Instructions Addendum to the Operating - SEW … · 4.6 Overview of types ... 9.5.3 BF30, BF30(FS)...

*20130546_0615*Drive Technology \ Drive Automation \ System Integration \ Services

Addendum to the OperatingInstructions

BF../BT.. Double BrakeDR..112 – 180 AC MotorsFunctional Safety

Edition 06/2015 20130546/EN

SEW-EURODRIVE—Driving the world

Contents

Addendum to the Operating Instructions – DR..112 – 180 AC Motors 3

Contents1 General information .................................................................................................................. 6

1.1 About this documentation ............................................................................................... 61.2 Structure of the safety notes .......................................................................................... 6

1.2.1 Meaning of signal words ................................................................................. 61.2.2 Structure of section-related safety notes ........................................................ 71.2.3 Structure of embedded safety notes ............................................................... 7

1.3 Rights to claim under limited warranty ........................................................................... 81.4 Exclusion of liability ........................................................................................................ 81.5 Product names and trademarks ..................................................................................... 81.6 Copyright notice ............................................................................................................. 8

2 Safety notes ............................................................................................................................... 92.1 Preliminary information .................................................................................................. 92.2 General information ........................................................................................................ 92.3 Target group ................................................................................................................. 102.4 Designated use ............................................................................................................ 112.5 Other applicable documentation .................................................................................. 122.6 Functional safety (FS) .................................................................................................. 122.7 Transport/Storage ........................................................................................................ 122.8 Installation ................................................................................................................... 132.9 Electrical connection .................................................................................................... 13

2.9.1 Brakemotor ................................................................................................... 13

3 Functional safety (FS) ............................................................................................................. 143.1 Underlying standards ................................................................................................... 143.2 TÜV certification ........................................................................................................... 143.3 Nameplate .................................................................................................................... 15

3.3.1 FS symbol on the nameplate ........................................................................ 153.3.2 FS symbol as sticker on the brake................................................................ 15

3.4 Traceability ................................................................................................................... 163.5 Unit combinations ......................................................................................................... 16

3.5.1 Motor combinations....................................................................................... 163.5.2 Possible combinations and restrictions......................................................... 173.5.3 Combination with frequency inverters from SEW‑EURODRIVE................... 183.5.4 Performance levels that can be achieved ..................................................... 19

3.6 Safety functions ............................................................................................................ 203.6.1 SBC – Safe Brake Control ............................................................................ 203.6.2 SBA (safe brake actuation) ........................................................................... 213.6.3 SBH – Safe Brake Hold ................................................................................ 22

3.7 Brake diagnostics ......................................................................................................... 233.8 Validation ..................................................................................................................... 23

4 Unit structure ........................................................................................................................... 244.1 Basic structure of a brakemotor with BF11, BF11(FS), and BT11(FS) ........................ 254.2 Basic structure of a brakemotor with BF20 – BF30, BF20(FS) – BF30(FS), and

BT20(FS) – BT30(FS) .................................................................................................. 264.3 Basic structure of BF.. and BF..(FS) ............................................................................ 27

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Contents

Addendum to the Operating Instructions – DR..112 – 180 AC Motors4

4.4 Basic structure BT..(FS) ............................................................................................... 284.5 Operating principle ....................................................................................................... 294.6 Overview of types ......................................................................................................... 304.7 Nameplate gearmotor with double brake ..................................................................... 314.8 Option HR and HT manual brake release .................................................................... 324.9 Diagnostic unit /DUE option for function and wear monitoring ..................................... 354.10 EI7.B built-in encoder option ........................................................................................ 35

5 Mechanical installation ........................................................................................................... 375.1 Connecting motor and optional equipment .................................................................. 375.2 Installation and setting of HR and HT manual brake release ....................................... 37

6 Electrical installation............................................................................................................... 386.1 General information ...................................................................................................... 386.2 Connecting motor and optional equipment .................................................................. 386.3 Connecting the double brake ....................................................................................... 38

6.3.1 Brake control................................................................................................. 396.3.2 Permitted brake controls ............................................................................... 396.3.3 Supply voltage .............................................................................................. 396.3.4 Switching equipment..................................................................................... 39

6.4 Connecting the diagnostic unit /DUE option for function and wear monitoring ............ 396.4.1 Designation of the components .................................................................... 40

7 Startup...................................................................................................................................... 427.1 Requirements ............................................................................................................... 42

8 Inspection/maintenance.......................................................................................................... 438.1 General inspection and maintenance work .................................................................. 448.2 Preliminary work prior to maintaining and replacing the double brake ......................... 44

8.2.1 General information ...................................................................................... 448.2.2 Wearing parts................................................................................................ 458.2.3 Order information for operating supplies and auxiliary material for

maintenance ................................................................................................. 468.3 Inspection and maintenance intervals .......................................................................... 468.4 Setting the working air gap of the double brake ........................................................... 478.5 Replacing brake disk/pressure plate of the double brake ............................................ 488.6 Replacing double brake ............................................................................................... 508.7 Changing the double brake braking torque .................................................................. 51

8.7.1 Replacing the brake spring for BF.., BF..(FS) and BT..(FS) double brake ......... 51

8.8 Disassembling optional equipment .............................................................................. 528.8.1 Disassembling HR and HT manual brake release ........................................ 528.8.2 Disassembling the diagnostic unit /DUE....................................................... 53

8.9 Retrofitting optional equipment .................................................................................... 548.9.1 Retrofitting HR or HT manual brake release................................................. 548.9.2 Retrofitting diagnostic unit /DUE for function and wear monitoring............... 56

9 Technical data.......................................................................................................................... 669.1 Braking torques and brake springs .............................................................................. 66 20

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9.2 Work done, working air gap, brake disk thickness ....................................................... 689.3 Possible brake control systems .................................................................................... 68

9.3.1 Permitted combinations ................................................................................ 699.3.2 Brake control for BF.. and BF..(FS) double brake......................................... 709.3.3 Brake control for the BT..(FS) double brake ................................................. 71

9.4 Operating currents for the BF.., BF..(FS), and BT..(FS) double brake ......................... 729.5 Switching times ............................................................................................................ 73

9.5.1 BF11, BF11(FS) double brake ...................................................................... 739.5.2 BF20, BF20(FS) double brake ...................................................................... 749.5.3 BF30, BF30(FS) double brake ...................................................................... 749.5.4 BT11(FS) double brake................................................................................. 749.5.5 BT20(FS) double brake................................................................................. 759.5.6 BT30(FS) double brake................................................................................. 75

9.6 Permitted braking work ................................................................................................ 769.6.1 Terms and definitions.................................................................................... 769.6.2 Determining the maximum permitted braking work....................................... 779.6.3 Overload ranges ........................................................................................... 78

9.7 Brake control wiring diagrams ...................................................................................... 829.7.1 BME brake control ........................................................................................ 829.7.2 BMH brake control ........................................................................................ 839.7.3 BMP brake control ........................................................................................ 849.7.4 BMK 3.0, BMK 1.5 brake control................................................................... 859.7.5 BMK 1.4 brake control .................................................................................. 869.7.6 BMT 2.2 brake control................................................................................... 879.7.7 BMV brake control ........................................................................................ 889.7.8 BST brake control ......................................................................................... 89

9.8 Safety characteristics ................................................................................................... 909.8.1 BF.. double brake.......................................................................................... 909.8.2 BF..(FS) and BT..(FS) double brake ............................................................. 90

9.9 Characteristic safety values ......................................................................................... 919.10 Diagnostic unit /DUE .................................................................................................... 91

10 Malfunctions ............................................................................................................................ 9210.1 Malfunction/malfunction load ........................................................................................ 92

Index ......................................................................................................................................... 93

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1 General informationAbout this documentation


1 General information

INFORMATIONThis addendum to the operating instructions for "DR.71 − 315, DRN80 – 315 AC Mo-tors" focuses on the BF.. and BT.. double brakes.

Please use the data specified in this addendum. This document does not replace thedetailed applicable "DR..71 – 315, DRN80 – 315 AC Motors" operating instructions.

