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WITTUR WSG-S2.4 Series, Operating Instructions Manual

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WITTUR WSG-S2.4 Series Operating Instructions Manual Download Page 83

Maintenance and repair

INTORQ | BA 14.0196 | 04/2016

45

7.3.2

Check the air gap

1. Stop the motor and control system!
2. Measure the air gap “s

L

” near the fixing screws between the armature plate and the stator using a feeler 

gauge.

3. Compare the measured air gap with the maximum permitted air gap “s

Lmax

” (

 16).

4. If required, replace both rotors completely. 

7.3.3

Replacing the rotor

1. Switch off voltage!
2. Disconnect the connection cable.
3. Loosen the screws evenly and remove them completely.
4. Remove the complete stator from the bearing shield. Pay attention to the connection cable.
5. Pull the complete rotor from the hub.
6. Check the gear teeth of the hub.
7. Replace the hub if it is worn.
8. Check the friction surface on the bearing shield. In case of strong scoring at the flange, replace the 

flange. In case of strong scoring on the bearing shield, rework the friction surface.

9. Measure the rotor thickness (new rotor) and head height of the sleeve bolts with a caliper gauge.
10. Calculate the distance between the stator and the armature plate as follows:

Distance = rotor thi s

LN - head height

(“s

LN

”  

16)

11. Unscrew the sleeve bolts evenly until the calculated distance between the stator and armature plate is 

reached.

12. Install and adjust the new complete rotor and stator (

 23).

13. Reconnect the connection cable.

   DANGER

Danger: rotating parts! 

The motor must not run during the check.

   DANGER

Danger: rotating parts! 

The brake must be free of residual torque.

Summary of Contents for WSG-S2.4 Series

Page 1: ...Version 0 10 Page 1 Subject to changes without notice Subject to changes without notice EN Translation of the Original Operating Instructions EN Gearless Lift Machines WSG S2 4 Reprinting translation or reproduction in any form whether in part or in full requires the prior written permission of WITTUR Holding GmbH Wittur Holding GmbH reserves the right to make changes in the information and pictur...

Page 2: ...notice EN These operating instructions are applicable to lift machines WSG S2 4 WITTUR Electric Drives GmbH reserves the right to correct or change the contents of this manual and these product details without prior notice We expressly reserve the right to make technical changes which improve the lift machines or their safety standards without prior notice No liability can be accepted for damage i...

Page 3: ...4 2 2 Motor connection Winding protection Fan 10 4 2 3 Speed Position measuring system 12 4 2 4 Brake 13 5 Commissioning 16 6 Operation and maintenance 17 6 1 General 17 6 2 Maintenance intervals 17 6 3 Regreasing the bearings 18 6 4 Replacing the traction sheave 18 6 5 Filter mats 18 6 6 Emergency evacuation 19 6 7 Testing the brake system to EN 81 20 6 8 Replacing the measuring system 21 6 9 Tro...

Page 4: ...ifts They may only be used for their intended purpose and with all safety devices in proper working order They may only be operated under the conditions described in this manual and with due regard to their perfor mance limits 1 3 Scope of delivery The WSG S2 lift machines are customised to meet individual requirements The exact scope of delivery can be found in the accompanying documentation 1 4 ...

Page 5: ...brake after installing the machine Repairs may only be carried out by the manufacturer or an authorised repair agency Unauthorised opening and tampering may result in injuries to persons and property The machines are not designed for direct connection to the three phase system but are to be operated via an electronic frequency inverter Direct connection to the mains may damage the motor beyond rep...

Page 6: ...e synchronous motor the traction sheave and the typetested safety brake which can be used to prevent uncontrolled upward movement of the car The nameplate of the lift machine is on the motor frame 3 Product overview Type code of lift machine Rated voltage Rated speed Rated torque Serial no Rated frequency Weight Drive Code Item Part WSG S2 4 1 Bolts 3x DIN 933 M12x35 8 8 2 Lock washers 3x NL 12 DI...

Page 7: ...Avoid excessive storage periods recommendation max one year After prolonged storage 3 months rotate the motor in both directions at a low speed 20 min 1 to allow the grease to distribute evenly in the bearings Measure the insulation resistance before initial operation of the machine If the value has dropped below 1k per volt of rated voltage the winding needs to be dried insulation meter voltage 1...

