by
switching valve (26) off, resulting in an
increased braking force, or by switching
valve (20) on, if the rpm is below the ramp.

When the system is stopped valves (20, 22

and 26) are left de-energized, ensuring
possible rest pressure is dumped to tank
through valve (26.1).

3.2.4 Applying the brakes by emergency or

power loss
®
If the SOBO braking system fails, all the
valves will be de-energized and the pressure
will drop to the setting of (27.1) and when
the time (set on 18.1) has expired the rest of
the oil is dumped through the orifice (27.2).

3.2.5 Monitoring
The hydraulic block is foreseen with 2 mini
mess connectors, where the included gauge
can be connected. One connection in port
(17) is showing the system pressure and
one connection in (P2) showing the actual
pressure at the brakes.

3.2.6 Hand pump

If the brake needs to be released without the
pump running, it is possible to use the hand
pump (HP).
The solenoid coil (26) must then be
connected to power, or manually overridden.

IMPORTANT
After using the hand pump (HP) the solenoid
valve (26) must be left in an open position!

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3.3 Hydraulic diagram

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4. Maintenance 4.2 Adjustment

Maintenance is important for the ability of A number of components demands the
the hydraulic power unit to control the correct setting or charging in order to make
brakes at any time. the braking system work properly.

Maintenance consists of inspection and The correct setting and how to adjust it can
service. be found in Appendix C & D.

All pressure control valves, flow control All components in the pump unit are pre-set
valves, pump regulators and signalling to the stated pressure from the factory, but
devices such as pressure switches are may need adjustment during initial
adjusted during the initial manufacture and commissioning.
subsequent commissioning.
4.3 Checks
The settings must be monitored By remaining alert and paying close
continuously during the initial stages of attention to detail it is possible to detect
operation and then subsequently at faults in their early stages and so prevent
reasonable intervals. them from developing into more serious
malfunctions. This is particular important
4.1 Inspection during the early stages, but also remains
Initial commissioning inspection is done to important throughout the service life of the
check if adjustment of the pump unit is pump unit.
necessary.
A constant attention should be kept for:
Later inspection is done on a regular basis. x External leaks
x Dirt
x Damage, especially to hoses and
CAUTION FIGURE 4.1
pipes
x Unusual noises from pump,
electrical motor, valves etc.

Caution
x Proper functioning of instruments

A maintenance log should be established to

System contains ensure the equipment is kept in operating
condition.
Accumulator
Depressurize system
Before maintenance

IMPORTANT (safety information)

Be aware that the system is equipped with a
hydraulic accumulator, and before any
maintenance work it should be ensured that
the system is completely without hydraulic
pressure by opening the valve (26).

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4.3.1 Check and Inspection plan

Service intervals periods

See Initial commissioning and
Inspection plan after commissioning.
chapter installation
Whatever comes first of:
Function
Test of each valve Before first real operation 6 months / 1000 h
Hydraulic oil
Level of oil Continuous Monthly / 160 h
If not using the level and
Continuous Weekly / 40 h
termo switch (3 litre tank)
Temperature Continuous Monthly / 160 h
Oil condition (sample) 6 months / 1000 h
Oil change 2 years / 4000 h
Filters
Oil filter cleaning (change
After one week 6 months / 1000 h
if necessary)
Air filter change 6 months / 1000 h
Accumulators
Gas pressure Daily 6 months / 1000 h
According to legal
Other checks
requirements
Adjustments
Valves etc. Continuous 6 months / 1000 h
Checks
Monthly / 160 h
External leaks Daily
or if decresing oil level
Dirt Monthly / 160 h
Damage Continuous Monthly / 160 h
Noises Continuous Monthly / 160 h
Instruments / electrical
Continuous 6 months / 1000 h
connections

NOTE:
During initial commissioning all items above
are continuously monitored with exception to
the changing of the oil and/or taking oil
samples.

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4.4 Function test

Testing component
Component Explantion
position
(see hydraulic diagram) Before action Action
2, 3, 4, 16, 17, 20, 4, 20: off 4: on Motor shall start and stop at the preset pressure signal from
21.1, A1, 40 pressure switch (40).
Testpoint: 17 For a period of 10 minutes motor shall not re-start proving all
connections on the pressure side are tight
Pressure shall remain stable.
A1, 20, 22, 26 4: on 4: off The motor (4) is switched off or dis-connected.
26, 27:on 20: on Opening valve (20) shall pressurize the brakes from the
Testpoint: P2 20, 22:off accumulator (A1).
For a period of 10 minutes the pressure shall remain stable
proving that brakes and tank valves (22 and 26) are tight.
The brake will be released, maybe with a little delay -
depending of the adjustment of throttle valve (20.1).
22, 22.1 4, 22: off 22: on When energizing (opening) valve (22), pressure in the brakes
26, 27:on shall drop to preset level of (22.1).
The brake will be applied with reduced pressure.
18.1, 26, 27, 27.1, 4: off 26, 27: off Opening valve (26) shall reduce the pressure, to the setting of
27.2, 33 20, 22, 26, the back-pressure valve (27.1), the rest of the oil is dumped
27:on to tank through the orifice (27.2). the time can be set on
(18.1)
The brake will be applied with reduced pressure for some
seconds after the time has expired then with the full force.
4, 22: off 26:on Motor shall start and stop at the preset pressure signal from
20:on 4: on pressure switch (40).
The brakes will be released.
26, 26.1 4, 20, 22, 26:off Opening valve (26) will drop the pressure to tank through the
23:off throttle valve (26.1).
26, 27: on The brake will be applied maybe with a little delay -
depending of the adjustment of throttle valve (26.1).
HP 4: off operate hand To release the brakes without electrical power to the motor
26:on or pump - it is possible to use the hand pump. Over ride valve (26) and
manual operate the hand pump until the brakes releases.
override After the test, remember to leave the valve free - not
20, 22, 27:off activated!!
21.1 Relief valve (21.1) is to secure the maximum pressure in
the accumulator.

