Emerson Leroy-Somer FFB Series Operating manual

2015.04 / a
en
Maintenance Guide
Reference: 5287 en -
Maintenance Guide
Brake motors
FFB

20
FFB Brake Motors Maintenance Guide
5287 en - 2015.04 / a
GENERAL WARNING
This document is an addition to the general manual ref. 1889 (recommendations), ref. 4850 (LSES motor), ref. 4155
(LSRPM motor), and manual ref. 5286 (FFB brake installation).
FFB brake motors are assemblies made of an asynchronous motor and a failsafe braking system (safety brake).
This brake motor benets from the experience of a global manufacturer, using cutting edge technologies - automation, selected
materials, thorough quality control - in our motor plants who have been awarded the ISO 9001 - Issue 2008 international
certication.
These symbols appear in this document whenever it is important to take special precautions during installation, operation,
maintenance or servicing of the brake motors.
General danger Electrical hazard Risk of physical injury
These recommendations, instructions and descriptions refer to standard use. They do not take account of non-standard
versions or special adaptations. Failure to comply with these recommendations can lead to premature wear and tear of the
motor and can invalidate the manufacturer warranty.
Make sure that the brake motor is compatible with its environment before its installation and also throughout its life.
The following preliminary precautions must be taken before working on any stationary device:
• Mains voltage disconnected and no residual voltage present
• Careful examination of the causes of the stoppage (blocked transmission - loss of phase - cut-out due to thermal
protection - lack of lubrication, etc.)
Electric brake motors are industrial products. They must therefore be installed by qualied, experienced and authorized
personnel. The safety of people, animals and property must be ensured when tting the motors into machines (please refer
to current standards).
Particular attention must be given to equipotential ground or earthing connections.
Safety of personnel: Protect all rotating devices before power-up. If a brake motor is started up without a coupling device
having been tted, carefully immobilize the key in its location. All measures must be taken to ensure protection against the
risks which arise when there are rotating parts (coupling sleeve, pulley, belt, fan, etc.). Personal protective equipment must
be worn. After work is carried out, the lids of the terminal box and its cover must always be closed.
Beware of backdriving:
- When the motor is switched off. The appropriate precautions must be taken: for example, for pumps a non-return valve must
be installed.
- When the brake motor is tted with an active brake release lock off system (DLM), it is vital to ensure safety (of people
and property) in exposed areas.
Before any intervention on the brake, check that it holds no load.
- After an operating period, certain parts of the brake motor may be hot and are likely to cause burns.

21
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FFB Brake Motors Maintenance Guide
5287 en - 2015.04 / a
LEROY-SOMER reserves the right to modify the characteristics of its products at any time in order to incorporate the latest
technological developments. The information contained in this document is therefore liable to be changed without notice.
CONTENTS
1 - IDENTIFICATION ............................................................................................................................................... 22
1.1 - Standard nameplate .................................................................................................................................. 22
1.2 - Special marking ......................................................................................................................................... 22
2 - EXPLODED VIEW AND PARTS LIST OF FFB BRAKE MOTORS .................................................................... 23
2.1 - Exploded view ........................................................................................................................................... 23
2.2 - Parts list ..................................................................................................................................................... 23
3 - SPARE PARTS................................................................................................................................................... 23
3.1 - Procedure ................................................................................................................................................. 23
3.2 - Brake motor spare parts............................................................................................................................. 23
4 - MAINTENANCE ................................................................................................................................................. 24
4.1 - Tooling ...................................................................................................................................................... 24
4.2 - Removing the FFB brake motor ................................................................................................................. 24
4.3 - Retting the FFB brake motor .................................................................................................................... 24
4.4 - Adjusting the air gap .................................................................................................................................. 25
5 - CHARACTERISTICS ......................................................................................................................................... 26
