Antec NDT Series Instruction manual

ELECTROHYDRAULIC BRAKES
NDT-NFT-NAT
Instructions for assembly, adjustment and maintenance
Technical data sheet number: BC.TDS.00015I
Author: Unitzer Bilbao
Reviewed by: Sales department.
Date registered: 01-11-2011
Rev.1. date 18-01-2012
Aplicación Nuevas Tecnologías, ANTEC S.A.
Ramón y Cajal, 74 – 48.920 Portugalete (Bizkaia)-Spain.
Tel.: [phone] Fax: [phone]
After Sales Service: [email protected]
www.antecsa.com Page 1-48

NDT-NFT-NAT ELECTROHYDRAULIC BRAKES
Instructions for assembly, adjustment and maintenance
T.D.S.: BC.TDS.00015I
Rev.01: January 2012.
www.antecsa.com Page. 2-48
1. INTRODUCTION. Page 3.
1.1. WHO IS THE TARGET AUDIENCE? Page 3.
1.2. SAFETY INSTRUCTIONS. Page 3.
1.3. RISK ASSESSMENT. Page 5.
1.3.1. IDENTIFICATION OF THE BRAKE'S POTENTIAL RISKS. Page 5.
1.3.2. ANALYSIS AND ASSESSMENT OF THE RISKS IDENTIFIED. Page 7.
1.3.3. MEASURES ADOPTED TO MINIMISE THE RISKS ANALYSED. Page 7.
1.4. GENERAL ASPECTS. Page 11.
2. BRAKE OPERATION. Page 14.
3. BRAKE ASSEMBLY. Page 16.
4. BRAKE ADJUSTMENT AND SETTING. Page 22.
5. BRAKE MAINTENANCE. Page 29.
6. CHANGING THE BRAKE SHOES. Page 30.
7. BRAKE OPTIONS. Page 33.
7.1. AUTOMATIC RECOVERY (RA). Page 33.
7.2. BRAKE OPEN SIGNALLING CONTACT (CSA). Page 38.
7.3. BRAKE SHOE LINING WEAR DETECTOR (DD). Page 41.
7.4. BRAKE MANUAL UNLOCK (DM). Page 42.
7.5. DESCENT VALVE IN TURBEL BRAKE LIFTER (VD). Page 43.
7.6. REDUCED TORQUE BRAKES (PR). Page 45.
7.7. SPECIAL PAINT (PE). Page 47.
7.8. PNEUMATIC OR HYDRAULIC OPENING OF THE BRAKE. Page 47.
7.9. BRAKE WITH TURBEL ATEX CERTIFICATION. Page 47.
8. SPARE PARTS. Page 48.
9. ONGOING IMPROVEMENT PLAN. Page 48.

NDT-NFT-NAT ELECTROHYDRAULIC BRAKES
Instructions for assembly, adjustment and maintenance
T.D.S.: BC.TDS.00015I
Rev.01: January 2012.
www.antecsa.com Page. 3-48
1. INTRODUCTION.
1.1. WHO IS THE TARGET AUDIENCE?
This manual has been written to aid with the installation, start-up, operation and
maintenance of the brake. It is designed to help workers who are going to manipulate the brake
and service technicians. It should therefore be made available to everyone who is going to
work with these brakes and it must be ensured that the instructions given are followed.
This manual is intended to clarify any constructive doubts and the basic functions of the
brake. We are sure that it will be an extremely useful information and reference tool for
operators and technicians.
1.2. SAFETY INSTRUCTIONS.
Various symbols appear throughout this manual which highlight the importance of the
section in question. They are usually related to safety, and therefore require special attention.
In the event of any problems or if you have any
questions regarding the brake, please do not hesitate to
contact the ANTEC After-Sales Service, specifying the
brake model and the Antec order number, data that can
be found on the label that each unit has.
NOTE
Due to ongoing improvements to our brake designs,
your brake may differ slightly from the one described in
this manual. ANTEC reserves the right to make any
changes deemed necessary.
NOTE
Warning: This symbol will be included at points
or in paragraphs that need special attention. It
usually refers to an operation in which special
care must be taken.