4.5 Dismantling the power unit 4.6.1 Remove the drain plug.
This should only be carried out in an The location of the drain is on the side of the
authorised hydraulic workshop. Ask for reservoir.
separate information.
4.6.2 Make sure that all the oil drains into a
secondary container for proper disposal.
4.6 Changing the oil
4.6.3 Mount the drain plug and tighten the plug
WARNING (12-15 Nm).
Disconnect all power to the hydraulic power
unit and relieve all internal oil pressure in the
system.

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4.6.4 Refill the oil reservoir to the top level mark in FIGURE 4.3
the sight glass located on the reservoir
sidewall. See fig 4.2.

FIGURE 4.2

CAUTION
Use only filtered oil of the right viscosity for
4.7.5 Remove the motor and manifold / mounted
refilling (see Appendix F).
assembly (25 – 35 kg).
It is stipulated that the oil added to the
system is filtered through a 10-micron purity
IMPORTANT
off-line filter unit to the following classes of
Lift straight up to protect the O-ring and all
purity: NAS 1638, Class 8, or ISO 4406,
parts.
Class 19/17/14.
FIGURE 4.4
4.6.5 Connect the electrical power again and start
the pump. Let the unit run 10 cycles
(pressurising/de-pressurising):
x With system pressurised bleed the
brakes.
x With system de-pressurised refill oil
if necessary.

4.7 Changing the oil and cleaning the

reservoir
This procedure is recommended always to
be carried out in a hydraulic workshop to
ensure clean environment.

WARNING
Disconnect all power to the hydraulic power 4.7.6 Clean the reservoir with a lint-free rag.
unit and relieve all internal oil pressure in the
system. 4.7.7 Refit the motor and manifold / mounted
assembly onto the reservoir. Be sure not to
4.7.1 Remove the drain plug. damage the O-ring during this step.
The location of the drain is on the side of the
reservoir.

4.7.2 Make sure all the oil drains into a secondary

container for proper disposal.

4.7.3 Mount the drain plug and tighten the plug

(12-15 Nm).

4.7.4 Unscrew the 4 screws with a metric T-

socket wrench.

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FIGURE 4.5 4.7.10 Connect the electrical power again and start
the pump. Let the unit run 10 cycles
(pressurising/de-pressurising).
x With system pressurised bleed the
brakes.
x With system de-pressurised refill oil
if necessary.

4.8 Changing the oil filter

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

The oil filter is placed in the filter housing.

4.7.8 Refit the 4 screws and torque tighten to 5 -
10 Nm. 4.8.2 Using a fork-spanner, turn the filter housing
counter clockwise until it is disconnected
FIGURE 4.6 from the filter manifold.

4.8.3 Remove the oil filter and clean the inside of

the filter housing and cavity. Insert a new oil
filter minding the orientation.

4.8.4 Clean the O-ring and Teflon-ring outside the

filter housing.
Renew O-ring and Teflon-ring if necessary.

4.8.5 Refit the filter housing.

4.7.9 Refill the oil reservoir to the top level mark in

the sight glass located on the reservoir
sidewall. See fig 4.7.

FIGURE 4.7

CAUTION
Use only filtered oil of the right viscosity for
refilling (see Appendix F).

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4.9 Changing the air breather FIGURE 4.10

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

The air breather consists of two parts:

x A strainer inside the reservoir.
x A filter in the cap.

NOTE
The 3-litre tanks does only have filter in the
cap.

FIGURE 4.8

4.9.2 The air breather is connected to the

reservoir with three small screws. Remove
these screws with a screwdriver.
Remove the air breather along with the
seals.

FIGURE 4.9

4.9.3 Mount a new complete air breather and

torque tighten the three small screws to 1-2
Nm.

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4.10 Measuring the gas pressure FIGURE 4.13

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

4.10.1 Oil pressure must be zero to measure the

gas pressure correctly. When working with a
hydraulic power unit it is recommended to
install two pressure gauges for measuring
accumulator pressure and brake pressure.
Unscrew the threaded cap on top of the
accumulator.
4.10.4 Open the top valve, measure the gas
FIGURE 4.11 pressure and close the top valve again.

FIGURE 4.14

4.10.2 Using the 6mm Allen key turn the plug by

turning it counter clockwise (¼ turn). The
screw is now loose without losing gas. 4.10.5 If the gas pressure does not meet the
required value (see Appendix C), the
accumulator must be recharged.
FIGURE 4.12

4.10.3 Mount the gas pressure gauge and close the

side valve.

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4.11 Recharging the accumulator FIGURE 4.17

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

FIGURE 4.15

4.11.3 If the gas pressure is too high open the side

valve to relieve gas.
Close the top valve when the gas pressure
is correct.

FIGURE 4.18

4.11.1 Establish a filling line between the gas

pressure valve and a gas tank.
The accumulator charger kit contains gas
pressure gauge and filling line.
Remember that the adaptor from the line
and to the gas tank is country specific and
may need to be ordered separately.
4.11.4 Open the side valve, relieve the pressure
completely and remove the gas pressure
FIGURE 4.16
gauge.

4.11.5 Tighten the plug (18 - 22Nm) using the 6mm

Allen key (hexagonal) and mount the
threaded end cap by use of hand.

