UMC-750/SS - Hydraulic Power Brake - Retrofit Kit

Introduction

This procedure applies to the following parts kit:

93-30-12323: HYD POWER BRAKE KIT UMC750/P
93-30-12455: HYD POWER BRAKE KIT UMC750SS

Note: HYD POWER BRAKE KIT is for Pre-Reboot machine ONLY.

UMC-750 Machine Version - Identification

Hydraulic Power Unit (HPU) assembly replaces the air actuated rotary brake boosters. The HPU has 110VAC hydraulic pump that is powered from PSUP PCB. The Pump ON/OFF contactor is driven by the 400psi Normally Closed (NC) pressure switch. The pump turns ON when pressure in the manifold falls below 350 psi and turns OFF when the pressure reaches 400 psi. The system has a hydraulic accumulator that is charged with the nitrogen to 300 - 330 psi. The accumulator stores the fluid to increase the time between the pump duty cycles and to keep the rotary brakes clamped when there is no power to the pump. Each axis has a Normally Open (NO) solenoid and the 100 psi NC pressure switch to monitor the status of the rotary brake. When the rotary brake is commanded to unclamp, 120VAC is applied to the solenoid coil and the pressurized hydraulic fluid from the rotary drains back to the pump tank.

Note: The pump is powered directly from the PSUP PCB. The E-STOP will not disable the pump. To disable the pump you must turn the machine OFF or disconnect the cable from 400 psi NC pressure switch.

Remove The Pneumatic Boosters

1

Power the machine OFF and disconnect the air supply.

Disconnect the B and C axes hydraulic brake lines from the boosters [1].

Disconnect and remove the airlines that routed from the CALM cabinet to the brake boosters.

Remove the B and C axes pneumatic solenoids from the CALM manifold and plug the ports on the manifold with 1/4" NPT plugs.

Remove the boosters along with the mounting bracket from the machine.

Note: Older machines were equipped with one oil reservoir for both boosters. This reservoir has an oil level sensor. The new system does not utilize this sensor. Cut the connector off the level sensors and make a jumper out of it to jump the Low Brake Oil input.

Install The Hydraulic Manifold

1

Turn the B axis hydraulic fitting [1] 90 degrees.

Mark and drill two mounting holes [2] and attach the hydraulic manifold [3] to the C axis cable support bracket [4] using BHCS and the nuts.

2

Connect the C axis hydraulic line to the C axis solenoid outlet fitting [1].

Connect the B axis hydraulic line to the B axis solenoid outlet fitting [2].

NOTE: If machine was equipped with the rotary brake pressure sensors, connect the B and C axis brake pressure cables to the corresponding pressure sensors.

Install The Hydraulic Pump

1

Attach the hydraulic pump assembly to the C axis cable support bracket. [1]

Adjust the height of the rubber feet [2] to level the pump assembly and tighten the jam nuts.

Connect the hydraulic return hose to the fittings [3] and [4].

Connect the hydraulic supply line to the fittings [5] and [6].

Fill the hydraulic pump tank with 3.5 quarts of the Mobil DTE24 hydraulic oil.

Install the Electrical Components

1

Install the snubber [1] onto the contactor [2].

Using the DIN rail [3] mount the contactor below the Wye - Delta assembly inside the control cabinet.

2

Refer to the diagram when making the electrical connections.

Connect the HPU CONTACTOR POWER cable to the P5/6/7 on the PSUP PCB. Connect the other end of the cable to the contactor terminals 1L1; 3L2 and A2 as labeled.

Connect the HPU CNTRL CONTACTOR cable to the 400 PSI NO switch on the pump output port. Connect the other end of the cable to the contactor terminals 1L1 and A1 as labeled.

Connect the HPU POWER cable to the contactor terminals 2T1 and 4T2 as labeled. Attach the green ground cable with the ring terminal to the control chassis near the contactor.

Connect the B and C axes solenoid cables to the corresponding plugs in the CALM cabinet.

If the machine was equipped with the rotary brake pressure monitoring, connect the B and C axes rotary brake pressure cables to the corresponding pressure sensors on the output ports of the hydraulic manifold.

3

Open the junction box on the HPU [1]

4

Inside the J-Box you should see the terminal block shown.
If installing/replacing an HPU wired to the I/O, orient the brass terminal connections in the 230V configuration (LEFT) as shown.
If installing/replacing an HPU wired to the PSUP, orient the brass terminal connections in the 120V configuration (RIGHT) as shown.

Note which wires are connected to each terminal. Ensure these wires are on the same terminal after reorienting the brass terminal connections.

Bleed The Air Out

1

Install the Schrader valve bleeding tools on both rotaries.

Route the hoses from both bleeding tools back into the pump tank and open the Schrader valves by turning the bleeding tool levers all the way clockwise.

Connect the air supply to the machine.

Power the machine ON.

The pump will turn on and the oil will flow through rotaries back to the pump.

NOTE: Make sure to monitor the oil level in the tank during the bleeding process. Add Mobil DTE24 as needed.

Let the pump run until there is no more air present in the bleeding hoses and close the Schrader valves by turning the bleeding tool lever all the way counterclockwise.

The pump will turn off automatically once the oil reach the operating pressure.

Remove both bleeding tools and install the caps on the Schrader valves.