Operating and Assembly Instructions FDW (Getriebebau NORD)

Operating and Assembly Instructions

for the electromagnetically released
Spring-Applied Brakes FDW / BRE 5…400
— Protection Class IP66 —

Issue 11.2021 page 1 of 22

Operating and Assembly Instructions FDW (Getriebebau NORD)

Table of contents
1. Preliminary Remarks
1.1 Introduction to the operating and assembly instructions
1.2 Conditions for assembly and operation
1.3 Structure and functionality

2. Product Description

2.1 Marking
2.1.1 Type label
2.1.2 Type code for FDW brakes (PRECIMA)
2.1.3 FDB brake nomenclature (Getriebebau NORD)
2.1.4 ATEX version marking

2.2 Technical information

2.2.1 Special features of the brake
2.2.2 Technical data

3. Assembly
3.1 Mechanical installation
3.1.1 Requirements and preparation
3.1.2 Counter friction surface
3.1.3 Hub and rotor
3.1.4 Brake
3.1.5 Sealing
3.1.6 Manual release

3.2 Electrical installation

3.3 Modifications and additions

3.3.1 Change of the braking torque

4. Operation
4.1 Brake in operation
4.1.1 Commissioning
4.1.2 Ongoing operation
4.1.3 Maintenance

4.2 Brake out of operation (malfunctions)

5. Disassembly / Replacement
5.1 Dismantling of the brake
5.2 Component replacement
5.3 Brake replacement / disposal
5.4 Spare parts

Issue 11.2021 page 2 of 22

Operating and Assembly Instructions FDW (Getriebebau NORD)

1. Preliminary Remarks

1.1 Introduction to the operating and assembly instructions

For validity, purpose and use, as well as terms and labels, see Chapter 1 "Information on the
Operating and Assembly Instructions" in the current issue of the General Introduction (...)
PRECIMA Spring-Applied Brakes. As noted there, please consult PRECIMA in case of doubt.
Technical questions, notes and suggestions for improvement can also be sent to the following
address:

Röcker Straße 16
D – 31675 Bückeburg
Phone number.: +49 (0) 57 22 / 89 33 2 -0
Fax number: +49 (0) 57 22 / 89 33 2 -2
E-mail: [email protected]

1.2 Conditions for assembly and operation

For personnel and product-related conditions, proper application, legal aspects and delivery
scope and state, see Chapter 2 "Conditions for Assembly and Operation" in the current issue of
the General Introduction (...) PRECIMA Spring-Applied Brakes

In addition, the following general conditions of operation apply to the FDW brakes:

Humidity: 0…100%

Duty cycle
(valid for installation on a self-ventilated motor with a speed of at least 750 min-1 or on a
force-ventilated motor):

S1-100% at an ambient temperature of -20…+40°C

S1-100% at -20…+60°C and power reduction through a fast-acting rectifier
S3-60% at -20...+60°C generally
S3-60% at -20…+80°C and power reduction through a fast-acting rectifier

Heating at ambient temperatures < -20°C (possible from FDW 10 / BRE 10)

Consultation with PRECIMA is required:

- with a PWM (pulse width modulation) control

Special conditions of operation of the ATEX version:

These dust-protected spring-applied brakes are suitable for use in Zone 22 areas (non-conductive
dust) and comply with the building regulations of equipment group ‫װ‬, category 3D according to
DIN EN 60079-31: 2014-12. Dust deposits must not exceed 5 mm.

Issue 11.2021 page 3 of 22

Operating and Assembly Instructions FDW (Getriebebau NORD)

The spring-applied brakes are suitable for application on three-phase motors with fan. For
three-phase motors controlled by a frequency converter, ventilation must be ensured by the
operator. External measures must also be taken to ensure that the brake command is executed
at the same time as the motor is switched off. Grounding must carried out on the machine of
which the brake is a component.

If the ambient temperature according to 2.2.4 is maintained, the surface temperature of the
spring-applied brake does not exceed 125 °C. In order to maintain the max. permissible
surface temperature, the brake is equipped with a PTC thermistor (100 °C). In the event of a
failure, the motor and the brake must be disconnected from the mains by means of a standard
trigger unit.

