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CMB 2 System
SB 28
Software-Release
1.0 and 1.1
www.pintschbubenzer.de
e-Mail: info@pintschbubenzer.de
PB88-0811-01/2
CMB 2 for
SB 28
Table of contents
1 Safety regulations ................................................................................... 3
1.1 Symbols in this manual...........................................................................................3
1.2 Warnings ................................................................................................................4
2 CMB .......................................................................................................... 6
2.1 Introduction .............................................................................................................6
2.2 Warranty .................................................................................................................6
2.3 Limitation of liability.................................................................................................6
2.4 Instructions and information for and obligations of the operator .............................7
2.5 Description and proper use.....................................................................................8
2.6 Shipment ..............................................................................................................10
3 Sensors .................................................................................................. 11
3.1 Contact force ........................................................................................................11
3.2 Brake pad temperature .........................................................................................11
3.3 Stroke ...................................................................................................................11
3.4 Brake disc speed (option) .....................................................................................12
3.5 Brake pad wear.....................................................................................................12
4 Connection and mounting .................................................................... 13
5 Operation ............................................................................................... 16
5.1 Display ..................................................................................................................16
5.2 Keypad .................................................................................................................17
5.3 Setting-menus.......................................................................................................17
5.4 Signals ..................................................................................................................18
6 Warnings and critical values................................................................ 19
7 Maintenance........................................................................................... 20
7.1 Maintenance tasks................................................................................................20
7.2 Replacement of sensors .......................................................................................20
7.3 Replacement of force measuring pin ....................................................................22
7.4 Replacement of profibus-chip ...............................................................................23
8 Putting out of service and disposal..................................................... 24
9 Trouble shooting ................................................................................... 25
10 Spare parts............................................................................................. 25
2
CMB 2 for
SB 28
1 Safety regulations
1.1 Symbols in this manual
The following symbols / pictographs are used throughout this manual to point out dangers and
information.
There may be other specific warning symbols / pictographs used to point out dangers more
precisely in certain situations.
3
CMB 2 for
SB 28
1.2 Warnings
Note: warnings and other security rules are presented like this throughout the manual:
The CMB / brake may only be used in the way described in chapter 2.5 “Description and
designated use”. The safety of your brake / brake-system depends on proper and regular
inspection and maintenance. Study the manual before starting the installation. If in doubt, please
don’t hesitate to contact our service-department or your local retailer.
Important!
The control system PINTSCH BUBENZER CMB is part of an essential safety
device.
Any misuse or insufficient handling or maintenance endangers life!
Warning!
A sudden startup of the installation endangers the life of the maintenance
personnel! Secure the drive and the installation against any accidental
movement before starting any work!
Danger of crushing
When working on the CMB, heavy tools are used. Particular attention
should therefore be paid to possible crushing points when: Using tools,
fitting and removing the brake, accessories or spare parts or unbolting the
brake from the pallet
4
CMB 2 for
SB 28
Safety distance!
A safety distance must be maintained to all hazardous zones to ensure
safety of personnel and prevention of damage to the CMB.
The standard common safety rules and regulations must also be observed under the pressure of
time. Accidents cannot be reversed. Work with care!
Before carrying out any work on the brake, measures must be taken against any dangers to the life
and health of persons and damage to the brake:
• Only closed shoes in a perfect condition must be worn. Open sandals, damaged or unsuitable
shoes must not be worn.
• Closed, tight-fitting working clothes must be worn. Wide work jackets and wide sleeves can be
dangerous.
• Long hair must be tied back.
Important!
Ensure that the CMB is set to its proper values according to the manual
after finishing all tasks!
5
CMB 2 for
SB 28
2 CMB
2.1 Introduction
This manual has been written to the best of our knowledge. It is intended to familiarize the
operation and maintenance personnel with the function, the handling, the maintenance and the
safety regulations of the product. Furthermore these instructions should make sure that trained
and qualified personnel is able to handle the product according to its designated use. However
the manual can’t cover all the possible circumstances at the place of operation. If you have any
questions concerning the product or this manual, please contact PINTSCH BUBENZER quoting
the type and serial number of product as given on the typeplate.
Copyright: The reprinting and duplication of all this technical documentation or extracts from it is -
except for internal requirements in connection with the operation of the device - permitted only with
the approval thereto in writing of PINTSCH BUBENZER GmbH. Permitting third parties to inspect
the device as described is prohibited. Similarly prohibited is the handing over of the device to third
parties and its replication.
2.2 Warranty
The warranty and its duration depend on the contract. For details on the supplier’s warranty please
refer to the terms of the contract. Any warranty- or liability-claims are excluded in case they occur
because of one or more of the following conditions:
• Non-designated use of theCMB.
