windlasses & winches electric brake

Drive technology 2

Table of contents

These operating instructions ......................................................................... 3 General information on the product.............................................................. 3 Safety information........................................................................................... 4 Technical data ................................................................................................. 6

Brake connection dimensions ...................................................................... 6 Tightening torques for various bolt sizes..................................................... 6 Bolt and hexagon socket screw key sizes for various brake sizes................ 6

Overview .......................................................................................................... 7 Brake (outer)................................................................................................ 7 Brake (inner)................................................................................................ 8

Installation ....................................................................................................... 9 Fitting .......................................................................................................... 10

Electrical connection ....................................................................................... 12 Commissioning ................................................................................................ 13

Function check............................................................................................. 14 Airgap check................................................................................................ 14

Mode of operation of the brake...................................................................... 15

Brake power supply connection................................................................... 15 Brake power supply disconnection ................................................................. 15 Running-in friction linings.............................................................................. 15 Operation ......................................................................................................... 16 Manual release ................................................................................................ 17 Maintenance .................................................................................................... 19

Airgap check................................................................................................ 20 Brake flange reversal ................................................................................... 21 Brake flange, friction lining group and armature plate replacement............ 23

Condensation water drainage.......................................................................... 25 Dismantling brake ........................................................................................... 26 Cleaning ........................................................................................................... 27 Troubleshooting .............................................................................................. 28 Spare parts....................................................................................................... 30 Additional equipment for brakes ................................................................... 31 Disposal ............................................................................................................ 31 Warranty ......................................................................................................... 31 Declaration of conformity............................................................................... 32 Index................................................................................................................. 33

Drive technology 3

These operating instructions ...

... explain the procedures for the handling and use of seawater-proof electromagnetic double-face spring-pressure operated brakes (SFB) and holding brakes (SFB-H). They contain information on procedures for safe

• Installation • Commissioning and • Maintenance The safety information relating to the handling and use of the brake are summarised in a separate chapter.

Before fitting the brake, it is in your own interest to familiarise yourself with the information contained in these instructions and the potential hazards relating to the use of the brake and to observe the applicable safety rules and regulations in particular.

... are intended for:

• Fitters • Mechanics • Brake operators These persons must be experienced in the use of electromagnetic brakes and have the necessary training.

... uses the following symbols:

∆ Safety information is emphasised by a bright triangle • indicates enumerations - accompanies working steps carried out by you

General information on the product

Description Seawater-proof electromagnetic double-face spring-pressure operated brakes (SFB) and holding brakes (SFB-H) are safety brakes that are applied mechanically when the current is disconnected. This ensures that the brake still operates in the event of a power failure. Both types of brake are designed for dry-running operation, must only be operated in a safe condition and fitted, commissioned, operated and maintained only by specially trained installation personnel.

Brakes with a rated voltage from 75V DC (low-voltage directive) carry the CE mark.

SFB

SFB series brakes are suitable for dynamic and static braking with minimum friction lining wear.

SFB-H

SFB-H series brakes are used only as holding brakes with emergency braking characteristics. The number of springs is increased compared to the normal brake, the maximum airgap reduced and wear with dynamic braking greater.

Use for the intended purpose SFB and SFB-H series brakes are used for braking electric motors, e.g. on ships, drilling rigs, crane systems, in rolling mills and steel works, mining, transport and cable railways. Use for any other than the intended purpose is considered improper and not for the intended purpose. If there is any doubt that the intended application of the brake may not for the intended purpose, please consult PINTSCH BAMAG.

Drive technology 4

Safety information

The safety information provided here is of a general nature. Special safety information is provided at the beginning of a chapter or specific point in the text. Observing all safety information will help prevent accidents and damage to the brake.

Safety rules and regulations must also be observed under the pressure of time. Accidents cannot be reversed.

∆ Electromagnetic fields The brake is not screened. In the immediate vicinity of the brake, electromagnetic fields can be produced, the strength of which depends on the site of the brake. The user must ensure compliance with the requirements of DIN VDE 0848, part 4, “Safety relating to electromagnetic fields in the range 0 Hz-30 kHz”.

∆ Pacemakers or implants

Persons with pacemakers or implants must avoid the area of electromagnetic brakes in any event. The strong electromagnetic fields pose a danger to life!