Technical data of the PTC thermistor:

Operating temperature: -25°C … 120°C
Tolerance range: ± 5°C
Cold resistance: < 100Ω
Max. operating voltage: 30 V
Max. measurement voltage: 7.5 V
Pill size: Ø < 4mm
Pill insulation: Kynar heat shrink tubing
Response time: < 3s
Insulation: PTFE
Nominal response temperature // colour
code: 100°C // red/red
Test voltage: 2.5 kV

➔Attention!
The operator is responsible for testing and effectiveness of the protective device. Proof
of the effectiveness of the installed protective device is required before commissioning.

In addition to the proper use according to 2.3 in the current issue of the General Introduction (...)
PRECIMA Spring-Applied Brakes, the following also applies to the ATEX version: When ignited
by hot or sparking objects, explosive dust concentrations can cause explosions, which
can result in serious or fatal injuries to people and considerable property damage!

The ATEX version may only be used as a holding brake and not as a working brake!

1.3 Structure and functionality

For structure and functionality of a spring-applied brake in general, see the corresponding
section (Chapter 3) in the current issue of the General Introduction (…) PRECIMA Spring-
Applied Brakes

Issue 11.2021 page 4 of 22

Operating and Assembly Instructions FDW (Getriebebau NORD)

2. Product description

2.1 Marking

2.1.1 Type label

The type label of the spring-applied brake contains all its important data. These data and the
contractual agreements for the brakes define the limits of their use.

2.1.2 Type code for FDW brakes (PRECIMA)

Example:

FDW 15 N H F M 20 H7 24 VDC

Operating voltage
Hub bore
Microswitch +) Options II **)
without abbreviation:
Sealing cap or
sealing washer +)
Flange Options I *)
Manual release
Brake design: N – standard; T – with tachobores
Brake size (sizes: 08, 10, 13, 15, 17, 20, 23, 26, 30)
Brake designation (series)

*) Options I are taken into account in these operating and assembly instructions, but, if desired,
must be specified when placing the order (➔ abbreviation, if applicable).

**) Options II must also be specified when placing the order and cannot be retrofitted. Furthermore,
they are not taken into account in these instructions. There are separate setting instructions
for option M (= microswitch), the only one included, which must also be observed.

+) The microswitch and the sealing washer are not standard options for the ATEX version

2.1.3 FDW brake nomenclature (Getriebebau NORD)

The following two diagrams show how an FDB brake is designated by Getriebebau Nord. Pos.1
to Pos.8 must be listed in any case, Positions 9 ff only when the corresponding option is used,
but then always in the sequence shown

Issue 11.2021 page 5 of 22

Operating and Assembly Instructions FDW (Getriebebau NORD)

2.1.4 ATEX version marking

The ATEX version is identified by a special adhesive label.

Lettering on the adhesive label: CE ll 3D Ex tc IIIB T 125 °C Dc

Issue 11.2021 page 6 of 22

Operating and Assembly Instructions FDW (Getriebebau NORD)

2.2 Technical information

2.2.1 Special features of the brake

In addition to the general description of the function of the brake (see General Introduction (...)
PRECIMA Spring-Applied Brakes / Chapter 3 "Structure and Functionality"; cf. 1.3), the higher
protection class is essential for FDW spring-applied brakes. Due to their closed housing and
their dustproof and waterproof cable gland, these brakes comply with protection class
IP66. However, with a continuous shaft (with sealing washer option) and when using a
flange, the sealing must be carried out by the customer (cf. also 3.1 Mechanical
installation).

For the ATEX version (dust-protected - Zone 22; temperature monitoring by PTC thermistor),
the special conditions or certain restrictions must be taken into account compared to the normal
BRE IP66 or FDW (cf. 1.2; 2.1.2; 2.1.3; 2.1.4)

2.2.2 Technical data

2.2.2.1 Nominal braking torques and number of springs

➔ Nominal braking torque / working brake = dynamic braking torque at 1 m/s friction speed
➔ Nominal braking torque / holding brake = static holding torque (= tearing off torque)
➔ For explanation see: General introduction (...) PRECIMA spring-applied brakes / Chapter 5

BR5 BR10 BR20 BR40 BR60 BR100 BR150 BR250 BR400

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

5 10 20 40 60 100 150 250 400

Nominal
braking 3.5 7 14 28 43 70 107 187 300
torques
MbN 3 6 12 23 34 57 85 125 200
[Nm]
2 4 8 17 26 42 65

— Permissible deviations of the actual braking torque:

Working brake up to BR40 (dynamic torque): -20/+30% (new and run-in*)
Working brake from BR60 (dynamic torque): -20/+30% (new) or ±20% (run-in*)
Holding brake (static holding torque): -10/+50% (new) or -10/+40% (conditioned*) —
* For explanation see: General introduction (...) PRECIMA spring-applied brakes / Chapter 5

BR5 BR10 BR20 BR40 BR60 BR100 BR150 BR250 BR400

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

Number 7 7 7 7 7 7 7 8 8
of
5 5 5 5 5 5 5 6 6
springs
for the 4 4 4 4 4 4 4 4 4
above
MbN 3 3 3 3 3 3 3

Issue 11.2021 page 7 of 22

Operating and Assembly Instructions FDW (Getriebebau NORD)

2.2.2.2 Dimensions, masses, fastening (Figure 2.1)

Figure 2.1:
Main dimensions
of the brake

a (air gap) and s (rotor thickness):

see 2.2.2.3
s (rotor thickness): see 3.2.2.4

Issue 11.2021 page 8 of 22

Operating and Assembly Instructions FDW (Getriebebau NORD)

Hub dimensions General brake dimensions Tachometer bores

[mm] [mm] dimensions [mm]
Size

(Number
Brake Bolt Thre
Hex Toothed of holes)
hub
Mounting Ø Brake / Brakes with circle ad
hub dimensions inside / flange Øe2
x thread dept
Ød H7 manual release
Ød H7 outside ±0.1
nominal
h
Ø
d d d1 m n1 n2 d6 / d8 g/h c v/w t/z e2 k2 p2
BR5 26** / 15 / 100
FDW 08
11/14/15 11/14*/15* 20 18 1.5 0.5 40 / 6 30 34 (3 x) M4 8
98 8 / 89
BR10 32 / 15 / 110
FDW 10
15/19/20* 14/15 25 20 2.5 1 48 / 7 43.5 40 (3 x) M5 12
120 8 / 111
BR20 42 / 20 / 130
FDW 13
15/20/25 15/20 33 20 3.5 1.5 54 / 9 39 54 (3 x) M6 12
145 10 / 132
BR40 52 / 20 / 140
FDW 15
20/25/30 20/25 42 25 3 2 60 / 9 42 65 (3 x) M6 12
168 10 / 151
BR60 62 / 25 / 165
FDW 17
- 25/30/35* - 30 3 - 70 / 8 46 75 (3 x) M8 15
188 12 / 172
BR100 72 / 25 / 220
FDW 20
- 30/35/40 - 30 3 - 80 / 11 51.5 85 (3 x) M8 15
213 12 / 196
BR150 80 / 25 / 250
FDW 23
- 35/40/45 - 35 4 - 90 / 8 58 95 (3 x) M8 15
245 12 / 224
BR250 40/45/ 90 / 99 *** / 35 / 330 (6 x)
FDW 26
- - 40 4 - 62 110 25
50/55* 276 12,5 19 / 258 M10
BR400 50/55/ 115 / 105 / 35 / 357 (6 x)
FDW 30
- - 50 4 - 64 138 25
60/65* 324 12.5 19 / 304 M10
Standard keyway of the hub as per DIN 6885/1-JS9
* deviating keyway as per DIN 6885/3-JS9 // ** can be obtained with Ø30 (7 mm deep) //
*** screw heads protrude for 2.5 mm (overall dimension = 101.5)

Mounting Tightening
Masses
dimensions torque
[kg]
[mm] [Nm]
Size
(Number of Screw-in
Brake without Bolt
Manual circle holes) x depth
manual release Flange Fixing screws
release thread without / with
and flange Øe1 ±0.1 flange
nominal Ø

e1 k1 b2 / b3 MA
BR5
FDW 08 1.60 0.05 0.28 72 (3 x) M4 6 / 10 3
BR10
FDW 10 2.00 0.08 0.49 90 (3 x) M5 8.5 / 6.5 6
BR20
FDW 13 3.60 0.10 0.92 112 (3 x) M6 12 / 8 10
BR40
FDW 15 5.20 0.13 1.22 132 (3 x) M6 13 / 12 10
BR60
FDW 17 7.20 0.17 1.34 145 (3 x) M8 14 / 13 25
BR100
FDW 20 11.00 0.24 2.35 170 (3 x) M8 24 / 13 25
BR150
FDW 23 16.30 0.29 2.30 196 (3 x) M8 15 / 14 25
BR250
FDW 26 25.00 0.80 4.10 230 (3 x) M10 23.5 / 16 50
BR400
FDW 30 37.50 0.90 6.20 278 (6 x) M10 17 / 14 50

