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INDUSTRIAL BRAKING SOLUTIONS
®
Custom Fluidpower’s industrial brakes reputation has been forged through many years of experience in providing industrial braking solutions to the resource sector, along with the desire to innovate and achieve.
Custom Fluidpower is a wholly Australian owned company, offering a combination of hydraulic, pneumatic and lubrication products and services in the agricultural, aerospace, exploration, industrial, marine, mobile, mining and material handling industries.
With branches Australia wide in Brisbane, Emerald, Mackay, Melbourne, Newcastle, Naval Base, and Perth, we can offer fast and reliable service when you need it.
We understand that there is a great variety in applications for braking systems and we are able to provide quality, innovative and cost effective solutions for most requirements.
PRODUCT RANGE
Product Range
HydraulicPower Units
Custom Safe Brakes manufactures hydraulic power units to operate hydraulically released, fail-safe, spring applied brake calipers.
Fail-SafeBrake Calipers
Custom Safe Brakes delivers hydraulically released fail-safe, spring applied brake calipers.
Electronic Brake Torque Control
Custom Safe Brakes have developed the EBTC system which monitors and controls the entire braking system over time regardless of any variation in braking torque.
Storm Brakes
Custom Fluidpower is the exclusive Australian distributor of the Hillmar range of storm brakes including rail clamps, rail brakes, thrusters and thruster disc brakes.
Applications
APPLICATIONSCustom Fluidpower is able to provide industrial braking solutions over a range of applications including wind turbines, mining applications, crane industry, marine and offshore industry.
Custom Safe Brakes is the specialised brakes division of Custom Fluidpower Pty Ltd.
The Custom Safe Brake brand has been developed after a lengthy and in-depth period of research and development.
The CSB series’ unique design means the brake focuses on safety by removing the risk of injury while undertaking pad change and regular maintenance.
The CSB is designed in Australia for tough mining conditions and is suitable for abrasive and corrosive environments.
We are able to provide you with new completely engineered brake systems, as well as retrofitting to existing installed caliper systems which will improve overall safety and braking efficiency.
CUSTOMSAFE BRAKES
Custom Safe Brakes
Custom Safe Brakes
Brake Caliper
Safety Features
Mechanical safety lockoutSafety package upgrade kits for existing calipersVisual pad wear indicatorOrganic non-asbestos brake pads or sintered metal padsFail-safe operationOn/Off and pad wear proximity switches
Standard Durability Features
Stainless steel pistonsStainless steel adjusting screw and pad retainersMarine/Corrosive environment proofLower operating pressureMoving parts minimisedMade rugged for Australian mining conditions
Hydraulic Power Unit
• Proportionalstoppingcapability• Custom designed and Australian built APU75 and APU220 power packs with a range of options including proportional braking
OtherBrakingSystemBenefits
•DesignedandmanufacturedinAustralia•3micronpressurefilterpreventsvalvecontamination• Customised solutions meeting your demands• Units available ex stock• Sun Hydraulics cartridge valve technology
PRODUCTDEVELOPMENT & TESTING
Product Development & Testing
The development of the CSB series of brake calipers has been about providing a technical solution that meets increased issues of safety, yet at the same time provides for higher levels of reliability and brake function for today’s increased demands relating to controlled braking applications.
The Custom Safe Brake has been developed in Australia by a team of technical and skilled individuals using the latest in engineering technology. The CSB Series Brakes are put through a rigorous testing process on our test rig facilities in our product development centre to ensure high performance and quality.
The CSB brake caliper will become the preferred option for many end users because of its simplicity of design, availability of replacement calipers, and localised spare parts and service capabilities across Australia.
ADVANTAGESOF DISC BRAKES
Reduced maintenance / ease of installation• Custom Fluidpower’s CSB Series brake • calipers have only a few moving parts whereas drum brakes have manyDrum brakes have many joints and links - • they wear down easily and are very sensitive towards corrosive conditionsThe reaction time of the drum brakes is very • long (1 sec.)The disc brake is less bulky and weighs less • compared to the drum type - usually half the size and weightBecause of its lower disc inertia, the braking • torque can be less with a disc brake - or the braking time can be shorter with the same forceThe drum brake has only one surface to • dissipate the energy - the disc has two surfaces
A brake actuator can operate more than one • brake caliper - each drum brake needs its own thrusterThe drum brake cannot be opened with a • remote signal in the case of power cut - the CSB brake will often be supplied with a hand pump for this purpose, or we can supply a hydraulic accumulator circuit to be operated by a battery back-upDrum brakes can only perform on/off functions • - CSB hydraulic disc brakes can be supplied with hydraulic controlling such as fast response, quick release, soft braking etc.Maintenance of drum brakes is difficult and • takes a long timeThe pads must be ”re-lined” - drilled out and • heated up
Drum Brakes CSB Brakes
Reaction time is more than 1 sec. Reaction time is only 0.05-0.1 sec.
Many moving parts in a drum brake - reduced life time
Only the piston moves in a CSB disc brake
Loss of braking force due to pad wear is very high with any drum brake
Loss of braking force due to pad wear is minimal, adjustment is fast and simple
Drum brakes need self-adjustment Pad wear indicators an option
Advantages Of Disc Brakes
Drum Brake and CSB Brake Comparison Table
Advantages of Disc Brakes Over Thruster/Drum Brakes
CSB 200 SERIES
CSB 200 Series
Standard Features
▪ Designed in Australia for tough mining conditions▪ Mechanical safety lockout▪ Lower operating pressure▪ Minimum moving parts▪ Stainless steel adjusting screw and pad retainers▪ Stainless steel pistons▪ Cartridge style spring pack▪ Safety package upgrade kit for existing calipers▪ Visual pad wear indicator▪ On / Off and pad wear proximity switches on both caliper halves
▪ Organic non-asbestos brake pads and sintered metal brake pads▪ Brake suitable for marine and corrosive environments▪ Custom designed APU75 power pack to operate brake - available with various options
The CSB 200 is a spring applied and hydraulically released fail-safe disc brake with a clamping force up to 12 000 N.