Page 8: ...before installing the lift machine Warning Cover the machine and especially the brakes when doing any machining or dust producing work in the shaft or machine room When using the machine in a shaft please take into account the patent situation The measuring system is only accessible from the rear side Therefore leave enough space between the wall and the rear side of the machine or ensure that the...

Page 9: ...ystem is properly isolated Before making any electrical connections check that the connecting cables are suitable for their specific application and for the relevant voltages and currents sufficiently dimensioned connecting cables torsion strain and shear relief as well as anti kink protection are provided the protective conductor is connected to the earthing terminal there are no foreign bodies d...

Page 10: ...h as PTC resistor detectors and thermostatic switches must be evaluated in the control system or the frequency inverter to protect the motor from overheating The separately driven fan must be properly connected and operated If required it can be switched in depen dence of the temperature by means of thermal switch S4 relay must be used Terminal strip for motor WAGO 2016 Cable cross section 0 5 16 ...

Page 11: ...o exceed 25 V DC To achieve the maximum precision the measurement voltage per PTC thermistor must not exceed 2 5 V DC Cable cross section required The currents specified under the machine data refer to duty type S3 40 This must be taken into account when selecting the cable cross section required The continuous r m s value required for the selected cable is approximated from I r m s cable I N moto...

Page 12: ...ntacts of flanged con nector socket exterior 16 A 17 DATA 4 2 3 Speed Position measuring system The basic version of the lift machines is equipped with an sendix 8 5873 SineCosine encoder from Kübler GmbH The encoder is connected by cable length 10m with open wire ends no plug Alternatively the machines can be equipped with ECN 413 or ERN 487 encoders from Heidenhain GmbH We can also provide other...

Page 13: ...ing must also be performed from the AC side at the same time Wiring with a varistor as shown in the circuitry suggestion on page 15 Note on the use of DC AC side switching AC side switching is recommended for normal operation since the lift machine is then decelerated in a con trolled manner to zero speed and the switching noise of the brake is negligible When braking in the event of a breakdown e...

Page 14: ... with gold contacts Both the n c and the n o contact connections are available Connection of the brakes The brake solenoids the brake control units and the monitoring contacts are connected to the mains in the brake terminal box Warning The microswitches must be evaluated separately for each partial brake to ensure compliance with the requirements of the type examination 2nd partial brake 1st part...

Page 15: ...gestion for brake control WSG S2 4 Circuitry suggestion for brake control DC side switching and separate control of the partial brakes AC side switching and separate control of the partial brakes K1 and K2 must swith simultaneously Brake terminal box 2 x Overexcitation rectifier to the 2 nd partial brake to the 2 nd partial brake Brake magnet Brake magnet to control cabinet release to control cabi...

Page 16: ...Check the proper functioning of the temperature monitoring devices e g by interrupting the temperature monitoring circuit Check the brake connection and the proper functioning of the brake monitoring switches Ensure that the brake operates correctly perform a brake test using one partial brake Has the measuring system been properly connected Check that the offset value indicated on the measuring s...

Page 17: ...any work on the machine or replacing parts make sure that the specified bolt screw strength class and the tightening torques are observed see table Secure the bolts screws with omnifit 100 or a similar product against accidental loosening 6 2 Maintenance intervals Dimension Tightening torque Nm Strength class 8 8 10 9 12 9 M4 2 8 4 1 4 8 M5 5 5 8 1 9 5 M6 9 6 14 16 M8 23 34 40 M10 46 67 79 M12 79 ...

Page 18: ...ts evenly Assembly Clean the traction sheave and the motor shaft Support the traction sheave by means of a hoisting gear Insert the feather key 5 into the shaft end Slide the traction sheave onto the motor shaft Fit the pressure disc 3 to the traction sheave and fasten it using three pairs of NORD LOCK washers 6 and M 12 bolts 1 Tighten the bolts alternately around the circle in three torque steps...