5.1 - Braking moments ...................................................................................................................................... 26
5.2 - Electromagnets.......................................................................................................................................... 26
6 - OPTIONS.......................................................................................................................................................27-32
6.1 - DLRA lever - Disassembly / Assembly ....................................................................................................... 27
6.2 - DLM lever - Disassembly / Assembly ........................................................................................................ 28
6.3 - DMD lever - Disassembly / Assembly ........................................................................................................ 29
6.4 - Indicators (Loosening / Wear) ................................................................................................................... 30
6.5 - Standard encoder (incremental, absolute) ................................................................................................ 31
6.6 - Forced ventilation ...................................................................................................................................... 32
6.7 - Connector kit - Assembly / Disassembly .................................................................................................... 32
6.8 - Particular conditions of use ....................................................................................................................... 32
7 - REPAIRING GUIDE ........................................................................................................................................... 33
8 - CONNECTION DIAGRAMS .......................................................................................................................... 34-36
8.1 - Motor: reminder ......................................................................................................................................... 34
8.2 - Brake ........................................................................................................................................................ 34
8.3 - Options ................................................................................................................................................34-36
9 - RECYCLING....................................................................................................................................................... 36

22
IDENTIFICATION
FFB Brake Motors Maintenance Guide
5287 en - 2015.04 / a
1 - IDENTIFICATION
1.1 - Standard plate
Motor nameplate (item 26a)
3 LS 90 L T
S1
IP55
V
230
380
400
415
460
6.85
4.10
3.95
4.00
3.90
50
50
50
50
60
1.80
1.80
1.80
1.80
2.07
0.82
0.85
0.82
0.78
0.82
1435
1425
1435
1445
1735
Hz min-1 kW A
633037E
IEC60034-1
IK08 Ta40°C clF 14.8 kg 1000m
cos ϕ
N° 999999999/001
IP
F-16915 ANGOULEME
NmMf UNVDC
6
5 3 4 11
9 1
Brake nameplate (item 26b)
FFB250NU001
Mf :
26 Nm
S N° : 4446890/000
U : 180 VDC I : 295 mA
Motor size : 145
Nmax : 4500 rpm
II 3 D Ex tc IIIB T125°C Dc
FFB 2
6.10 kg
26 78
11 10
Indispensable information found on the nameplates:
1
Motor series, frame size
2
FFB brake type
3
Speed of rotation (rpm)
4
Rated power (kW)
5
Motor voltage (V)
6
Motor and brake manufacturing no.
7
Mf: Braking torque (N.m)
8
U: Brake coil voltage (VDC)
9
Duty - Duty (operating) factor
10
I: Coil current (mA)
11
Specic (ATEX) marking
Information to be remembered for spare part orders
Denition of symbols
T: Impregnation index
IE2: Efciency class
IP-- IK--*: Protection indices
Ins. Cl.F: Insulation class
(Ta) 40°C: Ambient operating temperature
cos P or j: Power factor
A: Rated current
∆: Delta connection
Y
: Star connection
*IK: Shock resistance
The motor can withstand a weak mechanical shock (IK 08
according to EN 50102). The user must provide additional
protection if there is a high risk of mechanical shock.
Bearings
DE: Drive end bearing
NDE: Non drive end bearing
Marking
: Legal mark of conformity of product to the requirements
of European Directives
C
US
166631
®: CSA certied product, UL conformity
Motor plate LSES112MU 4kW, 4p, 400V
Y
Brake motor plate with inverter LSES112MU 4kW, 4p,
400V
Y
1.2 - Special marking
Upon receiving the brake motor, check that the information
nameplate complies with contractual specications.
(e.g. brake motor operating in dusty explosive atmospheres;
in this case: non conductive dust.)

23
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EXPLODED VIEW AND PARTS LIST OF FFB BRAKE MOTORS
FFB Brake Motors Maintenance Guide
5287 en - 2015.04 / a
1300
1303
1302
0054
0006
0050
0002
1110
0071
0084
0021
0022
0005
0023
0039
0039
0005
0030 0060
0060
0004 0001 0629 0026 0014 0059 0629
1304
1301
1300
1100
1305
1306
1101
1306
1102
1103 1107
1200
1104
1105
1500
1503 1501
1504
1400
1401
0007
0009
0027
0013
1407
1406
1402
1505
1502
1106
1108
1305
1101
1102
1107 1200
1108 1109 1106
1400
1401
0008 0007
1406 1407
0013
0027
0009
1402
1105
1104
1103
1306
1100 FFB1
FFB2 ---> FFB5
+ DLRA
IM B14
IM B3
IM B5
3 - SPARE PARTS
3.1 - Procedure
Always indicate the following when ordering spare parts:
- complete motor type, its number and the information
indicated on the information plate (refer to §1);
- serial no. of the brake information plate item 26b;
- the numbers and descriptions of the parts (record the part
marks in the exploded view §2.1 and their description in the
parts list §2.2).
