Industrial Solutions

Acceptance Code

thyssenkrupp
1 APPROVED

This approval does not release the vendor / supplier

from full responsibility for his design and fabrication.

1/30/2018 chad.meyers@thyssenkrupp.com

Date Name

Name: 33000-0334-801
33000-0334-801 Date: 05-01-2018
HPU & CONTROLS description Revision: 1
Author: JH

Description of the hydraulic system for TKIS TINTAYA

3.1 General
The hydraulic unit has been developed to be used together with failsafe brake callipers specified in
the settings report - See Appendix C.
For other uses contact Svendborg Brakes. The pump can be connected to one or more brakes.

The hydraulic power unit 3000-0334-801 consists of 3 main items:

• Cabinet 9893-0001-942. (tagged 1260-HPU-6050)

• Power unit 1013-0128-854.
• SOBO iQ Slave 6997-0345-100.

The SOBO iQ Master Unit, 6997-0345-001 (tagged 1260-CP-6050), is located in customer E-house.

Except for the dimension drawing and mounting/handling instructions this manual holds no further
information about the cabinet.

The power unit is described in details including functionality, assembling/mounting, pressure settings,
spare parts, description of main parts, maintenance, trouble shooting, choice and handling of hydraulic
medium etc.

3.2 Function
See the hydraulic diagram section 3.3.

3.2.1 System energy

In the hydraulic system an electro motor (4) and a pump (2) converts electrical power into oil pressure
and oil flow.

Pressure is limited by:

• The pressure sensor (20.1) that turns off the motor when the preset pressure is reached.
• A pressure relief valve (16).

Pressure is monitored by a pressure sensor (20.1). If pressure drops below the pre-set value the motor
will restart, boosting the pressure.

The check valve (17) prevents pressure from going back to tank, when motor stops.

The accumulator (A1) serves as a pressure back-up that prevents the motor from frequent restarts
and for Energy storage for SOBO braking in case of power-off.

3.2.2 Releasing the brakes

Power is connected to the electrical motor (4) and the solenoid valves (20 and 26) are energized, and
the pressure will release the brake.
The valves (20 and 26) are kept energized at all time when the brakes are released.

NOTE:

As long as there is a healthy system with full power available valve (27) is energized.
Project: DUS00037 Tintaya

Supplier Name: Svendborg Brakes

3.2.3 Applying the brakes - SOBO®

Purchase Order: 4500001931

The parts active in the SOBO® braking system are: Supplier Document Title: Functional description of HPU system

Document Number: TUS-EQM-1931-DZ-0001-017

• A main accumulator (A1). Revision Number: 1

• The directional valves (20 and 26). Tag Numbers: 1260-CVB-6000

• The throttle valves (26.1). Related DCN Codes:

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 Name: 33000-0334-801
33000-0334-801 Date: 05-01-2018
HPU & CONTROLS description Revision: 1
Author: JH

• A small accumulator (34).

Accumulator (33) has no function for the SOBO® braking.

The main accumulator secures enough oil to feed the braking sequence also in case of a network
failure, if the system is supplied with a UPS (Uninterrupted Power Supply).

Valves (20 and 26) and the small accumulator (34) are the heart of the SOBO® system.

By switching the valves (20 and 26) on and off with flow in and out through the throttle valves, the
pressure in the brakes can be controlled.
The small accumulator (34) is used to increase the controlled oil volume, thus increasing the oil flow
response time, with the same size of throttle. 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 and 26) are left de-energized, ensuring possible rest pressure
is dumped to tank through valve (27.2).

3.2.4 Applying the brakes by emergency or power loss

If the SOBO® braking system faults, 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 throttle valve (27.2).

3.2.5 Parking braking

For parking of the system, the valve (23) can be energized (open) and the brakes will be applied.

CAUTION
In order to maintain the warranty, never use the parking braking as emergency braking, the system
can be damaged.

3.2.6 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 (22)
showing the actual pressure at the brakes.

Pressure transmitter (P4) monitors the pressure in the system and indicates the brake position. The
signals will be used for SOBO® controller.
Motor (4) and Level/Thermo switch (5c) are controlled by SOBO® controller.

3.2.7 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 open position!

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 Name: 33000-0334-801
33000-0334-801 Date: 05-01-2018
HPU & CONTROLS description Revision: 1
Author: JH

3.3 Hydraulic diagram

HPU cabinet tagging: 1260-HPU-6050

®
®

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 Name: 33000-0334-801
33000-0334-801 Date: 05-01-2018
HPU & CONTROLS description Revision: 1
Author: JH

4.4 Function test

Testing component
Component Explanation

position

(see hydraulic diagram) Before action Action

2, 3, 4, 16, 17, 19, 4, 20: off 4: on Motor(4) shall start and stop at the pre-set pressure signal
20, 20.1, A1 from pressure sensor (20.1).

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, 23, 26 4: off 20: on The motor(4) is switched off or dis-connected.

26, 27: on Opening valve (20) shall pressurize the brakes from the
Testpoint: 22 20, 23: off accumulator (A.1).

For a period of 10 minutes the pressure shall remain stable

proving that brakes and tank valves (23 and 26) are tight.

The brake will be released.

18.1, 26, 27, 27.1, 4: off 26, 27: off Opening valve (26) shall reduce the pressure, to the setting of
27.2 20, 23: off the back-pressure valve (27.1), the rest of the oil is dumped
Test point: 22 26, 27: on to tank through the orifice (27.2), the time can be set on
(18.1).

The brake will be applied with reduced force for some

seconds after the time has expired then with the full force.

4, 23: off 26: on Motor (4) shall start and stop at the pre-set pressure signal
20: on 4: on from pressure transmitter (20.1).

The brakes will be released.

26, 26.1 4, 20, 23: off 26: off Opening valve (26) will drop the pressure to tank through the
Test point: 22 26, 27: on throttle valve (26.1).

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 (HP). Over ride valve
manually over (26) and operate the hand pump (HP) until the brakes
ridden releases.
20, 23, 27: off After the test, remember to leave the valve free - not
activated!!

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