Page 19: ...r weight In case of balance the cabin has to be weighted down with suitable additional mass The motor winding has to be short circuited via the motor contactors With the short circuit the motor cre ates a brake torque which is dependent on the motor speed This prevents an uncontrolled acceleration of the elevator It is possible that the brake torque which is created by the motor short circuit is n...

Page 20: ...es must be kept open separately even if the safety circuit is open This should be done using suitable electric circuitry or by hand This state must not be maintained in the long term Observe the lift during this test If it does not decelerate close the open brake circuit immediately Separate operation of the individual brakes The only method by which the partial brakes can be released separately i...

Page 21: ...emble the measuring system only if this is necessary because of a defect Remember to readjust the offset value after reassembly see the inverter operating instructions Disassembly 1 Loosen 2 x bolts 2 Remove 2 x bolts with washers 3 Loosen fixing bolt 4 Unscrewing the fixing bolt cau ses the encoder to disengage from the motor shaft Assembly 1 Screw the fixing bolt into the motor shaft This causes...

Page 22: ...tage too low Brake shoes mechanically blocked Overexcitation rectifier defective Check electrical connection Check braking voltage supply voltage Remove mechanical blocking Replace overexcitation rectifier Delay in braking system release Overexcitation rectifier defective Replace overexcitation rectifier Braking system does not engage Brake shoe mechanically blocked Remove mechanical blocking Dela...

Page 23: ...0 V X3 X4 Rated speed e g 07 75 min 1 with DT 320 mm v 0 63 m s suspension 2 1 11 119 min 1 with DT 320 mm v 1 0 m s suspension 2 1 19 191 min 1 with DT 320 mm v 1 6 m s suspension 2 1 X5 X6 X7 Traction sheave design Traction sheave diameter width groove design groove geometry X8 X9 Variant code brake measuring system modifications DZ dual curcuit brake measuring system Sendix 8 5873 2048 Inkr BIS...

Page 24: ...20 HB 30 formbeständige Keilrille HRC 55 Typical number of carry ing ropes and dia 8 x dia 8 mm 9 x dia 10 mm DE bearing self aligning roller bearing NDE bearing ball bearing Permissible shaft load up to 45 kN Drive motor synchronous motor Number of pole pairs 8 Thermal class 155 F Degree of protection IP 33 Overload capability 1 9 fold Imax IN Winding protection triple PTC 150 C triple therm swit...

Page 25: ...ate 13 06 2016 Version 0 10 Page 25 Subject to changes without notice Subject to changes without notice EN 9 Dimension drawing 6 mounting holes Ø 28 and 4 threaded holes M 24 motor WSG S2 4 Æ DT 320 400 BT 105 120 105 150 L 854 869 857 902 C 100 107 100 122 weight mG kg 445 447 460 474 inertia JG kgm2 1 03 1 06 1 62 2 06 shaft loads up to FS kN 45 ...

Page 26: ... ECN 413 EnDat SSI 503 325 021 xx D Pack Arkel ADrive CT unidrive SP ECN 413 EnDat SSI 502 452 021 xx emotron Dietz DSV 5445 ECN 413 EnDat SSI 501 112 022 xx Fuji Frenic ECN 413 EnDat 502 679 022 xx KEB F5 ECN 413 EnDat 502 363 022 xx LTi DRiVes Lust CDD 3000 ECN 413 SSI 505 677 022 xx RST Elektronik FRC ECN 413 EnDat 508 752 022 xx GEFRAN SIEI AVY L M ERN 487 503 499 022 xx Vacon NXP ECN 413 EnDa...

Page 27: ...ode GM 8 003290 EN Date 13 06 2016 Version 0 10 Page 27 Subject to changes without notice Subject to changes without notice EN 10 2 Cable set for motor and brake motor cable brake cable magnet brake cable monitoring xx cable length m 05 5 m 10 10 m 15 15 m ...

Page 28: ...wden cable for releasing can be delivered if required The standard length of the Bowden cable is 3 m Other lengths on request Installation Install the manual brake releasing device with the brake dis connected from the power supply Lock the car and the counterweight Ensure that the re quired safety measures are observed for the lift system Install the lever block Insert the Bowden cable into the b...