FIGURE 4.19

4.11.2 Open the gas tank valve and the top valve to
fill gas into the accumulator.
Close gas tank valve and wait several
minutes for the new gas to equalize to the
accumulator temperature.

Measure the gas pressure.

If the pressure is too low apply more gas.

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5. Trouble Shooting
5.1 Failure intro
Locate which part of the braking system that causes the failure and proceed to the corresponding section.

Failure

Brakes are Brakes are

failsafe active

Brakes will not Brakes will not

close open

Brakes are free

of pressure

NO

See chapter 5.2

"PU doesn't release
pressure"

Brakes will not Brakes will not

open close

Brakes and Brakes have enough pressure

PU works (according to appendix D)
but behave
unexpected NO
or unusual YES

See chapter 5.3

"PU doesn't set pressure"

See chapter 5.4

"Other PU failure PU is working OK.
Failure is caused by the
brakes.

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5.2 Power unit does not release pressure

5.2 PU doesn't release pressure

Failure in solenoid or it's power supply

- Try manual override - if this releases the pressure failure is in the
Valve between brakes
coil or its power supply.
and tank doesn't open
- Try disconnecting the electrical plug from the coil - if this releases
pressure failure is in the power supply.

Defective or dirty (choked) valve or nozzle

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

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

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5.3 Power unit does not set / build pressure

5.3 PU doesn't give (enough) pressure

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

- Power supply failure or motor wrongly connected

- Defective motor
Motor isn't running
- Oil level too low or oil too hot (cut off by level/thermo switch)
- Defective pressure switch

Motor is running the

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

Motor is running but

speed decreases before - Power supply has too low voltage
system has reached the - Defective motor
right pressure.

- Coupling between motor and pump is broken

Motor is running but no
- Defective pump
pressure is generated
- Defective safety releif valve

Motor is running but runs

Defective check valve
backwards after it stops

- Safety relief valve out of adjustment or defective

Pressure is generated - Pressure switch setting too low
but not sufficient - Defective pump
- Leaking valves

Pressure is generated
but isn't transferred to Valve between pump and brakes doesn't open when it should
brakes on command

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

Pressure is generated
but is transferred to tank
Valve(s) between brakes and tank doesn't close when it should
when it should have
been to the brakes

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5.4 Other failures

5.4 Other failures

Do you get the right signals from

- level/thermo switch
Failure in
- pressure switches or transmitters in the pump line
instrumentation
- pressure switches or transmitters in the brake line
- pressure switches or transmitters for accumulator monitoring

Failure in brake pad or brake pad not bedded in?

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

Air in the braking system?

Slow brake Valves not working correctly due to oil contamination?
Orifices too small for viscosity (low oil temperature)?

Viscosity too low due to too high oil temperature?

Too fast braking
Precharged pressure in the accumulators are wrong?

Ambient temperature too high?

Excessive operating
Pump running continously (due to leaky valves, external leaks or
temperature
wrong component adjustment?

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Appendix A - Dimension drawing

d
ase e
Rel

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Appendix B - Spare part drawing

ork
In W

CONFIDENTIAL

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Appendix B - Spare parts list

For brake control unit 3000-0278-805
according to Spare Part Drawing and Hydraulic Diagram (section 3.3)
Rec. Adjustment
Mounting
spare method
torque [Nm]
Pos Qty Description SB item no parts qty.
(see apx.
(note 2)
(note 1) C & D)
15 1 FILTER ELEMENT 10 MICRON 1701-2024-003 2
15 1 FILTER HOUSING 1701-1024-002 Note 3
15 1 O-RING Ø40,0X2,0 9810-2999-003 1
15 1 BACK-UP RING PTFE 9813-0999-004 1
MAX SETTING 210
16 1 RELIEF VALVE 40-350BAR 9103-5000-801 1 50 2
BAR
17 1 CHECK VALVE 6010-0024-001 1 3
DIRECTIONAL POPPET 2/2 NORMALLY
20, 22 2 2222-0024-801 1 50
VALVE CLOSED
DIRECTIONAL POPPET 2/2 NORMALLY
26 1 2222-1024-801 1 50
VALVE OPEN
26 1 HANDLE FOR VALVE 9322-0000-801
20, 22, 26 3 COIL 24 VDC - UL 2224-0024-002 1
DIR POPPET VALVE 3/2
27 1 2232-0024-004 1 50
INCL COIL
MAX SETTING 210
21.1 1 RELIEF VALVE 40-350BAR 9103-5000-801 1 50 2
BAR
22.1 1 RELIEF VALVE 35-140BAR 9101-0000-801 1 50 2

27.1 1 RELIEF VALVE 5-100BAR 9101-0024-001 1 50 2

20.1, 26.1 2 THROTTLE VALVE ADJ 6001-2024-002 1 50

THROTTLE VALVE
27.2 1 6001-2061-001 1 50
CAVITY "T-8A"
PRES SWITCH 25-350BAR INCL. BOLTS AND
40, 42 2 4003-5022-803 1 3 1
FLANGE PLUG
5 1 TANK 6L 1200-6000-008
5 1 SEALING F/ TANK GCP06 1290-4999-001 1
5a 1 LEVEL GLASS 1231-1024-004 1 8-10
BREATHER AND FILLING
5b 1 10 MICRON 1712-1024-001 1 3
STRAINER
5c 1 LEVEL/THERMO 1232-2096-001 1 20
5d 1 TANK COVER 1220-2000-010
5f 1 MAGNETIC PLUG F/TANK 1290-2999-040 1 15
2 1 GEAR PUMP 1,1 CCM/REV 0305-1064-801 24
3 1 COUPLING 9803-1032-801 1 13
MOTOR 3X400V 50HZ
4 1 IP 55 5140-0999-001 9
0,70KW
A1 1 ACCU BLOCK W/FITTINGS 4890-1000-801 53
ACCU BLOCK W/SUN
A2 1 4890-1000-006 53
T13A CAVITY
18.1 1 FLOW CONTROL VALVE 6003-1061-001 1 50
18.2 1 CHECK VALVE 6010-0043-001 1 17
TEST POINT MALE
17, P2 2 9009-1010-040 1 30