∆ Protective barriers Mark out a working area of sufficient size around the brake. Cordon off points allowing public access with protective barriers around the working area of the brake.

∆ Safety distance A safety distance should be maintained to all hazardous zones to ensure safety of personnel and prevention of damage to the brake.

∆ Avoid negligent behaviour Refrain from any actions that could affect the safety of the brake.

∆ Do not dismantle the brake completely The brake may only be dismantled to the extent specified in the operating instructions. Any dismantling of the assemblies over and beyond the extent specified is forbidden.

∆ Do not place or leave anything lying around in this area Because of the electromagnetic fields, no objects must be placed or left lying around in the area of the brake. This applies in particular to metal objects.

Safety information

Drive technology 5

∆ Do not store any objects in this area Do not store any flammable objects in the immediate vicinity of the brake.

∆ Work with care Before carrying out any work on the brake, measures must be taken against any dangers to the life and health of persons and damage to the brake:

• Only closed shoes in a perfect condition must be worn. Open sandals, damaged or unsuitable shoes must not be worn.

• Closed, tight-fitting working clothes must be worn. Wide work jackets and wide sleeves can be dangerous.

• Long hair must be tied back.

Work should only be carried out on the brake when:

• All dangerous movements have stopped • Accidental and unexpected operation of the brake is made impossible by suitable measures • If the brake is loaded, other safety devices provide a braking and holding function.

∆ Danger of crushing When working on the brake, heavy tools are used. Particular attention should therefore be paid to possible crushing points when:

• Using tools • Fitting and removing the brake, accessories or spare parts • Unbolting the brake from the pallet

∆ Unusual changes In the event of unusual changes to the brake, the brake power supply must immediately be disconnected. Any unusual changes, e.g. development of smell at the brake, must immediately be reported to the person concerned or the customer service department notified in order to prevent the brake suffering further damage.

∆ Overvoltage protection For brakes with coil outputs from 100 W and higher, overvoltage protection must be provided to prevent damage to the coil on disconnection of the brake power supply.

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Technical data

Brake connection dimensions

Hub Bore H7 Keyway

Keyway width DIN 6885 page 1; P9

Brake adapter flange

Centring seat Inner centring Outer centring

H7 f8

Tightening torques for various bolt sizes The following tightening torques apply to nuts and bolts:

Bolt size

Tightening torque MA (Nm)

8.8 10.9

M8 25 36

M10 49 72

M12 85 125

M14 135 200

M16 210 310

M18 300 430

M20 425 610

M22 580 830

M24 730 1050

Bolt and hexagon socket screw key sizes for manual release bolts of various brake sizes

Brake size SFB, SFB-H brake

Manual release bolts DIN 912 self-locking

Hexagon socket screw key DIN 911, key size:

from 6.3 to 63 M8 6

100 M10 8 from 160 to 400 M12 10 from 630 to 1000 M16 14

Component Description

Drive technology 7

Overview

Brake (outer) Manual release bolts under lock bolts

Airgap measuring bolt

Housing

Brake adapter flange

Rating plate

Condensation water drain bolt for vertical installation

Brake rating plate

Brake designation Braking torque

Factory set airgap Maximum airgap Brake serial number

D I N S L A K E N

Overview

Drive technology 8

Brake (inner) Cap nut

Sealing ring

Housing

O-ring

Lock nuts

Brake flange

Friction lining group

Manual release bolts

Armature plate

Bolt

Spring

Coil body group with brake adapter flange

Stud bolts

Connecting cable

Drive technology 9

Installation

The brake can be fitted horizontally or vertically.

Prior to fitting the brake, the following safety information must be observed:

∆ Shutdown equipment prior to fitting brake Before fitting the brake, it must be ensured that the equipment to which the brake is to be fitted

• is shutdown and • secured to prevent accidental activation.

∆ Do not use any grease The brake is designed for dry-running operation. For this reason, no greases or oils must be used during installation of the brake. Greases and oils reduce the braking action. The hub in particular must not be oiled or greased.

∆ Danger of crushing When carrying out work on the brake, heavy tools are used. Particular attention should therefore be paid to possible crushing points when:


∆ Use lifting equipment The brake can weigh between 19 and 750 kg depending on type. For brake installation purposes, lifting gear or another crane can be used.