Page 29: ...ut notice EN 11 Spare parts Item Part Description Motor 01 traction sheave acc machine nameplate type code X5 X6 X7 02 Measuring system depending on spec ECN 413 SSI 2048 incr clamping ring ECN 413 ENDAT 2048 Inkr clamping ring ERN 487 2048 Inkr clamping ring Brake system 04 Overexcitation rectifier BEG 561 255 130 05 Micro switch brake monitoring ET 37 74 210 0807 06 ...

Page 30: ......

Page 31: ......

Page 32: ......

Page 33: ...2 01189 Dresden www wittur edrives de Fax 49 0 351 40 44 111 Germany Technical information 01 12 2012 Re WSG S2 4 Traction sheave shaft Annex calculation of the shaft Werkstoff Stahl DIN EN 10 083 1 42CrMo4 Denticulation steel DIN EN 10 083 1 42CrMo4 Brake Motor Traction sheave ...

Page 34: ......

Page 35: ...ope s center m 3 14 n Rotary speed rpm i Ratio of the car suspension 1 2 Use as braking element part of the protection device against unintended car movement act ing in up and down direction permissible brake torque tripping rotary speed and character istics 1 2 1 Nominal brake torque and response times with relation to a brand new brake element Nominal brake torque Nm Maximum tripping rotary spee...

Page 36: ...tification drawing no 5018294 or 5019746 including stamp dated 2016 03 18 shall be in cluded to the EU type examination for the identification and information of the general construction and operation and distinctness of the approved type 2 6 The EU type examination certificate may only be used in combination with the corresponding annex and enclosure List of authorized manufacturer of the serial ...

Page 37: ...of 2015 12 02 Page 1 of 1 Authorised Manufacturer of Serial Production Production Sites valid from 2016 03 18 Company INTORQ GmbH Co KG Address Wülmser Weg 5 31855 Aerzen Germany Company INTORQ Shanghai Co Ltd Address No 600 Xin Yuan Nan Road Building no 6 Zone B Nan Hui District Lingang 201306 Shanghai P R China END OF DOCUMENT ...

Page 38: ......

Page 39: ...www intorq com setting the standard www intorq com INTORQ BFK455 28 Electromagnetically Released Spring Applied Brake Translation of the Original Operating Instructions ...

Page 40: ...his documentation applies to the Product key Not coded Supply voltage hub bore options INTORQ B FK A A B C D Legend for the product key INTORQ BFK455 Product group Brakes Product type Spring applied brake Type 455 Size 28 A A B C D ...

Page 41: ...on identification Rated holding voltage Rated holding power Hub diameter Type number Rated torque Date of manufacture Label product traceability Example Type see product key QR Code Type number Serial number Manufacturer for the holding voltage for setting the air gap Lüftspannung Release voltage 205 V DC Haltespannung Holding voltage 103 V DC Nur mit BEG 561 255 130 betreiben Only use with BEG 56...

Page 42: ... TD09 Amended by new chapter on manual release installation Tables of dimensions and switching times were changed Supplement for spare parts list and the spare parts order 33002468 3 0 04 2013 TD09 Limitation of the adjustability Note on the suppressor circuit added to the Electrical installation chapter Values for characteristic torque 2x2065 Nm added to Dimensions table 33002468 4 0 01 2015 SC R...

Page 43: ...n data 17 3 4 Switching energy switching frequency 19 3 5 Emissions 20 4 Mechanical installation 21 4 1 Important notes 21 4 2 Necessary tools 21 4 3 Assembly 22 4 4 Installation 23 4 5 Manual release 29 4 6 Cover ring assembly 34 5 Electrical installation 35 5 1 Important notes 35 5 2 Bridge half wave rectifier optional 36 5 3 Electrical connection 38 6 Commissioning and operation 39 6 1 Importan...

Page 44: ...ys be in a complete and perfectly readable condition 1 2 Terminology used 1 3 Conventions in use This document uses the following styles to distinguish between different types of information Term In the following text used for Spring applied brake Electromagnetically Released Spring Applied Brake Drive system Drive systems with spring applied brakes and other drive components Spelling of numbers D...