Issue 11.2021 page 9 of 22

Operating and Assembly Instructions FDW (Getriebebau NORD)

2.2.2.3 Air gaps, rotor values

Nominal Min. Rotor Max. Min. Rotor Max. rotor speed [min-1]
braking air thickness air rotor moment - permissible speeds higher than
Size (new)
torques gap gap thickness of inertia indicated may be applicable through
[Nm] [mm] [mm] [mm] [mm] [kgm2] special measures on request -
nmax nmax
MbN amin snew amax smin J
Working brake Holding brake++
5
BR5 3.5 0,015
0,2 7,5 -0,1 0.6 7.1 6000
FDW 08 3 x 10-3
2
10
BR10 7 0,045
0,2 8,5 -0,1 0.7 8.0 6000
FDW 10 6 x 10-3
4
20
BR20 14 0,173
0,3 10,3 -0,1 0.8 9.8 6000
FDW 13 12 x 10-3
8
40
BR40 28 0,45
0,3 12,5 -0,1 0.9 11.9 6000
FDW 15 23 x 10-3
17
60
BR60 43 0,86 4500
0,3 14,5 -0,1 1.0 13.8 3600
FDW 17 34 x 10-3 (6000+)
26
100
BR100 70 1,22 4500
0,4 16 -0,1 1.1 15.3 3600
FDW 20 57 x 10-3 (6000+)
42
150
BR150 107 2,85 4500
0,4 18 -0,1 1.1 17.3 3600
FDW 23 85 x 10-3 (6000+)
65
250
BR250 187 6,65 3000
0,5 20 -0,1 1.2 19.3 1800
FDW 26 125 x 10-3 (4500+)

400
BR400 300 19,5 3000
0,5 20 -0,1 1.2 19.3 1800
FDW 30 200 x 10-3 (4500+)

+ for max. 5 seconds on request ➔ at high speeds a damping should

++

be provided between rotor and hub (version NRB2, see 2.1.3)

Issue 11.2021 page 10 of 22

Operating and Assembly Instructions FDW (Getriebebau NORD)

2.2.2.4 Friction work, friction power

Max. Max.
Max. Max. permissible Friction work /
permissible permissible
permissible friction work / 0.1 mm
Size friction friction work /
friction power** braking wear
power** braking
[J/h] [J] [J]
[J/h] [J]
Working brake lining Holding brake lining
PRmax WRmax PRmax WRmax Qr 0.1
BR5 / FDW 08 288 x 103 3 x 103 144 x 103 1.5 x 103 16 x 106
BR10 / FDW 10 360 x 103 6 x 103 180 x 103 3 x 103 30 x 106
BR20 / FDW 13 468 x 103 12 x 103 234 x 103 6 x 103 42 x 106
BR40 / FDW 15 576 x 103 25 x 103 288 x 103 12 x 103 70 x 106
BR60 / FDW 17 720 x 103 35 x 103 360 x 103 17 x 103 85 x 106
BR100 / FDW 20 900 x 103 50 x 103 450 x 103 25 x 103 140 x 106
BR150 / FDW 23 1080 x 103 75 x 103 540 x 103 37 x 103 170 x 106
BR250 / FDW 26 1260 x 103 105 x 103 630 x 103 52 x 103 230 x 106
BR400 / FDW 30 1440 x 103 150 x 103 720 x 103 75 x 103 310 x 106

** with a uniform timely distribution of the braking

2.2.2.5 Electrical parameters

Electrical Electrical
Rated Rated
power power
Voltage current Voltage current
Size (average Size (average
[VDC] (benchmark) [VDC] (benchmark)
value) value)
[A] [A]
[W] [W]
P20°C = U= IN = P20°C = U= IN =
24 1.14 24 4.30
BR5 103 0.30 BR100 103 1.05
FDW 08
29 FDW 20
110
180 0.16 180 0.59
205 0.14 205 0.59
24 1.67 24 4.00
BR10 103 0.39 BR150 103 0.94
FDW 10
40 FDW 23
101
180 0.22 180 0.58
205 0.20 205 0.53
24 1.78 24 5.70
BR20 103 0.56 BR250 103 1.40
FDW 13
49 FDW 26
140
180 0.26 180 0.78
205 0.23 205 0.68
24 2.67 24 7.27
BR40 103 0.55 BR400 103 1.77
FDW 15
59 FDW 30
189
180 0.33 180 1.16
205 0.28 205 0.89
24 3.69
BR60 103 0.82
FDW 17
87
180 0.46
205 0.44