1.1 About this documentationThis addendum and the "DR..71 – 315, DRN80 – 315 AC Motors" operating instruc-tions" are part of the product. The documentation is intended for all employees whoperform assembly, installation, startup, and service work on the product.The "DR..71 – 315, DRN80 – 315 AC Motors" operating instructions provide all the in-formation regarding AC motors without safety-rated attachments.In addition, the "Gearmotors with BF../BT.. Double Brakes" catalog applies and pro-vides important information regarding project planning.Make sure this documentation is accessible and legible. Ensure that persons respon-sible for the machinery and its operation as well as persons who work on the deviceindependently have read through the documentation carefully and understood it. If youare unclear about any of the information in this documentation, or if you require furtherinformation, contact SEW‑EURODRIVE directly.Always use the latest edition of the documentation and software.The SEW‑EURODRIVE homepage (www.sew‑eurodrive.com) provides a broad selec-tion of documentation downloads in various languages.If required, you can also order printed and bound copies of the documentation fromSEW‑EURODRIVE.

1.2 Structure of the safety notes1.2.1 Meaning of signal words

The following table shows the grading and meaning of the signal words for safetynotes.

Signal word Meaning Consequences if disregarded

DANGER Imminent hazard Severe or fatal injuries.

WARNING Possible dangerous situation Severe or fatal injuries.

CAUTION Possible dangerous situation Minor injuries

NOTICE Possible damage to property Damage to the drive system or itsenvironment.

INFORMATION Useful information or tip: Simplifieshandling of the drive system.

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1General informationStructure of the safety notes


1.2.2 Structure of section-related safety notesSection-related safety notes do not apply to a specific action but to several actionspertaining to one subject. The hazard symbols used either indicate a general hazardor a specific hazard.This is the formal structure of a safety note for a specific section:

SIGNAL WORD

Type and source of hazard.Possible consequence(s) if disregarded.• Measure(s) to prevent the hazard.

Meaning of the hazard symbols

The hazard symbols in the safety notes have the following meaning:

Hazard symbol Meaning

General hazard

Warning of dangerous electrical voltage

Warning of hot surfaces

Warning of risk of crushing

Warning of suspended load

Warning of automatic restart

1.2.3 Structure of embedded safety notesEmbedded safety notes are directly integrated into the instructions just before the de-scription of the dangerous action.This is the formal structure of an embedded safety note:• SIGNAL WORD Type and source of hazard.

Possible consequence(s) if disregarded.

– Measure(s) to prevent the hazard.

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1 General informationRights to claim under limited warranty


1.3 Rights to claim under limited warrantyCompliance with the provisions in this addendum to the operating instructions is a pre-requisite for maintaining the guaranteed functional safety properties for this drive.Performing any actions that go beyond those described in the addendum to the oper-ating instructions, or failure to comply with the requirements, will shift the responsibilityfor the traceability of the safety components and the liability for functional safety to theoperator.A requirement of fault-free operation and fulfillment of any rights to claim under limitedwarranty is that you adhere to the information in the operating instructions and the ad-dendum to the operating instructions. Read the operating instructions and the adden-dum to the operating instructions before you start working with the unit.

1.4 Exclusion of liabilityYou must comply with the information contained in the operating instructions and theaddendum to the operating instructions to ensure safe operation of the electric motorsand to achieve the specified product characteristics and performance features.SEW‑EURODRIVE assumes no liability for injury to persons or damage to equipmentor property resulting from non-observance of the operating instructions and the corre-sponding addendum. In such cases, any liability for defects is excluded.

1.5 Product names and trademarksThe brands and product names in this documentation are trademarks or registeredtrademarks of their respective titleholders.

1.6 Copyright notice© 2015 SEW‑EURODRIVE. All rights reserved.Unauthorized reproduction, modification, distribution or any other use of the whole orany part of this documentation is strictly prohibited.

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2Safety notesPreliminary information


2 Safety notes2.1 Preliminary information

The following basic safety notes must be read carefully to prevent injury to personsand damage to property. The user must ensure that the basic safety notes are readand observed. Ensure that persons responsible for the machinery and its operation aswell as persons who work on the unit independently have read through the documen-tation carefully and understood it. If you are unclear about any of the information inthis documentation, or if you require further information, please contactSEW‑EURODRIVE.The following safety notes are primarily concerned with the use of the unit described inthese operating instructions. If you use other components from SEW‑EURODRIVE, al-so refer to the safety notes for these particular components in the corresponding docu-mentation.Also observe the additional safety notes provided in the individual chapters of thisdocument.

2.2 General information

WARNINGDanger of fatal injury during operation as the motors and gearmotors can have live,bare (in the event of open connectors/terminal boxes) and movable or rotating partsas well as hot surfaces.

Severe or fatal injuries.

• All work related to transport, storage, installation, assembly, connection, startup,maintenance and repair may only be carried out by qualified personnel.

• For transport, storage, installation, assembly, connection, startup, maintenanceand repair it is important that you adhere to the information in the following docu-ments:– Warning and safety signs on the motor/gearmotor– All the project planning documents, startup instructions and wiring diagrams

related to the drive– System-specific regulations and requirements– National/regional safety and accident prevention regulations.

• Never install damaged products.

• Never operate or energize the unit without the necessary protection covers orhousing.

• Use the unit only for its intended purpose.

• Make sure the unit is installed and operated properly.

This documentation provides additional information.

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2 Safety notesTarget group


2.3 Target groupThe document is for everyone who plans, configures and starts up safety-rated brakesand safety-rated braking systems.Any work with software may only be performed by adequately qualified personnel.Qualified personnel in this context are persons who have the following qualifications:

• Appropriate instruction.• Knowledge of this documentation and other applicable documentation.• SEW‑EURODRIVE recommends additional product training for products that are

operated using the respective software.Any mechanical work on the components may only be performed by adequately quali-fied personnel. Qualified personnel in the context of this documentation are personsfamiliar with the design, mechanical installation, troubleshooting and maintenance ofthe product, who possess the following qualifications:• Training in mechanical engineering, e.g. as a mechanic or mechatronics technician

(final examinations must have been passed).• Knowledge of this documentation and other applicable documentation.All electrical work on connected units is to be performed exclusively by adequatelyqualified electricians. Qualified electricians in the context of this documentation arepersons familiar with electrical installation, startup, troubleshooting and maintenanceof the product, who possess the following qualifications:

• Training in electrical engineering, e.g. as an electrician or mechatronics technician(final examinations must have been passed).

• Knowledge of this documentation and other applicable documentation.• Knowledge of the relevant safety regulations and laws.• Knowledge of all other standards, directives and laws named in this documenta-

tion.The above mentioned persons must have the authorization expressly issued by thecompany to install, operate, program, configure, label and ground units, systems andcircuits in accordance with the standards of safety technology.All work in the areas of transportation, storage, operation and waste disposal must becarried out by persons who are trained appropriately.

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2Safety notesDesignated use


2.4 Designated use• When using a DR.. AC motor with double brake, observe that the double brake

may only be used as a holding brake except for emergency stops. The designateduse is applying the double brake at standstill (n ≤ 20 1/min) and for emergency stopbraking operations. Double brakes are thus holding brakes with emergency stopfunction.

• The dimensioning of the drives with double brake considers 6050 emergency stopbraking operations during the life cycle with a maximum of 10 emergency stopbraking operations per day. Observe a minimum rest period of 6 minutes betweenemergency stop braking operations. The limits of project planning clearly definehow often the system can perform emergency stop braking.

• When dimensioning the double brake, observe the valid project planning specifica-tions of SEW‑EURODRIVE and the resulting application limits. If the application re-quirements or technical properties of the double brake change, project planning ofthe double brake and a check of the application limits must be performed again.

• SEW‑EURODRIVE recommends to stop the drive with stop category 1 accordingto EN 60204-1.

• Air-cooled versions are designed for ambient temperatures of -20 °C to +40 °C andinstallation altitudes of max. 1000 m above sea level. Observe the deviating infor-mation on the nameplate. The ambient conditions must comply with all the specifi-cations on the nameplate.

• In order to determine the performance level (PL) of the safety function of a system,the system manufacturer must perform an overall evaluation. The specifications inthis document are to serve as a basis for further evaluation according toDIN EN ISO 13849.

• The double brake must not be exposed to oils, acids, gases, vapors, or radiation.

• Operation in potentially explosive areas is not permitted.

• Permitted vibration stress: Motors with double brake are not suited for operation inareas with increased vibration stress of level 1 (Vibration level 1) according toDIN ISO 10816:1997-08.