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Brak
ing
Torq
ue N
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Brake Caliper Selection Chart
200
400
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800
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CSB 200 Series
CSB 300 Series
CSB 300 SERIESStandard Features
▪ Designed In Australia for tough mining conditions▪ Mechanical safety lockout▪ Lower operating pressure▪ Minimum moving parts▪ Stainless steel adjusting screw and pad retainers▪ Chromed stainless steel pistons▪ Long life spring pack▪ On / Off and pad wear proximity switches on both caliper halves
▪ Organic non-asbestos or sintered metal brake pads▪ Brake suitable for marine and corrosive environments▪ Custom designed power pack to operate the brake - available with various options
The CSB 300 is a spring applied and hydraulically released fail-safe disc brake with a clamping force up to 80KN.
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CSB 300 Series
? + DPad Wear Indicators
Minimum Disc 800
Maximum Coupling 412
Pressure Port
Drain Port
Mounting Bracket
278)130
DC
Y40
9.8
230
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259.
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461.
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F:/Data/Customers/Custom Brakes/FILE LOCATION:
-DATE:
-DATE:Barry Whitaker
-
DATE:
10 Aitken Way Kewdale WA 6105Telephone: (08) 9441 3200
Fax: (08) 9441 3299
This drwaing or any information ordescriptive matter set out heron is
the confidential and sole property ofCUSTOM FLUIDPOWER PTY LTD
and must not be disclosed, loaned,copied or used for manufacturing,tendering or for anyother purpose
without their written permission.
Andrew Cotterell
Spring Applied Brake
0
CSB3000
CSB3000-300008-08-2007
WEIGHT:
A3SHEET 2 OF 4
SCALE: 1:5
DWG NO:
TITLE:
REVISION:DO NOT SCALE DRAWINGMATERIAL: APPROVED:
CHECKED:
DRAWN:
Custom Brakes Australia
PROJECT NO: Project Number
Pad Retainer
Pad RetractionSpring Pad Adjusting Screw
55
490
140
200
31
(20) DDisc Width
~PRELIMINARY~ Drawing Subject To Change
Disc Centre Distance ( 800 Disc Shown)
DCX = (Disc Radius x 0.866) - 68.4DCY = (Disc Radius x 0.500) + 209.8
09-08-2007
CSB 3000 Series
CSB 3000 SERIESStandard Features
▪ Designed in Australia for tough mining conditions▪ Mechanical safety lockout▪ Lower operating pressure▪ Minimum moving parts▪ Stainless steel adjusting screw and pad retainers▪ Stainless steel pistons▪ Cartridge style spring pack▪ On / Off and pad wear proximity switches on both caliper halves
▪ Organic non-asbestos or sintered metal brake pads▪ Brake suitable for marine and corrosive environments▪ Custom designed power pack to operate the brake - available with various options
The CSB 3000 is a spring applied and hydraulically released fail-safe disc brake with a clamping force up to 120KN.
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ue N
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Brake Caliper Selection Chart
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CSB 3000 Series
Common Features
COMMON FEATURES
Common Features
200 Series 300 Series 3000 Series
Weight excl. bracket Kg 21 68 130
Brake pad width (mm) 70 130 200
Area brake pad organic cm² 80 290 596
Area brake pad sintered metal cm² 54.5 200 360
Max wear of pad half mm 8 10 10
Pressure connection ports BSPP 2x1/8" 2x1/4" 2x1/4"
Drain connection ports BSPP 1x1/8" 2x1/8" 2x1/4"
Min pipe size (mm, ID) 8 8 8
Max operating pressure (bar) 230 230 230
Temperature range °C -20 to 70 -20 to 70 -20 to 70
Disc thickness (mm) (standard - other options avail.) 12 to 40 20 to 50 20 to 50
Min. disc diam. (mm) 300 500 800
Max outer coupling diameter (mm) (disc diam less) 180 300 412
ELECTRONIC BRAKE TORQUE CONTROL
Custom Brakes have developed the EBTC system which monitors and controls the entire braking system over time regardless of any variation in braking torque.
