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Braketronic
Braketronic

Impulse G+ Series 3

Mondel Braketronic Instruction Manual


Part Number: 140-10318-R3

April 2006
© Copyright 2006 Magnetek Material Handling 6/7/2006
Page 2 of 20
Braketronic Instruction Manual

140-10318-R3


SUPPLEMENTS FORMING PART OF THIS MANUAL:


































DATE OF MANUFACTURE:

APPLICABLE DIMENSION PRINT:

EXPLODED VIEW:

PARTS LIST:





Installation and Maintenance
Instructions

Braketronic
Impulse G+ Series 3
6/7/2006
Page 3 of 20
Braketronic Instruction Manual

140-10318-R3

Table of Contents

Chapter 1.0: Braketronic Warnings and Cautions............................................................................... 4
Chapter 2.0: General Description........................................................................................................ 5
Chapter 3.0: Installation .................................................................................................................... 10
Chapter 4.0: Electrical Connections .................................................................................................. 11
Chapter 5.0: Operational Test ........................................................................................................... 12
Chapter 6.0: Parameter Settings / Timing Charts ............................................................................. 13
Chapter 7.0: Servicing....................................................................................................................... 19
Chapter 8.0: Long Term Storage....................................................................................................... 20 6/7/2006

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Braketronic Instruction Manual

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Chapter 1.0: Braketronic Warnings and Cautions

Read and Understand All Warnings And Notices Printed In This Manual Before Commencing
Installation, Adjustment Or Repair.


Anyone involved in the installation or service of this brake must have:

Received specific training.

Had experience on similar equipment.

Knowledge of the equipment on which the brake is installed.

The ability to understand the terminology.

The ability to understand the diagrams.


Do not proceed unless technically qualified for the work involved.


Chapter 4.0: ELECTRICAL CONNECTIONS Warnings and Cautions

Unexpected movement or hazardous voltage can cause injury or death. Disconnect,
lock out, and tag out the power source that feeds this device to prevent power from being applied
while work is carried out.



Before working on a Braketronic system, ensure that power has been disconnected for at least 3
minutes. Internal capacitors hold a charge and hazardous voltages remain present at terminals
and components up to 3 minutes after power is turned off.


Do not connect power directly to terminals T1, T2 and T3 under any circumstances.


Chapter 5.0: OPERATIONAL TEST Warnings and Cautions

Review and verify the following checklist before switching on the power source feeding this
system:

Components are as supplied by the factory.

Writing is correct per relevant diagram.

Enclosures are grounded in accordance with local electrical codes.

Power supply is within the specified range, and the correct voltage/polarity is available at
the power supply input terminals.

Brake adjustments are complete in accordance with the relevant brake instruction manual.


Before conducting an operational test, remove all tools, chocks and other equipment which may
create a hazard when the machine is operating.


Before attempting to operate any motion in any application, advise and account for the location
and security of all personnel involved. 6/7/2006

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Braketronic Instruction Manual

140-10318-R3

Chapter 2.0: General Description

2.1: The Braketronic system provides a means of varying the braking torque developed by spring

applied, thruster released, shoe and disk brakes.

2.2: Single, or multiple, brakes may be operated in parallel from one Braketronic Controller.

2.3: Braking torque modulation is achieved by either of the following methods:


2.3.(a): Continuous variation controlled by external means, (usually a pedal operated
potentiometer).



2.3.(b): Preset rate variation controlled by an internally generated ramp signal.

2.4: Control of torque is achieved by modulating the electrical supply voltage and frequency to the

thruster pump motor. This varies the speed of the pump impeller and thus the pressure and volume

of hydraulic fluid delivered to the thruster piston.

2.5: The thruster piston extends offsetting the torque spring force applied to the brake shoes as follows:



2.5.(a): Maximum frequency & voltage supplied to the thruster produce full motor speed with

maximum pump output. Piston output will overcome torque-spring force and move the shoes away

from the brake wheel; braking torque falls to zero and shoe clearance reaches its maximum .



2.5.(b): Thruster piston output force varies with pump motor speed. As pump speed and piston

force decrease, the torque-spring force available to the brake shoes increases. This allows the

shoes to close on the brake wheel. Braking torque develops and increases as thruster pump output
decreases.


2.5.(c): Maximum brake torque is generated as motor and pump speed fall to the level at which the

thruster piston is no longer able to offset torque-spring force.


NOTE: Interruption of power to the thruster produces the maximum available braking

torque.

2.6: When using the pedal, or similar remote control and all conditions for operation are met, the output

voltage and frequency produced by the Braketronic controller will vary, depending upon the position

of the pedal, as follows:



2.6.(a): With the pedal released (OFF), the Braketronic supplies rated voltage and frequency to the

thruster motor. The motor will run at its rated RPM to fully release the brake.



2.6.(b): When foot pressure is applied to the pedal, and internal switch trips after the pedal leaves

the released (OFF) position. This switch signal causes the controller output to decrease, at a

preset ramp rate, quickly moving the shoes into light kiss contact with the brake wheel.



2.6.(c): As pressure on the pedal increases, a potentiometer arranged to sense pedal position,

adjusts the controller to produce a gradual increase in braking torque.


2.6.(d): When the pedal is fully depressed, the controller output continues to decrease to the point

where the thruster is unable to offset any torque spring force and maximum braking torque is
produced.


2.6.(e): A small decrease in pedal pressure changes the position of the controller potentiometer,

producing an increase in controller output which increases the thruster motor RPM. The thruster

motor speed increase acts to offset torque spring force and decrease the braking torque. 6/7/2006

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Braketronic Instruction Manual

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2.6.(f): When pressure on the foot pedal is completely removed, the internal switch resets to

produce maximum controller output and quickly move the shoes clear of the wheel.


Note: When circumstances permit, ramp rate parameters are factory set for operation

with a specified brake, or brakes. However, a digital operator is supplied with each

Braketronic controller to allow on-site modification of any parameter.

2.7: Wireless Remote Control, (supplied by others), can be used to regulate the output of a

Braketronic controller. Braking characteristics are similar to those offered by the pedal operator

while allowing the operator considerable mobility. Operation is generally as follows:



2.7.(a): When the wireless Brake Master Switch is not operated, the Braketronic unit supplies

rated voltage and frequency to the thruster motor, and fully releases the brake.



2.7.(b): Initial movement of the Brake Master Switch activates a primary relay. This sets the

controller output to a value that quickly moves the shoes into light kiss contact with the brake
wheel.

2.7.(c): Advancing the Brake Master Switch to nearly full travel, produces a continued, but

slower, decrease in controller output with a corresponding increase in brake torque.

2.7.(d): When the Brak