NDT-NFT-NAT ELECTROHYDRAULIC BRAKES
Instructions for assembly, adjustment and maintenance
T.D.S.: BC.TDS.00015I
Rev.01: January 2012.
www.antecsa.com Page. 4-48
A number of general safety rules must be followed when handling Antec brakes:
1. All workers and technicians must wear appropriate gear when handling the brake (safety
clothes, boots, helmet, goggles, etc.).
2. Always keep warning signs (if any) in good condition and adhere to them. During repairs or
maintenance, place a card to inform other workers that an Antec brake is being repaired in that
machine and that the power supply has been disconnected, if applicable.
3. Find out the exact specifications of the liquids used to ensure health and safety.
4. Make sure electrical apparatus (if any) is properly earthed to prevent electric shocks.
5. Respect the limits established for each brake element and for the brake itself.
6. Before switching on any machine fitted with Antec brakes ensure that the brake is properly
fitted.
These are the general safety rules to be followed with any Antec product.
Danger of death: This symbol will be included at
points or in paragraphs that need special
attention. It usually refers to an operation that
might involve a death hazard.
High temperatures: This symbol will be included
at points or in paragraphs that need special
attention. It usually refers to an operation that
might involve danger of high temperatures.
NOTE This symbol will be used to highlight an
important comment or piece of information.

NDT-NFT-NAT ELECTROHYDRAULIC BRAKES
Instructions for assembly, adjustment and maintenance
T.D.S.: BC.TDS.00015I
Rev.01: January 2012.
www.antecsa.com Page. 5-48
1.3. RISK ASSESSMENT.
1.3.1. IDENTIFICATION OF THE BRAKE'S POTENTIAL RISKS.
In this section we will list the risks derived from the brakes made by Antec, S.A. in the
event of malfunction (disassembly and assembly) and during their use by the end customer.
Risks when assembling and disassembling brakes:
Description of the
risk identified Measurement of the risk Indication Preventive solution adopted
Fall to a different
level Step ladder: 2m slant
Inform the operator. Basic
training.
Preventive inspection of
stepladders.
Fallen material Maximum weight: 10-45
Kg.
Operator training.
Use of safety footwear.
Use of gloves for a better
grip on parts.
Cuts and blows Use of tools for portable or
manual assemblies.
Operator training.
Use of protective gloves for
certain assembly
operations.
Projection of solid
or liquid particles
Oil leaks through the
drum/casing joint,
maximum interior
pressure: 5 bar.
Operator training. Setting
of maximum filling levels
Use of protective goggles.
Trapping
Manipulation of parts
during assembly.
Thrustor in operation,
movement of the shank.
Operator training.
Use of protective gloves.
Burns
Preheating stove,
Ext. temp. 60 ºC
Thrustor in operation,
Ext. temp. 100 ºC
Operator training. Sticker
indicating the risk of burns
at the heat source.
Use of protective gloves.
Electrocution Use of test voltages. 185-
910 V. Operator training. Indicative sticker.

NDT-NFT-NAT ELECTROHYDRAULIC BRAKES
Instructions for assembly, adjustment and maintenance
T.D.S.: BC.TDS.00015I
Rev.01: January 2012.
www.antecsa.com Page. 6-48
Hazardous
substances
Use of chemical products
(oils, solvents, contact
glue, etc.)
Operator training.
Use of protective gloves.
Physical fatigue,
back disorders.
Inadequate postures
adopted during assembly
and test.
Lifting of weights.
Maximum weight: 15-20
Kg.
Operator training.
Use of support belts.
Physical comfort
agents
Poor lighting (330/390
lux).
High level of noise
(LAeq = 93 dB(A)).
Use of ear protection.
Risks of brakes use:
Description of the
risk identified Measurement of the risk Indication Preventive solution adopted
Burns Thrustor in operation,
Ext. temp.: 100 ºC
Hazard warning in the
operation and maintenance
instructions.
Hazard warning on the unit.
Trapping
Thrustor in operation,
vertical movement of the
shank. Brake opening and
closing.
Brake operating, trapping
by shoes-drum.
Indication in instructions.
Placement of a protective
cap on large models.
Electrocution Voltages of AC operation
(185-910 V.)
Indication in instructions.
Waterproof terminal box,
IP 65.