Page 45: ... heat energy QE J Maximally permissible friction energy for one time switching thermal parameter of the brake QR J Braking energy friction energy QSmax J Maximally permissible friction energy for cyclic switching depending on the switching frequency RN Ohms Rated coil resistance at 20 C Sh 1 h Switching frequency the number of switching operations evenly spread over the time unit Shue 1 h Transiti...

Page 46: ... from the start of torque rise until reaching the braking torque tue s Over excitation time U V Voltage UH V DC Holding voltage after voltage change over UL V DC Release voltage before voltage change over UN V DC Rated coil voltage in the case of brakes requiring a voltage change over UN equals UL SIGNAL WORD Icon Indicates the type of danger Signal word Characterizes the type and severity of dang...

Page 47: ...rake consists of different types of material Recycle the metal and plastic parts Ensure professional disposal of assembled circuit boards according to the applicable environmental reg ulations DANGER DANGER indicates a hazardous situation which if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in deat...

Page 48: ...ally 1 9 Legal regulations Liability The information data and notes in these Operating Instructions met the state of the art at the time of printing Claims referring to drive systems which have already been supplied cannot be derived from this information illustrations and descriptions We do not accept any liability for damage and operating interference caused by inappropriate use unauthorised mod...

Page 49: ...ified product characteristics Only qualified skilled personnel are permitted to work on and with INTORQ components According to IEC 60364 or CENELEC HD 384 qualified skilled personnel are persons who are familiar with the installation mounting commissioning and operation of the product who have the qualifications necessary for their occupation who know and apply all regulations for the prevention ...

Page 50: ...d beyond their corresponding power limits Any other use or excessive usage is considered improper Usage conditions for the INTORQ spring applied brake Humidity no restrictions In the event of condensation or moisture formation provide for appropriate ventilation to ensure that all components will dry quickly Ambient temperature 5 C to 40 C At high humidity and low temperature Take measures to prot...

Page 51: ...96 04 2016 13 3 Technical specifications 3 1 Product description Versions Fig 1 Design of a BFK455 spring applied brake Basic module 1 1 Stator 3 Complete rotor 6 Flange 1 2 Pressure springs 4 Hub 8 Coil 2 Armature plate 5 Shaft 13 Cover ring ...

Page 52: ... their corresponding com pression springs 1 2 and electromagnetic coils 8 Each brake circuit can be operated individually due to the separate supply lines for each stator and armature plate 36 Each brake circuit has a micro switch which monitors the switching state of the spring applied brake Using the associated switching device the supply voltage AC voltage is rectified and when the brake is rel...

Page 53: ...micro switches function correctly we recommend testing the switching status refer to ta ble 6 in both the released and applied braking states 3 1 5 Encapsulated design optional This design not only avoids the penetration of spray water and dust but also the spreading of abrasion par ticles outside the brake This is achieved by a cover seal over the armature plate and rotor 3 1 6 Project planning n...

Page 54: ... 912 Minimum thread depth Tightening torque without flange with flange without flange with flange without flange with flange mm Thread mm mm mm mm MA Nm MA Nm BFK455 28 314 M16 6 x M16x210 6 x M16x220 25 22 5 206 265 Tab 1 Dimensions of the BFK455 28 CAUTION The minimum thread depth of the end shield must be maintained Tab 1 If the required thread depth is not maintained the fixing screws may run ...

Page 55: ...ease 10 Holding 10 Brake release Holding UL V DC UH V DC PN W PH W RN 5 IL A BFK455 28 103 52 2 x 434 2 x 108 5 2 x 24 5 2 x 4 21 205 103 2 x 97 2 x 2 12 360 180 2 x 298 6 2 x 1 21 Tab 2 Coil power ratings of the BFK455 28 t1 Engagement time t11 Reaction delay of engagement t2 Disengagement time up to M 0 1 Mdyn t12 Rise time of the braking torque Mdyn Braking torque at a constant speed of rotatio...

Page 56: ...e for safety reasons e g with hoists and lifts the spark suppressor can also be connected in parallel to the brake coil Circuit proposals 36 If the drive system is operated with a frequency inverter so that the brake will not be de energised before the motor is at standstill AC switching is also possible not applicable to emergency braking Disengagement time The disengagement time is the same for ...

