Version 04.06
Operating and assembly instructions spring-loaded brake FDW – ATEX
Operating and assembly instructions
Spring-loaded brake FDW
Type of protection IP 65 - dust-protected design
Zone 22, category 3D, T 125°C (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 װ, 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 20°C).
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
W
Rmax
max.
Brakes
size
MbN
Standard
(Nm)
P
Standard
(W)
friction
energy
per
braking
(J)
FDW 08 5 33 1,5x103 140x103 3 x M4 3
FDW 10 10 42 3,0x10
FDW 13 20 50 6x10
FDW 15 40 63 12x10
FDW 17 60 75 17x10
3
180x103 3 x M5 6
3
230x103 3 x M6 10
3
280x103 3 x M6 10
3
360x103 3 x M8 25
P
R
max.
admissible
friction
power
(J/h)
Fastening
screws
Tightening
moment of
the screws
MA (Nm)
FDW 20 100 96
FDW 23 150 114
FDW 26 250 150
FDW 30 400 210
25x10³ 450x10³
37x10³ 540x10³
52x10³ 630x10³
75x10³ 720x10³
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
(max. switching energy) is the switching
Rmax
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 P
is the switching
max
energy W which is achievable every hour.
If during operation both P
and W
max
max
are
simultaneously nearly reached, the diagram
(W
depending on the hourly switching time)
max
shown in the operating instructions has to be used.
3 x M8 25
3 x M8 25
3 x M10 50
6 x M10 50
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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 08 10 13 15 17 20 23 26 30
a
+0,1
Nom
a
max
Rotor size (new) 7,5 8,5 10,3 12,5 14,5 16 18 20 20
Dimensions indicated in mm
Control PTC thermistor: Resistance (at 20°C) < 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
0,2 0,2 0,3 0,3 0,3 0,4 0,4 0,5 0,5
0,5 0,6 0,8 0,8 0,8 0,9 0,9 1,0 1,0
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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 20°C) < 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).
Operating and assembly instructions spring-loaded brake FDW – ATEX
Bahnhofstraße 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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