• Retrofitting the safety-rated BF..(FS) and/or BT..(FS) double brake is not permitted.Replacing an existing BF.. double brake with a safety-rated BF..(FS) or BT..(FS)double brake is not permitted.

• When installed in machines, startup (i.e. start of designated operation) is prohibiteduntil it is determined that the machine complies with the local laws and directives.In the EU/EC area of applicability, the Machinery Directive 2006/42/EC must be ob-served.

In addition, the following applies to the BT..(FS) double brake:• In order to use a BT..(FS) double brake for entertainment technology, according to

DIN 56950-1, the bearing structural elements made of steel must be dimensionedaccording to DIN EN 1993-1 (all lower parts) and DIN EN 1994-1-1, and designedaccording to DIN 18800-7 and DIN EN 1090-2. DIN EN 1999-1-1 andDIN EN 1090-3 apply to structural elements made of aluminum.

• The project planning specifications for the BT..(FS) double brake already considersthe standard requirements of DIN 56950-1 for use in entertainment technology,e.g. dimensioning for 400 operating hours or requirements regarding the loads oc-curring in case of malfunctions.

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2 Safety notesOther applicable documentation


2.5 Other applicable documentationThe following publications and documents have to be observed as well:

• "DR..71 – 315, DRN80 – 315 AC Motors" operating instructions

• "Safety-Rated Brake System" system manual

• "Gearotors with BF../BT.. Double Brake" catalog• "Safety-Oriented BST Brake Module for Control Cabinet Installation" operating in-

structions• Addendum to the operating instructions "Safety-Rated Encoders – DR..71 – 315,

DRN80 315 AC Motors – Functional Safety", if necessary

2.6 Functional safety (FS)All work on the brakemotor or geared brakemotor with functional safety motor options– indicated by the FS logo on the nameplate – may heavily influence the functionalityand the suitability for use in functional safety.SEW‑EURODRIVE recommends commissioning SEW‑EURODRIVE Service to per-form the work.If you carry out work on brakemotors or geared brakemotors with safety-rated motoroptions yourself, note that the responsibility for the traceability of the functional safetymotor options and the liability regarding functional safety is then passed to the opera-tor.In addition to the qualifications listed above, persons that perform work on brakemo-tors or geared brakemotors with functional safety motor options must have the follow-ing knowledge:

• Functional safety.• The relevant safety regulations and laws, especially with the requirements of

EN ISO 13849 and all other standards, directives and laws specified in this docu-mentation.

• The content of the comprehensive operating instructions and other applicabledocuments.

The unit may not perform safety functions without higher-level safety systems unlessthese functions are described and expressly permitted in the relevant documentation.

2.7 Transport/StorageInspect the shipment for damage as soon as you receive the delivery. Inform the ship-ping company immediately about any damage. If necessary, suspend startup.Tighten the eyebolts securely. They are only designed for the weight of the motor/gearmotor; do not attach any additional loads.The installed lifting eyebolts are in accordance with DIN 580. The loads and regula-tions specified in that document must always be observed. If the gearmotor is equip-ped with two eyebolts, then both of these should be used for transportation. In thiscase, the tension force vector of the slings must not exceed a 45° angle in accordancewith DIN 580.

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2Safety notesInstallation


2.8 InstallationMake sure that the supports are even, the foot and flange mounting is correct and ifthere is direct coupling, align with precision. Resonances between the rotational fre-quency and the double line frequency caused by the structure are to be avoided. Re-lease the brake (if installed), turn rotor manually, check for unusual grinding noise.Check the direction of rotation in decoupled state.Only install or remove belt pulleys and couplings using suitable devices (heat up) andcover with a touch guard. Avoid improper belt tension.Make the pipe connections that may eventually be required. Mounting positions withshaft ends pointing upwards should be equipped with a cover to prevent foreign ob-jects from falling into the fan. Ensure that ventilation openings are not obstructed andthat exhaust air, including air from adjacent units, cannot be drawn in again straightaway.

2.9 Electrical connection2.9.1 Brakemotor

All work may only be carried out by qualified personnel. During work, the machinemust be at standstill, de-energized, and safeguarded against accidental restart. Thisalso applies to auxiliary circuits e.g. anti-condensation heating or forced cooling fan.Check that no voltage is applied.Exceeding the tolerances in EN 60034-1 (VDE 0530, part 1) – voltage + 5%, frequen-cy + 2%, curve shape, symmetry – increases the heating and influences electromag-netic compatibility. Also observe standard EN 50110 (and, if applicable, other nationalregulations, such as DIN VDE 0105 for Germany).Observe the wiring information and any differing data on the nameplate as well as thewiring diagram in the terminal box.

INFORMATIONDuring electrical connection according to EN 60204-1 especially observe sections 14and 15.

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3 Functional safety (FS)Underlying standards


3 Functional safety (FS)The double brake may not perform safety functions without higher-level safety sys-tems unless these functions are described and expressly permitted in the relevantdocumentation. The double brake complements a safe braking system. Only the safebraking system as a whole allows for achieving various safety classes up to perform-ance level e (PL e) depending on the selected system architecture (category), the suit-able brake control and the existing diagnostics function for the double brake.SEW‑EURODRIVE assumes responsibility for the delivered brakemotor or gearedbrakemotor with safety-rated double brake in terms of compliance with the functionalsafety regulations regarding the safety-rated double brake. To detect deviations fromthe delivery state, safety-relevant connection elements are sealed. SEW‑EURODRIVErecommends having SEW‑EURODRIVE Service carrying out work for which thesealed connecting elements must be opened.If you perform this work yourself, the responsibility of the safety-rated double brakeand the liability regarding the functional safety is passed to the user.Each safety-rated double brake has a unique motor assignment to provide for tracea-bility. To ensure the assignment after replacing the safety-rated double brake, observethe information in chapter "Retraceability" (→ 2 16).

3.1 Underlying standardsThe safety assessment of the brake is based on the following standard and safetyclass:

Underlying standards double brake

Safety class/underlying standard Performance Level (PL)/EN ISO 13849-1

Further, the safety-rated BT..(FS) double brakes meet the requirements for entertain-ment technology, DIN 56950-1.

3.2 TÜV certificationThe following certificate is available for the described safety-rated BF..(FS) and BT..(FS) double brakes:• Certificate of the TÜV NORD Systems GmbH & Co. KGThe TÜV certificate is available for download on the SEW‑EURODRIVE website(www.sew‑eurodrive.de).

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3Functional safety (FS)Nameplate


3.3 NameplateThe motor nameplate is sufficient for identifying the double brake. You do not have todisassemble the drive to identify the double brake. An exemplary nameplate is shownin chapter "Nameplate motor with double brake" (→ 2 31).

3.3.1 FS symbol on the nameplateDrives from SEW‑EURODRIVE can be equipped with optional motor options for func-tional safety.Frequency inverters, encoders or brakes, or other accessories, can be integrated inthe AC motor as safety-related components either individually or in combination.SEW‑EURODRIVE indicates the integration of functional safety by the following FSlogo and a two-digit number on the nameplate of the motor.The number is a code that indicates which components in the drive are safety-related.Observe the following excerpt from the valid code table for all products.

Functional safety

Inverter (e.g.MOVIMOT®)

Brake Manual brakerelease moni-

toring

Brake moni-toring

Motor pro-tection

Encoder/Encodermounting

02 x

04 x

11 x x

If the FS logo on the nameplate contains the code "FS 11", for example, the motor isequipped with a combination of safety-rated double brake and safety-rated encoder.If the drive bears the FS mark on the nameplate, you must adhere to the information inthe following documents:

• "Safety-Rated Brake System" system manual

• "Gearmotors with BF../BT.. Double Brake" catalog• Addendum to the "Safety-Rated Encoders – DR..71 – 315, DRN80 315 AC Motors

– Functional Safety" operating instructions• The addendum to the operating instructions at hand.

3.3.2 FS symbol as sticker on the brakeIn addition to the FS symbol on the nameplate of the motor, there is a yellow FS logowithout a specific number attached to the nameplate of the brake. The symbol indi-cates the use of the brake as safety-rated component.