The features are:
Independent control voltage•Battery support for closed loop electronics and •emergency stoppingMechanical torque control back-up to support •electronicsQuick change out of electronic system board•Fast adjustment of stopping time•Easy operation and setup•
Electronic Brake Torque Control
Electronic Brake Torque Control
1300 781 178 www.custom.com.au
Non Controlled
Stop
8 second Controlled
Stop
20 second Controlled
Stop 40 second Controlled
Stop
Dark Blue : Braking ForceLight Blue: VelocityGreen: Hydraulic Control Pressure
APU75POWER UNITStandard Features
APU75 Power Unit
Options
On / Off control – controlled torque application for conveyors and quick lift for control of cranes etc.• Stand alone or brake assembly integration• Valve covers to protect and offer tamper resistance• Stainless steel enclosures with optional wiring and rain covers• Remote customer specified pressure switches• Larger volume tanks• Integral hand pump•
Modular System - flexible design options allowing for easy upgrade, size selection of pump, motor, reservoir and operating controls to suit your braking needs
Compact Size - increases your mounting location options and reduces weight
Comprehensive Manuals - with every unit in hard and electronic copy making set up and trouble shooting easy with all components simply marked in relation to the power unit
Pilot Operated Pressure Relief and Pressure Compensated Flow Control Valves - easy to set up without expensive equipment or specialist personnel
TENV Motor - keeps dust, dirt and water out and helps extend motor bearing life
Fitted with Sun Cartridge Valves - quality and reliability that comes with the best cartridge valve in the world
Aluminium Manifold - hard anodized, 2.6 litre tank, stainless steel 316 for years of corrosion resistant life
3µm Pressure Filter and 5µm Breather - providing a clean reliable system
Submerged Robust Gear Pump -with tang drive, simple to service
Two Test Points - easy testing and trouble shooting
Helicoil Mounting Threads - mounting problems are elminated
Australian Made - providing you with local support and readily available parts at economical prices
Dimensions (Standard unit) Width 329 mm Depth 300 mm Height 362 mm
Weight (Standard unit) 23 kg
Control options On / Off operation Control application, single counter pressure Quick lift, accumulator boost, extra DCV’s Control application, per 02 plus extra cct to full torque Control application per 02, plus full redundancy On / Off operation per 01, plus full redundancy Control application per 02, plus delay to counter pressure Option 05 plus monitor DCV via external checks & P/Switch Option 09 proportional pressure control - closed loop braking
Electric motor Installed power 0.75 kW Frame size T-DA80 Std supply *415VAC/3ph/50Hz Current - full load 1.9 Amp IP rating - standard 56 Material SG Iron
Control voltages 12VDC, 24VDC, 48VDC, 110VAC, 240VAC
Output capacity Output standard 1.26 L/min (nom) Option 2 -1.68 L/min (nom)
Pressure rating Bar 210
Pressure switch Standard - single contact type Voltage rating VAC10-250 VAC Current rating 5 Amp Optional - dual digital Voltage rating VDC 24 or 48 Current rating 250 m Amp
Tank size Standard 3.0 L Optional 5.0L Optional 10L
Oilfilter Standard - 3 um
Airfilter Standard - 5 um screw / spin on Optional - 3um spin on Optional - expansion chamber (sealed system)
Hand pump Available with larger 5.0 L tank
Omega kits Mounting power unit to caliper, pre-piped
APU75 Power Unit
APU220POWER UNIT
APU220 Power Unit
Standard Features
Designed and Built in Australia - for tough mining conditions
Compact Modulated Design – increases the mounting location options and reduces weight
Purpose Built - to compliment CSB range of Fail Safe Disc Calipers
TENV Electric Motor - Keeps the dust, dirt and water out and helps extend motor bearing life
SUN Cartridge Valves - quality and reliability that comes with the best cartridge in the world
Stainless Steel Tank – for years of corrosion resistant life
10micronfilter - providing a clean and reliable system
Ductile Iron Manifolds – offering compact circuitry and strength
Submerged Robust Gear Pump – simple to service with tang drive
Test Points – for easy testing and troubleshooting
Helicoil Mounting Threads – mounting problems are eliminated
Submerged Robust Gear Pump -with tang drive, simple to service
Two Test Points - easy testing and trouble shooting
Helicoil Mounting Threads - mounting problems are elminated
Australian Made - providing you with local support and readily available parts at economical prices
Options
On / Off control – controlled torque application for conveyors and quick lift for control of cranes etc.• Stand alone or brake assembly integration• Valve covers to protect and offer tamper resistance• Stainless steel enclosures with optional wiring and rain covers• Remote customer specified pressure switches• Larger volume tanks• Integral hand pump•
Approximate Dimensions (Standard unit)
25L 50L
Width 670 850
Depth 400 400
Height 700 750
APU220 Power Unit
Approximate Weight (Standard unit dry) 130 kg
Control options On / Off operation Control application, single counter pressure Quick lift, accumulator boost Control application, per 02 plus extra counter pressure Control application per 02, plus full redundancy On / Off operation per 01, plus full redundancy Control application per 02, plus redundancy and extra counter pressure Option 05 plus monitor DCV via external checks & P/Switch Option 09 proportional pressure control - closed loop braking
Electric motor Installed power 2.2 kW Frame size 100LA Std supply *415VAC/3ph/50Hz Current - full load 4.5 Amp IP rating - standard 55 Material SG Iron
Control voltages 12VDC, 24VDC, 48VDC, 110VDC, 110VAC
Output capacity Output standard 3.0 L/min (nom) Output optional -5.0 L/min (nom)
Pressure rating Bar 210
Pressure switch Standard - single contact type Voltage rating VAC10-250 VAC Current rating 5 Amp Optional - dual digital Voltage rating VDC 24 or 48 Current rating 250 m Amp
Tank size Standard 25 L Optional 50 L
Oilfilter Standard - 10 um
Airfilter Standard - 5 um screw / spin on Optional - 3um spin on Optional - expansion chamber (sealed system)
Hand pump Available with larger 6.0 L tank
RETROFITUpgrade Your Existing Brake Calipers
Do you want the features of the Custom Safe Brake series for calipers already installed at your plant?
Custom Fluidpower has made available a “kit” whereby you can convert your same series brake calipers of another similar brand into a Custom Safe Brake with easily adjustable on/off and pad wear switches.
This kit is supplied complete in all respects and, if necessary, we can also supply the spring packs.
The kit comes complete with adjusting spanners.
Cablelengthsfortheindicatingswitchescanbesuppliedtosuityourspecificrequirements.
Talk to us today about how your braking systems can be upgraded to maximise safety and maintenance.