Issue 11.2021 page 11 of 22

Operating and Assembly Instructions FDW (Getriebebau NORD)

2.2.2.6 Switching times

Nominal
Disconnection Response Connection Response Connection
braking
Size time delay time delay time
torque
[ms] [ms] [ms] [ms] [ms]
[Nm]
switched on the DC side switched on the AC side
MbN = t2 = t11DC = t1DC = t11AC = t1AC =
BR5
FDW 08
5 35 18 38 60 90

BR10
FDW 10
10 60 20 50 100 145

BR20
FDW 13
20 85 25 65 220 280

BR40
FDW 15
40 100 20 70 150 225

BR60
FDW 17
60 120 22 82 200 290

BR100
FDW 20
100 150 35 115 300 420

BR150
FDW 23
150 270 45 145 320 570

BR250
FDW 26
250 300 58 178 400 600

BR400
FDW 30
400 400 65 195 550 900

**switched with fast-acting rectifier (overexcitation)

— The indicated switching times are to be understood as benchmarks with tolerances for the
nominal air gap —

t2 = disconnection time = time between the switching on of the

current and the ceasing of the braking torque (Mb ≤ 0,1*MbN)

– Overexcitation by a fast-acting rectifier results in approx. half as

long disconnection times –

t1 DC = connection time = response time during braking with

interruption on the DC side by mechanical switches = time between
Figure 2.2:
Switching
the switching off of the current and the reaching of the full braking
times torque (Mb ≥ 0.9*MbN)

t1 AC = connection time = response time during braking with

disconnection on the AC side, i.e. by interruption of a separately
powered rectifier

t11 DC / t11 AC = response delay = time between the switching off of

the current and the increase in the braking torque (included in the
respective connection time)

– Depending on the operating temperature and the wear status of the brake discs, the actual response delays
(t2, t1 DC, t1 AC) can deviate from the benchmarks indicated here. When the voltage is reduced by a fast-acting
rectifier, connection times are shortened –

Issue 11.2021 page 12 of 22

Operating and Assembly Instructions FDW (Getriebebau NORD)

3. Assembly
3.1 Mechanical installation

3.1.1 Requirements and preparation

- Check the unpacked spring-applied brake as to being undamaged and complete of all parts
(according to the delivery note). Complaints regarding recognizable transport damage must be
made immediately to the deliverer, while claims for recognizable defects and incompleteness
must be made to PRECIMA (cf. also 2.5 in the General Introduction (…) PRECIMA Spring-
Applied Brakes).
- Compare the nameplate of the brake with the agreed characteristics and the actual conditions

➔Attention!
Should any ambiguities or contradictions be revealed during the inspection, the brake
must not be installed and put into operation without consulting PRECIMA.

3.1.2 Counter friction surface

3.1.2.1 Motor end shield etc. as a counter friction surface

- Check whether the provided counter friction surface meets the requirements ( material: steel,
cast steel, cast iron - no aluminium / stainless steel with limitations -; surface quality Rz 6.3)
and whether it is free of grease and oil. In addition, an even contact and sealing surface in the
area of the surrounding O-ring (in the magnet housing groove) must be available.

3.1.2.2 Flange

- If the counter friction surface is supplied in the form of a flange (item 7, Figure 3.1), this
component — which lies directly on the motor end shield — is fixed there together with the
brake (see also 3.1.3, 3.1.4 and Figure 3.1). The brake is sealed against the flange by means
of an O-ring (item 13) (analogous to the motor end shield for brakes without flange). However,
the flange itself contains no further sealing element and must be sealed with respect to
its mounting surface.

➔Attention!
If the counter friction surface does not meet the requirements, the brake must not be
installed and put into operation without consulting PRECIMA. Grease and oil on the
counter friction surface must be removed completely before continuing!

