SEW-Eurodrive BMG T Series User manual

Gearmotors \ Industrial Gear Units \ Drive Electronics \ Drive Automation \ Services
BMG..T Double Disc Brakes
for Stage Applications
O perating Instructions
A6.C86
Edition 06/2004
11295228 / EN
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Operating instructions – BMG..T Double Disc Brakes for Stage Applications
3
Contents
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
1 Important Notes................................................................................................. 4
1.1 Safety and warning instructions................................................................ 4
2 Safety Notes ...................................................................................................... 5
3 Certificate........................................................................................................... 6
4 Structure of the BMG..T Stage Brake.............................................................. 7
4.1 Basic structure.......................................................................................... 7
4.2 Unit designation........................................................................................ 7
5 Installation/Startup............................................................................................ 8
5.1 Mechanical installation.............................................................................. 8
5.2 Electrical installation ................................................................................. 8
5.3 Startup ...................................................................................................... 8
6 Inspection / Maintenance ................................................................................. 9
6.1 Inspection and maintenance periods........................................................ 9
6.2 Checking the dual circuit braking function ................................................ 9
6.3 Customer service.................................................................................... 12
7 Technical Data................................................................................................. 13
7.1 BMG..T braking torque ratings................................................................ 13
7.2 Brake control systems............................................................................. 13
7.3 BMG..T operating currents...................................................................... 14
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4
Operating instructions – BMG..T Double Disc Brakes for Stage Applications
1Safety and warning instructions
Important Notes
Betriebsanleitung
1 Important Notes
1.1 Safety and warning instructions
Always follow the safety and warning instructions in this publication!
This documentation contains safety requirements and additional information on the
BMG..T double disc brake for use in stage applications.
A requirement of fault-free operation and fulfillment of any rights to claim under
guarantee is that you adhere to the information in the operating instructions.
Consequently, read the operating instructions before you start working with the brake!
The operating instructions contain important information about servicing and should be
kept close to the unit. This document supplements the "AC Motors, Asynchronous
Servomotors" operating instructions and limits the application notes according to the
following information.
The guidelines in this documentation must be strictly observed for safety
applications. This applies in particular to the requirements of the employer's
liability insurance association and TÜV.
Disposal This product consists of:
•Iron
• Copper
•Aluminum
• Plastic
Please dispose of the parts in accordance with the applicable regulations.
Electrical hazard
Possible consequences: Severe or fatal injuries.
Hazard
Possible consequences: Severe or fatal injuries.
Hazardous situation
Possible consequences: Slight or minor injuries.
Harmful situation
Possible consequences: Damage to the unit and the environment.
Tips and useful information.
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Operating instructions – BMG..T Double Disc Brakes for Stage Applications
5
2
Safety and warning instructions
Safety Notes
2 Safety Notes
• The requirements for the emergency stop relay and the permitted circuit variants are
specified in detail in the following sections and must be strictly observed.
•The system/machine manufacturer must perform a system/machine-specific
risk analysis. The use of BMG..T double disc brakes for stage applications
must be taken into account in this analysis.
•The switching equipment of the external voltage supply for the brakes must at
least comply with category 3 to EN 954-1 or with a comparable national stan-
dard.
•In normal operation, the manual release lever for the brake must not be
attached. This prevents the brake from being released unintentionally. The
brake must not be converted to enable lockable manual release.
General
information
•Please also consider the supplementary safety notes in the individual sections
of these operating instructions.
• During and after operation, the brakes may have live and moving parts and their
surfaces may be hot.
•All work related to transport, putting into storage, setting up/mounting,
connection, startup, maintenance and repair may only be performed by trained
personnel observing
– The corresponding detailed operating instruction(s) and wiring diagrams
– The specific regulations and requirements for the system
– National/regional regulations governing safety and the prevention of accidents
•Severe injuries and damage to property may result from
– Incorrect use
– Incorrect installation or operation
– Removal of required protective covers or the housing when this is not permitted
•If work is carried out on the electrical section of the system, the supply voltage
must be disconnected.
Designated use • The BMG..T double disc brakes are certified as safe components of mobile flying
equipmentor riggingsystems forstage applications to DIN 56925, DIN 56921-11 and
DIN 56950. Drives fitted with BMG..T brakes must fulfill the requirements in the
above standards. The "Driving mechanisms" section in particular must be observed.