A1 1 ACCU 0,75L 210BAR 4807-5024-001 90 4

33 1 ACCU 0.32L 210BAR 4803-2024-001 90 4
34 1 ACCU 0,075L 250BAR 4800-8024-001 90 4
HAND PUMP N22, 6CCM,
HP 1 0350-0031-001 1
250BAR
HANDLE F/HANDPUMP
HP 1 0350-9031-001 1
N22 - CLEAR
PRES GAUGE
PG 1 4013-5999-003 1
5000PSI/BAR Ø63MM

PG 1 TEST HOSE 800MM 9009-3010-008 1

BRACKET & CABINET

1 9893-0001-912
W/SOBO+P-OUT
6 VIBRATION DAMPER 9820-3074-008 6
HOSE STEEL COVERED
1 0590-0999-835
1/4"X0,675M

1 JB. FOR 1013-0128-836 1013-0128-336 1

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

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Appendix C - Hydraulic settings

Extract from production settings report:

HYDRAULIC SETTINGS
Item no.: 1013-0128-836 / 350056_SB-DK
Order no.: 350056
Rev. Index: C
Rev. Date: 30-04-2015 BSFI205_MS BSFI322_MS BSFI3060_DS BSFI3120_DS

3000-0278-802
3000-0278-801 3000-0278-803 3000-0278-804
3000-0278-805
HPU:
HPU QTY: 2 6 1 1
Pos: Test Point: Tolerance Unit: Note:
16 SYSTEM RELIEF VALVE +/-10 BAR * Ĺ 150 150 230 230
21.1 ACCUMULATOR RELIEF VALVE +/-10 BAR * Ĺ 150 150 230 230
40 MOTOR PRESSURE SWITCH +10/-2 BAR - Ļ 120 90 150 190
BRAKE RELEASE PRESSURE
*
42 SWITCH (OPEN) +5/0 BAR Ĺ 65 35 75 150
A1 MAIN ACCUMULATOR +/-3 BAR - 50 30 90 160
33/A2 2-STAGE ACCUMULATOR +/-3 BAR - 80 40 100 150
34/A2 SOBO ACCUMULATOR +/-3 BAR - 25 15 30 55
22.1 MAX LIFT RELIEF VALVE +/-3 BAR - Ļ 60 35 70 140
18.1 2-STAGE DELAY SEC # 5 +/-1 5 +/-1 1 +1/-0 1 +1/-0
27.1 2-STAGE RELIEF VALVE +/-3 BAR Ļ 35 20 40 75
**THROTTLE VALVE +1/2
-
27.2 - 1/4 TURNS 1/2 1/2 1/2 1/2
20.1 **SOBO THROTTLE VALVE - IN TURNS - 1 1/2 1 1/2 1 1/2 1 1/2
26.1 **SOBO THROTTLE VALVE - OUT TURNS - 1 1 1 1
HP RELIEF HAND PUMP +10/-2 BAR - Ĺ 100 50 105 190

**SETTING FROM FULLY CLOSED TO OPEN

Ĺ = Raising
Ļ = Falling
* = Set by Motor running
- = Set by Motor stopped
# = Set by timer (two stage)

Setting approved :

C.SEMRAU
Initials

05-03-2015
Date

SF-CD 44 / A / 28.01.2015
www.svendborg-brakes.com

For actual information on how to adjust the settings see Appendix B – Spare parts and
Appendix D - Adjustment

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

Adjustment Item drawing/Photo Description

Item type
method
The pressure switches have fixed
hysteresis.

Precise adjustment of set point to

actuate on increasing pressure
1. Lower system pressure to 0 Bar.
2. Increase pressure slowly and
check if micro switch is actuated at
desired switch pressure.
3. If necessary, readjust by turning
the adjustment screw
4. Repeat step 1 - 3 until micro
switch operates at desired switch
pressure.
Pressure
1 switch Precise adjustment of set point to
actuate on decreasing pressure
1. Increase pressure up to a point
clearly above the desired switch
pressure
(At least, switch pressure plus max.
hysteresis; not above max. operating
pressure).
2. Lower pressure slowly and check if
micro switch is actuated at desired
switch pressure.
3. If necessary, readjust by turning
the adjustment screw.
4. Repeat step 1 - 3 until micro
switch operates at desired switch
pressure.
The system safety valve (Pos. 16 –
Tamper relief valve) is preset at the factory to
proof cap
the correct pressure / setting.
Do not adjust this valve.
Adjustment
If the tamper proof cap is broken or
screw
missing the power unit is no longer
Relief valve Lock covered by Svendborg Brakes
or nut warranty.
Counter
2
pressure valve For other relief valves if adjustment is
(same item) needed, remove the tamper proof
cap, loosen the lock nut and screw
out (counter-clockwise) to decrease
maximum pressure setting.
Screw in (clockwise) to increase
maximum pressure.
Remember to re-tighten the lock nut.

See section 4.10 - Measuring the

accumulator gas pressure & 4.11
4 Accumulator
Charging / recharging the
accumulator.

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Appendix E - Electrical diagram

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Appendix F - Recommended Fluid

Name: DEB-DIVE-005

DATA SHEET Date: 19.05.2014

Revision: I

RECOMMENDED FLUID FOR DISC BRAKES & HYDRAULICS

PRESSURE FLUIDS / OIL TYPES
The following oil types are recommended by Svendborg Brakes – other types corresponding to these can be used.

