Brake Package for Cranes
Electro-Hydraulic Brake Package makes converting an Electric
Overhead Traveling (EOT) Crane from cab control to radio remote
or pendant control easy. The conversion requires changing
the operation of the bridge brake from a foot pedal to an
electrically operated brake. With the Two-Step Electro-Hydraulic
Brake Package, the existing foot pedal system remains in place,
and there is no need to re-size or change the existing manual
brake system. This eliminates the chance for error in sizing
a totally new brake and potential damage to the mechanical
structure of the crane during installation of the new brake.
Electro-Hydraulic Brake Packages are designed to be installed
in parallel with an existing manually operated, cab-mounted,
hydraulic foot brake. Several available configurations allow
for use with a variety of crane power sources, such as 110,
220, and 440 VAC, and 250 VDC. Brake operation can be controlled
by any Cattron-Theimeg Portable Remote Control systems, as
well as by pendant. The standard brake package offers two
(2) adjustable steps of brake application and a brake release
function, thus providing the operator with precise control
of the crane brakes without unnecessary load sway due to abrupt
stopping. A parking brake release function for a Wagner™
HM parking brake is optionally available (PKK) model. An optional
three (3) step package is also available by special configuration
of the PKK brake model.
Electro-Hydraulic Brake Package is adjustable and can be tailored
to meet your crane size, load size, and stopping distance
requirements. The system includes a long-life hydraulic pump,
driven by a continuous duty electric motor. The pump develops
the required brake pressure; the pressure is then held in
the accumulator storage chamber, where it is ready for application
to the brake cylinder upon command. When applied to the brake
cylinder, the pressure varies, depending upon which electric
valve is actuated and its associated pressure relief setting.
of braking is independently adjustable to correspond directly
to the operator's stopping rate requirements. The amount of
brake application pressure is selected by the portable remote
control or pendant operator. Normally, a soft brake is automatically
applied when bridge control is brought to neutral. When faster
stops are required, hard brake pressure is selected with a
push-button on the portable remote or pendant remote.
installed and interfaced with the crane's control circuits,
the brake systems will not permit the movement of the crane
unless brake pressure is above a minimum level necessary to
stop the crane. Any loss of power applies accumulated brake
pressure to the brake cylinder. This provides brake pressure
even when the crane power is turned off.
Effectiveness: Bypasses the intermediate pneumatic step
used on some current braking systems, thus reducing cost
and improving reliability without sacrificing safety.
Panel Mounting: The brake assembly, minus the motor and
pump, is mounted on a single panel, in a pre-wired, plumbed,
and tested NEMA 12 enclosure. Only three (3) hydraulic connections
are required for a complete installation. An optional NEMA
4 or NEMA 4X (IP66) cabinet is recommended for severe environments
(acidic fumes, salt water, etc.) to further guard against
Down Transformer: All AC systems operate on 110 volts; therefore,
the appropriate step-down transformer is provided as part
of the system when requested.
Valve: All BP 102 and BP202 brake packages work in conjunction
with the manual foot brake existing on a crane. The manual
system must remain operational; therefore, a hydraulic shuttle
valve is included to automatically select either foot pedal
operation or radio operation, without interaction between
Gauges: Two pressure gauges are provided to monitor the
brake cylinder line and pressure stored. This allows ease
of adjustment and a visual indication of the different increments
of braking while monitoring the system operation. The second
gauge shows the stored charge in the accumulator, which
must be present to stop the crane in case of pump failure.
A spin-on, in-line brake fluid filter is built into this
system to catch any small amount of debris which would cause
possible valve failures. This filter is easily disconnected
and cleaned without disturbing system piping. It has a service
gauge to indicate when the filter should be replaced.
Valve Manifold: A specially designed, single block manifold
for significantly reducing the amount of pipes, fittings,
and hoses, and increasing reliability and ease of maintenance.
remote or Pendant Conversion: The BP 102 and BP 202 Electro-Hydraulic
Brake Packages can be used for converting an existing EOT
to either a portable remote control or pendant control operation.
All parts used in the Two-Step Electro-Hydraulic Brake Package
can withstand temperatures at or below 158ºF (70ºC). Both
the valves and the motor have been rated at that temperature
for continuous operation. This means that the brake system
is operational for cranes used above furnaces and in other
high temperature environments where the ambient temperature
does not exceed 158ºF (70ºC). Outdoor operations are good
at low temperatures because there is no air compressor and
no frozen water that is inherent with electro-pneumatic
Release Valve: This provides an easy method of releasing
fluid from the brake panel after transferring from radio
to manual operation. It also simplifies maintenance; the
valve is electrically operated and normally ties into a
remote/manual selector switch.
The accumulator is a storage device which will provide a
source of pressure should the pump become inoperative. The
pre-charge inlet requires no special tools to apply pressure
or to check the pre-charge. It has a special stirred valve
(like that on an automobile tire), making a tire pressure
gauge all that is required to check the pre-charge pressure.
Fluid Compatibility: All components are designed for use
with DOT-3 brake fluid, the type suggested by the manufacturers
of most existing and new manually-operated foot pedal type
interfaces: The Two-Step Electro-Hydraulic Brake Packages
interface directly to a variety of control applications.
They can be used on any remote control crane, and with multiple
voltages, such as 110, 220 and 440 VAC or 250 VDC. A user
can upgrade an existing crane at any time and can easily
interface into any portable remote control or pendant system.
VAC, 2-step brake
VAC, 2-step brake
VDC, 2-step brake
VAC, 2-step brake plus parking release
VDC, 2-step brake plus parking release