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3 Functional safety (FS)Traceability


3.4 TraceabilityAll safety-rated brakes have a unique motor assignment. This assignment is canceledwith a brake replacement. This is why you should proceed as follows for a brake re-placement:• Report the new assignment to SEW‑EURODRIVE or• provide for a corresponding traceability yourself.

INFORMATIONPerforming any actions that go beyond those described in the addendum to the oper-ating instructions, or failure to comply with the requirements, will shift the responsibili-ty for the traceability of the safety components and the liability for functional safety tothe operator.

3.5 Unit combinations3.5.1 Motor combinations

The described double brake are designed for combination with the following AC mo-tors. It is not permitted to adapt them to other motors.For use in functional safety, the BF.. double brake is available as a safety-rated dou-ble brake as an option. In this design, the double brakes are referred to as BF..(FS)double brakes.BT..(FS) double brakes are only available for use in functional safety applications.The following table shows the fixed assignment of motor and double brake.Industry applications

Size Associated motor size

Double brake for use in industrial applications in standard design

BF11 DR..112, DR..132

BF20 DR..160

BF30 DR..180

Double brake for use in industrial applications in safety-rated design

BF11(FS) DR..112, DR..132

BF20(FS) DR..160

BF30(FS) DR..180

Entertainment technology applications

Size Associated motor size

Double brake for use in entertainment technology applications in safety-rated design

BT11(FS) DR..112, DR..132

BT20(FS) DR..160

BT30(FS) DR..180

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3Functional safety (FS)Unit combinations


3.5.2 Possible combinations and restrictionsThe following table shows an overview of possible combinations and restrictions of therespective double brake with other drive components or drive options.

BF.. double brake BF..(FS) double brake BT..(FS) double brake

Size 11, 20, 30 11, 20, 30 11, 20, 30

Safety-rated design No Yes Yes

Area of applicationHolding brake

Yes(with emergency stopfunction)



Working brake No No No

Braking torques Restrictions dependingon dimensioning

Restrictions dependingon dimensioning

Restrictions dependingon dimensioning

Brake optionsManual brake release

HR and HT

HR and HT

HR and HT

Inspection/maintenanceInspection

Maintenance

Permitted

Restriction depending ontask

Permitted


Permitted


Motor type DRS112 – DRS180

DRL132 – DRL180

DRS112 – DRS180

DRL132 – DRL180

DRS112 – DRS180

Motor optionsMotor protection /TF

Motor protection /TH

Flywheel fan /Z

Optional

Optional

Not permitted

Required

Not permitted

Not permitted

Required

Not permitted

Not permitted

Gear unit/motor combi-nation with pinion bore/pinion shaft end

Restriction of the permit-ted braking torques



Gear unitRM.., R.07, R.17

WT.., W..10, W..20, W..30

BS.., PS..

Hollow shaft with shrinkdisk

Not permitted

Not permitted

Not permitted

Not permitted

Not permitted

Not permitted

Not permitted

Not permitted

Not permitted

Not permitted

Not permitted

Not permitted

TorqLOC®

Gear unit adapter

Compound gear unit

Overhead trolley drives

ATEX gear unit

Mounting to industrialgear unit

Not permitted

Not permitted

Not permitted

Not permitted

Not permitted

Not permitted

Not permitted

Not permitted

Not permitted

Not permitted

Not permitted

Not permitted

Not permitted

Not permitted

Not permitted

Not permitted

Not permitted

Not permitted

Input shaft assembly Not permitted Not permitted Not permitted

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3 Functional safety (FS)Unit combinations


BF.. double brake BF..(FS) double brake BT..(FS) double brake

Special designs No No No

MeasuresSEW‑EURODRIVE

Standard • Additional assemblysteps

• Additional documenta-tion

• Traceability up tobatch monitoring

• Manipulation protec-tion at critical points

• Additional assemblysteps

• Additional documenta-tion

• Traceability up tobatch monitoring

• Manipulation protec-tion at critical points

Category B 31) 31)

B10d value Specification per size Specification per size Specification per size1) According to the standard, category 3 requires brake diagnostics of the double brake. This is not part of the double brake. Realizethe diagnostics in the braking system.

3.5.3 Combination with frequency inverters from SEW‑EURODRIVEThe drives for the double brake can be used with the following control technology:

Control cabinet technology Permitted Not permitted

MOVIDRIVE® B X

MOVIAXIS® X

MOVITRAC® B X

Line operation Permitted Not permitted

Asynchronous motor withoutfrequency inverter

X

For unit combinations of BF.., BF..(FS), and BT..(FS) double brake with various brakecontrols, refer to chapter "Permitted unit combinations" (→ 2 69).

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3Functional safety (FS)Unit combinations


3.5.4 Performance levels that can be achievedBF..(FS) and BT..(FS) double brakes complement a safe braking system consisting ofseveral system components.The achievable performance level of the safe braking system with double brake ac-cording to EN ISO 13849-1 is mainly determined by:

• The selected safety structure, category (Cat.)

• The mean time to dangerous failure (MTTFd).

The MTTFd value is calculated specifically for the application based on the B10d val-ue for the brake and the switching frequency of the application.

• The diagnostic coverage (DCavg).

The diagnostic coverage is fulfilled by implementing brake diagnostics separatelyfor each partial brake of the double brake.

– A DCavg value < 60% does not fulfill the regulatory requirement.

– With a DCavg value ≥ 60%, performance level d (PL d) can be achieved in a safebraking system.

– With a DCavg value ≥ 90%, performance level e (PL e) can be achieved in a safebraking system.

• The failure due to a common cause (CCF) with categories 2, 3, and 4.The achieved performance level must be determined for the selected safe brakingsystem based on an overall evaluation of the system. The required characteristic safe-ty values (→ 2 90) and safety characteristics (→ 2 91) for the double brake arespecified in this document.The characteristic safety values of other components by SEW‑EURODRIVE are alsoavailable on the SEW‑EURODRIVE homepage at www.sew‑eurodrive.com on the In-ternet and in the SEW‑EURODRIVE library for the Sistema software of the Institute forOccupational Safety and Health of the German Social Accident Insurance (IFA, for-merly BGIA).Exemplary concepts for achieving different performance levels are shown in the "SafeBraking System" system manual.

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3 Functional safety (FS)Safety functions


3.6 Safety functionsThe following safety functions can be realized with a safe braking system:

• SBC (safe brake control)• SBA (safe brake actuation)• SBH (safe brake hold)

INFORMATIONSafety functions SBA and SBH are defined by SEW‑EURDORIVE in accordance withthe standard DIN EN 61800-5-2. SBA and SBH additionally require the safety func-tion SBC for safe switching off of the power supply of the brake.

Depending on dimensioning and use in the application, a drive can generate a highertorque than can be decelerated or held by the brake. Therefore, if safety functionsSBA and SBH are activated, the drive power supply must be switched off by the STOsafety function.

3.6.1 SBC – Safe Brake ControlThe SBC safety function provides a safe output signal for controlling a brake. Thismeans no power is supplied to release the brake electrically.

t1t

V

18014400788450571

Safety function enabled

v = Speed

t = Time

t1 = Point of time when SBC safety function is triggered

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3Functional safety (FS)Safety functions


3.6.2 SBA (safe brake actuation)When activated, the SBA safety function uses the electromechanical brake in order tostop the motor shaft safely. This braking operation is considered an emergency stopbraking. The motor shaft is held safely at standstill.

t1 t2 t

V

36028803062772363

Safety function active, safe brake actuationSafety function active, safe brake hold

v = Speedt = Timet1 = Point of time when SBA is triggeredt2 = Point of time when SBA has stopped the motor shaft and holds it safely.

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3 Functional safety (FS)Safety functions


3.6.3 SBH – Safe Brake HoldOnce activated, the SBH safety function uses the electromechanical brake to hold thecurrent position of the motor shaft safely. The motor shaft is already stopped when thefunction is activated.

t1 t2 t

V

9007207768616459

Safety function enabled

v = Speed

t = Time

t1 = Point of time when SBH is triggered

t2 = Point of time when SBH is deactivated

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3Functional safety (FS)Brake diagnostics


3.7 Brake diagnosticsBrake diagnostics is required for the double brake according to EN ISO 13849-1 de-pending on the required performance level. The diagnostic coverage (DCavg) mustmeet the regulatory requirements. Brake diagnostics provides additional informationfor the user regarding the state and performance of the double brake. This allows youto detect potential errors in time and initiate maintenance/repair.Brake diagnostics for the double brake must detect the following possible failures sep-arately for the partial brake 1 and 2:• Double brake does not close• Insufficient braking torqueTo prevent faulty diagnostic results, SEW‑EURODRIVE recommends to additionallydiagnose the potential failure "Double brake does not open".Brake diagnostics is not part of the double brake and must be realized within the sys-tem. SEW‑EURODRIVE offers the brake diagnostics solution as software for the con-troller of the performance classes advanced/power. Brake diagnostics fulfills the regu-latory requirements and allows for achieving performance level e (PL e).

