ELEKTROMAG METHODS 404, Unique Industrial Estate, Off. Veer Savarkar Marg, Post Box No. 9141, Prabhadevi, Bombay - 400 025. TEL : 6662 4444 Fax : 6662 4455/2430 5358 EMAIL : emag@emagindia.com WEBSITE : http://www.emagindia.com INSTALLATION & OPERATION INSTRUCTIONS FOR MTOB TYPE ELECTRO HYDRAULIC THRUSTOR DESIGN : ‘A general view of the Brake is given in the attached drawing. Second arm 11 and Thrustor arm 6 are secured in base 9 by means of pins. The force necessary for pressing brake shoes 14 against the drum is created by main spring 5 supported in bracket 2. The central rod 15 is passed through a pivoted square bush fitted on Thrustor lever 3. The Thrustor lever 3 is connected to Thrustor Arm 6, Thrustor 1 and assembly rod 4 by pins. The force of the spring is transmitted to Second Arm 11 by means of Assembly Rod 4 The working length of the main spring is fixed by spring pressure adjustor nuts 13 for adjusting braking torque. Spring length is reduced to increase the torque and spring length is increased to reduce the torque (Torque is inversely proportional to spring length). The stroke adjuster nuts 12 at the extreme end of assembly Rod 4 serve to adjust idle stroke of the thrustor. It is important to note that thrustor will have an idle stroke only when the brake is mounted on the corresponding brake drum. This idle stroke is adjusted to approximately 40% of the rated thrustor stroke (for rated thrustor stroke refer to thrustor catalogue or thrustor Name Plate). OPERATION : When the brake is applied i.e when no supply is given to the thrustor, one end of the compressed main spring 5 presses against the bracket 2 which transmits the pressure to arms 6, 11, central Rod 15 and the thrustor lever 3. Under the action of the main spring, the levers turn over pins used to connect the Arms to the Base and press the brake shoes against the surface of the brake drum creating the necessary braking moment. When the brake is applied, a gap exists between the shoe clearance bolt head 8 and base 9. When current is switched ON, the thrustor lifts upwards and thrustor lever 3 pushes the assembly rod 4. The main spring 5 gets compressed and second arm 11 moves back until the shoe clearance bolt-head 8 rests on base 9. Thus when the second arm 11 is completely released off the drum, the thrustor force further pushes back the Thrustor Arm 6 and the drum is free to rotate.INSTALLATION ASSEMBLY: 1. When the drum is located on a machine at the extended shaft end of the motor brake is fitted on to it with the Arm 6 and 11 moved apart by raising thrustor lever 3 manually. 2. When the drum is located on a machine between the shaft bearings, the second arm 11 can be thrown open by unlocking and removing stroke adjustment nuts 12 After mounting, the brake should be assembled in reverse order. 3. The drum should be of the exact size of brake (mm to mm and inches to inches) and should be free from oil, paint or grease on the working surface. 4. The centre height of the brake should coincide with the centre of the drum. 5. Non-parallelity and inclination of the lining surfaces in relation to the drum surface should not exceed 0.1 mm for 100 mm of the drum width 6. The brake should be fastened to the base of the mechanism or floor by means of bolts with nuts and spring washers. All foundation bolts should be checked for tightness, otherwise there may be vibrations. Spares required for replacement of nor and Tear 4. 1.No. Thrustor (No. 1) 2. 1 set (2 Nos.) Brake shoe with lining (No. 14) 3. 1.No. Main spring (no. 5)GENERAL DETAILS APPLICABLE FOR THRUSTOR BRAKES PRECAUTIONS The brake should be used only for the duty cycle specified or ordered The maximum number of switching operations per hour is 720. The temperature of the drum during working of brake should not exceed 200 degree C The lining should be replaced if their thickness is reduced to less than half the original thickness. The thrustor stroke should be maintained as specified in the name plate of the thrustor The working length of the main spring should correspond to that given in the nameplate for the specified torque There should be no cracked or damaged parts especially in the spring and bracket The levers and the bracket should oscillate on their pins without seizing but also without free play. The brake parts such as pins, rod etc. should be lubricated periodically. ADJUSTMENTS After assembly, the brake should be adjusted for the following :- Providing of the idle stroke as explained earlier. On switching ON, thrustor will rise only for its rated — stroke. (60% working stroke + 40% idle stroke) Setting of the main spring as per the details in the name plate for the required torque. The spring length can be increased, if the torque required is less. Obtaining a uniform releasing movement of the brake shoes by adjusting shoe clearance bolt 8 for a gap of 1.5 MM between the bolt head and base 9 The thrustor stroke should be reset periodically to compensate for lining wear. The shoe clearance bolt should also be adjusted simultaneously.GENERAL INS THRUSTORS “ELEKTROMAG’ make Thrustors incorporate a rotor-stator-driven centrifugal impeller which pumps oil under a piston to exert an upward thrust on the thrust bar. They are designed to meet all relevant Indian Standard requirements, and are carefully inspected and tested to ensure that they comply with these requirements, and are safe in operation. Thrustors are supplied without oil, and must not be operated until they have been filled with the correct grade and qty. of oil, (Transformer Oil conforming to