∆ Do not use a crane that is being fitted with brakes Under no circumstances should the crane to which brakes are being fitted be used for lifting purposes.

∆ Protection of inner brake Dirt, oil and spray water reduce the braking capacity. Friction linings, brake flange and armature plate must be protected when the brake is open.

Installation

Drive technology 10

Fitting Alignment during fitting depends on the position of the motor or gear shaft.

Brake Motor

The brake must be prepared for fitting according to the following procedure:

- Remove cap nuts and sealing rings

- Remove housing

- Simultaneously tighten manual release bolts evenly clockwise, so that the friction lining group moves freely

Brake flange

Manual release bolts

Armature plate

Airgap

Coil body group


- Check that the lining group moves freely

If the friction lining group does not move freely:

- Simultaneously further tighten manual release bolts carefully and evenly clockwise

Prior to fitting the brake:

- Fit hub fully on the motor shaft

Key

Motor shaft

Hub

- Secure the hub axially with the shaft and washer or circlip.

Installation

Drive technology 11

With suitable lifting gear, lift the brake so that the adapter flange and brake can be cleaned and sealing compound applied, e.g. Curil K2.

- Subsequently clean the motor flange and apply sealing compound.

- Lift the brake with suitable lifting gear and carefully position the teeth of the friction lining group over the teeth of the driving hub.

- Feed the connecting cable through the opening in the adapter flange as shown as illustrated.

- Have electrical connections made by a qualified electrician. Also observe the safety information in the chapter “Electrical connection”.

- After electrical connection, bolt the brake adapter flange to the motor flange.

∆ Observe bolt tightening torque. The prescribed tightening torque must be observed when tightening bolts (see “Technical Data)”.

- Simultaneously unscrew both manual release bolts evenly counter-clockwise until the bolt heads just make contact with the brake flange.

∆ Do not unscrew manual release bolts with force If the manual release bolts are unscrewed with force over and beyond the resistance, the brake can be damaged.

∆ Ensuring correct braking action A check should be made to ensure that the manual release bolts are unscrewed properly. If the manual release bolts are tightened, the brake will not operate or be restricted.

∆ Remove foreign bodies on O-ring and contact surfaces. When fitting the housing, the housing O-ring and contact surfaces must be from foreign bodies, otherwise the housing will not provide a proper seal.

Connecting cable and opening in brake adapter flange

Drive technology 12

- Clean O-ring and contact surface.

- Fit the housing noting the installation position, the mark on the housing must correspond with the mark on the adapter flange.

Electrical connection

During installation, electrical connection of the brake must be established.

∆ Only qualified electrician Only a qualified electrician may connect the brake to the DC supply and check the current flow, taking into all safety measures. Incorrect connection may have fatal consequences!

∆ Earthing The brake must be earthed in compliance with the applicable regulations.

∆ Disconnect system from the supply The supply must be disconnected before carrying out any work on the electrical system.

∆ Provide overvoltage protection Brakes with a coil output of 100 W and higher must be provided with overvoltage protection to prevent damage to the coil on disconnection of the brake power supply.

∆ Prevent brake overheating To prevent the brake overheating, it must be ensured that the motor to be braked does not continue to run in the event of an undesired power failure.

∆ Do not switch on

Disconnect the power supply to the motor before connecting the brake.

- Provide a “Do not switch on” sign at the switching point.

- Establish electrical connection.

- Remove the sign.

Marks (notches) Brake adapter flange Housing

Drive technology 13

Commissioning

Prior to commissioning the brake, the following safety information must be observed:

∆ Overloading the brake The operator is obliged to adjust the motor for the brake in such a way that the brake cannot be overloaded. Overloading the brake would cause heavy brake lining wear.

Note: As a result of chemical degreasing at the factory, the armature plate and brake flange may have a bluish discoloration; this is not an indication of thermal overload.

∆ Risk of burns!

During operation, the brake can reach temperatures up to 80°C. Any contact with the hot brake housing must therefore be avoided.

∆ Maintain maximum speed range In order to prevent damage to the brake, the brake must be operated also during commissioning only within the permissible speed range.

Note: Loading case and technical data sheets must be observed.

Function check A function check must be carried out prior to each initial use. Observe the safety information before carrying out the function check:

∆ Do not place or leaving anything lying around in this area

Remove all metal or flammable objects from the working area of the brake.