For motors with a xing ange, specify the ange and its
dimensions (IM B5 smooth holes, IM B14 tapped holes or
built-in assembly MI) and the details of the coupled reduction
gear if applicable.
To ensure proper operation and safety of our brake motors,
always use original manufacturer parts.
Maintenance kits are available. Refer to LSAS or the
following sites:
www.leroy-somer.com
or
www.emersonindustrial.com\Services-pour-systemes-d-entrainement.aspx
Otherwise, the manufacturer shall waive any liability in
case of damage.
3.2 - Spare parts
Item (item)
Type Polarity 30 50 39 54 1101 1107 1300 1306 1402
LS 71 L, M 2; 4; 6 6202 C3 6201 C3
gasket disc1gaskets
LS 80 L 2; 4; 6 6204 C3 6203 CN
(F)LS(ES) 80 LG 4 6205 C3 6204 C3
(F)LS(ES) 90 SL, L 2; 4; 6 6205 C3 6204 C3
(F)LSES 90 LU 4 6205 C3 6205 C3
(F)LS(ES) 100 L 2; 4; 6 6206 C3 6205 C3
(F)LSES 100 LG 4 6206 C3 6205 C3
(F)LSES 100 LR 4 6206 C3 6205 C3
LSES 112 M 4 6206 C3 6205 C3
Item (item)
Type Polarity 30 50 39 54 1101 1107 1300 1306 1402
(F)LS(ES) 112 MG 2; 4; 6 6206 C3 6205 C3
gasket disc1gaskets
(F)LSES 112 MU 4 6206 C3 6206 C3
LS(ES) 132 S, SU 2; 4; 6 6208 C3 6206 C3
(F)LS(ES) 132 SM, M 2; 4; 6 6308 C3 6207 C3
LSES 160 MR 4 6309 C3 6308 C3
LSES 160 MP 2 ; 4 6309 C3 6208 C3
(F)LSES 160 M 4 ; 6 6309 C3 6210 C3
(F)LSES 160 L, LR 4 6309 C3 6210 C3
1. When changing the brake disc only, the braking moment is achieved only once the friction surfaces are run in.
2 - EXPLODED VIEW AND PARTS LIST OF FFB BRAKE MOTORS
2.1 - FFB brake motor exploded view
2.2 - FFB brake motor parts list
Item Description Qty Item Description Qty Item Description Qty
1 Stator 1 30 Front bearing (DE) 1108 Wire guide (item 1105) 1
2 Housing 1 39 Front sealing gasket (DE) 1 1109 Obturating cap 2
4 Rotor 1 50 Bearing brake side (NDE) 1 1110 Brake supply unit 1
5 Front shield (DE) 1 54 Sealing gasket on brake side (NDE) 1 1200 Compression spring 3 to 10
6 Back shield (NDE) 2 59 Preload washer 1 1300 O-ring (between item 6 and item 1100) 1
7 Fan 1 60 Internal circlips (DE item 30) 1 1301 Splined ring key (item 1302) 2
8 Fan spacer (item 7) 0 or 1 71 Terminal box 1 1302 Splined ring 1
9 Locking circlips (item 7) 1 or 2 84 Terminal board 1 1303 Locking circlips (item 1302) 1
13 Fan cover 1 629 Drain hole plug 1 or 2 1304 Spacer 0 or 1
14 Assembly rods 3 or 4 1100 Friction face plate 1 1305 Fixing screw (item 1100) 3 or 4
21 Shaft end key (DE) 1 1101 Brake disc 1 1306 O-ring (item 1101) 2
22 Shaft end spacer 1 1102 Armature 1 1400 Extension/shaft link screw (item 1401/4) 1
23 Tightening screw (item 22) 1 1103 Safety pins 3 or 4 1401 Extension shaft 1
25 Lifting eye (H.A. ≥ 100) 2 1104 Adjustment spacer 3 or 4 1402 VLS gasket (item 1105) 1
26a Motor nameplate 1 1105 Brake yoke 1 1406 Cover closing hatch 1
26b Brake nameplate 1 1106 Fixing screw (item 1105/1100) 3 or 4 1407 Fixing screw (item 1406) 4
27 Cover xing screw (item 13) 4 1107 O-ring 1 1500 to 1505: DLRA option (see § 6.1)
xx Spare part

24
CORRECTIVE MAINTENANCE
FFB Brake Motors Maintenance Guide
5287 en - 2015.04 / a
4 - CORRECTIVE MAINTENANCE
Before any operation on the brake, always
disconnect the brake motor from its power supply
(Putting in writing).
