Industrial brake installation manual

CREATION DATE: 09/09/2016 SCOPE: FMLF65J

REVISION DATE: 09/15/2016 1 / 16 REVISION: EN01
INDEX

1 SAFETY INSTRUCTIONS: ................................................................................................................... 3

1.1 Symbols used: ............................................................................................................................... 3
1.2 General instructions: ..................................................................................................................... 3
2. PRODUCT DESCRIPTION: .................................................................................................................. 3
2.1. Operating principle: ....................................................................................................................... 3
2.2. Labelling: ....................................................................................................................................... 4
2.3. Dimensions: .................................................................................................................................. 5
2.4. Technical characteristics: .............................................................................................................. 6
2.5. Packaging:..................................................................................................................................... 6
2.6. Warranty: ....................................................................................................................................... 7
3 MECHANICAL SETTING-UP: ............................................................................................................... 7
3.1 Before beginning: .......................................................................................................................... 7
3.2 Tools:............................................................................................................................................. 7
3.3 Assembly: ...................................................................................................................................... 7
3.4 Tightening torques of the screws: ................................................................................................. 8
3.5 Braking torque adjustment: ........................................................................................................... 8
4 ELECTRICAL INSTALATION: .............................................................................................................. 9
4.1 Before beginning: .......................................................................................................................... 9
4.2 Tools:............................................................................................................................................. 9
4.3 Brake wiring: ................................................................................................................................. 9
5 CHECKING THE OPERATION: .......................................................................................................... 10
6 MAINTENANCE: ................................................................................................................................. 10
6.1 Checking of the air-gap: .............................................................................................................. 11
6.2 Checking the winding: ................................................................................................................. 11
7 SPARE PARTS: .................................................................................................................................. 11
7.1 Replacing the disc: ...................................................................................................................... 11
8 POTENTIAL FAILURES: ..................................................................................................................... 14

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1 SAFETY INSTRUCTIONS:

1.1 Symbols used:

Danger - Warning.

Electrical hazard.

Information.

1.2 General instructions:

Any intervention should be done by trained personnel and in

possession of this manual.

- Brake installation.

Danger of uncontrolled movement.

Electrical hazard.

- Maintenance.

During maintenance work, ensure that the braking mechanism is at rest and there is no risk of
accidental start.

Danger of uncontrolled movement.

Electrical hazard.

2. PRODUCT DESCRIPTION:

2.1. Operating principle:

The FMLF65J brake is included within the type of brakes of compression springs. In the absence of
current, the springs, disposed in its housing, exert a force on the movable plate that prevents movement
of the friction disc. By connecting the electromagnet, the magnetic field generated attracts the movable
plate, moving it and thereby releasing the friction disc.

The next picture allows to appreciate the main components that constitute a brake EVO.

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 Fig. 1

Number Description
1 Housing
2 Disc
3 Hub
4 Cable
5 Torque adjustment screws
6 Front setscrews
7 Holes for rear setscrews
8 Window for checking the air gap

Table 1

2.2. Labelling:

All ALZOLA brakes incorporate two labels. In the first one the main technical features of the brake are
listed. The second one specifies the serial number.

Fig. 2

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2.3. Dimensions:

Fig. 3
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2.4. Technical characteristics:

Model FMLF65J
Static torque
65
(-5, +10) [N·m]
Dynamic torque
65
(-5, +10) [N·m]
Nominal air gap [mm] 0.2 / 0.4
Maximum air gap [mm] 0.6
Over-excitation YES
Voltage [VDC] 24 / 15
Current [A] 2.7 / 1.7
Coil resistance [Ω] 8.9 ± 5%
Power [W] 65 / 25
Duty cycle [%] 50
Maximum connections 1500
per hour [Conct/h]
Weight [Kg] 12
Insulation class F (155ºC)

Table 2

2.5. Packaging:

The brakes are supplied in batches of 30 units in the European pallet.

Fig. 4

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 2.6. Warranty:

Unless there is a specific agreement with the customer, the warranty will ALZOLA generals, set in
supply conditions.

Any modification or manipulation performed on the brake without the express authorization of ALZOLA,
like any use outside the technical specifications set by ALZOLA, involve the removal of the guarantee
and the cancellation of ALZOLA responsibility regarding the disagreement.

3 MECHANICAL SETTING-UP:

3.1 Before beginning:

Check that the brake is right for the machine. In the nameplate supervise that both the operating
voltage and the braking torque, correspond to the requirements for installation.

3.2 Tools:

Allen wrenches

Screwdriver

Measuring gauges

Torque wrench

3.3 Assembly:

1º- Check perpendicularity between the shaft and the bearing surface of the brake.

Danger: Do not hang the brake by their cables. It can result in damage to the
brake or / and the fall of it.

2º- Insert the slotted hub on the shaft of the machine and place it on its correct position.

Danger: the clearances can cause dysfunction.