The general temperature range for our standard ranges of products using hydraulic oil are -20°C to +60°C (-4°F to
+140°F) however the BSAK and BSAB brake series are generally approved for lower temperatures.
These are approved for usage at -40°C in wind turbines and for -30°C in other applications.

When quick brake reaction times are critical and operating at temperatures below 0°C (+32°F) it is recommended to use
the oil types listed in the Cold section as these types provides the most constant reaction times.
Extreme temperature applications may require special options. Please contact Svendborg Brakes.

Cold / special option Standard Special option

-40°C - +60°C -20°C - +40°C +10°C - +60°C +30°C - +70°C
Mineral oil
-40°F - +140°F -4°F - +104°F +50°F - +140°F +86°F - +158°F
Shell Tellus S4 VX 32 Tellus S2 V32 Tellus S2 V46 Tellus S2 V68
Mobil /
- DTE 10 Excel 32 DTE 10 Exel 46 DTE 10 Exel 68
EXXON
Texaco Rando Ashless 8401 Rando HDZ32 Rando HDZ46 Rando HDZ68
Valvoline - Ultramax HVLP32 Ultramax HVLP46 Ultramax HVLP68
-40°C - +50°C -20°C - +40°C +10°C - +60°C +30°C - +70°C
Synthetic oil
-40°F - +122°F -4°F - +104°F +50°F - +140°F +86°F - +158°F
Mobil - SHC 524 SHC 525 SHC 526
(1)
Bio Oil -40°C - +50°C -20°C - +30°C +10°C - +60°C +30°C - +70°C
(Ester or Colza oil) -40°F - +122°F -4°F - +86°F +50°F - +140°F +86°F - +158°F
Shell - Naturelle HF-E15 Naturelle HF-E32 Naturelle HF-E46
General: Mineral Pressure Fluids according to DIN 51524 Part 3
(1) There must be less than <200PPM water in the oil, due to the seals.

Viscosity
Recommended viscosity range: 20-200 cSt at working temperature. Generally Svendborg Brakes systems are designed
to allow higher viscosity in short periods.

Filtration
The oil in a hydraulic system and the oil added to the hydraulic system must always be filtered. The level of cleanliness
in a hydraulic system is an important factor to the lifetime of the system.
When refilling the hydraulic tank, it is stipulated that the oil added to the system is filtered through a 10-micron purity off-
line filter unit to the classes listed below.

The hydraulic system, supplied by Svendborg Brakes, has a build-in oil filter with a standard 10-micron purity filter. To
maintain a reliable system it is recommend that only hydraulic oil of the following classes of purity is used: NAS 1638,
Class 8, or ISO 4406, Class 19/17/14.
It is recommended that the filter is changed at a minimum, once every six months or more often depending on the level
of exposure to contamination.

Service life of pressure fluids

Mineral oil: 8.000 Hours or at least once a year.
Other fluids: 2.000 Hours or at least once a year.

Change of pressure fluid

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

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

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Appendix G - Recommended spare parts

ACCUMULATOR CHARGER KIT

Goes for 4899-9024-002
B, DK, D, SF, NL, N, A, PL, S, CH, CZ

With adaptor for

South-East Asia, ARG, BS, GB, GR, IRL, JA, M, NZ, P, E, TR, CY
4899-9024-006
Africa except for Arab countries

Arab countries, BG, COI, F, RG, Israel, MEX, RO, H 4899-9024-007

Canada, USA, Puerto Rico 4899-9024-003

Italy 4899-9024-001

Japan 4899-9024-005

Taiwan 4899-9024-008

Korea 4899-9024-009

South & Middle America except Argentine, Venezuela and Mexico 4899-9024-010

AUS 4899-9024-011

China 4899-9024-004

FILTER FILLING STATION 1702-0024-001

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HYDRAULIC SETTINGS
Item no.: 1013-0128-836 / 350056_SB-DK
Order no.: 350056
Rev. Index: C
Rev. Date: 30-04-2015 BSFI205_MS BSFI322_MS BSFI3060_DS BSFI3120_DS

3000-0278-802
3000-0278-801 3000-0278-803 3000-0278-804
3000-0278-805
HPU:
HPU QTY: 2 6 1 1
Pos: Test Point: Tolerance: Unit: Note:
16 SYSTEM RELIEF VALVE +/-10 BAR * Ĺ 150 150 230 230
21.1 ACCUMULATOR RELIEF VALVE +/-10 BAR * Ĺ 150 150 230 230
40 MOTOR PRESSURE SWITCH +10/-2 BAR - Ļ 120 90 150 190
BRAKE RELEASE PRESSURE
*
42 SWITCH (OPEN) +5/0 BAR Ĺ 65 35 75 150
A1 MAIN ACCUMULATOR +/-3 BAR - 50 30 90 160
33/A2 2-STAGE ACCUMULATOR +/-3 BAR - 80 40 100 150
34/A2 SOBO ACCUMULATOR +/-3 BAR - 25 15 30 55
22.1 MAX LIFT RELIEF VALVE +/-3 BAR - Ļ 60 35 70 140
18.1 2-STAGE DELAY SEC # 5 +/-1 5 +/-1 1 +1/-0 1 +1/-0
27.1 2-STAGE RELIEF VALVE +/-3 BAR Ļ 35 20 40 75
**THROTTLE VALVE +1/2
-
27.2 - 1/4 TURNS 1/2 1/2 1/2 1/2
20.1 **SOBO THROTTLE VALVE - IN TURNS - 1 1/2 1 1/2 1 1/2 1 1/2
26.1 **SOBO THROTTLE VALVE - OUT TURNS - 1 1 1 1
HP RELIEF HAND PUMP +10/-2 BAR - Ĺ 100 50 105 190