4.1 - Tooling (not supplied)
Tools
Function
Adjustment shims Air gap adjustment
Torque wrench Tightening for assembly of brake parts
Open end, handle, box
wrench (M8/10/16, etc.)
Removal of the face plate, extension,
yoke, DLRA, DLM, DMD
Special socket Screw and unscrew the shaft end
extensions
Hub puller Splined ring removal
Bearing puller
Bearing change: refer to manual §3.2
Mallet (leather or plastic) Lift the keys from the splined ring
Multimeter Voltage check
Ohmmeter (indicator lamp) Coil resistance measurement, micro-
contact adjustment
Circlip pliers
Circlip removal
VLS assembly jet Gasket tting
Large at blade screwdriver Fan removal
2 threaded rods: M5
(FFB1), M6 (FFB2 and 3)
and M8 (FFB4 and 5)
and corresponding nuts
Retting the armature on yoke
2 large at blade
screwdrivers Fan removal
Always record the connections of the supply
wires and options before disconnection.
Similarly, record the position of anges with
respect to the stator and the fan's direction on the rotor.
4.2 - Removing the FFB brake motor
- Remove the brake motor using appropriate tools.
- Disconnect the brake motor from its supply.
- Open the terminal box, record the wires and their position
(supply of the brake motor, encoder, probes, etc.). Always
record the connections of the supply wires and options before
disconnection.
- Disconnect the supply wires from the motor and brake
supply terminal strips (+ and - terminals).
- Disconnect the rectier bridge and check the stator isolation
(> 10 MOhms).
- If the brake is tted with a DLRA, DLM or DMD system,
unscrew the lever rod(s) (item 1502, 1605).
- Unscrew the cover screws 27, remove the metal cover 13.
- Remove the fan 7 by removing the axial locking circlips 9.
- Extract the fan 7 using two screwdrivers as levers.
- Remove the VLS gasket 1402.
- Unscrew the xing screws from the yoke 1106.
- Remove the yoke 1105 from the brake, remove the O-ring
1107, extract the armature 1102 while recording its angular
position.
- Remove the brake disc 1101 while recording the assembly
direction (large hub shoulder on motor side).
- Unscrew the xing screws 1305 from the face plate, then
remove the face plate 1100.
- Unscrew the extension 1401 while blocking the drive shaft.
- Remove the circlips 1303.
- Extract the splined ring 1302 using a puller.
- Remove the keys 1301 from the ring.
- Find all the faulty parts to order spare parts. Refer to §2.
• Clean the parts:
- by blowing the electrical parts and the brake parts 1100 to
1108 (no solvents, no humid products);
- using a non greasy degreasing product for mechanical
parts (item 1101 excepted);
- using a scraper for joints.
• Change the gaskets and bearings. Refer to §2 and 3.
4.3 - Retting the FFB brake motor
Clean the bleeding ports and plugs before retting.
Verify that no pollution distorts item 1105.
Tightening screw according to NF E 25030-1 or
VDI2230.
- Reverse the procedure for retting: keys 1301, ring 1302,
face plate 1100 (with locating pin: position the outer spigot
opposite the coil cable), brake disc 1101.
- Position the armature 1102 (non through drill hole on one
face located at 9 o'clock with respect to the yoke cable) on
the yoke 1105 tted with its springs. Screw the two threaded
screws through the yoke into the armature while ensuring it
does not protrude the braking face (slight recess). Press the
armature onto the yoke using two nuts mounted onto the rods
(tighten each rod gradually).
- Install the O-ring 1107 inside its groove between the
armature 1102 and the yoke 1105.
- Mount the yoke and armature onto the face plate using the
xing screws 1106 (tighten to torque).
- Check that the brake disc turns freely.
- Remove the two threaded rods: the brake disc is blocked.
- Ret the fan 7 and its holding washers 8and 9.