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 Fig. 5

4º- Place the brake on the machine, and attach to it by tightening the corresponding 4 fixing screws.
It is desirable to ensure a correct concentricity between the shaft of the machine and the central hole
of the brake.

3.4 Tightening torques of the screws:

The torque of the screws must be respected: insufficient tightening may cause displacement of
separation hubs and subsequent transmission of the braking torque to the fastening screws with shear
risk thereof. Excessive tightening may compromise the safety of brake. The use of torque wrenches is
recommended.

Screw type
Torque [N·m]
(Metric-Class)
M8 - 8.8 18.2
M10 - 8.8 36

Table 3

3.5 Braking torque adjustment:

The FMLF65J brakes allow manually adjust the braking torque. This regulation is carried out by
tightening the three screws from the rear of brake. These screws tightening (clockwise) involves
increasing the braking torque while loosening (counter-clock wise) involves the reduction of the braking
torque.

Both tightening and loosening will be held in the three screws gradually and simultaneously: all screws
should turn the same degrees.

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 Fig. 6

4 ELECTRICAL INSTALATION:

4.1 Before beginning:

CAUTION: Electrical hazard.

CAUTION: Danger of uncontrolled movement.

CAUTION: Risk of cause irreparable damage to the brake.

4.2 Tools:

Screwdriver

4.3 Brake wiring:

The FMLF65J brakes are DC. It should prevent voltage peaks that can
damage the windings. Placing varistors capable of absorbing surges is
recommended.
Ensure that the voltage on the supply system is right for the brake (see
nameplate).

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 The FMLF65J brakes consist of a single coil, that must be connect according to the following diagram:

Fig. 7

5 CHECKING THE OPERATION:

CAUTION: Danger of uncontrolled movement.

Power the brake. The movable plate will be attracted to the brake housing, releasing the disc, and
allowing movement of the axis of the machine.

Disconnect the brake immediately if you observe:

- The brake produces a loud noise during connection / disconnection.

- The shaft does not turn free once it has been unlocked.

See paragraph 8: "POTENTIAL FAILURES".

6 MAINTENANCE:

The FMLF65J brakes are designed to operate maintenance free. In any case, it is recommended to
check the following:

Task Frequency
Checking of the air-gap Biannual
Checking of the coils Annual

Table 4

Any intervention should be done by trained personnel and in

possession of this manual.

During maintenance work, ensure that the mechanism to stop the

device is idle and there is no risk of accidental starting.

Do not damage the cables during maintenance works.

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 6.1 Checking of the air-gap:

For checking the air-gap, being the brake locked (braking), insert the measuring gauges in the
clearance seen in each of the three windows on the periphery of the brake. The 0.2mm gauge should
be able to be inserted through the three slots visible. The 0.6 gauge should not be able to enter by any
of the slots. An excessive air gap may cause the electromagnet was not able to release the brake.
Under this circumstance will proceed to replace the brake disc (section 7.1).

Fig. 8

6.2 Checking the winding:

Checking the resistance: Check that the winding resistance is correct. A measure different from the
indicated in the nameplate would be a sign that the coil has been damaged. In this case it would be
necessary to replace the brake as a whole. See the nominal resistance value in paragraph 2.4
"Technical characteristics".

7 SPARE PARTS:

The only spare part that is provided for this brake is its friction disc.

7.1 Replacing the disc:

Danger: The following process involves brake release, with the risk of
uncontrolled movement of the machine to which it is coupled.

1. Once secured machine, place the brake horizontally as shown in the following image, disconnect
the power cables, and remove the three screws M8x70 assembly. It will perceive that the brake tend
to open itself.

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 Fig. 9

2. Manually pressing between them the two sides of the brake assembly to prevent its disassembly,
turn over it, and remove the top shell to remove the disc.

Fig. 10

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3. Replace the disc, place the top case, turn over the brake again compressing their faces, and
tighten the screws of assembly.

Fig. 11

4. Check the air-gap according to paragraph 6.1.

5. You may have to adjust the torque according to paragraph 3.5.
6. Assembly the brake in the machine according to paragraph 3 and 4.
7. Check the right operation of the brake according to paragraph 5.

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8 POTENTIAL FAILURES:

Failure Possible causes Solutions

Wrong voltage. Apply the correct voltage.

Air-gap too large (damaged

The brake does not work. Replace the disc.
disc).

Broken coil. Replace the brake.

The brake is connected to AC

The brake acts late. Connect it to DC.
power.

Particles prevent movement of

Brake does not release. Replace the brake.
the movable plate.

Wrong voltage. Apply the correct voltage.

The brake heats a lot.
The winding is shorted. Replace the brake.

Table 5

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NOTES:

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www.alzolabrakes.com

ALZOLA BRAKES S.L.

C/ Uzbina, nº11, Pol. Jundiz 01015
Vitoria-Gasteiz · Spain
Tel.: +34 945 291 679
Fax: +34 945 291 677
[email protected]
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