IS:335- 1983-EHV Grade or equivalent). The relevant BS No. for this oil is BS:148, Grade B. INSTALLATION Mounting & Filling : Mount the thrustor within 10° from vertical position (right angle) to avoid leakage of oil. Connect it by pin-joints to its load so that side pressure, which may cause binding, is avoided. The thrustor must be free to pivot slightly when working. The thrustor is supplied without oil and must not be energized until it has been filled with oil, All Thrustors are fitted with Filler and Drain Plugs. Wipe away any dirt accumulated around the oil filler plug in the tank cover. There is also an oil level plug at the side on the top of the tank for Thrustors ‘ET-275' to ‘ET-5650'. For ‘ET-240° level plug is not provided. Remove both Filler and Side Plugs and fill oil SLOWLY through the top plug hole until it overflows through the side plug hole. Replace both plugs and operate the thrustor electrically or by hand several times: it wll operate in a jerky and irregular manner initially due to the fall of the oil level as trapped air is feleased from the cylinder. Remove the plugs and top-up the oil level. Repeat this process until a smooth operation of the thrustor is obtained on repeated operation ‘Take great care that only clean oil is used and that no dirt enters the thrustor. Oil for the Thrustor The oil used is transformer oil to 1S:335-1983 (EHV Grade or equivalent). It is essential that only clean oil is used for topping up. This oil is suitable for operation at temperatures down to -10°C. but the thrustor may be sluggish at lower temperatures. For operation in ambient temperature down to -45°C. The use of Mobil AERO HFA (or equivalent) is recommended.Approximate Oil Capa THRUSTOR TYPE OIL CAPACITY ET & ET-275/2100 2.5 Litres ET & ET-3150/3250 45 ET & ET-5500/5650 9 ET-240 2 CONNECTIONS These units are wound for direct-on-line starting. The direction of rotation of the motor does not matter. MAINTENANCE = Thrustor U The thrustor is lubricated by its operating oil. It is recommended that the oil is changed afer the first three months of operation and that subsequently it is drained ‘and examined every 12 months. If it is clean it may be re-used but otherwise the thrustor must be refilled with new oil (See Installation — Mounting & Filling). To drain the oil from the tank, remove he drain plug from the bottom of the tank. It is advisable to check periodically that the oil is full in the thrustor tank, as evaporation may take place with a hard worked thrustor. If it is necessary to dismantle and overhaul the thrustor at any time, take great care that no dirt drops into the tank or remains in the piston or other parts when the unit is reassembled. The piston must always be able to move freely up and down in the cylinder — check this by lifting and lowering the motor cap of “ET-240' and thrust bar along with T- Connector for all other Thrustors several times. Under normal conditions an oil change will probably be required every two years, but in a dusty atmosphere it may require changing more often. If oil is not changed regularly, sludge, water and acid may form due to oxidation. Motor Bearing Lubrication All motors have the bearings correctly charged with grease when they leave the workshop of ELEKTROMAG. This will suffice as lubrication for two years of Continuous running under normal conditions. After two years of normal running, thebearing end caps should be dismantled and the bearings, housings and caps washed out with a mixture of eight parts of petroleum spirit and one part of light machine oil (note — this mixture is highly inflammable), taking care to exclude all dirt and dust. The bearings should be examined, and if worn, replaced. Bearings should then be lightly packed with grease. Fill the grease cavities in the housings and caps with grease to about two-thirds of their capacities to ensure that the supply of grease is always in contact with the bearings (do not pack too tightly, however, as overheating might result). Care should be taken that no dirt, grit or moisture enters the bearing housing. The Shell Alvania Grease RA used for the thrustor motors is a lithium base grease suitable for high and low temperatures. It must not be mixed with grease of any other base. Fitting of bearings © When fitting a bearing, the parts should be lubricated with a little oil. The bearing should be driven onto the shaft by light, distributed blows applied to the inner race as near to the shaft as possible. A short length of pipe fitting closely round the shaft is the best tool to use. Never strike any part of a ball or roller bearing with a hammer. If motor is removed, for any reason, then care should be taken to protect the bearings from dirt. Ventilation Occasionally, remove dirt from internal and external surfaces of stator and rotor so as to allow uninterrupted ventilation. Renewals & Spares When ordering new parts or spares, all of the nameplate details should be quoted. Two separate nameplates have been provided for the Thrustor and Brake. The name plate on the Thrustor will show the rate of thrust, stroke, voltage and current The nameplate on the Brake will show the Brake Dia., Braking Torque, and compressed spring length marked as "SPG OVER —-- CUPS For further information and guidance, please consult Customer Care Executives of “ELEKTROMAG’ at Email ID emag@emagindia.com OR at postal address of 404, Unique Industrial Estate, Off. Veer Savarkar Marg, Prabhadevi, Mumbai — 400 026.us, A | 4 Pea | aioe | sec LI 400 & 500 DA. 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