- Ret the cover 13.
- Ret the control rod of the DLRA, DLM lever(s) if necessary.
If Encoder option: see §6.5
If Forced Ventilation option (VF) + Encoder: refer to §6.6 and
6.5.
Include sufcient
distance around the
brake for access and
intervention.

25
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CORRECTIVE MAINTENANCE
FFB Brake Motors Maintenance Guide
5287 en - 2015.04 / a
4.4 - Air gap adjustment
Adjust the air gap when normal loosening is no longer
possible. Always check the pad's thickness when adjusting to
ensure pad wear does not exceed the R dimension in mm (i.e.
R/2 on either side of the disc 1102). Its change is compulsory
before the lenght R between each brake lining reaches:
Brake size
Minimum R dimension
FFB1, FFB2, FFB3 9 mm
FFB4, FFB5
15 mm
Exceeding R dimension can cause security
problems (quick decrease of braking torque Mf).
- Unscrew the screws 27 holding the metal cover 13.
- Remove the metal cover 13.
- Clear the O-ring 1107 to gain access to the air gap.
- Check the air gap between the yoke 1105 and armature
1102 in 3 points at 120°.
- Release spacers 1104, move them closer to the yoke 1105.
- Screw the xing screws 1106 while measuring the air gap
between the yoke and the armature to obtain a dimension of
0.3 mm. If release lever (DLM or DMD) presence, set to 0.6
mm.
- Screw the spacers 1104 in abutment on friction face-plate
(tighten to 2 Nm ±10% torque).
- Tighten xing screws 1106 brake yoke on face-plate to the
torque as follows: FFB1: 4.9 N.m; FFB2 and 3: 8.5 N.m; FFB4
and 5: 21 N.m ±10%.
- Check the value of the air-gap again.
- Reposition the O-ring 1107 into its groove.
- Fasten the cover 13 with its screws 27.
When DLRA or DLM mounted, refer to §6.1, 6.2.
1102
R
lining

26
CHARACTERISTICS
FFB Brake Motors Maintenance Guide
5287 en - 2015.04 / a
5 - CHARACTERISTICS
5.1 - Braking moments
The braking moment is defined according to the number of springs and their colour, based on the values indicated in the table
below.
Running-in: All brake linings, complete brake (Brake disk only: see section 3.2) are already run-in in the factory before assembly
onto the motor. The dynamic braking moment indicated is optimum (tolerance -10 to +40 %).
Braking moments (N.m) specied for information; in case of normative restriction, please consult us.
FFB1 FFB2 FFB3 FFB4 FFB5
Nbr of
springs Colour Mf (N.m) Colour Mf (N.m) Colour Mf (N.m) Colour Mf (N.m) Colour Mf (N.m)
3
Purple
(RAL 4008)
4.5
White
(RAL 1013)
11 - -
Brown
(RAL 8017)
41 - -
4
6
15
-
-
55
-
-
57.5 19
Orange yellow
(RAL 2000)
37 69 - -
6
9
23
45
83
Black
(RAL 9005)
120
710.5 26 52 96 140
8
12
30
59
110
160
9- - - - 67 - - 180
10
- - - - 74 - - 200
5.2 - Electromagnets
As certain direct current coils are difficult to differentiate by
their dimension, measure the coil's resistance using an
Ohmmeter on an appropriate calibre and compare with the
value indicated in the table below.
These values are theoretical, calculated for an ambient
temperature of +20°C.
Characteristics of the electromagnets ±5 %, at +20°C
180V coil
ESFR VMA 31 to 34
20V coil
Type
brake
Intensity
A
Resistance
Ω
Power
W
Intensity
A
Resistance
Ω
Power
W
FFB1
0.232
776
42
1.974
10.1
39
FFB2
0.295
610
53
2.633
7.6
53
FFB3
0.345
522
62
2.793
7.2
56
FFB4
0.339
530
61
3.602
5.6
72
FFB5
0.547
329
98
4.211
4.8
84

27
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OPTIONS
FFB Brake Motors Maintenance Guide
5287 en - 2015.04 / a
6 - OPTIONS
6.1 - DLRA lever
- Exploded view
1500
1502
1503 1504
1501
1505
0008
0007
0009
0013
0027 1406 1407
- Parts list
Item Description Qty Item Description Qty
7 Fan 1 1500 Stud 2
8 Fan thrust washer 0 or 1 1501 DLRA calliper 1
9 Locking circlips 1 1502 DLRA control rod 1
13 Fan cover 1 1503 Spiral spring under nut 2
27 Cover xing screw 3 or 4 1504 Locknut 2
1406 Cover closing hatch 1 1505 Return spring (item 1501) 1
1407 Fixing screw 4
• Disassembly:
- Unscrew the rod from the lever 1502 (if mounted on the
lever).