• Improper handling, setup, operation and maintenance of the brake by the operating company.
• Neglection of the regulations and notes in this manual concerning transport, setting up,
operation and maintenance of the brake.
• Improper maintenance and repairs of the CMB.
• Improper monitoring of components, which are prone to wear.
• Catastrophes, external objects and forces and force majeure.
• Changes at the brake without approval of PINTSCH BUBENZER.
The information in this manual has been checked thoroughly. Nevertheless we can’t accept liability
for errors.
All the technical information, data and instructions on or for the operating and maintenance of the
product as contained in these operating instructions are up to date at the time of printing and are
given to the best of our knowledge and with account being taken of our experience and findings up
to the present time.
We undertake no liability for losses and operational disruptions which come about as a result of
operating errors, non-observation of these operating instructions or unprofessional repairs. We
draw explicit attention to the fact that only original spare parts and original accessories have been
checked and approved by us.
Every form of liability is excluded for the use of spare parts and accessories that are not original
ones.
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CMB 2 for
SB 28
Conversions and changes of every form to the brake are not permitted for reasons of safety and
any such conversions and changes made render liability for any loss/damage resulting there from
to be excluded.
We are liable for any errors of omission or commission for which we are responsible within the
framework of the warranty obligations entered in the main contract whereby the advancing of
further claims is excluded. The advancing of claims for damages - regardless of the legal
foundation on which they are based - is excluded.
The operating instructions represent an important component of the product. Thus, for example, if
the product is passed on to a third party as a component of a system, then these operating
instructions are to be passed on to this third party as operator of this system. The operator of the
system containing the product is to ensure that these operating instructions are available to his
operating personnel at all times!
In order to ensure that the health and safety of the operating personnel is not endangered as well
as to ensure the proper working of the device, the operator is obliged to instruct his personnel on
the safe and proper operating, maintaining and servicing of the device as well as on how the
device should be operated in the proper manner. In this connection the relevant supervision and
notifying obligations are to be observed and any special operational circumstances taken account
of!
Our customer service department is at your disposal should you require technical information on
any of PINTSCH BUBENZER GmbH's products and how to use these correctly. See below for the
address and telephone number.
Should you have any questions of this device, please contact our customer service department.
7
CMB 2 for
SB 28
The brake monitoring system CMB 2 (Computer Monitored Brake) is meant to collect the operating
data at electro-hydraulic disc brakes of the series SB 28. It consists mainly of a central electrical
box with display and keypad as well as several sensors mounted at the brake. The CMB may be
connected to the crane PLC via a Profibus-connection.
Sensors at the brake are continuously collecting the relevant data from the brake. These data are
transferred via a field-bus-system to a PLC or the process-control unit (even wireless) and
visualized.
• Contact force.
• 2 x Brake pad temperature
• Release stroke
• 2 x Brake pad wear
• Brake disc speed (optional)
It is possible to achieve a preventive maintenance which is meant to allow for an enhanced brake
performance. Brake models SB28 can be equipped with an optional CMB 2 device which includes
several analogue and digital sensors to monitor the brake operational parameters.
The sensors are pre-wired at the factory according to corresponding wiring diagram (section 4). A
Profibus cable has to be used between the electronic box and user’s control system or remote
readout device.
Any other use or any further change of the CMB is strictly forbidden!
Ignoring the regulations for the designated use and /or the instructions for
setup and maintenance endangers life and leads to the loss of any
warranty by the manufacturer!
8
CMB 2 for
SB 28
Fig. 1:
9
CMB 2 for
SB 28
2.6 Shipment
The CMB is ready mounted, wired and tested at the brake. It has to be connected according to the
wiring diagram in this manual.
LED RESET
pushbutton
Display
Profibus-
IC Chip
Profibus-
Voltage
DP-Slave
switch
Terminal
Keypad
Power
connection
Fig. 2:
10
CMB 2 for
SB 28
3 Sensors
Brake pad
Reserve temperature
stroke
The brake shoe pin on the thruster side is designed as a force measuring load cell. The measuring
range is:
SB 28: 0 to 70 kN
• The signal at terminal (14) and (15) of 4 mA corresponds to 0 kN contact force.
• A signal of 20 mA corresponds to a contact force of 70 kN contact force.
Each brake pad is equipped with a temperature sensor type PT100. It achieves a higher resistance
value with rising temperature. The temperature is read directly at terminals (1), (2), (3) and (4)
Furthermore a one-sided dragging of the brake in released condition is detectable by a
temperature difference of > 30 °K at the brake pads.
3.3 Stroke
An inductive touchless sensor with integrated amplifier creates a signal of 4 – 20 mA for a stroke of
0 – 100 mm at the terminals (11), (12) and (13).