Page 57: ...y Shmax depends on the amount of heat QR refer to Figure 3 At a pre set switching frequency Sh the permissible amount of heat is QSmax With high speeds of rotation and switching energy the wear increases strongly because very high temper atures occur at the friction surfaces for a short time A A Switching energy Q J B Switching frequency Sh 1 h S hmax S hue ln 1 Q R Q E Q smax Q E 1 e Shue Sh ...

Page 58: ...e Heat Since the brake converts kinetic energy as well as mechanical and electrical energy into heat the surface temperature varies considerably depending on the operating conditions and possible heat dissipation Un der unfavourable conditions the surface temperature can reach 130 C Noise The switching noise during engagement and disengagement varies depending on the air gap braking torque and bra...

Page 59: ...tes 4 2 Necessary tools NOTICE The toothed hub and screws must not be lubricated with grease or oil Type Torque wrench Bit for hexagon socket screws Open jawed spanner Measuring range Nm Wrench width mm Adjustment tubes wrench size mm BFK455 28 40 400 14 24 Multi meter Caliper gauge Feeler gauge ...

Page 60: ... the spring applied brake 2 Check for completeness 3 Check the nameplate data especially the rated voltage 4 3 3 Overview Brake size Minimum requirements Use as counter friction surface Material1 Evenness mm Axial run out mm Roughness Miscellaneous 28 S235 JR C15 EN GJL 250 0 1 0 1 Rz10 Threaded holes with mini mum thread depth 16 Free of grease and oil Tab 4 Counter friction face design of the en...

Page 61: ...isplacement for example by using a circlip 4 2 NOTICE The toothed hub and screws must not be lubricated with grease or oil NOTICE When you have ordered a version with flange attach the hub first 23 then continue with the Assembly of the counter friction faces Mounting the first hub onto the shaft 4 Hub 4 1 Key 15 End shield NOTICE For reverse operations we recommend also glueing the hub to the sha...

Page 62: ...ugh holes in the flange to the threads of the fastening bore holes In the following sections only assembly for the version with flange will be described Assembly of the first rotor Fig 6 Mounting of the rotor 6 Push the rotor 3 onto the hub 4 and check whether it can be moved by hand Flange option 4 Hub 15 End shield 6 Flange 3 Rotor 6 Flange 15 End shield 4 Hub 15 6 4 15 6 4 3 ...

Page 63: ...he shaft 5 9 Secure hub 4 against axial displacement e g by using a circlip 4 2 NOTICE Only in the case of rotors with mounting paste on their gear teeth Remove cover films from both front ends of the rotor Protect friction surfaces against contact with mounting paste After the mounting excessive mounting paste must be removed properly 4 Hub 3 Complete rotor 4 2 Circlip 5 Shaft 4 1 Key 4 2 4 4 1 3...

Page 64: ...gn the through holes in the complete stator 1 to the threads of the fastening bore holes Assembly of the second rotor Fig 9 Mounting of the rotor 12 Push the complete rotor 3 onto the hub 4 and check whether it can be moved by hand 1 Stator complete 4 Hub 6 Flange 3 Shaft 4 2 Circlip 15 End shield 1 Stator complete 4 Hub 15 End shield 3 Complete rotor 6 Flange ...

Page 65: ...onnection and energize the brake 35 17 Use a torque key to re tighten the supplied fixing screws 10 with the required tightening torque 16 18 Switch off the power NOTICE Only in the case of rotors with mounting paste on their gear teeth Remove cover films from both front ends of the rotor Protect friction surfaces against contact with mounting paste After the mounting excessive mounting paste must...

Page 66: ...justing the air gap during the initial installation 2 Loosen the bolts 10 DANGER Danger rotating parts Switch off the voltage The brake must be free of residual torque NOTICE Do not insert feeler gauge more than 10 mm between armature plate 2 and stator 1 1 NOTICE First correctly adjust the air gap with every 2nd bolt 10 sleeve bolt 9 The other three sleeve bolts should be screwed into the stator ...