3.8 ValidationTo determine the safety of a machine, the plant manufacturer must carry out an over-all evaluation.Check the effectiveness of each risk minimization at the end. This includes checking ifthe required performance level PLr is achieved for each implemented control-relatedsafety function.

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4 Unit structureValidation


4 Unit structureThe following sections provide an overview of the unit structure of a AC motor withBF.., BF..(FS), or BT..(FS) double brake. The illustration focuses on the specific differ-ences that result from the mounting of the double brake.Various other details are not illustrated as they are already described in the corre-sponding "DR..71 – 315, DRN80 – 315 AC Motors" operating instructions or the ad-dendum to the "Safety-Rated Encoders – DR..71 – 315, DRN80 – 315 AC Motors –Functional Safety" operating instructions.Check in particular for:

• Basic structure of the motor incl. options for power connection (e.g. /KCC)

• Fan cooled or forced air cooling (e.g. /V)

• Optional motor protection and temperature monitoring (e.g. /TF, /KY)• Optional encoder systems (e.g. /EI7.B, /EG7., /AG7.)• Requirements for operation of AC motors with inverterIf there is no information on these options in the following sections, refer to the docu-ments mentioned above.

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4Unit structureBasic structure of a brakemotor with BF11, BF11(FS), and BT11(FS)


4.1 Basic structure of a brakemotor with BF11, BF11(FS), and BT11(FS)The following figure shows an example of an exploded view. The figure helps you toassign the parts in the parts lists. Deviations are possible depending on the size anddesign of the brakemotor with double brake.Basic structure of a brakemotor with BF11, BF11(FS), and BT11(FS) double brake:

[1275]

[157]

[1274]

[1265]

[137]

[1264]

[1263]

[698]

[1187]

[1185]

[70]

[41][48]

[44]

[1]

[71]

[62]

[36]

[32]

[1187]

[35]

[1556]

[1186]

[170]

[95]

[550]

[22]

[1185]

[1273] [1275]

[123]

[132]

[131]

[1119]

[112]

[392]

[13]

14747670667

[1] Rotor [95] Oil seal/sealing ring [1185] Screw[13] Cap screw [112] Terminal box lower part [1186] Screw[22] Hex head screw [123] Screw/hex head screw [1187] Closing piece[32] Retaining ring [131] Cover gasket [1263] Terminal[35] Fan guard [132] Terminal box cover [1264] Terminal[36] Fan [137] Screw [1265] Retaining plate[41] Shim/cup spring [157] Clamping strap complete [1273] Plug[44] Deep groove ball bearing [170] Forced cooling fan, cpl. [1274] Plug[48] Spacer ring [392] Gasket [1275] Plug[62] Retaining ring [550] Complete double brake [1556] Closing piece[70] Driver [698] Complete connector[71] Key [1119] Cable gland

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4 Unit structureBasic structure of a brakemotor with BF20 – BF30, BF20(FS) – BF30(FS), and BT20(FS) – BT30(FS)


4.2 Basic structure of a brakemotor with BF20 – BF30, BF20(FS) – BF30(FS),and BT20(FS) – BT30(FS)

The following figure shows an example of an exploded view. The figure helps you toassign the parts in the parts lists. Deviations are possible depending on the size anddesign of the brakemotor with double brake.Basic structure of a brakemotor with BF20 – BF30, BF20(FS) – BF30(FS), andBT20(FS) – BT30(FS) double brake:

[170]

[1186]

[1556]

[1185]

[1187]

[1187]

[1185]

[35]

[32][36]

[62]

[71]

[1]

[31][44]

[48]

[41]

[70]

[22]

[19]

[17]

[550]

[95]

[698]

[157]

[1273]

[1274]

[1275]

[1263]

[1264]

[137]

[1265]

[390]

[123]

[132]

[131]

[378]

[1119]

[112]

14747668235

[1] Rotor [71] Key [1119] Cable gland[17] Hex nut [95] Oil seal/sealing ring [1185] Screw[19] Cap screw [112] Terminal box lower part [1186] Screw[22] Hex head screw [123] Screw/hex head screw [1187] Closing piece[31] Key [131] Cover gasket [1263] Terminal[32] Retaining ring [132] Terminal box cover [1264] Terminal[35] Fan guard [137] Screw [1265] Retaining plate[36] Fan [157] Clamping strap complete [1273] Plug[41] Cup spring with BF20 –

BF30, BF20(FS) – BF30(FS),BT20(FS) – BT30(FS)

[170] Forced cooling fan, cpl. [1274] Plug

[44] Deep groove ball bearing [378] Screw plug [1275] Plug[48] Spacer ring [390] Closing plug [1556] Closing piece[62] Retaining ring [550] Complete double brake[70] Driver [698] Complete connector

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4Unit structureBasic structure of BF.. and BF..(FS)


4.3 Basic structure of BF.. and BF..(FS)The following figure shows an example of an exploded view. The figure helps you toassign the parts in the parts lists. Deviations are possible depending on the size anddesign of the double brake.

INFORMATIONIn the following, partial brake I and II are distinguished.

The partial brake I is placed inside at the motor end.

The partial brake II is placed outside at the fan end.

Basic structure of BF.. and BF..(FS) double brake:

[54][68]

[66]

[67]

[1259][66]

[69]

[69]

[1645]

[28]

[1272]

[68]

[60]

[1176] / [1177]

/ [1179]

[49]

[50] / [276]

/ [1312]

[1261] [1256]

[1258]

[1257]

[42]

[718]

[1256]

14334971403

[28] Closing cap [1176] Standard brake spring partial brake II[42] Brake endshield [1177] Blue brake spring partial brake II[49] Pressure plate partial brake I [1179] White brake spring partial brake II[50] Standard brake spring partial brake II [1256] Set screw for pressure plate partial brake I and

II (only with BF20, BF20(FS), BF30 and[54] Magnet body complete partial brake I BF30(FS))[60] Hex head screw partial brake I [1257] Magnet body complete partial brake II[66] Sealing strip partial brakes I and II [1258] Pressure plate partial brake II[67] Setting sleeve partial brake I [1259] Hex head screw partial brake II[68] Brake disk partial brakes I and II [1261] Setting sleeve partial brake II[69] Circular spring partial brakes I and II [1272] Screw plug[276] Blue brake spring partial brake I [1312] White brake spring partial brake I[718] Damping plate partial brake I [1645] Damping plate partial brake II

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4 Unit structureBasic structure BT..(FS)


4.4 Basic structure BT..(FS)The following figure shows an example of an exploded view. The figure helps you toassign the parts in the parts lists. Deviations are possible depending on the size anddesign of the double brake.

INFORMATIONIn the following, partial brake I and II are distinguished.

The partial brake I is placed inside at the motor end.

The partial brake II is placed outside at the fan end.