Retrofit
TOOLS FOR REPAIRS & MAINTENANCE
Workshop Test Bench (for APU37 and APU75 only) Part No. 800-8038-001
Consisting of: 1 only test bench with built in electrical stop start and visual indicators to • operate a brake power unit in a workshop environment and complete full testing and adjustments required. Customer to supply disconnect plug
Accumulator Charging Kit (for all power units) Part No. 800-8037-001
Consisting of: 1 only accumulator charging kit and all accessories required to charge • power unit accumulators1 only pressure reducing valve and bottle adaptor•
On-Site Power Unit Service Tool Kit (for all power units and calipers) Part No. 800-8040-001
Consisting of: 1 only large lockable site tool box• 1 carry bag, and set of tools required to carry out adjustments and • replacement of cartridges1 hand pump, complete with hose and fittings to carry out, motor on/off, • and brake on/off, pressure switch setting testsCaliper spring pressure test• 1 only dial indicator and magnetic base• 2 only pressure gauges able to fit on test points• 1 only manual solenoid override• 1 funnel and 3 litre measuring unit• Hand tools for basic removal and servicing brake power units and calipers•
Please contact us for pricing on the above.
Part No. 490-1279-002BSFI 200 series calipers 1 only - spanner
Part No. 490-0109-803BSFI 300 series calipers 1 only - spanner
Part No. 800-8018-001BSFI 3000 series calipers 1 only - spanner long handle
Tools For Repairs & Maintenance
Special tools and equipment required for servicing and maintaining CSB and similar series brake calipers, and APU37, APU75 and APU220 power units.
Brake Pad Adjusting Spanners
PLANT OPERATION& MAINTENANCE
Plant Operation & Maintenance
How The Custom Safe Brake Disc Caliper Can Enhance Your Plant’s Operation And Maintenance
The Custom Safe Brake has built-in enhanced features that introduce distinct advantages over similar products so that:
Brake pads and maintenance can be undertaken safely1. Caliperscanbefittedwithbothon/offandpadwearswitches2.
Want Total Brake Caliper Operational & Maintenance Information?
The designs of disc brake calipers from some suppliers other than Custom Fluidpower, inthe200seriesconfiguration,donothavethefacilitytoinstallbothon/offandpadwear indicating switches.
Custom Fluidpower have recognised this and in the design of the CSB 200 series calipers, we have a feature which allows you to monitor whether the caliper is in its open or closed position (brake on or off) AND provide indication for brake pad wear.
We have installed simple LED proximity switches that allow for ease of installation and adjustment. Switches are installed on both sides of the caliper, and if there are dimensional constraints, this can be accommodated, including the use of 90 degree connections.
Maintain Brakes In A Safe Manner
Currently, brake calipers as supplied by some manufacturers other than Custom Fluidpower do not have any facilities that allow for safe maintenance – the safe removal of brake pads – to be undertaken. To replace the brake pads in a caliper disc brake, the caliper has to be hydraulically released from the brake disc. This therefore requires that, in order for the brake to remain in the “open state”, hydraulic pressure must be maintained.
Under these circumstances, there is a “what-if” scenario if there was an interruption to the hydraulic pressure, and the consequences that would pose whilst maintenance of the caliper is being undertaken.
In the Custom Safe Brake design, we have introduced the capability which allows the caliper to be mechanically locked in the released (open) position and allows the maintainer to interrupt the hydraulic pressure without fear of the brake caliper closing.
This is part of the standard design of the CSB range of caliper disc brakes available from Custom Fluidpower.
The process to achieve this is as simple as:
Apply hydraulic pressure (either via the hydraulic • power unit or hand pump) to open (release) the brakeRemove the brass cap item 11, on both • sides of the caliperFit locking nut item 10. This can be • located easily as it is stowed on the CSB version of the brake caliper bracket. Tighten to about 20NmRelease the hydraulic pressure. Tag-out the • hydraulic power unit or, if using a hand pump, disconnect the hand pump hose from the caliper. The caliper will remain in “locked open” positionUnderta• ke the maintenance, such as replacing brake pads. With the brake caliper in its locked open configuration, there is no way a person can be injured when they are changing brake padsAfter the pads have been replaced, or other • maintenance completed, remove the tag-out, apply the required hydraulic pressure, either via a hand pump or the supplied hydraulic power unitLoosen and remove the locknut item 10, and • place on its stowage position on the bracket. Fit brass cap item 11Release the hydraulic pressure. The brake • and the hydraulic power unit can now be returned to normal service
Lock Nut (10)
Brass Cap (11)
Plant Operation & Maintenance
CUSTOMFLUIDPOWER PROJECTS
