Operating and assembly instructions spring-loaded brake FDW ATEX

Version 04.06

Operating and assembly instructions

Spring-loaded brake FDW
Type of protection IP 65 - dust-protected design Zone 22, category 3D, T 125C (non-conducting dust)

Please carefully read and pay attention to these operating and assembly instructions.

Important information Safety information and warnings:

Impending danger because of current!

Dangerous situation!

Important information on explosion protection!

Safety information and instructions: Paying attention to and observing theses operating instructions is a prerequisite for a troublefree operation and the compliance with possible warranty claims. For this reason, first study the operating instructions before connecting the brake. In order to protect persons and property, strictly meet all the safety information and instructions included in these operating instructions. When being ignited through hot or sparking objects, explosive dust concentrations can cause explosions which might result in serious or fatal injuries of persons as well as severe damage to property. It is an absolute prerequisite that the persons who are responsible for using brakes in potentially explosive atmospheres have been trained in the correct use of those brakes.

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Operating and assembly instructions spring-loaded brake FDW ATEX

General information and instructions: The dust-protected spring-loaded brakes are suited for the use in zone 22 (nonconducting dust) and conform with the building regulations of device group , category 3D as per DIN 50 014 and DIN 50 281-1-1. Dust deposits must not exceed 5 mm. Ambient temperature -20 C to +40 C Under the prescribed and established operating conditions the surface temperature of the spring-loaded brake will not exceed 125 C refer to technical data on page 4. In order to warrant the max. admissible surface temperature, the spring-loaded brakes are equipped with a PTC thermistor detector (100 C) (resistance < 100 Ohm at 20C). In case of a malfunction, motor and brake have to be isolated from the power system through a commercial tripping unit. The operator is responsible for controlling and testing the protective equipment as to its efficiency. Prior to commissioning, an evidence of the efficiency of the protective equipment is required. The designation is as follows: CE Ex ll 3D T 125 C for zone 22 (non-conducting dust) The brake must not be opened for inspection in an explosive atmosphere. Prior to opening, always switch off the voltage and secure it against an accidental reclosure. Spring-loaded brakes are suited to be connected with three-phase a.c. motors. In case of voltage-operated three-phase a.c. motors, the operator has to warrant and care for a ventilation of the brake. External measures and actions have to safeguard that the braking command is simultaneously given with switching off the motor. The spring-loaded brake is a component of a device and/or of a machine and earthing arrangements have to be made there.

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Operating and assembly instructions spring-loaded brake FDW ATEX

Design: Spring-loaded brakes type FDW ATEX are designed as enclosed brakes IP 65. The spring-loaded brakes are delivered with a firmly adjusted braking torque and air gap. Mode of functioning: By means of applying a direct voltage to the excitation winding in the magnet body (item 1) a magnetic force is created which will act upon the armature plate (item 5). Via the air gap a, this will be drawn towards the magnet body (item 1) against the compressive force of the spring (item 3). The braking rotor (item 2) will be released and the braking torque cancelled. Sketch: 1 Magnet housing 2 Rotor 3 Spring 4 Hub 5 Armature plate 6 O-ring 7 Fastening screw 8 Banjo bolt 9 Cu-washer 10 Circlip 11 Key 12 Screw plug

Assembly: Assembly conditions: Rotor and brake surfaces must be free from oil and grease. A suitable counter friction surface (steel or GG Rz 6,3) must be available. The hub is to be brought into such a position that there is a coverage rotor/hub. Assembly: The spring-loaded brakes will be delivered in a preassembled condition. Insert circlip ring (item 10) into the keyway Insert key (item 11) into the motor shaft Push hub (item 4) onto the shaft and lock it by means of circlip (item 10) Push rotor (item 2) onto hub (item 4) you must be able to easily move the rotor on the hub. Tighten brake body with 3 fastening screws for tightening torque refer to table in technical data. The air gap of the brake is given by constructional dimensions.

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Operating and assembly instructions spring-loaded brake FDW ATEX

Electrical connection of the brakes The coil voltage (VDC) is visible on the motor type plate and has also been embossed into the magnet housing. Operating voltage 90 % to 110 % of the nominal voltage of the spring-loaded brake. Technical data:
Table 1

Brakes size

MbN P Standard Standard (Nm) (W)

FDW 08 FDW 10 FDW 13 FDW 15 FDW 17 FDW 20 FDW 23 FDW 26 FDW 30

5 10 20 40 60 100 150 250 400

33 42 50 63 75 96 114 150 210

WRmax max. friction energy per braking (J) 1,5x103 3,0x10 6x10
3 3 3 3

PR max. admissible friction power (J/h) 140x103 180x10 230x10 280x10 360x10
3 3 3 3

Tightening Fastening moment of the screws screws MA (Nm) 3 x M4 3 x M5 3 x M6 3 x M6 3 x M8 3 x M8 3 x M8 3 x M10 6 x M10 3 6 10 10 25 25 25 50 50

12x10 17x10

25x10 37x10 52x10 75x10

450x10 540x10 630x10 720x10

Since wear and tear of the brake depends on several factors of influence such as operating frequency, switching energy per switching operation, braking torque and climatic conditions the values indicated with regard to max. switching energy can only be guidance values. W Rmax (max. switching energy) is the switching energy which must not be exceeded with braking operations from max. > 1500 min-1. Braking operations from a speed of > 1500 min-1 considerably reduce the max. admissible switching energy per switching operation. In this case, please contact the manufacturers for advice. The maximum switching power Pmax is the switching energy W which is achievable every hour. If during operation both Pmax and W max are simultaneously nearly reached, the diagram (W max depending on the hourly switching time) shown in the operating instructions has to be used.

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Operating and assembly instructions spring-loaded brake FDW ATEX

Inspection / maintenance
Safety measures and actions De-energise motor and brake and protect them from an accidental reclosure. The brake must not be opened for inspection in an explosive atmosphere. Inspection: Turn out the radially arranged screw plug (item 12), measure the existing air gap (feeler gauge 5 mm wide) and compare it with table 2 - below. Screw down the screw plug (item 12) again pay attention to O-ring and secure it with locking paint. To be noted! When the max. air gap is reached, the brake rotor has to be exchanged!
Table 2

FDW aNom +0,1 amax Rotor size (new)

Dimensions indicated in mm

08 0,2 0,5 7,5

10 0,2 0,6 8,5

13 0,3 0,8 10,3

15 0,3 0,8 12,5

17 0,3 0,8 14,5

20 0,4 0,9 16

23 0,4 0,9 18

26 0,5 1,0 20

30 0,5 1,0 20

Control PTC thermistor: Resistance (at 20C) < 100 Ohm To be noted: Cable diameter 3,7 mm The working air gap cannot be readjusted. When assembling the controlled brake, the Cu-washers under the fastening screws have to be replaced. Inspection intervals: When using the spring-loaded brakes: as a working brake at least every 3000 operating hours, refer to additional information as a holding brake depending on operating conditions and load every 2 to 3 years with emergency-stop properties refer to additional information

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Operating and assembly instructions spring-loaded brake FDW ATEX

Inspection of brake: Measure the air gap. When the max. admissible air gap has been reached, disassemble the brake and replace the rotor Evaluate the armature disk Control rotor/hub connection Control function of the PTC thermistor: Resistance (at 20C) < 100 Ohm Additional information: The necessary inspection / maintenance intervals must be individually established and have to be calculated by the plant manufacturers. Disassemble the brake in the reverse order that is required for an assembly (page 3).

Bahnhofstrae 68 31691 Helpsen Phone: +49 57 24 95 51 0 Fax: +49 57 24 30 96 E-mail: info@precima.net

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