Basic structure of the BT..(FS) double brake:

[54]

[68]

[66]

[67]

[1259][66]

[69]

[69]

[1253]

[1252]

[1255]

[1254]

[1256]

[28]

[1272]

[68]

[60][1176] / [1177]

/ [1179]

[49]

[50] / [276]

/ [1312]

[1261]

[1258]

[1257]

[42]

[1256]

13243701643

[28] Closing cap [1179] White brake spring partial brake II[42] Brake endshield [1252] Absorber partial brake I[49] Pressure plate partial brake I [1253] O-ring partial brake I[50] Standard brake spring partial brake II [1254] Absorber partial brake II[54] Magnet body complete partial brake I [1255] O-ring partial brake II[60] Hex head screw partial brake I [1256] Set screw for pressure plate partial brake I

and II (only with BF20(FS), BF30(FS))[66] Sealing strip partial brakes I and II [1257] Magnet body complete partial brake II[67] Setting sleeve partial brake I [1258] Pressure plate partial brake II[68] Brake disk partial brakes I and II [1259] Hex head screw partial brake II[69] Circular spring partial brakes I and II [1261] Setting sleeve partial brake II[276] Blue brake spring partial brake I [1272] Screw plug[1176] Standard brake spring partial brake II [1312] White brake spring partial brake I[1177] Blue brake spring partial brake II

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4Unit structureOperating principle


4.5 Operating principleThe double brake from SEW‑EURODRIVE is a DC-operated, electromagnetic diskbrake that opens electrically and is applied automatically using spring force if the volt-age supply is not present or faulty. Without electrical control, the double brake remainsclosed (fail-safe principle). With this operating principle, the double brake meets therequirements of the basic safety principles.If the brake coil is supplied correctly with the specific DC voltage, the generated mag-netic field overcomes the force of the brake springs. The pressure plate is retracted bythe magnet body. The brake disk is free. The rotor can turn. If the brake coil is in a de-energized state, the pressure plate is pushed against the brake disk back by the mag-net body in the original position using the force of the brake springs. The rotor is de-celerated and held at standstill. The number and type of brake springs determine thebraking torque.With the optional, manual brake release with automatic re-engaging function, you canrelease the double brake manually, e.g. for testing purposes. The HR manual brakerelease allows for simultaneous release of both partial brakes via a manual releaselever. As an alternative, the HT manual brake release allows for the partial brakes (I orII) to be released separately or simultaneously. An additional lever mechanism allowsfor a direct selection of the partial brake with HT manual brake release. The patentedjoint in the manual brake release of the options HR and HT for double brakes signifi-cantly reduces the force required to actuate the manual brake release.The safety-rated BF..(FS) or BT..(FS) double brake is a redundant double brake, con-sisting of 2 equivalent partial brakes. If the project planning specifications ofSEW‑EURODRIVE are observed, in case of failure of one partial brake, the remainingpartial brake is dimensioned to solely decelerate and hold the load by means of anemergency stop braking.If the working air gap is too large, the distance between pressure plate and magnetbody is too large. In this case, the double brake cannot be released electrically. Thismeans a failure e.g. due to too much brake lining wear is excluded.The safe state of the double brake is the closed double brake, if e.g.:

• The voltage supply of the double brake is interrupted• The energy stored in the brake coil is reduced• The pressure plate is pushed again the brake disk by the force of the brake

springs.

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4 Unit structureOverview of types


4.6 Overview of typesIndustry applicationsThe following motor/double brake combinations are available for industry applications:

Motor type Type Max. possiblenominal braking

torqueNm

Possible reduced braking torque stepsNm

DRS112, DRS132,DRL132

BF11,BF11(FS) 2 × 110 2 × 80 2 × 55 2 × 40 2 × 28 2 × 20

DRS160, DRL160 BF20,BF20(FS) 2 × 200 2 × 150 2 × 110 2 × 80 2 × 55 2 × 40

DRS180, DRL180 BF30,BF30(FS) 2 × 300 2 × 200 2 × 150 2 × 100 2 × 75 -

Entertainment technology applicationsThe following motor/double brake combinations are available for entertainment tech-nology applications:

Motor type Type Max. possiblenominal braking

torqueNm

Possible reduced braking torque stepsNm

DRS112, DRS132 BT11(FS) 2 × 110 2 × 80 2 × 55 2 × 40 2 × 28 2 × 20

DRS160 BT20(FS) 2 × 200 2 × 150 2 × 110 2 × 80 2 × 55 2 × 40

DRS180 BT30(FS) 2 × 300 2 × 200 2 × 150 2 × 100 2 × 75 -

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4Unit structureNameplate gearmotor with double brake


4.7 Nameplate gearmotor with double brakeThe following figure shows an example of a nameplate:

Ar/min

Made in Germany

Th.Kl.

kWHz01.1234567801.0001.15R107 DRS112M4BT11HT/ES7S/TF/U/DUE

1435/10 230/4004 S3/15% 14.1/8.10.84Cosφ

50

155(F)

kg 240.026

Inverter duty VPWMV

IP 54

3~IEC60034

NmVbr 400 AC

2x552xBMT2.2

1885782DE

i141.83 3780Nm

CLP220 Miner.Öl/16.9lIM M3

V

2

∆/

[1]

[11]

[3]

[4]

[5]

[7]

[13]

[14]

[15]

[6] [16]

[17]

[2]

[18]

[19]

[20]

[9]

[10]

[12]

[8]

14222191755

[1] Type designation[2] Serial number[3] Nominal frequency[4] Nominal power/duty type[5] Power factor for AC motors[6] Thermal class[7] Nominal speed of the motor/speed of the gear unit output shaft[8] Maximum output torque[9] Gear unit ratio[10] Oil type and oil fill volume[11] Weight[12] Mounting position[13] FS logo, indicating an integrated motor option with functional safety[14] Number of phases and underlying rating and performance standards

(IEC 60034-X and/or equivalent national standard)[15] Degree of protection according to IEC 60034-5[16] Nominal voltage[17] Nominal current[18] Brake voltage[19] Nominal braking torque per partial brake[20] Used brake control per partial brake

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4 Unit structureOption HR and HT manual brake release


4.8 Option HR and HT manual brake releaseThe double brake can be released manually with a manual brake release. Two de-signs of the manual brake release are available:

1. HR: Is a manual brake release with automatic re-engaging function. A manual re-lease lever is included in the delivery. The HR option allows for simultaneous re-lease of both partial brakes with the screwed in manual release lever [51].

Pull the manual release lever [51] towards the fan wheel. It is not permitted to pullthe lever towards the terminal box. The correct direction to pull the lever is speci-fied by the arrow on the fan guard.

As soon as the motor is taken into operation, the manual release lever must be re-moved and fastened to the stator using the provided clamps [46].

2. HT: Has the same function as the HR option with additional lever mechanism of themanual brake release. The HT manual brake release allows for individual releaseof the partial brakes or of simultaneous release of both partial brakes. The simulta-neous release is performed by means of the screwed in manual release lever [51].

Pull the manual release lever towards the fan wheel. It is not permitted to pull thelever towards the terminal box. The correct direction to pull the lever is specified bythe arrow on the fan guard.

To deactivate the release function of partial brake I, press the lever mechanism ofpartial brake I downwards with the actuator element [1191]. If the addition manualrelease lever is operated, only partial brake II is released.

If you let go of the manual release lever and the lever mechanism, they return totheir initial position. If the manual release lever is used again, both partial brakesare released simultaneously.

To deactivation the release function of partial brake II (only partial brake I is re-leased), use the actuator element of the lever mechanism of partial brake II. After-wards, partial brake I can be release by using the manual release lever.

The assignment of the lever mechanism for the partial brakes I and II is indicatedon the closing piece of the fan guard (slotted cover and on the lever mechanismitself):

• "I" for the lever mechanism to deactivate partial brake I

• "II" for the lever mechanism to deactivate partial brake II

As soon as the motor is taken into operation, the manual release lever must be re-moved and fastened to the stator using the provided clamps [46]. The protrudingactuator elements [1191] for the lever mechanism remain unchanged in thescrewed in position.