Custom Fluidpower Projects
2009
Project: Anderson Point | Customer: David Brown | End User: Anderson Point 2 x CSB3120-40D-103, 1 x APU75-02-24-20, 4 x CSB204-30D-102, 2 x APU75-02-24-20
Project: Mangoola Train Loadout | Customer: Downer EDI | End User: Mangoola Coal 2 x CSB3100-40D-102, 1 x APU75-02-24-20
Project: Worsley Biomass | Customer: FALK Australia | End User: Worsley 1 x CSB208-30D-100, 1 x APU75-02-22-120, 2 x CSB204-30D-100, 2 x APU75-02-22-120
Project: Marradong & Saddleback | Customer: Siemens | End User: Worsley5 x CSB202-30D-102, 5 x APU75-02-22-42, 1 x CSB204-30D-102, 1 x APU75-02-22-421 x CSB206-30D-102, 1 x APU75-02-22-42, 1 x CSB315-180D-102, 1 x APU75-09-22-42
Project: Worsley Reclaimer Drives | Customer: FALK Australia | End User: Worsley 1 x CSB208-30D-100, 2 x APU75-02-22-73
Project: Belt Tensioners | Customer: Prog Eng Tech | End User: BHPB Crinum6 x CSB3120-30A-102, 3 x APU75-02-24
Project: CC5 & CC6 power unit | Customer: CQPA | End User: RG Tanna Coal1 x APU220-05-24-107
2008
Project: Krupp Stacker | Customer: Siemens | End User: BHPB 2 x BSFI 206-30S-100, 2 x APU75-02-25-24
Project: BHPB MAC MC01 Conveyor | Customer: Siemens | End User: BHPB 1 x BSFI 204-30S-100, 1 x APU75-02-24-20
Project: BHPB MAC MC06 Conveyor | Customer: Siemens | End User: BHPB 1 x BSFI 200.5-30S-100, 1 x APU37-02-24-14
Project: Newman Hub Train Positioner | Customer: Brevini | End User: BHPB APU220-03-24-98
Project: RGP4 ThyssenKrupp | Customer: Siemens | End User: BHPB 2 x BSFI 206, 2 x APU75-02-24-20
Custom Fluidpower Projects
Project: RGP4 ThyssenKrupp | Customer: Siemens | End User: BHPB 4 x BSFI206, 4 x APU75-02-24-20
Project: FMG Cloudbreak CV112 | Customer: David Brown | End User: FMG 8 x BSFI327, 2 x APU220-03-24
Project: FMG Cloudbreak Upgrade | Customer: David Brown | End User: FMG 4 x CSB204-30D-100, 4 x APU75-02-24-20, 1 x CSB206-30D-100, 1 x APU75-02-24-20, 2 x CSB3120-40D-102, 1 x APU75-02-24-20
Project: Argyle Upgrade | Customer: FALK Australia | End User: Argyle Diamond MineCV1F109: 2 x CSB203-100D-102, 1 x APU75-02-24 proportional, CV1E104A 2 x CSB205-30D-102,1 x APU220-02-24 proportional, CV1E104B 2 x CSB205-30D-102, CV1E104C 2 x CSB205-30D-102, CV1E104D 2 x CSB205-30D-102, CV1E103A 2 x CSB205-30D-102, 1 x APU220-02-24 proportional,CV1E103B 2 x CSB205-30D-102, CV1E102 2 x CSB202-30D-102, 1 x APU75-02-24-20
Project: Worsley | Customer: FALK Australia | End User: Worsley 4 x CSB208-30D-100, 4 x APU75-02-22-24
Project: Carborough Downs Conveyor | Customer: Aus Con Eng | End User: VALE 6 x CSB3100, 1 x APU220S-09-24-121
Project: NCIG Stage 1 | Customer: Thiess | End User: NCIG CV08, 4 x CSB3080-40D-102, 1 x APU220S-09-24-119 CV09, 4 x CSB3080-40D-102, 1 x APU220S-09-24-119 CV21, 4 x CSB3080-40D-102, 1 x APU220S-09-24-119
Project: PWCS Upgrade | Customer: David Brown | End User: PWCS 6 x CSB3025, 6 x APU75-02-24-101
Project: DRE26 | Customer: BMA Blackwater | End User: BMA Blackwater Mine 2 x CSB3106
2007
Project: Hope Downs | Customer: Brevini | End User: Pilbara Iron9 x 200 Series Calipers, 2 x 300 Series Calipers, 11x APU37/75 Power Units
Project: FMG | Customer: David Brown | End User: Fortescue Minerals35 x 200 Series Calipers, 4 x 500 Series Calipers, 5 x 3000 Series Calipers, 42x APU75/220 Power Units
Project: FMG Train Indexer | Customer: Brevini | End User: Fortescue Minerals14 x 200 Series Calipers, 1 x APU220 Power Unit
Project: FMG Tippler | Customer: Metso Minerals | End User: Fortescue Minerals4 x 200 Series Calipers, 2 x APU220 Power Units
Custom Fluidpower Projects
2006
Project: CD4 Positioner | Customer: Brevini | End User: BHP 12 x 200 Series Calipers, 1 x APU220 Power Unit
Project: CD4 Tipper | Customer: Metso | End User: BHP 4 x 200 Series Calipers
Project: RGP3 Mine Site | Customer: Siemens | End User: BHP 27 x 200 Series Calipers, 6 x 3000 Series Calipers, 33 x APU37/75 Power Units
Project: RGP3 Port | Customer: Siemens | End User: BHP 12 x 200 Series Calipers, 3 x 300 Series Calipers, 7 x 3000 Series Calipers, 16 x APU37/75 Power Units
Project: Yandi | Customer: Brevini | End User: Pilbara Iron21 x 200 Series Calipers, 4 x 3000 Series Calipers, 19 x APU37/75 Power Units
Project: Dampier Port | Customer: Falk | End User: Pilbara Iron2 x 200 Series Calipers, 7 x 300 Series Calipers, 2 x 3000 Series Calipers, 11 x APU37/75 Power Units
Project: CD1 Positioner | Customer: Brevini | End User: BHP 15 x 200 Series Calipers, 1 x APU220 Power Unit
Project: CD4 Positioner | Customer: Brevini | End User: BHP 13 x 200 Series Calipers, 1 x APU220 Power Unit
Project: Rotary Cooler | Customer: Sumitomo | End User: QLD Nickel Yabalu 1 x 200 Series Calipers, 2 x APU37 Power Units
Project: Pulley Brake | Customer: Barclay Mowlem | End User: Curragh Coal2 x 3000 Series Calipers, 1 x APU220 Power Unit
Project: Coke Carriage | Customer: Bowen Coke | End User: Bowen Coke2 x 200 Series Calipers, 1 x APU37 Power Unit
2005
Project: RGP2 | Customer: Siemens | End User: BHP19 x 200 Series Calipers, 19 x APU37/75 Power Units