Page 67: ...LN is too large 4 5 Manual release The manual release is mounted when the double spring applied brake is installed No power is applied to the brake 1 Mount the first rotor 3 the first complete stator 1 and the second rotor 3A according to section 4 4 1 steps 1 through 12 23 and 26 4 5 1 Components of the manual release Fig 13 Manual release NOTICE The manual release is designed for activation via ...

Page 68: ...ding holes of the stator using a suitable tool Fig 15 Installation of the tension rods 3 Assemble four pre assembled tension rods 12 14 with one spring 12 5 each Carry out steps 4 and 5 separately for each side of every lever NOTICE The plates are not symmetric The pin with the greater distance from the axis of rotation must be oriented towards the outside The lever must also face outwards 1 15 3A...

Page 69: ... heads of the manual release levers are completely sunk into the clips 12 11 6 Position the second complete stator 1A in front of the complete stator 1 Insert the pre assembled tension rods 12 14 into the through holes Ø12 mm of the first complete stator 1 in the process Fig 17 Pre assembly of the brake with manual release on the motor 7 Screw four lock nuts 12 8A between the motor end shield and ...

Page 70: ...ighten ing make sure that the clips 12 11 are parallel to the rear of the stator 1A Check using a caliper gauge If there are dimensional differences where X 0 1 mm see Figure 19 this should be corrected by loosening the lock nut 12 8 at the smaller dimension and tightening the lock nut 12 8 at the larger dimension until the clips 12 11 are adjusted in parallel to the back of the brakes as shown in...

Page 71: ...17 Correct the setting if necessary until both feeler gauges can be moved by the same force 18 Check that the manual release functions properly Attach pipe sections onto the levers and press them together to check whether the motor shaft can rotate freely 19 Connect the Bowden cable not included in this delivery and pull until the motor shaft can be freely ro tated NOTICE The actuation force betwe...

Page 72: ... ring 13 into the groove of the complete stator 1 and flange 6 end shield 5 Press the lips of the second cover ring into the groove of the first and second complete stator 1 6 Re establish the electrical connection NOTICE Brakes without flange require a groove at the end shield for the lip of the cover seal 1 Stator complete 6 Flange 13 Cover ring NOTICE Cover ring with condensation drain hole Att...

Page 73: ... stop is carried out without the required suppressor circuit the control unit may be destroyed Observe the correct polarity of the suppressor circuit NOTICE To functionally test the individual brake circuits the power supply must be able to be switched off individually For a new over energizing during switch on it is also necessary to open switches K1 K3 The protective circuitry contained in the I...

Page 74: ...y electromagnetic DC spring applied brakes which are ap proved for the use with such rectifiers Other use is only permitted with the approval of INTORQ Once a set over excitation time has elapsed the bridge half wave rectifiers switch over from bridge rectifi cation to half wave rectification NOTICE Recommended current load for the micro switches DC current 10 mA 100 mA at 12 V AC current 10 mA 5 ...

Page 75: ...60 V Rectifier type Bridge half wave rectifier Output voltage for bridge rectification 0 9 x U1 Output voltage for half wave rectification 0 45 x U1 Ambient temperature storage operation C 25 70 Type Input voltage U1 40 Hz 60 Hz Max current Imax Over excitation time tue 20 Min V Rated V max V Bridge A half wave A at U1 min s at U1 Nom s at U1 max s BEG 561 255 130 160 230 255 3 0 1 5 1 870 1 300 1...

Page 76: ...embly with metal surface good heat dissipation 2 For other assembly e g adhesive 5 3 Electrical connection DANGER There is a risk of injury by electrical shock The brake must only be electrically connected when no voltage is applied NOTICE Compare the coil voltage of the stator to the DC voltage of the installed rectifier ...

Page 77: ...to the brake 4 Measure the AC voltage at the motor terminals The measured level must be zero 5 Close the switching contact for the brake The brake is released DANGER The live connections and the rotating rotor must not be touched The drive must not be running when checking the brake DANGER Danger rotating parts The brake must be free of residual torque The motor must not run DANGER There is a risk...

Page 78: ...e table 6 9 Open the switching contact for the brake The brake is applied 10 Check the switching status of the micro switch see table 6 11 Switch off DC voltage for the brake 12 Screw the bridges onto the motor terminals 13 If necessary remove the neutral conductor from the neutral point step 2 The preparations for commissioning are completed 6 3 Commissioning 1 Switch on the drive system 2 Carry ...