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4Unit structureOption HR and HT manual brake release


The following figure shows the basic structure of the HR manual brake release:

[51]

[47]

[46]

[1188]

[53]

[56]

[58]

[1189]

[1195]

[1193]

14337862155

[46] Holding fixture manual release lev-er

[58] Hex nut

[47] O-ring [1188] Spacers[51] Manual release [1189] Stud[53] Complete releasing lever [1193] Hex head screw[56] Stud [1195] Compression spring

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4 Unit structureOption HR and HT manual brake release


The following figure shows the basic structure of the HT manual brake release:

[51]

[47]

[46]

[1188]

[53]

[56]

[58]

[1189]

[1195]

[1193]

[1191]

14194045963

[46] Holding fixture manual release lev-er

[1188] Spacers

[47] O-ring [1189] Stud[51] Manual release [1191] Cap screw[53] Complete releasing lever [1193] Hex head screw[56] Stud [1195] Compression spring[58] Hex nut

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4Unit structureDiagnostic unit /DUE option for function and wear monitoring


4.9 Diagnostic unit /DUE option for function and wear monitoringThe /DUE option (Diagnostic Unit Eddy Current) is a contactless measuring system forfunction and wear monitoring of the double brake and the continuous measurement ofthe current working air gap of the respective partial brake.The measuring system consists of:• 2 sensors, installed in the magnet body of the double brake• 1 common evaluation unit in the motor terminal box that is supplied via a DC 24 V

voltage.It is a contactless measuring system, based on the current eddy principle. A high-fre-quency alternating current flows through the sensors. The electromagnetic field indu-ces eddy currents in the pressure plate that change the alternating current resistanceof the sensor. The evaluation unit transforms the change in impedance to an electricalsignal (4 – 20 mA) that is proportional to the working air gap of the double brake.The evaluation unit is equipped with:

• 2 analog outputs

– 1 electrical signal (4 – 20 mA) per partial brake indicating the distance betweenpressure plate and sensor (current working air gap)

• 4 digital DC 24 V outputs

– 1 function output (NO contact) per partial brake, indicates the open state of therespective partial brake

– 1 wear output (NC contact) per partial brake, indicates that the maximum work-ing air gap of the respective partial brake is reached

• 5-pin DIP switch

– To set the maximum permitted wear limit• 4 LEDs

– 2 red LEDs that indicate the state of wear of the respective partial brake

– 2 green LEDs that indicate the function of the respective partial brakeIf the double brake is ordered with the /DUE diagnostic unit, the function and wearmonitoring function is already installed, calibrated and the permitted wear limit for thedouble brake is set at the factory.

4.10 EI7.B built-in encoder optionThe drives of size DR..112/132 with BF11 or BF11(FS) double brake can optionally beequipped with a EI7.B type encoder integrated in the drive.For motors with BF11(FS) double brake and drives of size DR..160 – 180, this optionis not available.The EI7.B built-in encoder is very compact. This way, the built-in encoder can be in-stalled between the double brake and the drive of the fan without additional length.The built-in encoder monitors the rotary motion of the motor shaft by scanning a mag-netic wheel integrated in the fan. The built-in encoder provides an HTL signal. Thereare 4 designs depending on the period per revolution (1, 2, 6, or 24).For connection by the customer, 3 connection types are available:

• Connection via terminal strip in terminal box• Connection via 4-pin M12 plug connector (AVSE)• Connection via 8-pin M12 plug connector (AVRE)

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4 Unit structureEI7.B built-in encoder option


For detailed information regarding the technical data of the EI7.B encoder system andthe electrical connection variants, refer to the "DR..71 – 315, DRN80 – 315 AC Mo-tors" operating instructions.The following figure shows the basic structure of the brakemotor with BF11 orBF11(FS) double brake and EI7.B built-in encoder:

1546

1539

1534

1529

1525

1545

1518 1521

1519 3615171520

119

629

632

1524

1522

129

132

131

1632

1635

1552

1526

14979452427

Basic equipment Parts for terminal strip connection[36] Fan [629], [632] Retaining screw[119] Retaining screw [1522] Connection unit[131] Gasket for cover[132] Terminal box cover Parts for M12 plug connector AV.E[1517] Encoder module [1525] Connector[1518], [1519] Flat head screw [1529] Protection cap[1520] Spacer [1534] Glass fiber sheathing[1521] Adapter [1539] Sleeve[1524] Terminal washer [1545] Reduction[1526] Grommet [1546] O-ring[1635] Cable ties [1552] Glass fiber sheathing

[1632] Connection box

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5Mechanical installationConnecting motor and optional equipment


5 Mechanical installation

INFORMATIONObserve the safety notes in chapter 2 of these operating instructions for the mechani-cal installation.

Make sure that the following requirements are met before you start installing the unit:

• The specifications on the nameplate of the gearmotor match the voltage supplysystem.

• The drive has not been damaged during transportation or storage.

• Ambient temperature between -20 °C and +40 °C or according to project planning.• You have ensured that there are no oils, acids, gases, vapors, radiation, etc. pres-

ent.• The installation altitude is max. 1000 m above sea level. For installation altitudes

above 1000 m above sea level, contact SEW‑EURODRIVE.

5.1 Connecting motor and optional equipmentObserve the information in the relevant chapter of the corresponding "DR..71 – 315,DRN80 – 315 AC Motors" operating instructions when installing the motor and optionalequipment. Observe the addendum to the operating instructions "Safety-Rated Encod-ers – DR..71 – 315, DRN80 315 AC Motors – Functional Safety", if necessary.

5.2 Installation and setting of HR and HT manual brake releaseIf the manual brake release was ordered with the double brake, the manual brake re-lease is installed and set at the factory.

INFORMATIONThe manual release lever of the double brake must not be screwed in during normaloperation in order to avoid an accidental release.

Keep the manual release lever in the provided clamps at the stator housing.

If the manual brake release is retrofitted, refer to the chapter "Retrofitting HR or HTmanual brake release" (→ 2 54) for the installation.

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6 Electrical installationGeneral information


6 Electrical installation

INFORMATIONObserve the safety notes in chapter 2 during installation.

WARNINGDisabling the functional safety.


• Only qualified personnel is allowed to carry out work on functional safety compo-nents.

• Any work on functional safety components must be carried out by strictly observ-ing the specifications in the operating instructions at hand and the respective ad-dendum to the operating instructions. Otherwise, the warranty will become void.

6.1 General informationThe double brake is released electrically. The brake is applied mechanically when thevoltage is switched off.These voltage disconnection types are distinguished:• Functional control

Control of the double brake outside functional safety.• Safe control

Control of the double brake for the use in functional safety.If you use contactors for voltage disconnection, observe the required utilization cate-gory of the contactors.

6.2 Connecting motor and optional equipmentObserve the information in the relevant chapter of the corresponding "DR..71 – 315,DRN80 – 315 AC Motors" operating instructions when installing the motor and optionalequipment. Observe the addendum to the operating instructions "Safety-Rated Encod-ers – DR..71 – 315, DRN80 315 AC Motors – Functional Safety", if necessary.

6.3 Connecting the double brakeConnect the double brake according to the enclosed wiring diagram.Terminals (cage clamps) are prepared for the double brake in the terminal box.The PE connection of the double brake is ensured within the drive. An additional earthconnection for the double brake is not necessary.The connectable cable cross section are restricted to a maximum of 2.5 mm2.

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6Electrical installationConnecting the diagnostic unit /DUE option for function and wear monitoring


6.3.1 Brake controlThe double brake has 2 independent partial brakes, each with one brake coil. There-fore, 2 separate and identical electronic controls are required.For realizing an SBA or SBH safety function with a double brake, a safe brake control(SBC safety function) is required in addition to the functional control. Further, discon-nect the energy supply of the drive with the STO safety function. The SBC and STOsafety functions must at least meet the required performance level of the doublebrake.Connect the brake control according to the enclosed wiring diagram.

6.3.2 Permitted brake controlsThe permitted brake controls are designed exclusively for installation in the controlcabinet. Control for the terminal box is not available.The following use of the double brake is not permitted:

• Operation without brake control (direct voltage supply)• Operation with non-SEW control• Supply via motor terminal board.

For permitted brake controls, refer to chapter "Technical data" (→ 2 68). Connectionmay only be performed according to the valid wiring diagram, see chapter "Brake con-trol wiring diagram" (→ 2 82).

6.3.3 Supply voltageThe motor nameplate data must match the voltage supply. Sufficient dimensioning ofthe voltage supply and the connected load is required (stability even with increased in-rush current).

6.3.4 Switching equipmentUse suitable contactors for switching the supply voltage of the brake control.The following list shows the contact rating of the contactors for the double brake volt-age supply.• For AC voltage:

Use contactors of utilization category AC-11, EN 60947-4-1.• For DC voltage:

Use contactors of utilization category AC-3 or DC-3, EN 60947-4-1.AC-3 applies to contact rating of contactors for cut-off in the DC circuit according toEN 60947-4-1.Also observe the notes in the respective wiring diagram.Using a semi-conductor relay is not permitted.

6.4 Connecting the diagnostic unit /DUE option for function and wearmonitoring

If you retrofit the diagnostic unit /DUE, observe chapter "Retrofitting the diagnosticunit /DUE for function and wear monitoring" (→ 2 56).