∆ Do not reach into rotating brake If the function check is carried out with the housing removed, reaching into rotating brake must be avoided in any event.

∆ Seal replacement All seals removed for the function check must be replaced with new seals.

Commissioning

Drive technology 14

Function check - With the housing removed, connect and disconnect the brake power supply several times

The armature plate moves during switching between the coil body group and friction lining group.

Airgap

After completing function check:

- The procedure for cleaning and fitting the housing is as described in the chapter “Installation” under the section “Fitting the brake”.

Checking the airgap To ensure correct operation of the brake, the airgap between the coil body group and armature plate must have the prescribed size. The minimum or maximum airgap is shown on the brake rating plate. The brake is set with the minimum airgap at the factory.

Check the airgap through the open tapped holes at three points:

Bolt with sealing ring

- Unscrew bolts with sealing rings from the housing

- Insert feeler gauge through the open tapped holes at all three points

- Measure the airgap between the armature plate and coil body group.

- Re-insert bolts with sealing rings and tighten. Old sealing rings cannot prevent the ingress of water.

Armature plate Friction lining group

Brake flange Coil body group

Drive technology 15

Mode of operation of the brake

Connection of the brake power supply On connection of the brake power supply, an electromagnetic field builds up. This causes the armature plate to be drawn towards the coil body group and the brake is released. The friction lining group of the brake can now rotate freely between the armature plate and brake flange.

Disconnection of the brake power supply On disconnection of the brake power supply, the electromagnetic field collapses and the brake is applied.

The pressure of the springs forces the armature plate against the friction lining group. The friction lining group simultaneously presses against the brake flange.

The mechanical friction is transferred to the motor shaft via the friction lining plate and driving hub. The motor is braked.

Running-in friction linings With the commissioning of the brake or after renewal of the friction lining group, the friction linings must be run-in. Only when this has been done is the specified braking torque fully transmitted.

Several controlled braking operations should be carried out, bearing in mind that the full braking power is not initially available. Braking under full load must be avoided.

Drive technology 16

Operation

The following safety information must be observed for operation of the brake:

∆ Usual changes In the event of any unusual changes to the brake, the brake power supply must immediately be disconnected. Any unusual changes , e.g. the development of smell at the brake, should immediately be reported to the person concerned or the customer service department notified in order to prevent the brake suffering further damage.

∆ Permissible braking energy The permissible braking energy can be determined from the thermal load diagram.

With a known switching energy per braking operation and number of braking operations per hour, the brake size can be determined. Example: Q = 100 kJ/switching energy and z = 35 braking operations/hour = brake SFB 100.

Braking speed n = 1500 rpm

Ene

rgy

per b

raki

ng o

pera

tion

Q

[kJ/

oper

atio

n]

Braking operation per hour z [1/h]

Drive technology 17

Manual release

Releasing the brake manually means briefly releasing the brake by manual actions and only in an emergency, e.g. in order to lower suspended loads carefully.

The following safety information must be observed before releasing the brake manually:

∆ Manual release only for emergencies Under no circumstances must the manual release be used for the purpose of maintaining temporary operation. It is intended for emergency use only.

It must be ensured when releasing the brake manually that the power supply to the brake remains disconnected and cannot be accidentally reconnected.

∆ Note position of load It is important to note the position of the load when releasing the brake manually and that the surrounding area is cleared before the load is lowered.

∆ High brake temperature Depending on the operating mode, the brake can reach high temperatures. It may therefore be necessary to wear protective gloves when releasing the brake manually. Contact with a hot brake when releasing the brake manually must be avoided as burns can result.

The housing can remain fitted when releasing the brake manually.

- Unscrew lock bolts with seals on the front of the housing. Figure 1

Lock bolts

Figure 1 Figure 2

Manual release

Manual release bolt

Hexagon socket screw key DIN 911

Air

gap

acco

rdin

g to

ratin

g pl

ate

Manual release

Drive technology 18

- Simultaneously turn both manual release bolts evenly clockwise. Figures 2 and 3 The armature plate is now drawn slowly towards the coil body group against spring pressure and the brake is released. Any suspended load should be observed when releasing the brake.

- Carefully lower the load with the aid of the manual release bolts. The speed at which the load is lowered can be accelerated by turning the bolts clockwise and decelerated by turning counter-clockwise.