• Technical data and information about the permitted conditions can be found on the
nameplate and in the documentation.
• BMG..T double disc brakes cannot be retrofitted.
•It is essential to observe all the specified information!
Transportation • Inspect the shipment for any damage that may have occurred in transit as soon as
you receive the delivery. Inform the shipping company immediately. It may be
necessary to preclude startup.
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Operating instructions – BMG..T Double Disc Brakes for Stage Applications
3Safety and warning instructions
Certificate
3 Certificate
The following certification is available for the BMG..T double disc brake for stage
applications:
• Product certificate of the Rheinisch-Westfälischer Technischer Überwachungs-Vere-
in e.V (RW TÜV)
The certification reports accompanying the respective certificates must be observed.
The conditions are listed in this publication. The sections "Safety Notes" and
"Installation/Startup" must be observed in particular.
54235AXX
Figure 1: Product certificate
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Operating instructions – BMG..T Double Disc Brakes for Stage Applications
7
4
Basic structure
Structure of the BMG..T Stage Brake
4 Structure of the BMG..T Stage Brake
4.1 Basic structure
The following sectional view is intended to explain the general structure. Its only purpose
is to facilitate the assignment of components to the spare parts lists. Discrepancies may
occur depending on the brake size and version!
4.2 Unit designation
The following motor/brake combinations are permitted for stage applications:
54283AXX
Figure 2: Basic structure of the BMG..T brake
42 Brake end shield
49 Pressure plate
50 Brake spring
52 Brake stationary disc
53 Manual release
54 Complete brake coil body
56 Stud
57 Conical coil spring
58 Hex nut
59 Dowel pin
60 Stud
61 Hex nut
65 Pressure ring
66 Rubber sealing collar
67 Counter spring
68 Complete brake disc
69 Annular spring
73 Stainless steel shim plate
95 Sealing ring
157 Clamping strap
265 Brake spring, red
69 526649
157 50
265
535456 5758
42 73 67 65 68 60 61 95 59
Brake type For motor size Rated braking torque [Nm]
BMG4T 90/100 40 (2 x 20)
20 (2 x 10)
BMG8T 112-132S 75 (2 x 37.5)
37 (2 x 18.5)
BMG15T 132M-160M 150 (2 x 75)
100(2 x 50)
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Operating instructions – BMG..T Double Disc Brakes for Stage Applications
5Mechanical installation
Installation/Startup
5 Installation/Startup
5.1 Mechanical installation
•In normal operation, the manual release lever for the brake must not be
attached. This prevents the brake from being released unintentionally.
•The drive may only be installed if
• The drive is undamaged (no damage caused by transportation or storage)
• It is certain that the following requirements have been met:
– Ambient temperature between -25 °C and +40 °C
– No oil, acid, gas, vapors, radiation, etc.
– Installation altitude max. 1000 m above sea level
5.2 Electrical installation
•As regards the safety of the switching equipment, it must comply at least with
category 3 to EN 954-1 or with a comparable national standard.
•The utilization category of the contactors for the brake control system must be
at least AC-3 in accordance with EN 60947-4-1 or a comparable national
standard.
•The brake is released electrically. The brake is applied mechanically when the
voltage is switched off.
– Connect the brake according to the wiring diagram supplied with the brake.
– The supply voltage must lie within the rated voltage range of the brake coil (see
Sec. "Technical Data").
• The brake can only be run with the SEW brake control system it is intended for (see
Sec. "Technical Data").
•Check the line cross sections – operating currents (see Sec. "Technical Data").
– Apply brake voltage according to the nameplate.
– Connect the brake control system according to the wiring diagram supplied with
the brake.
– For motors in thermal class H, install the brake rectifier in the switch cabinet!
– Use only copper cables with the following temperature ranges as connection
cables: Temperature range: 60/75 °C
•Comply with the applicable regulations issued by the relevant employer's
liability insurance association regarding phase failure protection and the
associated circuit/circuit modification!
5.3 Startup
• For startup, in addition to the safety notes in these operating instructions, it is essen-
tial that you comply with the safety notes in the operating instructions for the motor
as well as the legal and liability insurance conditions.
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Operating instructions – BMG..T Double Disc Brakes for Stage Applications
9
6
Inspection and maintenance periods
Inspection/Maintenance
6 Inspection/Maintenance
• Use only genuine spare parts in accordance with the valid parts list!