- Unscrew the xing screws 27 from the cover, remove the
metal cover 13.
- Remove the fan 7 by removing the axial locking circlips 9.
- Extract the fan 7 using two screwdrivers as levers.
- Unscrew the two locknuts 1504, remove the spiral springs
1503.
- Remove the return spring 1505.
- Remove the calliper 1501.
- Unscrew the two studs 1500.
After loosening, check that the brake is in the
applied position once the maintenance
operations are performed.
• (Re)Fitting:
Proceed the other way round of dismantling. Screw studs at
the following torque: FFB1: 5.75 Nm; FFB2 and 3: 9.9 Nm;
FFB4 and 5: 24 N.m ±10%.
- When screwing the locknuts 1504 again, add a 1.6 mm
clearance between the calliper 1501 and the yoke 1105.
- After tting the cover, loosen the xing screws 1407, fully
screw the control rod 1502 onto the calliper 1501.
- Position the cover closing hatch 1406 while checking
that the lever's travel is effective (in brake release
position).
- Tighten the xing screws 1407.

28
OPTIONS
FFB Brake Motors Maintenance Guide
5287 en - 2015.04 / a
6.2 - DLM lever
- Exploded view
1505
1605
1602
0008
0007
0009
0013 0027 1406 1407
1502
1500
1501 1503 1504
1600 1603
1601 1604 1800
- Parts list
Item Description Qty Item Description Qty
7 Fan 1 1503 Spiral spring under nut 2
8 Fan thrust washer 0 or 1 1504 Locknut 2
9 Locking circlips (item 7) 1 1505 Return spring (item 1501) 1
13 Fan cover 1 1600 Stud (item 1601) 2
27 Cover xing screw (item 13) 3 or 4 1601 Latch 1
1406 Cover closing hatch 1 1602 Rotation axis (item 1601) 1
1407 Fixing screw (item 1406) 4 1603 Locknut 2
1500 Stud (item 1501) 2 1604 Return spring (item 1601) 1
1501 DLRA calliper 1 1605 Control rod (item 1601) 1
1502 DLRA control rod 1 1800 Spacer 1
• Operation
Releasing the brake and maintaining it in position: push
the control rod DLRA 1502 by applying a force towards the
rear of the brake motor, then swivel the rod of the DLM 1605
clockwise. Release the DLRA rod 1502 to lock the brake in
the released position.
• Disassembly:
- Unscrew the control rods of the levers 1502 and 1605 (if
mounted on their base).
- Unscrew the screws 27 from the cover, remove the metal
cover 13.
- Remove the fan 7 by removing the axial locking circlips 9.
- Extract the fan 7 using two screwdrivers as levers.
- Remove the return spring 1604.
- If applicable, unscrew the latch stop 1606.
- Unscrew the hexagonal spacer (catcher springs) DLM 1800.
- Unscrew the rotation axis of the latch 1602 then remove the
latch 1601.
- Unscrew locknuts 1603.
- Unscrew studs 1600.
- Remove the DLRA according to the procedure in section 6.1.
• Reassembly:
Proceed the other way round of dismantling. Screw the
rotation axis of the bolt 1602 at the following torque: FFB1, 2
and 3: 5.75 Nm; FFB4 and 5: 9.9 Nm, ±10%.
Screw the hexagonal spacer DLM 1800 to the torque of
5.75 Nm ±10% for FFB1 in 5. Screw the studs at the following
torque: FFB1 : 5.75 Nm; FFB2 and 3: 9.9 Nm; FFB4 and 5: 24
Nm, ±10%.
After any loosening operation, check that the
brake is in the applied position once the
maintenance operations are performed.
Working position of the DLM lever:
16051605
1502
Item 1605
unlocked
Locking
direction
Item 1605
locked