- Set down the load.

Cancelling manual release - Simultaneously loosen the manual release bolts evenly counter-clockwise and unscrew until the bolt heads

just make contact with the brake flange. Figure 4

- Refit the lock bolts with new seals.

∆ Ready to operate condition After setting down the load, the brake must immediately be restored to a ready to operate condition. Note: The brake is only ready to operate when the manual release bolts have been turned back to their original position. Figure 4

Brake released Figure 3

Brake applied Figure 4

Air

gap

0 m

m

turn clockwise

Air

gap

acco

rdin

g to

ratin

g pl

ate

turn counter-clockwise

Drive technology 19

Maintenance

Brake maintenance must be carried out in strict observance of the safety information provided here.

∆ Danger to life through incorrect maintenance

Incorrectly maintained brakes can be dangerous. For this reason, only trained personnel may open and maintain the brake.

∆ Disconnect power supply

Before carrying out any maintenance work on the brake, the power supply must be disconnected and the appropriate sign provided at the switching point.

∆ Danger of crushing When working on the brake, heavy tools are used. Particular attention should therefore be paid to possible crushing points:


∆ Only qualified electrician Only a qualified electrician may replace electrical components such as coil bodies, contactors. For safety reasons, no description for the replacement of these parts is provided in these operating instructions.

∆ Use lifting equipment The brake can weigh between 19 and 750 kg depending on type. For maintenance purposes, lifting gear or another crane can be used.

∆ Do not use a crane being maintained Under no circumstances should the crane whose brakes are being maintained be used for lifting purposes.

∆ Active electromagnetic fields

On completion of maintenance work, all tools must initially be removed from the working area of the brake.

On connection of the brake power supply, the electromagnetic fields of the brake become active.

Maintenance

Drive technology 20

Maintenance for the SFB and SFB-H is limited to:

• Airgap check • Brake flange reversal • Friction lining group replacement • Brake flange and armature plate replacement • Condensation water drainage

Checking the airgap Regular airgap checks are an integral part of maintenance routines. The inspection intervals vary depending on the use of the brake. Weekly inspection will ensure perfection functioning of the brake with average use.

See Commissioning, page 16.

If the airgap should exceed the specified maximum airgap, the brake flange must be reversed or the friction lining group replaced.

Maintenance

Drive technology 21

Brake flange reversal

∆ Observe maximum airgap

Under no circumstances must brake flange reversal take place before the maximum airgap is reached.

∆ Observe safety information The safety information at the beginning of the maintenance chapter must be observed.

Note: The brake flange can only be reversed once! The friction lining group must subsequently be replaced and refitted.

When the maximum airgap is reached, the brake flange can be reversed:

- Disconnect the power supply.

- Remove cap nuts and sealing rings on housing and remove the housing.

- Simultaneously tighten manual release bolts evenly clockwise with two hexagon socket screw keys (DIN 911). The friction lining group can now move freely.

- Unscrew hexagon nuts.

- Remove brake flange and clean as described in the chapter “Cleaning”.

- Reverse brake flange and fit with the “new” side facing the armature plate.

Vor derWendung:Luftspalt größer als Maximal-Wert

Nach derWendungLuftspaltnormal

Before brake flange reversal: Maximum-airgap exceeded.

After brake flange reversal: Airgap according to rating plate

Maintenance

Drive technology 22

∆ Attention The brake components are provided with small notches for marking purposes. The notches must be located one on top of the other in a line. Failure to observe this will result in brake malfunction or failure.

Brake flange


Armature plate

Coil body group

- Tighten hexagon nut. When tightening the hexagon nuts, the tightening torque must be observed.

- Simultaneously loosen manual release bolts evenly counter-clockwise until the bolt heads just make contact with the brake flange.

∆ Remove foreign bodies on O-ring and contact surfaces When fitting the housing, the O-ring of the housing or the contact surface must be free from foreign bodies.

- For cleaning and fitting the housing, proceed as described in the chapter “Installation”.

- Subsequently check the airgap as described at the beginning of the chapter.

Maintenance

Drive technology 23

Brake flange, friction lining group and armature plate replacement

∆ Observe safety information Prior to replacement, the safety information at the beginning of the maintenance chapter must be observed.