3.1.3 Hub and rotor (Figure 3.1)

➔Stop!
Before the assembly, check the thickness of the rotor according to the information in
2.2.2.3. Snew is the value for a new rotor (tolerance = 0/-0.1 mm), smin is the lowest
permissible rotor thickness. When installing a new rotor, the values must be s = s new; in
case of a reassembly (e.g. after a maintenance-related dismantling) the values must be s
> smin, otherwise the rotor must be replaced.

Issue 11.2021 page 13 of 22

Operating and Assembly Instructions FDW (Getriebebau NORD)

The rotor, as a rotating component of the motor to be braked, is fixed onto the shaft via the hub.

- Insert the first circlip (item 14) into the rear radial groove of the shaft
- Insert the feather key (item 15) into the axial groove of the shaft
- Push the toothed hub (item 6.1) or the hex hub (item 6.2) onto the shaft and over the feather
key
- Fix the hub axially by inserting the second circlip (item 16) into the front radial groove of the
shaft
- If necessary, mount the counter friction surface (= flange; item 7)
- Push the rotor (item 3.1 or 3.2) onto the hub, the rotor should still be axially displaceable

➔Attention! Make sure that the rotor/hub pair runs smoothly!

(air gap)

Figure 3.1:
Assembly of the
brake
(sectional view)

(Through-
going
shaft)

Issue 11.2021 page 14 of 22

Operating and Assembly Instructions FDW (Getriebebau NORD)

3.1.4 Brake (Figure 3.1) ➔ for self-installation of the manual release, see 3.1.6 first

The brake is attached to the motor (possibly through the holes in the intermediate flange) and, if
required, can be also supplemented with additional components:

- Place the brake on the rotor, insert and screw in the fixing screws with the underlying Cu
washers (item 11) until the magnet housing rests on the counter friction surface
- Tighten the fixing screws with the tightening torque according to 2.2.2.2
- Screw the manual release lever (item 5.1) into the manual release bracket (item 5) with the
attached washer and tighten it on the hexagonal surfaces ( only for brakes with manual
release = H option ) ➔ screw-in torque:
Size Thread lever Screw-in torque [benchmark in Nm]
BR5/10 // FDW 08/10 M5 5
BR20/40 // FDW 13/15 M6 8
BR60…150 // FDW 17…23 M8 18
BR250…400 // FDW 26…30 M10 25

➔Attention!
The Cu washers under the fixing screws may only be used once for sealing and must be
replaced with new ones for each reassembly!
The setting of the manual release (option H) adjusted at the factory or by the customer
(➔ 3.1.6.3) must not be changed!

3.1.5 Sealing (Figure 3.1)

Depending on whether the brake is mounted over a continuous shaft or not, sealing measures
must still be taken:

- With a not continuous shaft, the pre-mounted sealing cap (item 9) will close the central
opening of the brake and no further measure is required
- With a continuous shaft, the pre-mounted sealing washer (item 10) only forms the first part of
the shaft seal. It must always be completed with a V-ring (item 10.1) to be installed on the
shaft

3.1.6 Manual release (Figure 3.2)

— only when assembly or disassembly is carried out by the customer —

The magnet housing has the necessary holes for assembly only if the brake was purchased
with the manual release option. A brake purchased without that option cannot be retrofitted
with a manual release!

3.1.6.1 Requirements for assembly or disassembly

- The brake must be dismantled and de-energized in order to assemble or disassemble the
manual release. For brake dismantling, see also 5.1
- The armature plate (item 2, Figure 3.2) must also be removed. To do so, unscrew all
hollow screws (item 12) so that the armature plate can be dismounted from the magnet
housing (item 1) and its inside with the spring holes and the inserted springs becomes visible

Issue 11.2021 page 15 of 22

Operating and Assembly Instructions FDW (Getriebebau NORD)

3.1.6.2 Carrying out the assembly or disassembly

The assembly is described below, the disassembly is to be carried out accordingly in reverse
order:

- Insert the rear O-ring (item 5.3, Figure 3.2) on both sides and the washer (item 5.4) above
it into the indentations of the magnet housing
- Position the armature plate (item 2) so that the two lateral holes come to rest over the
inserted O-rings and washers
- Fasten the armature plate by screwing all hollow screws (item 12) into the magnet housing
until the visible rear surfaces are slightly below the sealing surface of the magnet housing
(the hollow screws have no axial supporting function when the brakes are closed)
- Push the washer (item 5.5) and the spring (item 5.6) onto the two fixing screws (item 5.7)
of the manual release and insert the screws so equipped into the holes of the magnet
housing
- On the opposite side, push the O-ring (item 5.8) and the sealing plate (item 5.9) onto the
inserted screws, pressing the O-rings into the corresponding indentations of the magnet
housing
- Position the manual release bracket (item 5) with the inserted bolts (item 5.2) and screw
the two actuating screws into the bolts