• Always install a new brake control system at the same time as replacing the brake
coil!
• Motors can become very hot during operation – danger of burns!
• Secure or lower the mobile flying equipment and rigging system (danger of falling).
• Isolatethe motorand brakefrom thepower supplybefore startingwork, safeguarding
them against unintentional power-up!
6.1 Inspection and maintenance periods
The necessary inspection/maintenance periods must be calculated by the system
manufacturer according to the specific project planning documents for individual
applications, in accordance with the directives of the employer's liability insurance
association. According to the "BGV C1" regulation of the employer's liability insurance
association, brakes for stage applications must be checked once a year.
The BMG..T brakes can only be disassembled by trained personnel.
6.2 Checking the dual circuit braking function
The BMG..T brakes can be checked both statically and dynamically. A static check may
not be suitable for some applications (due to the higher reference torque). The system
operator determines the procedure that is to be used and how often a check is to be
performed (see the inspection and maintenance periods).
The following table lists the reference torque ratings to be applied. Regardless of the
inspection and test procedure used, the test should only be carried out by
qualified personnel!
During maintenance, the mobile flying equipment or rigging system must not be
subject to load.
Brake type Rated
braking
torque
Permitted
load torque Dynamic reference
torque
Static
reference
torque
BMG4T 40 (2 x 20) 13 16 32
20 (2 x 10) 6.5 8 16
BMG8T 75 (2 x 37.5) 25 31 62
37 (2 x 18.5) 12 15 30
BMG15T 150 (2 x 75) 50 62 125
100 (2 x 50) 35 44 88
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Operating instructions – BMG..T Double Disc Brakes for Stage Applications
6Checking the dual circuit braking function
Inspection/Maintenance
Dynamiccheckto
DIN 56921 or
DIN 56925
The BMG..T brakes have a dual circuit braking function. If one brake circuit fails, the
other is able to hold the load. The following section describes how to check the
effectiveness of this backup brake system. The effectiveness is checked in accordance
with the periods specified by the system operator (see the inspection and maintenance
intervals). To check the effectiveness, one of the two brake discs is removed from the
power flow by inserting distance blocks.
1. Secure or lower the mobile flying equipment and rigging system (danger of
falling)!
2. Remove protective canopy and encoder.
3. Remove the rubber sealing collar.
4. Release the brake manually or electrically.
5. Remove one brake disc from the power flow by inserting three distance blocks above
the studs (see Figure 3 on page 11). When doing so, loosen the adjusting screws of
the distance blocks until the air gap is applied completely at the bridged brake disc.
6. Set the working air gap for the brake disc in the power flow to 0.25 mm. At this point
the brake motor is free to rotate!
7. Apply the brake.
8. The brake system in the power flow; that is, the one that has not been bridged using
distance blocks, must be able to cope with the dynamic reference torque ratings
listed in the following table, i.e. 125 % of the permitted load torque.
9. Remove distance blocks.
10.Repeat points 4 to 9 for the second brake disc.
11.Reset the working air gap.
12.Install the rubber sealing collar.
13.Attach the encoder and protective canopy.
Brake type Rated
braking
torque
Permitted
load torque Dynamic reference
torque
Static
reference
torque
BMG4T 40 (2 x 20) 13 16 32
20 (2 x 10) 6.5 8 16
BMG8T 75 (2 x 37.5) 25 31 62
37 (2 x 18.5) 12 15 30
BMG15T 150 (2 x 75) 50 62 125
100 (2 x 50) 35 44 88
If one of the brake systems cannot cope with the specified dynamic torque, stop
the test immediately. This means that the dual circuit brake function is not
ensured. Stop the mobile flying equipment or rigging system, remove the brake
and check it.
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Operating instructions – BMG..T Double Disc Brakes for Stage Applications
11
6
Checking the dual circuit braking function
Inspection/Maintenance
54248AXX
Figure 3: Checking the dual circuit brake function with distance blocks
[1] Distance block (3x)
[2] Air gap
[3] Adjusting screw
[4] Brake disc not in the power flow
[5] Brake disc in the power flow
[1]
[2]
[3]
[4]
[5]
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Operating instructions – BMG..T Double Disc Brakes for Stage Applications
6Customer service
Inspection/Maintenance
Static check Brakes in the BMG..T series have a dual circuit braking function. The permitted load
torque during operation is much lower than the rated braking torque.