• A stroke of 0 mm corresponds to a current of 20 mA.
• A stroke of 10 mm corresponds to a current of 18.4 mA.
• A stroke of 60 mm corresponds to a current of 10.4 mA.
• A stroke of 100 mm corresponds to a current of 4 mA.
The reserve stroke of 10 mm (min. 5 mm, max. 15 mm) is monitored by this sensor.
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CMB 2 for
SB 28
On the front face of the brake disc, there are two or four impulse devices. A proximity switch
generates a corresponding number of impulses per disc rotation at the terminals (5) and (6) which
are transferred to the CMB.
At each brake pad carrier a digital is mounted, emitting a signal to the CMB via the terminals (7),
(8), (9) and (10) when the minimum brake pad thickness is reached.
12
CMB 2 for
SB 28
Danger!
The applied electrical voltages are dangerous to life!
The electrical connection and all other electrical tasks must only be done
by a trained electrician!
Important!
The CMB may be connected to a 115 V AC or a 230 V AC connection,
depending on the setting. Before connecting the CMB and switching it on
the first time, make sure the correct control voltage is set. The CMB may
be damaged, if it is connected to the wrong voltage!
• Set the voltage selection switch to the correct value (110 / 230 V) if necessary.
• The CMB is set to 230 V ex work.
• The setting is done by moving the switch (Fig. 6) sideways.
• Connect the CMB via the PROFIBUS-connection to the crane control.
Fig. 6:
13
CMB 2 for
SB 28
14
CMB 2 for
SB 28
15
CMB 2 for
SB 28
5 Operation
Important!
Please note the following rule:
Brake pad 1: Brake pad at spring tube side
Brake pad 2: Brake pad at thruster side
Warning!
A sudden startup of the installation endangers the life of the maintenance
personnel! Secure the drive and the installation against any accidental
movement before starting any work!
5.1 Display
The operating data can be read at a 4-line display. There are two screens with 4 values each.
These screens are shown alternating.
By pressing the RESET-button shortly ((< 1 Sec), the actual screen remains visible. Pressing the
button shortly once again changes the display mode back to the original alternating display.
Screen 1: Screen 2:
STROKE [mm] SPEED [RPM]
TEMP 1 [°C] / [°F] COUNTER
TEMP 2 [°C] / [°F] PAD WEAR 1 [OK]
TORQUE [Nm] / [lb ft] PAD WEAR 2 [OK]
• In case of an error or warning a third screen appears. This screen displays the faults and
recommended actions. E.g.
ERROR Stroke
Check setting of 10 mm reserve stroke
Fig. 7:
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CMB 2 for
SB 28
5.2 Keypad
The CMB can be operated via a keypad mounted on the circuit board.
Fig. 8:
5.3 Setting-menus
Important!
The Menus 2 – 5 contain the calibrating of the sensors. They are set ex
work. These setting must only be altered by authorised and trained
personnel.
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CMB 2 for
SB 28
5.4 Signals
Important!
Wichtig!
Diese
These
Signale
Signals
können
can be
vom
transferred
Kunden über
to theden
crane-PLC
Profibus via
in der
a Profibus
Kran-PLC
connection.
weiter verarbeitet
Otherwise
werden.
the signals
Sonst bleiben
only remain
es Meldungen
in the CMBinand
derdo
CMB
notohne
affect
Auswirkungen
the operation
aufofden
theweitern
installation!
Betrieb!
Offset Type
Signal Range
(Byte)
Metric US
0 INT Thruster Stroke 0…100 mm
INT Brake pad temperature -51…394
2 -46…201 °C °F
Side 1
INT Brake pad temperature -51…394
4 -46…201 °C °F
Side 2
6 INT Brake torque 0…30.000 Nm 0…22127 lb ft
8 DW Brake cycle counter 0… 99.999.999
12 INT Speed (Option) 0…2000 RPM
14.0 BOOL Heartbeat Bit 1Hz 0…1
14.1 BOOL Common Error bit 0…1
14.2 BOOL Stroke Error bit 0…1
14.3 BOOL Torque Error bit 0…1
14.4 BOOL Temp. 1 Error bit 0…1
14.5 BOOL Temp. 2 Error bit 0…1
14.6 BOOL Air gap 1Error bit 0…1
14.7 BOOL Air gap 2 Error bit 0…1
15.0 BOOL Pad wear 1Error bit 0…1
15.1 BOOL Pad wear 2 Error bit 0…1
15.2 BOOL Signal Release control 0…1
15.3 BOOL Signal Hand release 0…1
15.4 BOOL Spare 0…1
15.5 BOOL Spare 0…1
15.6 BOOL Spare 0…1
15.7 BOOL Spare 0…1
INT = Integer
DW = Double word
Bool = Boolean
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CMB 2 for
SB 28
SB 28
Warning message in Terminal Time
Condition
crane monitoring system : No. delay
Brake pad 1 temperature maximum 14.4 T1 > 200°C
Brake pad 2 temperature maximum 14.5 T2 > 200°C
Brake pad 1 air gap low 14.6 T1 > ( T2 + 30 K )
Brake pad 2 air gap low 14.7 T2 > ( T1 + 30 K)
Remaining brake pad thickness upper
Brake pad 1 – brake pad wear 15.0 5s
edge 5mm
Remaining brake pad thickness upper
Brake pad 2 – brake pad wear 15.1 5s
edge 5mm
Brake reserve stroke low 14.2 5s S < 5 mm
Brake reserve stroke high 14.2 5s S>15 mm AND S<55 mm
19
CMB 2 for
SB 28
7 Maintenance
Warning!