**SETTING FROM FULLY CLOSED TO OPEN

Ĺ = Raising
Ļ = Falling
* = Set by Motor running
- = Set by Motor stopped
# = Set by timer (two stage)

Setting approved :

C.SEMRAU
Initials

05-03-2015
Date

SF-CD 44 / A / 28.01.2015
www.svendborg-brakes.com

407
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 6997-0296-001_B

SOBO Cont roller wit h UPS and Overspeed saf et y relay

P1298 - 1 HPU

This project meet s t he f ollowing

International standards:

Symbols: IEC 60617

Circuit diagrams and lists: IEC 61082
Reference system: IEC 61346
Terminals: IEC 61666

457
 Proj ec t dat a
S upplier Dat a P roject descript ion Revision Dat a

Rem arks/ com m ent s

458
Customer

459
460
461
462
 Customer

B ra ke c o m m a n d I n p u t 1
O p e n = B ra ki n g
B ra ke c o m m a n d I n p u t 2
O p e n = B ra ki n g
B ra ke c o m m a n d I n p u t 3
O p e n = B ra ki n g

463
R e se t I n p u t
C l o se d = R e se t
Safety Input 1
C l o se d = S O B O B ra ki n g e n a b l e d
O p e n = 2 st a g e B r a ki n g c o m m a n d
 -Op e ra ti o n NO
C
2 30 VAC-30 VDC / 0 ,5A NC
1 -2 = B ra ki n g
2 -3 = n o t B ra ki n g
-S a fe ty Ou tp u t NO
C
2 30 VAC-30 VDC / 0 ,5A NC
4 -5 = O ka y
5 -6 = S a fe ty Fa u l t
-Ro l l b a ck Ou tp u t NO
C
2 30 VAC-30 VDC / 0 ,5A NC
7 -8 = Ro l l b a ck Fa i l u re
8 -9 = No Ro l l b a ck Fa i l u re
-Ou t o f Ba nd Ou tp u t NO
C
2 30 VAC-30 VDC / 0 ,5A NC
10 -1 1 = Ou t of Ba n d Fa i l u re
11 -1 2 = No Ou t of Ba n d Fa i l u re

464
-L i m i t Ou tp u t NO
C
2 30 VAC-30 VDC / 0 ,5A NC
1 3-1 4 = L i m i t Rea ch e d
14 -1 5 L i m i t n o t Rea ch e d
-S e n so r f a i l u re NO
C
2 30 VAC-30 VDC / 0 ,5A NC
1 6 -1 7 = S e n so r F a i l u re
1 7 -1 8 = N o S e n so r F a i l u re
 S
-RPM 1
+
S p e e d si g n a l 0 1 -
S
-RPM 2
+
S p e e d si g n a l 0 1 -
465
 1
-Q2 0
2
Li fti ng Val ve 24VDC / 0,8A PE
1
-Q2 6
2
B ra ki n g V a l v e 2 4 V D C / 0 , 8 A PE
1
-Q2 2
2
M ax. Li ft Val ve 24VDC / 0,8A PE
1
-Q2 7
2
2 Stage 24VDC / 0,8A PE

466
-B5c
LEVEL/T HERM O
Low Oil level/
T e m p . sw i t c h .
220VAC
24VDC /

NC if OK
-B4 0
PRESSURE SW.
S y st e m P r e ssu r e
220VAC
24VDC /

-B4 2
PRESSURE SW.
B r a ke R e l e a se P r e ssu r e
220VAC
-M 4
24VDC /
HPU

50Hz
Motor

3x400V
467
 Number Name

01 = SOBO +CP -F1

02 = SOBO +CP -F2
03 = SOBO +CP -G1
04 = SOBO +CP - GB1
05 = SOBO +CP - B1
06 = SOBO +CP -KIN 1
07 = SOBO +CP -KIN 2
08 = SOBO +CP -KIN 3
09 = SOBO +CP - KSA1
10 = SOBO +CP - KSA2
11 = SOBO +CP - KSA3
12 = SOBO +CP - K2ST
13 = SOBO +CP - SOBO1
14 = SOBO +CP -KOS

-X

468
 Li s t of Doc ument s
Funct ion (= ) Locat ion (+ ) Sheet K ind of Docum ent Descript ion

469
 Li s t of Part s
Funct ion (= ) Locat ion (+ ) P osit ion(-) A mount Type Descript ion

470
 Li s t of Part s
Funct ion (= ) Locat ion (+ ) P osit ion(-) A mount Type Descript ion

471
472
 6997-0296-002_B

SOBO Cont roller wit h UPS and Overspeed saf et y relay

P1298 - 2 HPU's

This project meet s t he f ollowing

International standards:

Symbols: IEC 60617

Circuit diagrams and lists: IEC 61082
Reference system: IEC 61346
Terminals: IEC 61666

473
 Proj ec t dat a
S upplier Dat a P roject descript ion Revision Dat a

Rem arks/ com m ent s

474
Customer

475
476
477
478
 Customer

B ra ke c o m m a n d I n p u t 1
O p e n = B ra ki n g
B ra ke c o m m a n d I n p u t 2
O p e n = B ra ki n g
B ra ke c o m m a n d I n p u t 3
O p e n = B ra ki n g