Figure 3.2:
Assembly /
disassembly
of the manual release
(offset
sectional view)

Lock by means of screw sealing wax after adjusting

Issue 11.2021 page 16 of 22

Operating and Assembly Instructions FDW (Getriebebau NORD)

3.1.6.3 Adjustment of the manual release

After the actual assembly, the manual release must still be adjusted in order to fulfil the
intended function:

- Tighten the two actuating screws (item 5.7, Figure 3.2) until the armature plate lies on
both sides of the magnet housing
- Turn back the two actuating screws by dimension Y or by X rotations according to 3.1.6.4
- The two screws must be locked by means of screw sealing wax in the correct setting
position.

3.1.6.4 Manual release setting values

Setting Number of
Thread
Type dimension Thread rotations
pitch
Y X
[mm] [mm]
BRE 10 / FDW 10 1 M4 0.7 1.5
BRE 20 / FDW 13 1 M4 0.7 1.5
BRE 40 / FDW 15 1 M5 0.8 1.3
BRE 60 / FDW 17 1 M6 1 1
BRE 100 / FDW 20 1.2 M6 1 1.2
BRE 150 / FDW 23 1.2 M6 1 1.2
BRE 250 / FDW 26 1.5 M8 1.25 1.2
BRE 400 / FDW 30 1.5 M8 1.25 1.2

3.2 Electrical installation

The electrical connection is only to be carried out in a de-energized state.

The operating voltage (DC) of the brake is indicated on the magnet housing
(cf. 3.1.1 and Figure 3.2).

3.3 Modifications and additions

3.3.1 Change of the braking torque

The braking torque can be adjusted by modifying the spring configuration in accordance with
2.2.2.1. Make sure that at least the springs arranged on the outside are evenly distributed.

Should the braking torque be changed on a brake with manual release, it is also necessary to
first disassemble and then reassemble the manual release. See 3.1.6.

Issue 11.2021 page 17 of 22

Operating and Assembly Instructions FDW (Getriebebau NORD)

4. Operation

4.1 Brake in operation

4.1.1 Commissioning

Before commissioning the brake, a functional test must be carried out first. This can normally
and readily be done together with the motor to which the brake is attached. For possible
malfunctions, see: 4.2.

➔Stop!
The full braking torque is only effective after the brake pads on the rotor have run in! ➔
Deviation values to MbN: see 2.2.2.1

4.1.2 Ongoing operation

Ongoing operation requires no special measures without malfunctions. Only the size of the air
gap (increasing because of the wear of the friction lining on the rotor) must be checked
according to the following arrangement (see also: 4.1.3), unless a special sensor for wear
monitoring has been installed on the brake. In order to do this, temporarily remove the screw
plug (item 17, Figure 3.1) in the inspection hole. In case of malfunctions, proceed according to
4.2. For ATEX version (= Holding brake) the function of the PTC thermistor has to be
controlled: The resistance at 20°C must be lower than 100 Ω (Thermistor cable Ø3.7 mm;
Configuration: see Figure 2.1).

Control intervals:

Working brake: + according to tool life calculation

+ as per specification to be given by the customer

Holding brake: + at least once every two years

+ as per specification to be given by the customer
+ provide shorter intervals in case of frequent emergency stops

➔Danger!
De-energise motor and brake and protect them from an accidental reclosure. The brake
must not be opened for inspection in an explosive atmosphere

4.1.3 Maintenance

4.1.3.1 Replacing the rotor

It is not possible to adjust the air gap for the closed brakes of the FDW series. When the
minimum rotor thickness smin according to 2.2.2.3 is reached, the rotor must then be replaced.
Functionality of the brake that falls below the minimum rotor thickness just in individual cases
does not change the above statement; proper use is then no longer available.