Before performing the static check described here, you must ensure that the transmis-
sion components are strong enough to cope with the test ratings. The strength must be
proven beforehand.
The static check is used to test the total braking torque of the individual brake discs; that
is, the braking circuits are subjected to load at the same time. Choose the static
reference torque according to the following table and apply the torque once you have
secured or lowered the mobile flying equipment and rigging system.
To check the backup and safety factors in a single test, 250 % of the permitted load
torque is applied as a static reference torque.
6.3 Customer service
Please have the following information to hand if you require the assistance of our
customer service team:
• Data from the nameplate (complete)
• Nature and extent of the fault
• Time and peripheral circumstances of the fault
• Presumed cause
Brake type Rated brak-
ing torque Permitted load torque Dynamic ref- erence
torque
Static refer-
ence torque
BMG4T 40 (2 x 20) 13 16 32
20 (2 x 10) 6.5 8 16
BMG8T 75 (2 x 37.5) 25 31 62
37 (2 x 18.5) 12 15 30
BMG15T 150 (2 x 75) 50 62 125
100 (2 x 50) 35 44 88
If the system cannot cope with the specified static torque during the test, stop the
test immediately. This means that the dual circuit brake function is not ensured.
Stop the mobile flying equipment or rigging system, remove the brake and check
it.
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Operating instructions – BMG..T Double Disc Brakes for Stage Applications
13
7
BMG..T braking torque ratings
Technical Data
7 Technical Data
7.1 BMG..T braking torque ratings
After the motor test run, deviations of ±0.05 mm can occur in the working air gap caused
by parallelism tolerances in the brake disc.
7.2 Brake control systems
SEW-EURODRIVE stipulates the following brake control systems as standard in
combination with brakes from the BMG..T series for installation in terminal boxes:
If you want to install the brake control system in a switch cabinet, SEW-EURODRIVE
stipulates the following brake control systems in combination with brakes in the BMG..T
series:
If you want to install a different brake control system, please contact SEW-EURODRIVE
to discuss the possibilities.
Brake type For motor
size Working air gap Braking torque settings
[mm] [mm] Rated
torque Type and no. of brake
springs
Order number of brake
springs
min. max. [Nm] stan-
dard red standard red
BMG4T 90/100
0,2 0,6
40 (2 x 20) 3 135 150 8 135 151 6
20 (2 x 10) 6
BMG8T 112-132S 75 (2 x 37.5) 3 184 845 3 135 570 8
37 (2 x 18.5) 6
BMG15T 132M-
160M 150 (2 x 75) 3 184 486 5 184 487 3
100 (2 x 50) 6
BMG4T BMG8T BMG15T
AC supply BG BGE BGE
24 VDC supply BS BSG BSG
BMG4T BMG8T BMG15T
AC supply BMS BME BME
24 VDC supply BS BSG BSG
P
if
kVA
Hz
n
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Operating instructions – BMG..T Double Disc Brakes for Stage Applications
7BMG..T operating currents
Technical Data
7.3 BMG..T operating currents
BMG4T BMG8T BMG15T
Motor size 90-100 112-132S 132M-160M
Max. rated braking torque [Nm] 40 75 150
Braking power [W] 50 65 95
Inrush current ratio IB/IH-6.37.5
Rated voltage VNBMG4T BMG8T BMG15T
IH[AAC] IH[AAC] IH[AAC]
24 DC 2.21)
1) Direct current with DC supply
2.772)
2) Direct current in BSG operation
4,152)
230 AC (208-233) 0.36 0.46 0.66
240 AC (234-261) 0.32 0.41 0.59
290 AC (262-293) 0.29 0.36 0.53
400 AC (370-414) 0.20 0.26 0.37
440 AC (415-464) 0.18 0.24 0.33
IBAccelerator current – brief inrush current
IHHolding current r.m.s. value in the connecting lead to the SEW brake rectifier
UNRated voltage (rated voltage range)
Permitted tolerances for rated voltage: Rated voltage range ± 10 %
Example: Rated voltage 230 VAC
Lower limit 208 VAC -10 %
Upper limit 233 VAC +10 %
P
if
kVA
Hz
n
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