Project: BMA Hay Pt | Customer: Brevini | End User: ThyssenKrupp44 x 200 Series Calipers, 4 x 500 Series Calipers
Project: Dampier Pt | Customer: Brevini | End User: Pilbara Iron13 x 200 Series Calipers, 1 x APU 220 Power Unit
Project: Marandoo | Customer: Falk | End User: Pilbara Iron4 x 200 Series Calipers, 4 x APU37 Power Units
Project: Elevator Drive | Customer: Hansen | End User: BMA1 x 200 Series Calipers, 1 x APU75 Power Units
Project: Slew Drive | Customer: Brevini | End User: BMA3 x 200 Series Calipers
Project: Conveyor Drive | Customer: John Holland | End User: BMA1 x 3000 Series Calipers, 1 x APU220 Power Unit
Custom Fluidpower Projects
Project: Bucket Wheel | Customer: Krupp | End User: BMA2 x 500 Series Calipers
Project: Expansion | Customer: Flender | End User: Alcan Cove14 x 200 Series Calipers, 14 x APU75 Power Units
Project: Conveyor LS | Customer: Monadelphous | End User: CQPA R.G. Tanna29 x 200 Series Calipers, 29 x APU75 Power Units
Pre 2005
Project: Conveyor Drive | Customer: Hansen | End User: BMA16 x 200 Series Calipers, 16 x APU75 Power Units
Project: Conveyor Drives | Customer: BMA | End User: BMA Goonyella2 x 200 Series Calipers, 9 x 300 Series Calipers, 4 x APU220 Power Units
Project: Conveyors | Customer: Gladstone Port | End User: Gladstone Port2 x 200 Series Calipers, 2 x APU220 Power Units
Project: Eastern Ranges | Customer: Barclay Mowlem | End User: Pilbara Iron2 x 200 Series Calipers, 2 x 300 Series Calipers, 3 x 3000 Series Calipers, 7 x APU37/75/220 Power Units
Project: Wharf Conveyor | Customer: BMA Hay Point | End User: BMA1 x 3000 Series Calipers, 1 x APU220 Power Units
Project: Expansion | Customer: Flender | End User: BHP30 x 200 Series Calipers, 12 x 300 Series Calipers, 2 x 500 Series Calipers, 6 x 3000 Series Calipers, 48 x APU37/75 Power Units
Dragline Application Projects
Date: 2005 | Project: DRE25 & 26 Hoist | Customer: Bucyrus Blackwater 8 x 3000 Series Calipers, 1 x APU300 Power Unit
Date: 2005 | Project: DRE17 Hoist & Drag | Customer: Bucyrus Peak Downs 8 x 3000 Series Calipers, 3 x APU300 Power Units
Date: 2005 | Project: DRE40 Hoist | Customer: Bucyrus Blackwater 4 x 3000 Series Calipers, 2 x APU220 Power Units
Date: 2005 | Project: DRE39 Hoist | Customer: BMA Blackwater 4 x 3000 Series Calipers, 2 x APU220 Power Units
Date: 2004 | Project: DRE37 Swing | Customer: Bucyrus Peak Downs 12 x 300 Series Calipers, 4 x APU220 Power Units
Date: 2004 | Project: DRE22/23 Hoist | Customer: Bucyrus Saraji 8 x 3000 Series Calipers, 4 x APU220 Power Units
Date: 2002 | Project: DRE38 Hoist & Drag | Customer: Bucyrus Blackwater 10 x 3000 Series Calipers, 2 x APU300 Power Units
Date: 2002 | Project: DRE38 Swing | Customer: Bucyrus Blackwater6 x 300 Series Calipers, 1 x APU300 Power Units
HILLMARBRAKING SYSTEMSEstablished in 1979, Hillmar Industries has established itself as an international leader in the design and manufacturing of storm brakes, thrusters, thruster disc brakes, hydraulic power units, industrial disc brakes and cable reels for clients around the world.
Due to their unique engineering expertise, Hillmar can meet the highest standards for safety, quality and performance and are an ISO 9001:2000 certified company.
Hillmar produces an extensive product range including: • Industrial Disc Brakes • Hydraulic Power Units • Storm Brakes (Rail Clamps, Rail Brakes) • Thruster Disc Brakes • Thrusters • Cable Reels and Accessories
Hillmar is currently the largest storm brake company in the world, and equal third largest in both cable reels and disc brake products. Hillmar has extensive experience in designing for multiple applications.
Custom Fluidpower is your exclusive Australian distributor of Hillmar.
Hillmar Braking Systems
Design Features
A vertical and horizontal float mechanism maximises • performance by ensuring the shoes are always in correct geometry with the railGuide wheels allow the mechanism to follow the rail • deviations and still provide protection to the brake shoesA field replaceable mechanism and hydraulic cylinder • allows for total inspection and servicing without removing the clamp enclosureExternal grease fittings are provided for easy • maintenanceA spring caging fork locks the rail clamp in the open • position for easy field maintenanceA visual indicator bar is provided to make toggle • adjustment easy in the event of pad wear as well as showing the operating position of clampA flow control valve is provided to regulate clamp • setting timeSAE O-ring oil ports eliminate oil leaks• An integral hand pump is available for easy manual• releaseElectrical components are pre-wired to a centrally • located electrical junction boxField replaceable serrated brake shoes simplify • maintenance and minimise downtimeModular design and removable enclosure provides • complete open access for ease of maintenanceStainless steel accessories include enclosure cover, • hydraulic reservoir, fasteners, brackets and spring cover
RAIL CLAMPS
The horizontal and vertical float ensures consistent braking and eliminates excessive wear on your rails.