NDT-NFT-NAT ELECTROHYDRAULIC BRAKES
Instructions for assembly, adjustment and maintenance
T.D.S.: BC.TDS.00015I
Rev.01: January 2012.
www.antecsa.com Page. 7-48
1.3.2. ANALYSIS AND ASSESSMENT OF THE RISKS IDENTIFIED.
Assessment of the risks identified, for this a value from 0-3 is assigned to each risk,
where 0 is the lowest risk (none) and 3 the maximum (high).
Description of the risk Risk during assembly / test
Risk of use Assessment
Fall to a different level Assembly 1 – low
Fallen material Assembly 1 – low
Cuts and blows Assembly 1 – low
Projection of solid or liquid
particles Assembly - Test 2 – medium
Trapping Assembly - Test - Use 1 – low
Burns Assembly - Test - Use 3 – high
Electrocution Test - Use 2 – medium
Hazardous substances Assembly 1 - low
Physical fatigue Assembly - Test 1 – low
Physical comfort agents Assembly 2 - medium
1.3.3. MEASURES ADOPTED TO MINIMISE THE RISKS ANALYSED.
Once the risks derived from the assembly and use of the brakes have been identified,
analysed and assessed, a series of measures are taken to eliminate the risks that are possible to
eliminate or to minimise them as much as possible.
To do so two, different paths are taken, varying the design or pointing out the risk if it
cannot be eliminated.
- Design variations.
The thrustors do not allow for significant design modifications, they are machines with an
aluminium shell that conveys heat in a fairly linear manner. Therefore, the most significant risk
of those identified refers to the high operating temperatures, which is not easy to eliminate. The
motor shells have therefore been fitted with a series of fins that allow for a greater cooling
surface and the turbines have been fixed so that their movement does not have an incidence in
increasing the temperature.

NDT-NFT-NAT ELECTROHYDRAULIC BRAKES
Instructions for assembly, adjustment and maintenance
T.D.S.: BC.TDS.00015I
Rev.01: January 2012.
www.antecsa.com Page. 8-48
- Special markings.
Faced with the impossibility of operating the devices at temperatures lower than 35 ºC,
the need is established to provide high temperature warnings in the operation and
maintenance instructions, and on the devices themselves, accompanied by a legend (the
client will mark it if they deem it appropriate).
Similarly, the electrocution risk will be indicated with a warning sign, this indication
will be in the operation and maintenance instructions and not in the actual unit, as access to
voltage areas (terminal box) is protected by an IP 65 cover.
The existing risk of trapping will be pointed out in the operation and maintenance
instructions, indicating the risk area (the thrustor’s shank and the brake shoes).
As for the risks derived from the products necessary for the manufacture and testing of
the units, in addition to the personal protection equipment necessary to carry out the work,
the following series of rules are established:
To minimise the risk of falls to different levels, the ladders must be inspected before
carrying out any work, rejecting those that are not in adequate conditions and providing
training and specific information to the workers.
CAUTION: High temperature. Do not touch.