479
R e se t I n p u t
C l o se d = R e se t
O v e r sp e e d S a f e t y I n p u t 1
C l o se d = S O B O B ra ki n g e n a b l e d
O p e n = 2 st a g e B r a ki n g c o m m a n d
 -Op e ra ti o n NO
C
2 30 VAC-30 VDC / 0 ,5A NC
1 -2 = B ra ki n g
2 -3 = n o t B ra ki n g
-S a fe ty Ou tp u t NO
C
2 30 VAC-30 VDC / 0 ,5A NC
4 -5 = O ka y
5 -6 = S a fe ty Fa u l t
-Ro l l b a ck Ou tp u t NO
C
2 30 VAC-30 VDC / 0 ,5A NC
7 -8 = Ro l l b a ck Fa i l u re
8 -9 = No Ro l l b a ck Fa i l u re
-Ou t o f Ba nd Ou tp u t NO
C
2 30 VAC-30 VDC / 0 ,5A NC
10 -1 1 = Ou t of Ba n d Fa i l u re
11 -1 2 = No Ou t of Ba n d Fa i l u re

480
-L i m i t Ou tp u t NO
C
2 30 VAC-30 VDC / 0 ,5A NC
1 3-1 4 = L i m i t Rea ch e d
14 -1 5 L i m i t n o t Rea ch e d
-S e n so r f a i l u re NO
C
2 30 VAC-30 VDC / 0 ,5A NC
1 6 -1 7 = S e n so r F a i l u re
1 7 -1 8 = N o S e n so r F a i l u re
 S
-RPM 1
+
S p e e d si g n a l 0 1 -
S
-RPM 2
+
S p e e d si g n a l 0 1 -
481
 1
-Q2 0
2
Li fti ng Val ve 24VDC / 0,8A PE
1
-Q2 6
2
B ra ki n g V a l v e 2 4 V D C / 0 , 8 A PE
1
-Q2 2
2
M ax. Li ft Val ve 24VDC / 0,8A PE
1
-Q2 7
2
2 Stage 24VDC / 0,8A PE

482
-B5c
LEVEL/T HERM O
Low Oil level/
T e m p . sw i t c h .
220VAC
24VDC /

NC if OK
-B4 0
PRESSURE SW.
S y st e m P r e ssu r e
220VAC
24VDC /

-B4 2
PRESSURE SW.
B r a ke R e l e a se P r e ssu r e
220VAC
-M 4
24VDC /
HPU

50Hz
Motor

3x400V
 1
-Q2 0
2
Li fti ng Val ve 24VDC / 0,8A PE
1
-Q2 6
2
B ra ki n g V a l v e 2 4 V D C / 0 , 8 A PE
1
-Q2 2
2
M ax. Li ft Val ve 24VDC / 0,8A PE
1
-Q2 7
2
2 Stage 24VDC / 0,8A PE

483
-B5c
LEVEL/T HERM O
Low Oil level/
T e m p . sw i t c h .
220VAC
24VDC /

NC if OK
-B4 0
PRESSURE SW.
S y st e m P r e ssu r e
220VAC
24VDC /

-B4 2
PRESSURE SW.
B r a ke R e l e a se P r e ssu r e
220VAC
-M 4
24VDC /
HPU

50Hz
Motor

3x400V
484
 Number Name

01 = SOBO +CP -F1

02 = SOBO +CP -F2
03 = SOBO +CP -G1
04 = SOBO +CP - GB1
05 = SOBO +CP - B1
06 = SOBO +CP - B2
07 = SOBO +CP -KIN 1
08 = SOBO +CP -KIN 2
09 = SOBO +CP -KIN 3
10 = SOBO +CP - KSA1
11 = SOBO +CP - KSA2
12 = SOBO +CP - KSA3
13 = SOBO +CP - K2ST PU 1
14 = SOBO +CP - K2ST PU 2
15 = SOBO +CP -KBRK PU1
16 = SOBO +CP -KBRK PU2
17 = SOBO +CP - KLF T PU 1
18 = SOBO +CP - KLF T PU 2
19 = SOBO +CP -KM L PU1
20 = SOBO +CP -KM L PU2
21 = SOBO +CP - SOBO1
22 = SOBO +CP -KOS

-X

485
 Li s t of Doc ument s
Funct ion (= ) Locat ion (+ ) Sheet K ind of Docum ent Descript ion

486
 Li s t of Part s
Funct ion (= ) Locat ion (+ ) P osit ion(-) A mount Type Descript ion

487
 Li s t of Part s
Funct ion (= ) Locat ion (+ ) P osit ion(-) A mount Type Descript ion

488
 Li s t of Part s
Funct ion (= ) Locat ion (+ ) P osit ion(-) A mount Type Descript ion

489
490
SOBO Settings
Order no.: 35056-SBDK Item no.: 6997-0296-001 SW Version: SOBO3.4.0.2 Projekt: P1298 - Conveyor J04

SET BRAKE1 BRAKE2 BRAKE3

GROUP VALUE DEFAULT GROUP VALUE DEFAULT
SB on site SB on site SB on site SB on site
NumberOfRamps 1 BrkMode 0 (TIME) 2 (DECELER)
NegMaxTorque OFF SimpleRamp ON
NegSOBO®Valve OFF Y0 1000 / 0 / 0 1500
NegMaxLift OFF X0 0
RO3 RollBack Y1 0
Setup RO4 Out of Band X1 10/ 0 / 0 60
Ramp
RO5 Limit Y2 0
RO6 Sensor Failure X2 0
*RO7 OFF Y3 0
*RO8 OFF X3 0
NegRO3,4,5,6.. OFF Distance 0
PPR1 12 Factor 0
PPR2 12 QBrkTIme 0
NegDirection OFF QuickBrk QBrkLv 0
RPM Limit 99999 QBMaxTqValve OFF
LimHyst 3 0RPM 0
LimitCount 0 Time1 0
NoRPMTimer 10 CVLevel1 0