Rail Clamps
RAIL BRAKESDesign Features
Hillmar’s well-proven design utilises the weight of • the crane to ensure reliable braking forcePrecision honed hydraulic cylinder• Emergency release spacers, which are supplied • as standard on Hillmar’s rail brakes, simplify maintenanceSAE O-ring oil ports eliminate oil leaks• Solid chrome plated guide rod ensures long life• Flow control valve to regulate brake setting time• The limit• switch is externally adjustable to ensure a clear control signal and easy maintenanceNo spring pre-compression ensures safety and • simplifies maintenanceComplete disassembly and rebuild requires no • special toolsField replaceable brake shoe simplifies • maintenance and minimises down timeA cycle counter is supplied (on the Hillmar power • unit) for ease of maintenance schedulingAvailable in either static or dynamic designs•
Mounted on a sill beam, rail brakes allow the load to be placed away from the truck.
Rail Brakes
THRUSTERSDesign Features
All Hillmar thrusters meet DIN 15430 standards and • therefore interchangeability is guaranteedA sight level gauge is incorporated in the design for ease • of maintenanceA drain plug is provided so the thruster need not be • removed from the brake to change the oilReserve stroke indicator to provide an easy method of • checking the brakes adjustmentsFully sealed for use in dusty environments• All pivot points are fitted with self-lubricating bushings• Very fast response times• Limit switches are also available to indicate the thrusters • positionVery reliable, and backed by Hillmar’s outstanding • warranty policyInstallations can be either horizontal or in the vertical • positionBoth pivoting ends can be rotated on 90 degree intervals • independent of each otherThe aluminium body comes anodised for superior • corrosion protection and better heat dissipationAvailable in any voltage and/or frequency to suit your • needs. 3-phase by designThe hydraulic system comes with a double seal oil • chamber Overload condition protection•
Thruster Rail BrakeThruster Disc Brake
Thrusters
THRUSTER DISC BRAKES - M SERIESDesign Features
Actuator can be installed horizontally for industrial • vertical motor applications such as slewingSimple adjustment of the ample air gap between the • brake pads and the discSintered metal or asbtestos free pads for all • applicationsEnclosed, adjustable brake spring with torque scale• 3-phase AC thruster actuator for brake release• Self-lubricating bushings used at all pivot points• Stainless steel spindles used throughout for corrosion • protectionAll component parts designed for maximum durability• Self centering mechanism as standard• Two position manual release mechanism•
Hillmar’s M Series thruster disc brakes use a unique mechanism to ensure that the friction linings lift off equally on either side of the disc regardless of lining wear.
The twin brake levers are synchronised by a simple mechanism that ensures they move equally.
The Hillmar device is unique in that it can be easily adjusted after brake installation.
Thruster Disc Brakes - M Series
BRAKING TORQUE AT FRICTION COEFFICIENT OF µ = 0.4DISC Ø TDB-M16
ES-25TDB-M16
ES-30TDB-M23
ES-50TDB-M23
ES-80TDB-M28ES-121
TDB-M28ES-201
TDB-M28ES-301
TDB-M37ES-401
mm Nm
250 200 270280 230 310315 260 355355 300 410 935400 345 470 1085 1600450 395 540 1255 1850 2700500 445 610 1425 2100 3100560 1630 2400 3550 5750630 1870 2750 4100 6600 9700 15000710 4700 7600 11200 17400800 5400 8800 12800 20100900 14700 231001000 16500 261001250 21100 33600
Dalrymple Bay Coal TerminalSupply of Hillmar rail clamps for stackers and reclaimers
BMA Hay PointSupply of Hillmar rail clamps and rail brakes to stackers, reclaimers and shiploaders
Port Waratah Coal Services (PWCS) NewcastleSupply of Hillmar rail clamps to ThyssenKrupp for stackersSupply of Hillmar rail clamps to Sandvik for reclaimersSupply of Hillmar rail clamps for retrofit to ship loader boom shuttle
Newcastle Coal Infrastructure Group (NCIG)Supply of Hillmar rail clamps to Sandvik for combined stacker/reclaimers, and ship loader
Abbot Point Coal Terminal BowenSupply of Hillmar rail clamps to Sandvik for combined stacker/reclaimerSupply of Hillmar rail clamps to FAM for combined stackers/reclaimers
DP World Newcastle PortSupply of Hillmar rail brakes and hydraulic power units for retrofit to existing ship unloaders
Cement Australia Brisbane PortSupply of Hillmar rail clamps for retrofit to existing ship unloader
Mangoola Coal ProjectSupply of Hillmar rail clamps to Mayer International for stackers
Xstrata Coal South Africa Goedgevonden CollierySupply of Hillmar rail clamps to Mayer International for stackers
Narrabri Coal ProjectSupply of Hillmar rail clamps to Nepean Conveyor for tripper
HILLMAR PROJECTS
Hillmar Projects
SERVICEYour Preferred Service Provider For All Brake Systems
To support the industrial braking solutions we supply, Custom Fluidpower provides localised service support from our branches in Newcastle, Brisbane, Emerald, Mackay and Perth. In addition, spare parts availability is also localised to support your installation, be it at a mine site, coal or iron ore terminal, or an industry to where we have delivered complete brake solutions. We have a number of experienced service fitters who have been specifically trained in all aspects of service and trouble-shooting.