A sudden startup of the installation endangers the life of the maintenance
personnel! Secure the drive and the installation against any accidental
movement before starting any work!
The CMB itself is maintenance-free. Mechanical damages and dirt can lead to malfunctions of the
sensors. Thus the sensors have to be cleaned regularly – depending on the environment. When
the brake pads of the SB 23 / SB 28 / SB 28S are worn, the brake-pad-wear-sensors have also top
be exchanged. The other sensors can be used.
Malfunctions of the sensors are indicated at the customer sided monitoring system. In this case,
the sensors have to be replaced. The new sensors are set to the same values as the old ones.
Refer to sections 7.2 and 7.3 for details.
Important!
The following tasks must only be carried out by a trained and skilled
worker. Wrong settings lead to internal errors and can lead to a malfunction
of the whole installation!
Stroke
Fig. 9:
20
CMB 2 for
SB 28
SW 17mm SW 14mm
SW 10mm
The Sensor Brake pad wear can be used again, after it has emitted a signal if the brake pad has
been changed immediately. If this is not the case, the sensor may be worn down too far by rubbing
on the disc for a longer period and will emit a signal too late, if it used again. If a sensor is reused,
the front has to be sealed with paint to prevent corrosion and malfunctions.
Temperature sensors
• Carefully loosen lock nut at temperature sensor (Wrench size 10 mm).
• Screw temperature sensor out of mounting block.
• Screw in new sensor until stop.
• Carefully tighten lock nut (Wrench size 10 mm).
21
CMB 2 for
SB 28
Danger of squeezing!
When you pull out the force measuring pin, the brake shoe may fall down.
Secure the brake shoe!
Fig. 10:
2.14
5 mm
5 mm
SW 13mm
Fig. 11:
• The force measuring pin is installed in the brake shoe at the thruster side.
22
CMB 2 for
SB 28
• The electrical connection is at the “inner side“ (between levers and thruster.
• Unscrew plug.
• Pull off plug.
• Unscrew lock nut at the rear of the brake shoe. (Wrench size 31 mm).
• Unscrew headless screw (Allen key size 5 mm).
• Unscrew inner headless screw (Allen key size 5 mm).
• Push measuring pin out.
• Check electrical connection for cleanliness.
• Carefully insert new pin into brake levers and brake shoe.
• When connecting the plug check for the correct orientation (refer to fig. 11).
• Screw plug back on.
• Align measuring pin.
• The bore at the pin has to coincide with the thread for the headless screw.
• Screw in headless screws.
• Secure outer headless screw with lock nut.
• Remount catch (2.7).
• Reset brake according to manual.
Fig. 12:
23
CMB 2 for
SB 28
When the CMB / brake is put out of service, the following instructions have to be heeded to help
avoiding dangers to life, material and environment:
The CMB must only be put out of service and disposed by trained and qualified personnel.
Always heed the applying laws and regulations to avoid dangers to life and health and to prevent
damages to the installation and environment!
Important!
Because of the weight of the CMB / brake always use proper lifting devices
and transport the brake using the lifting ore!
Danger of injury!
Warning!
A sudden startup of the installation endangers the life of the working
personnel! Secure the drive and the installation against any accidental
movement before starting any work!
Danger!
The applied electrical voltages are dangerous to life!
The electrical connection and all other electrical tasks must only be done
by a trained electrician!
Take care that the hydraulic fluids, lubricants and other used substances
as well as oil-soiled parts are disposed environmental friendly and in
compliance with the corresponding laws and regulations!
Electronic scrap has to be disposed separately.
24
CMB 2 for
SB 28
9 Trouble shooting
10 Spare parts
Notice!
The use of spare parts, not meant for this brake, can lead to a malfunction
of the brake or damage the brake!
Only use original PINTSCH BUBENZER spare parts!!
25