Friction lining group consists of:

• Friction lining plate and • Friction lining

This group is subject to wear due to braking operations and must be replaced when worn. The replacement time depends on the braking frequency. Replacement is also necessary if the friction lining group has come into contact with

• Oil • Grease • or similar

Brake flange and armature plate

Like the friction lining group, both these components are subject to wear. It is recommended to also replace the brake flange and armature plate with each second replacement of the friction lining group. Further use will reduce the life of the new friction linings.

Procedure for the replacement of all three groups.

- Disconnect power supply.

- Remove housing.

- Simultaneously tighten manual release bolts evenly clockwise. The friction lining group now moves freely.

- Unscrew hexagon nuts on brake flange

Only for brake flange replacement:

- Remove brake flange and replace. Dispose of old brake flange.

Only for friction lining group replacement:

- Remove brake flange and clean as described in the chapter “Cleaning”.

- Remove friction lining group and replace.

∆ Following replacement, the cooling ribs of the friction lining group must point towards the brake flange.

Cooling ribs

Maintenance

Drive technology 24

Only for friction lining group replacement:

- After fitting the friction lining group, the brake flange with the initial side can be fitted as described in the section “Brake flange reversal”. The marks on the brake flange must correspond with those of the other brake components.

Only for replacement of all three components:

∆ Stand at the side of the brake When replacing the armature plate, the full spring pressure of the brake is exerted. If the work is not carried out correctly, parts of the brake can loosen through the spring pressure and cause injury. It is therefore important to stand at the stand of the brake when the following work is carried out:

- Loosen manual release bolts evenly and remove.

- Remove armature plate and replace. When changing the armature plate, it must be ensured that the pressure springs do not fall out of the coil body group.

- Fit new armature plate with the recess facing the coil body group.

Provided on one side of the armature plate is a recess. The side with the recess must face the coil body group (see illustration).

Recess.

This side must face the coil body group.

To be noted for installation:

The marks on the components must be in one line, as described in the chapter “Maintenance”.

- Fit new brake flange and tighten with hexagon nuts. The mark on the brake flange must correspond with those on the other brake components.

- Simultaneously unscrew manual release bolts evenly counter-clockwise until the bolt heads just make contact with the brake flange.

∆ Remove foreign bodies on O-ring and contact surfaces When fitting the housing, the O-ring of the housing or contact surface must be free from foreign bodies.

- For cleaning and fitting the housing, proceed as described in the chapter “Installation” under the section “Fitting the brake”.

- Subsequently check the airgap as described at the beginning of the chapter.

Following replacement of the friction lining group, the brake must be prepared for normal operation as described in the chapter “Commissioning”.

Maintenance

Drive technology 25

Condensation water drainage The condensation water must be drained from the brake once a year. Depending on the place of installation and the climatic conditions in which the brake is operated, more frequent drainage of the condensation water may be necessary. The maintenance interval for a specific place of use should be determined by draining the condensation water on a trial basis.

∆ Fitting new seals New seals must be fitted after draining the condensation water.

- Unscrew condensation water drain plug and remove the seal.

With horizontal installation, the condensation water can be drained from the plug located below.

Condensation water drain plug with vertical installation

- Drain condensation water.

- Fit condensation water drain plug with new seal and tighten.

The brake is now ready to use again.

Drive technology 26

Brake removal

∆ Danger to life through incorrect brake removal Incorrect brake removal can be dangerous. Only trained personnel may therefore open and remove the brake.

∆ Shutdown equipment and secure Before carrying out any work, the equipment must be shutdown and secured to prevent accidental starting.

∆ Disconnect power supply Before carrying out any work on the brake, the power supply must be disconnected and a warning sign provided at the switching point. It must also be ensured that power cannot accidentally be connected while working on the brake.

∆ Danger of crushing When carrying out work on the brake, heavy tools are used. Particular attention must therefore be paid to possible crushing points when:


∆ Lifting equipment The brake can weigh between 19 and 750 kg depending on type. If necessary, lifting gear should be used for maintenance purposes.

∆ Do not use the crane on which the brake is being removed for lifting purposes Under no circumstances must the crane whose brake is being removed be used for lifting brake components.

For removal of the complete brake, the procedure is in reverse to that described in the chapter “Installation”. Disconnection of the electrical connections must be carried out only by a qualified electrician.