Issue 11.2021 page 18 of 22

Operating and Assembly Instructions FDW (Getriebebau NORD)

➔Stop!
Even after the rotor has been replaced, the full braking torque is only effective again after
the brake linings on the rotor have run in!
➔ Deviation values to MbN: see 2.2.2.1

➔Attention!
When replacing the rotor, the mechanical components involved in the build-up and
transmission of the braking torque must be checked for excessive wear (armature plate,
hollow screws) or integrity (springs) and replaced if necessary!

4.2 Brake out of operation (malfunctions)

The table below shows typical malfunctions during ongoing operation (in some cases also during
commissioning), their possible causes and instructions for their correction.

Malfunction Possible cause Remedy

Brake does not

release Air gap too large Replace the rotor

Brake is not supplied with Check electrical

voltage connection

Voltage at the Check magnetic coil

magnetic coil too low supplied voltage

Armature plate mechanically Remove mechanical

blocked blockage

Brake releases with Air gap too large Rotor must be replaced
delay

Voltage at the Check magnetic coil

magnetic coil too low supplied voltage

Brake is not Voltage at the Check supply voltage

applied magnetic coil too high of the magnetic coil

Armature plate mechanically Remove mechanical

blocked blockages

Brake is applied Voltage at the Check supply voltage

with delay magnetic coil too high of the magnetic coil

Issue 11.2021 page 19 of 22

Operating and Assembly Instructions FDW (Getriebebau NORD)

5. Disassembly / Replacement

5.1 Dismantling of the brake

Dismantling of the brake shall be carried out analogous to the assembly, but in reverse order, and
only when the brake and the motor are switched off, de-energized and torque-free.

➔Danger!
The disassembly of the brake will result in a suspension of its passive braking function.
There are no risks associated with this suspension!

5.2 Component replacement

The only component that can be regularly replaced on site is the rotor when it reaches the wear limit
(see 4.1.3.1); when the hub shows signs of noticeable wear, it can be replaced if necessary.
Furthermore, all other components listed in 5.4 Spare parts can also be generally replaced.

➔Attention!
Before reassembling a brake, the fastening elements must be checked for proper
functionality and replaced if necessary! It is fundamental to replace the Cu washers arranged
under the screws, since their sealing function is no longer guaranteed if they are used
multiple times!

5.3 Brake replacement / disposal

The components of our spring-applied brakes have to be recycled separately due to the presence of
different materials. The official regulations must also be observed.
Important code numbers of the Waste Catalogue Ordinance (German designation: AAV) are given
below. Depending on the material composition and the type of disassembling process, other key
numbers may also apply to the components made from these materials.

- Ferrous metals (key no.160117)

- Non-ferrous metals (key no.160118)
- Brake pads (key no.160112)
- Plastics (key no. 160119)

5.4 Spare parts

Figure 5.1 shows all the spare parts that can be ordered for the FDW spring-applied brakes, which
are listed below.

When ordering spare parts, please provide the brake lettering data (see 2.1.1)!

➔Attention!
PRECIMA Magnettechnik GmbH excludes any liability and warranty for damage resulting from
the use of non-original spare parts and accessories (cf. 2.2.3 in the General Introduction (…)
PRECIMA Spring-Applied Brakes).

Issue 11.2021 page 20 of 22

Operating and Assembly Instructions FDW (Getriebebau NORD)

(air gap)

Figure 5.1:
Spare parts
(sectional view)

(Through-
going
shaft)

Position Designation Position Designation

1 Magnetic body 6.2 Hub for rotor 3.2
2 Armature plate 7 Flange
Rotor complete (aluminium
3.1 9 Sealing cap
version)
Rotor complete (plastic
3.2 10 Sealing washer
version)
Fixing screw including Cu
4 Spring 11
washer
5 Manual release complete 12 Hollow screw
5.1 Manual release lever 13 O-ring (magnet housing)
6.1 Hub for rotor 3.1 17 Screw plug with O-ring

Issue 11.2021 page 21 of 22

Operating and Assembly Instructions FDW (Getriebebau NORD)

Document history
Issue Version Description
05.2020 0.0 Created

General: FDW as general brake type designation, BR5..BR400

as NORD-specific brake size designation (instead of BRE...)
2.1.3: Adaptation of Getriebebau NORD nomenclature
10.2021 1.0 2.2.2: Table values for holding brakes/high braking torques omitted
2.2.2.1: Definition of nominal braking torques added; tolerance values
revised.
4.1.2: Supplements for ATEX version

Issue 11.2021 page 22 of 22