Our services include site service visits, workshop capabilities, and the overhaul/refurbishment of brakes and hydraulic power units, not only for those of our own brand, but for all brands of industrial brakes. All service is supported by detailed service reports that outline the issues investigated, and reports on the findings, complete with recommendations for the ongoing serviceability and life of the brake systems. Where brakes are workshop repaired, they undertake complete testing prior to final painting and dispatch.
Our customers are encouraged to participate in the inspections, and discuss any issues of concern with our service fitters. If our service fitters cannot for whatever reason, answer a technical issue, then they will automatically call a more senior applications engineer within Custom Fluidpower, for direction and advice. This is all part of the philosophy of our service attitude to our existing and potential customers.When requested, Custom Fluidpower also undertakes complete installation and commissioning of brakes as delivered.
Service
Typical service assignments cover:
The service of brake systems for mine winder •applications, including that of the hydraulic power units.The service of brake systems as delivered for •applications on draglines for hoist, swing and drag. This involves on-site and workshop servicing.The service and/or change-out of old braking •systems to that of more modern, robust and purposeful brakes (for example, replace drum brakes with disc caliper brakes)Pad change-out, spring pack replacement for caliper disc brakes as installed on •high speed and low speed braking applications
Custom Fluidpower has the only brake test facility in Australia. This allows Custom Fluidpower a distinct advantage of being able to undertake product testing and development.
Please do not hesitate to discuss your service requirements with us.
TRAININGYour Preferred Training Provider For All Brake Systems
To support our range of braking products, Custom Fluidpower provides localised training support from our branches in Newcastle, Brisbane, Emerald, Mackay and Perth.
Training is conducted in a classroom environment, be it at your facility, or ours. We cover:
The correct operation and maintenance of caliper disc brakes, particularly related to the correct • change-out of brake pads and adjustment of air gapsThe correct operation and maintenance of hydraulic power units, how to set relief valves, correct oils • to be used, any field adjustments that may need to be under takenReview of all maintenance and operation manuals as delivered for the supplied brake systems• The correct procedures for ordering replacement parts•
If you would like to receive a proposal for training for your particular site, then please discuss your requirements with us. Training packages can be tailored to suit your specific needs.
Training
Custom Fluidpower is one of the largest hydraulics, pneumatics and electronics solutions providers in Australia and is known for our innovation in using hydraulics, pneumatics and electronics.
Our organisation is proudly customer focused, which means our emphasis is not just on components and parts, it’s on delivering total engineered solutions.
Custom Fluidpower’s services include:Total circuit design and supply• Power unit manufacture • Turn key projects• Hydraulic manifold design and manufacture• Field service and fault diagnosis • Workshop repairs and component rejuvenation• Site installation and commissioning• Hydraulic and pneumatic component sales and technical support• On site component life and performance monitoring• In-house test facilities• Fluid power training•
Since its formation in 2000, Custom Fluidpower has enjoyed growth year to year, including additional branches throughout Australia and increased manifold manufacturing facilities.
Custom Fluidpower is wholly Australian owned and operated. The company is staffed with over 180 varied skilled personnel covering design, engineering, business development, product specialists, technicians, trainers and management. Together they form a team that can provide extensive fluid power services to industry.
Through the strength of our people we aim to exceed industry expectations by delivering superior solutions and demonstrating excellence in customer service.
We are committed to be consistently innovative with our products and services and to provide safe high quality fluid power and industrial systems.
OTHERCUSTOM FLUIDPOWER SERVICES
Other Custom Fluidpower Services
AdelaidePh 61 03 9794 5088Fax 61 03 9794 5388Email [email protected]
Brisbane36 Huntington PlaceBanyo QLD 4014Po Box 1143Eagle Farm QLD 4009Ph 61 07 3307 8200Fax 61 07 3267 3777Email [email protected]
EmeraldLot 4 Industrial DrivePo Box 1512Emerald QLD 4720Ph 61 07 4987 8400Fax 61 07 4987 5388Email [email protected]
MackayShed 1/26 Len Shield StPaget QLD 4740Po Box 10097Mt Pleasant QLD 4740Ph 61 07 4963 7111Fax 61 07 4952 5026Email [email protected]
Melbourne200 Alexandra PdeFitzroy VIC 3065Ph 61 03 9794 5088Fax 61 03 9794 5388Email [email protected]
Naval Base1216 Rockingham Rd(Cnr Hope Valley Rd)Naval Base WA 6165Ph 61 08 9236 1511Fax 61 08 9410 0922Email [email protected]
Newcastle14-16 Gross StPo Box 230Carrington NSW 2294Ph 61 02 4953 5777Fax 61 02 4954 4122Email [email protected] Perth10 Aitken Way Kewdale WA 6105Po Box 434Welshpool DC WA 6986Ph 61 08 9441 3200Fax 61 08 9441 3299Email [email protected]
Custom Fluidpower Pty Ltd | ABN 61 090 926 659
www.custom.com.au
Carrington14-16 Gross StPo Box 230Carrington NSW 2294Ph 61 02 4918 6000Fax 61 02 4918 6066Email [email protected] www.ftint.com.au
FluidTech International Pty Ltd | ABN 98 128 446 382
Singleton12 Magpie StPo Box 2001Singleton NSW 2330Ph 61 02 6571 2748Fax 61 02 6571 2738Email [email protected] www.ftint.com.auA member of the Custom Fluidpower Group
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