Drive technology 27

Cleaning

Following extended operating times, abrasive dust can collect inside the brake assembly. No particular maintenance is necessary. It is recommended to clean the inside of the brake assembly as part of other maintenance routines.

∆ Disconnect power supply

Prior to cleaning the brake, the power supply must be disconnected and a warning sign provided at the switching point.

∆ Wear protective goggles Protective goggles should be worn when blowing out the brake to prevent abrasive dust going into the eyes.

∆ Do not use any corrosive chemicals Do not use any corrosive chemicals for cleaning the armature plate and brake flange. Only use grease dissolving cleaning agents and suitable cleaning materials.

∆ Danger of crushing When cleaning the brake, heavy tools are used. Particular attention should be paid to possible crushing points when:

• Using tools • Fitting and removing the brake, accessories or spare parts

For blowing out the brake:

- Disconnect power supply.

- Unscrew cap nuts and seals on the front of the housing and remove the housing.

- Blow out brake.

∆ Remove foreign bodies on O-ring and contact surfaces When fitting the housing, the O-ring of the housing or contact surface must be free from foreign bodies.

- For cleaning and fitting the housing, proceed as described in the chapter “Installation” under the section “Fitting the brake”.

Subsequently check the airgap as described in the chapter “Maintenance”.

Drive technology 28

Troubleshooting

This chapter contains information on clearing possible faults on the brake. Some faults can be cleared without outside help. Other faults may have to be referred to a qualified electrician for clearance.

∆ Shutdown equipment before maintenance and secure Shutdown the equipment before carrying out any work and secure the same against accidental starting.

Fault Possible cause Remedy 1

Brake releases only partly or incorrectly

Brake flange incorrectly fitted Armature plate sticks on one side

Reverse brake flange Replace armature plate

2 High friction lining wear

Brake works against the motor Excessive switching operations Brake size too small

Consult a qualified electrician Reduce switching frequency or reduce load to be braked. Fit larger brake Check loading case

3 Brake does not transfer full braking torque

Pressure springs missing Friction lining plate has come into contact with oil, grease or similar media Brake is still in the running-in phase

Check number of pressure springs and use the full number of springs if necessary Renew friction lining plate, thoroughly clean armature plate and brake flange and replace if necessary Perform several dynamic braking operations appropriate to brake operation

Troubleshooting

Drive technology 29

Fault Possible cause Remedy 4

No braking Manual release bolts are not loosened Contactor contacts do not open

Simultaneously turn manual release bolts evenly anticlockwise until the bolt heads just make contact with the brake flange. Consult a qualified electrician

5 Braking too slow

Operation takes place in an a.c. circuit Contactor contacts do not open Incorrect overvoltage protection

Consult a qualified electrician Consult a qualified electrician Consult a qualified electrician

6 Brake is not released

Power supply failed Maximum airgap exceeded Coil damaged

Consult a qualified electrician Readjust airgap Consult a qualified electrician

7 Brake released too slowly

Insufficient coil voltage Operation takes place in an a.c. circuit Switching time at rated excitation insufficient Maximum airgap reached

Consult a qualified electrician Consult a qualified electrician Consult a qualified electrician Readjust airgap

8 Coil damaged Excessive coil voltage Brake was used without overvoltage protection

In any event, consult a qualified electrician and have the coil body replaced Adjust rated voltage For foil outputs above 100 W, overvoltage protection must be provided

Drive technology 30

Spare parts

Only original spare parts must be used otherwise the warranty for the brake will be invalidated and any liability on the part of PINTSCH BAMAG will cease to apply.

Important information for the SFB-H: The friction lining group and brake flange are marked with the letter “H” and may only be used for SFB-H series brakes.