GENERAL
Delay 0 (OFF) Time2 0
BrkTime 1000 Parking CVLevel2 0
CountLevel 99999 Time3 0
Rollback
MaxTorque OFF CVLevel3 0
MaxLift OFF Time4 0

BRAKE1, BRAKE2, BRAKE3

DeactTime 999 CVLevel4 -100
GMEnabled OFF Kp 0.5
GMRatio 0 Lift DeadBand 1
GearMon.
DeadBand 10 CutOffLv 10
Reg.
Delay 100 Kp 0.5
PWBrk 21 Brake DeadBand 1
PWLift 42 CutOffLv 10
PFM
MinOff 21 HiLimPer 30
MaxOff 420 LoLimPer 30
MODBUS NODE 41 OutOfBand ABSLv 0
MODBUS
COM 2 RS232 OFF HiLimAbs 30
SimpleRamp OFF LoLimAbs 30
Y0 0 SET
GROUP VALUE DEFAULT
X0 0 SB on site
Y1 (Ya) 0 HWSafetyMode OFF
Ramp X1 (Xa) 0 SWSafetyMode OFF
Config
Y2 (Yb) 0 CVRamp 0

SAFETY
X2 (Xb) 0 MaxOff 1000
Y3 (Yc) 0 Values shaded should not be changed! (Access Level 2 required)
X3 (Xc) 0
Kp 0.5 If column “SET” is empty, then value is equal to default.
Lift Deadband 1 Column “SB” shows the settings when the system is leaving Svendborg Brakes facility.

START
CutOffLv 999 Column “on site” is for notes by commissioning or later changes at the customer plant.
Reg.
Kp 0.5
Brake Deadband 1
CutOffLv 999 Settings approved:
HiLimPer 30
LoLimPer 30 SJU 19-05-2015
OutOfBand ABSLv 0 Initials Date
HiLimAbs 30
LoLimAbs 30 Jernbanevej 9, 5882 Vejstrup, Denmark Phone +45 63 255 255 email: [email protected] web: www.svendborg-brakes.com

SR6997-template_-
SR6997-0296-001_35056_CV-J04_- 30-01-2013

491
492
SOBO Settings
Order no.: 35056-SBDK Item no.: 6997-0296-002 SW Version: SOBO3.4.0.2 Projekt: P1298 - Conveyor J04

SET BRAKE1 BRAKE2 BRAKE3

GROUP VALUE DEFAULT GROUP VALUE DEFAULT
SB on site SB on site SB on site SB on site
NumberOfRamps 1 BrkMode 0 (TIME) 2 (DECELER)
NegMaxTorque OFF SimpleRamp ON
NegSOBO®Valve OFF Y0 1000 / 0 / 0 1500
NegMaxLift OFF X0 0
RO3 RollBack Y1 0
Setup RO4 Out of Band X1 10/ 0 / 0 60
Ramp
RO5 Limit Y2 0
RO6 Sensor Failure X2 0
*RO7 OFF Y3 0
*RO8 OFF X3 0
NegRO3,4,5,6.. OFF Distance 0
PPR1 12 Factor 0
PPR2 12 QBrkTIme 0
NegDirection OFF QuickBrk QBrkLv 0
RPM Limit 99999 QBMaxTqValve OFF
LimHyst 3 0RPM 0
LimitCount 0 Time1 0
NoRPMTimer 10 CVLevel1 0

GENERAL
Delay 0 (OFF) Time2 0
BrkTime 1000 Parking CVLevel2 0
CountLevel 99999 Time3 0
Rollback
MaxTorque OFF CVLevel3 0
MaxLift OFF Time4 0

BRAKE1, BRAKE2, BRAKE3

DeactTime 999 CVLevel4 -100
GMEnabled OFF Kp 0.5
GMRatio 0 Lift DeadBand 1
GearMon.
DeadBand 10 CutOffLv 10
Reg.
Delay 100 Kp 0.5
PWBrk 21 Brake DeadBand 1
PWLift 42 CutOffLv 10
PFM
MinOff 21 HiLimPer 30
MaxOff 420 LoLimPer 30
MODBUS NODE 41 OutOfBand ABSLv 0
MODBUS
COM 2 RS232 OFF HiLimAbs 30
SimpleRamp OFF LoLimAbs 30
Y0 0 SET
GROUP VALUE DEFAULT
X0 0 SB on site
Y1 (Ya) 0 HWSafetyMode OFF
Ramp X1 (Xa) 0 SWSafetyMode OFF
Config
Y2 (Yb) 0 CVRamp 0

SAFETY
X2 (Xb) 0 MaxOff 1000
Y3 (Yc) 0 Values shaded should not be changed! (Access Level 2 required)
X3 (Xc) 0
Kp 0.5 If column “SET” is empty, then value is equal to default.
Lift Deadband 1 Column “SB” shows the settings when the system is leaving Svendborg Brakes facility.

START
CutOffLv 999 Column “on site” is for notes by commissioning or later changes at the customer plant.
Reg.
Kp 0.5
Brake Deadband 1
CutOffLv 999 Settings approved:
HiLimPer 30
LoLimPer 30 SJU 19-05-2015
OutOfBand ABSLv 0 Initials Date
HiLimAbs 30
LoLimAbs 30 Jernbanevej 9, 5882 Vejstrup, Denmark Phone +45 63 255 255 email: [email protected] web: www.svendborg-brakes.com

SR6997-template_-
SR6997-0296-002_35056_CV-J04_- 30-01-2013

493
494