NDT-NFT-NAT ELECTROHYDRAULIC BRAKES
Instructions for assembly, adjustment and maintenance
T.D.S.: BC.TDS.00015I
Rev.01: January 2012.
www.antecsa.com Page. 9-48
To avoid the falling of materials during manipulation, adequate information will be
provided to staff on the correct manipulation of loads. Tools with a comfortable grip must be
used and they must be kept clean and in good condition. CE marked safety footwear will
also be used to minimise injuries in the event of materials falling on lower extremities.
Gloves with the CE marking will be used to increase adherence and reduce the risk of
dropping tools.
To avoid the risk of blows and cuts caused by objects, portable or manual tools, or
projections of solid or liquid particles, or the risk of trapping, safety gloves will be used to
increase adherence (their use during drilling operations or others with a possible risk of
trapping/tangling is not prudent), and safety footwear, which will have a reinforced toecap, a
rubber sole with a well-marked pattern and without fittings, to avoid slipping and electrical
contacts. Safety goggles will also be used whenever there is work where solid or liquid
particles could be projected. Training and information will be provided to workers
concerning the correct use of the tools. The machines must only be operated by experienced
operators that have perfect knowledge of the work to be carried out, the characteristics of the
equipment used, the risks entailed and the ways to prevent them.
For the use of pneumatic tools: For the operation of pneumatic tools: always purge the
air conduits and verify the state of the flexible tubes and the connection hoses. A moving
machine will not be manipulated without having checked its total safety, including the
protection of moving parts. Never use hands or feet to slow down the machine.
To avoid the risk of electrocution, before using a device or electrical installation make
sure it is in a perfect state. To use a device or electrical installation, only move the control
devices planned for this purpose by the builder or designer. In the event of damage or
accident, cut off the electrical supply as a first measure. Any anomaly observed in the
electrical installations must be immediately communicated to the electrical service.
The risk of contact with hazardous substances and chemical products will be avoided by
using appropriate protection gloves for chemical risks during their manipulation. The safety
data sheets of all chemical products will be requested from suppliers. The instructions
contained in the Safety Data Sheets of the products will be followed regarding the hazards,
precautions, fires, accidents, intoxication etc. Chemical products will be kept in the original
container. In the event of transferring to a container with different labelling. Training and
information will be provided to workers.

NDT-NFT-NAT ELECTROHYDRAULIC BRAKES
Instructions for assembly, adjustment and maintenance
T.D.S.: BC.TDS.00015I
Rev.01: January 2012.
www.antecsa.com Page. 10-48
To reduce the risks of physical fatigue caused by inadequate postures and back
disorders, raising arms above shoulder level will be avoided. Tasks that involve different
groups of muscles will be alternated. Maintaining the same posture during extended periods
of time will also be avoided. If possible the standing-seated posture will be allowed.
Training and information will be provided for the correct handling of loads (straight back,
bent knees, etc.).
Recommendations are included to protect the back when manually handling loads.
Whenever possible, to move or transport loads the auxiliary means available will be used.
Tasks that require handling very heavy loads will be carried out with the aid of another
worker. There will be periodic rests when these activities are lengthy or staff rotation among
those who carry out these tasks. Back protection belts will be used at the moment when this
activity will be carried out and information concerning its use will be provided.
The risks created by physical comfort agents such as lighting will be avoided in the
event of requests by the workers, if they consider the lighting to be poor, by increasing the
number of lamps of their location.
To avoid the risks created by chemical agents, the indications of the installation
manufacturer and the chemical product suppliers will be followed when handling them. With
the aim of assessing the risk, it would be necessary to carry out measurements and see the
need for localised suction. Protective breathing equipment will be used that offers protection
against organic vapours. The protection equipment must have the corresponding EC marking.
Training and information will be provided concerning the correct use and maintenance of the
breathing protection equipment. Containers with lids will also be provided to workers to
collect the waste impregnated with residues and thus reduce the emission of vapours.
Recipients or containers must not be left open after use.
Physical agents as well as the noise level shall be avoided at this work position as
required by R.D. 1316/1989, depending on the levels that could affect the workers. WORK
POSITION WITH LEVELS GREATER THAN 90 dB. It will be obligatory to provide each
worker with adequate information and training regarding the assessment of their exposure to
noise and the potential risks to their hearing, in addition to the preventive measures adopted,
the use of hearing protection and information on the results of the medical examination of
their hearing. Workers exposed to these levels must undergo periodic medical checkups, at
least once per year, and all workers must use hearing protection. The risk areas must be
indicated and access to them limited, in addition to developing a program of technical
measures destined to reducing such effects.