For the brake types SFB and SFB-H, spare parts can be ordered from PINTSCH BAMAG Dinslaken:

The following must be specified when ordering spare parts:

Brake size (type)

Brake serial number

Spare part item number and designation

Quantity

Brake type and serial number and coil voltage are specified on the rating plate

Driving hub: Specify bore, keyway and length

Adapter flange: Specify outside diameter and thickness

Housing: Specify largest outside diameter

Designation of spare parts Item Designation 1.1 Coil body group 1.2 Friction lining group 1.3 Brake flange 1.4 Armature plate 1.5 Bolt 1.6 Cheese-head bolt, self-locking 1.7 Hexagon nut, self-locking 1.8 Pressure spring 2 Cover group 3 Adapter flange 4 Housing 6 O-ring 7 Cheese-head bolt 8 Cheese-head bolt 9 Screwed sealing plug 10 Stud bolt 11 Cap nut 13 Sealing ring 14 Sealing ring 15 Driving hub (Pinion)

Drawn offset by 90°

Drive technology 31

Additional equipment for brakes

The following additional equipment is available for all SFB and SFB-H series brakes:

• Function monitoring via microswitch • Function monitoring via proximity switch • Lateral connection box • Lateral connection box with rectifier (up to SFB 63 possible) • Provision for tachogenerator • Anti-condensation heater (space heater) • Increased braking torque • Reduced braking torque The operating instructions relating to the additional equipment must be observed.

Disposal

Brakes must be sorted and disposed. The currently applicable disposal regulations must be observed.

Warranty

PINTSCH BAMAG warrants its products subject to its general conditions of sale (AVB) as well as the general delivery conditions of the electrical industry (ZVEI).

The following are excluded from the warranty:

q Damage caused by the user, incorrect connection, incorrect operation or improper maintenance.

q Damage due to force majeure.

q Damage resulting from using the brake for purposes other than those described in the operating instructions.

Drive technology 32

EC declaration of conformity

Seawater-proof electromagnetic double-face spring-operated brake SFB and SFB-H This declaration refers to the brake. It applies only to the original condition of the brake manufactured by us. Any modification made without our prior written permission will result in this declaration being rendered invalid.

Type

Serial number

The brake conforms to the following standards and directives of the European Community Council: Conformance of the designated product with the requirements defined in Directive 73/23/EEC of 19 February 1973 for harmonisation of the statutory regulations of the member countries relating to electrical equipment within specific voltage limits and the protective requirements defined in its supplements is verified by conformance with the following standards:

Harmonised European Stands:

EN 60204-1 Date of issue 1993.6

DIN VDE 0580 Date of issue 1994.10

IEC standards

Provision of the CE mark according to the low-voltage directive. Year of first provision 1997

Issued by PINTSCH BAMAG Antriebs- und Verkehrstechnik GmbH

Place, date Dinslaken, 5.11.1997

Legally binding signatures

Managing Director Commercial Director

This declaration certifies conformance with the mentioned directives, but does not contain any assurances of qualities.

The safety information accompanying the supplied product document must be observed.

Drive technology 33

Index

A Additional equipment 31 Airgap, check 14, 20 Airgap measuring bolt 7 Armature plate Replacement 23 Position 8

B Brake adapter plate 8 Brake flange Replacement 23 Position 9 Reversal 21 Brake, mode of operation 15 Brake power supply 5

C Cleaning 27 Coil body group 8 Commissioning 13 Condensation water drainage 25 Condensation water drain plug Vertical installation 25 Horizontal installation 25 Connecting cable 8 Connection dimensions 6 Connection, electrical 12 Cooling ribs 23

D Disposal 31 Driving hub 10

E EC declaration of conformity 32 Electrical connection 12

F Fitting, brake 10 Friction lining group Replacement 23 Position 8 Friction linings, running-in 15 Function check 13

H Housing 7

I Installation 9

M Maintenance 19 Manual release 17 Manual release bolts Bolt sizes/ Key sizes 6 Position 8 Mode of operation of the brake 15

O Operation 16

P Pressure springs 9 Product description SFB 3 SFB-H 3

R Rating plate Contents 7 Position 7 Removal, brake 26

S Safety information General 4, 5 Special 9, 11, 12, 13, 16, 17, 19, 21-27 Spare parts 30 Symbols 4

T Technical data 6 Thermal load diagram 16 Tightening torques 6 Troubleshooting 28

U Use for the intended purpose 3

W Warranty 31

Date of issue 06/2000 PINTSCH BAMAG ANTRIEBS- UND VERKEHRSTECHNIK GMBH holds the copyright to these instructions. No part of the data and diagrams in these instructions may be reproduced, circulated or used for the purpose of competition or otherwise or made available to unauthorised persons or third parties without the prior written permission of the publishers.

The illustrations and data in these instructions are subject to technical changes necessary for product improvement without prior notice.

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