Page 79: ...ue Measure the DC voltage at the brake The measured DC voltage after the over excitation time see bridge half wave rectifier 36 must correspond to the holding voltage see table 5 A deviation of 10 is permissible If faults occur once go through the troubleshooting table in chapter 8 If the fault cannot be fixed or elim inated please contact your customer service DANGER Danger rotating parts The run...

Page 80: ...air gap must not be re adjusted after it has been correctly adjusted during the initial installation of the brake on the motor This could result in a loss of braking torque Component Cause Effect Influencing factors Friction lining Braking during operation Wear of friction lining Friction work Emergency stops Overlapping wear during start and stop of drive Active braking via the drive motor with s...

Page 81: ...g conditions and brake loads must be de fined for every application For the spring applied brakes the maintenance intervals and maintenance oper ations listed in the table below must be followed The maintenance operations must be carried out as described in the detailed descriptions 7 2 1 Maintenance intervals Type Time interval for service brakes for holding brakes with emergency stop BFK455 28 a...

Page 82: ...otating parts The running rotor must not be touched DANGER There is a risk of injury by electrical shock Live connections must not be touched NOTICE Brakes with defective armature plates socket head cap screws springs or counter friction faces must always be replaced completely Observe the following for inspections and mainte nance works Contamination by oils and greases should be removed using br...

Page 83: ...k the gear teeth of the hub 7 Replace the hub if it is worn 8 Check the friction surface on the bearing shield In case of strong scoring at the flange replace the flange In case of strong scoring on the bearing shield rework the friction surface 9 Measure the rotor thickness new rotor and head height of the sleeve bolts with a caliper gauge 10 Calculate the distance between the stator and the arma...

Page 84: ...ng information with the order Order number of the brake Position number of the spare part Fig 22 BFK455 28 spring applied brake Item Designation Variant 1 Stator complete Voltage 3 Complete rotor Rotor complete noise reduced 4 Hub Bore diameter 6 Flange 10 Fixing screws Socket head cap screw set DIN912 for mounting to the motor for flange with through hole 12 Complete manual release 13 Cover ring ...

Page 85: ... V 360 V 180 V Braking torque Nm see torque gradation Cable length Standard 1000 mm Armature plate Standard Micro switch Monitoring the switching function Rotor Aluminium Noise reduced rotor with sleeve Hub mm for hole diameter see dimensions Fixing screw set For mounting For mounting with flange Counter friction face Flange Seal Cover ring Complete manual release Rectifier BEG 561 255 130 BEG 561...

Page 86: ...ive or incorrect Check and correct Check cable for continuity using a multimeter Replace the complete stator if a cable is defective Defective or incorrect rectifier Measure rectifier DC voltage using a multimeter If DC voltage is zero Check AC rectifier voltage If AC voltage is zero Switch on power supply Check fuse Check wiring If AC voltage is OK Check rectifier Replace the defective rectifier ...

Page 87: ...ete stator to the manufacturer Voltage too high Brake voltage does not match the rectifier Adjust rectifier and brake voltage to each other Voltage too low Brake voltage does not match the rectifier Adjust rectifier and brake voltage to each other Defective rectifier diode Replace defective rectifier with a suitable undamaged one AC voltage is not mains voltage Fuse is missing or defective Select ...

Page 88: ...Notes INTORQ BA 14 0196 04 2016 50 Notes ...

Page 89: ...Co Ltd р ᐸ ђ ค䭽 ݹ 䐥 ਭ ਭᾲжᾲ ᓝ No 600 Xin Yuan Nan Road Building No 6 Zone B Nicheng town Pudong 201306 Shanghai 86 21 20363 810 86 21 20363 805 info cn intorq com INTORQ US Inc USA 300 Lake Ridge Drive SE Smyrna GA 30082 USA 1 678 236 0555 1 678 309 1157 info us intorq com INTORQ India Private Limited India Plot No E 7 3 Chakan Industrial Area Phase 3 Nighoje Taluka Khed Pune 410501 Maharashtra 91 ...

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