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6 Electrical installationConnecting the diagnostic unit /DUE option for function and wear monitoring


If the diagnostic unit /DUE was ordered with the double brake, the function and wearmonitoring is installed and calibrated at the factory. The customer must connect thediagnostic unit, see wiring diagram (→ 2 58). The switching point of the wear moni-toring is set for the maximally permitted value for the double brake at the factory. Ac-cording to the "code table" (→ 2 56), a reduced value can be set.For the state of the evaluation unit, refer to chapter "Status display of the evaluationunit" (→ 2 65).

6.4.1 Designation of the componentsThe system comprises 2 sensors and one dual-channel evaluation unit. The functionmonitoring of the double brake is realized via 2 digital signals (NO contact). Two digitaloutputs (NC contact) signal if the wear limit was reached. Further, 2 current outputsallow for continuous monitoring of the wear of the double brake. In addition to the out-puts, LEDs at the evaluation unit indicate the function and the wear of each partialbrake. Further, diagnostics is possible with various blinking codes of the LEDs, see"Status display of the evaluation unit (→ 2 65).

B2 A

1

B1

1s

OU

T2

1k

FC

T2

WE

AR

2

OU

T1

FC

T1

WE

AR

1

ZE

RO

INF

GN

D

AG

ND

DC

24

V

GN

D1

DUE-2K-0

0

21195536

[1]

[5]

[4]

[2]

[3]

2s3s

5s4s

6s

2k3k

4k5k

6k7k

8k9k

10k11k

[6]

[7]

13243682955

[1] DIP switches S1 – S5[2] Terminals 1s – 6s[3] Terminals 1k – 11k[4] Fastening of terminal box (PE)[5] Line clip[6] LEDs for function and wear, partial brake II[7] LEDs for function and wear, partial brake I

The connection designation of the terminals are as follows:

Terminal Designation Description Color coding

1s A2 Sensor 2 connection 1 Brown (BN)

2s GND2 Sensor 2 shield Black (BK)

3s B2 Sensor 2 connection 2 White (WH)

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6Electrical installationConnecting the diagnostic unit /DUE option for function and wear monitoring


Terminal Designation Description Color coding

4s A1 Sensor 1 connection 1 Brown (BN)

5s GND1 Sensor 1 shield Black (BK)

6s B1 Sensor 1 connection 2 White (WH)

Terminal Designation Description

1k OUT2 Analog output working air gap partial brake II

2k FCT2 Digital output function partial brake II

3k WEAR2 Digital output wear partial brake II

4k OUT1 Analog output working air gap partial brake I

5k FCT1 Digital output function partial brake I

6k WEAR1 Digital output wear partial brake I

7k ZERO Input calibration zero value

8k INF Input calibration infinite value

9k AGND Signal ground AGND

10k GND Ground potential GND

11k DC 24 V DC 24 V supply

The LEDs have the follow meaning:

LEDs Designation Description

Green [6] FCT2 Partial brake II is open. Electromagnet is active. Pres-sure plate is in contact with magnet body.

Red [6] WEAR2 The current working air gap of partial brake II reachedor exceeded the preset maximum working air gap.

Green [7] FCT1 Partial brake I is open. Electromagnet is active. Pres-sure plate is in contact with magnet body.

Red [7] WEAR1 The current working air gap of partial brake I reached orexceeded the preset maximum working air gap.

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7 StartupRequirements


7 Startup7.1 Requirements

INFORMATION• Observe:

– The safety notes in this documents and all other applicable documents.– The relevant legal and professional association stipulations.

• If you encounter problems, observe chapter "Malfunctions" in the correspondingoperating instructions and the addendum to the operating instructions at hand.

WARNINGDisabling the functional safety.


• Only qualified personnel is allowed to carry out work on functional safety compo-nents.

• Any work on functional safety components must be carried out by strictly observ-ing the specifications in the operating instructions at hand and the respective ad-dendum to the operating instructions. Otherwise, the warranty will become void.

• Never operate a motor with safety-rated double brake on a third-party inverter.

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8Inspection/maintenanceRequirements


8 Inspection/maintenance

WARNINGDeactivation of the double brake functions due to incorrect maintenance work orchange to the technical properties.


• Adhere to the work steps and limit values described in this document while per-forming maintenance work.

• If changes are made to the technical properties, e.g. changing the brakingtorque, repeat project planning for the drive with double brake according to theproject planning specification of SEW‑EURODRIVE.

INFORMATIONSEW‑EURODRIVE recommends commissioning SEW‑EURODRIVE Service to per-form maintenance work, especially for FS..(FS) and BT..(FS) double brakes for func-tional safety.

If you perform maintenance work yourself, the responsibility of the double brake andthe liability regarding the functional safety is passed to the user.

Maintenance work for the double brake that may be performed by the customer:

Type of maintenance work BF.. BF..(FS)BT..(FS)

Description of worksteps

Setting the working air gap X X (→ 2 47)

Replacing brake disk/pressureplate

X - (→ 2 48)

Replacing double brake X X (→ 2 50)

Changing the braking torque X - (→ 2 51)

Changing the brake spring X - (→ 2 51)

Retrofitting/replacing the HR orHT manual brake release

X X (→ 2 54)

Retrofitting/replacing the diagnos-tic unit /DUE

X X (→ 2 56)

X Maintenance work permitted only if the following notes are observed

- Maintenance work not permitted. Contact SEW‑EURODRIVE if required.

INFORMATIONFor all numbers of spare parts needed during maintenance work, refer to the respec-tive exploded view drawings in chapter "Unit structure" (→ 2 24).

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8 Inspection/maintenanceGeneral inspection and maintenance work


8.1 General inspection and maintenance workObserve the following points for inspection and maintenance:

• Use only genuine spare parts in accordance with the valid spare parts list. Availa-ble via SEW‑EURODRIVE Service.

• Always install a new brake control at the same time as replacing the brake coil andvice versa.

• Isolate the motor and double brake from the power supply before starting work,safeguarding them against unintentional power-up.

• The information give in the "DR..71 – 315, DRN80 – 315 AC Motors" operating in-structions apply.

WARNINGRisk of crushing if the load falls or in the event of uncontrolled unit behavior.


• Secure or lower application (danger of falling)

• Safeguard and/or protect the driven machine against touching

• Isolate the motor, double brake, and forced cooling fan, if installed, from the pow-er supply before starting work, safeguarding them against unintentional re-start.

• Only use genuine spare parts from SEW‑EURODRIVE in accordance with thevalid spare parts list.

CAUTIONThe surfaces of the drive can be very hot during operation.

Risk of burns.

• Let the double brake cool down before starting to work on it.

8.2 Preliminary work prior to maintaining and replacing the double brake8.2.1 General information

If installed, remove the encoder and/or forced cooling fan before performing mainte-nance work at the motor and double brake. Proceed as described in the respectivedocumentation to remove and install the encoder and/or forced cooling fan. Especiallywith safety-rated encoders, adhere to the specifications in the respective addendum tothe operating instructions.Before you complete the maintenance work, restore all protection devices at the drive.Application requirements deviating from the original project planning of the doublebrake require a new project planning of the drive with double brake.If changes to the technical properties of the double brake are required, perform projectplanning of the drive with double brake again.

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8Inspection/maintenancePreliminary work prior to maintaining and replacing the double brake


8.2.2 Wearing parts

WARNINGDeviating functional safety due to use of incorrect wearing parts or due to a doublebrake deviating from the original.


• Replace the double brake only with an identical double brake including all optionsas delivered from SEW‑EURODRIVE.

If the double brake is replaced, replace the following wearing parts:

• Gasket [392] (only DR..112/132)

• Sealing ring [95]

• O-ring of manual brake release [47]

• Hex nuts of manual brake release [58]

• Tie rods of motor [13] (only DR..112/132)

• Screw [19] and flange nut [17] (only DR..160/180)

• Driver [70]• Key [71]• Retaining ring [62]Order the wearing parts from SEW‑EURODRIVE prior to the double brake replace-ment.To order the correct design of the double brake and the wearing parts, the item num-ber of the spare and/or wearing parts and the serial number of the drive (see motornameplate) is required.

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8 Inspection/maintenanceInspection and maintenance intervals


8.2.3 Order information for operating supplies and auxiliary material for maintenanceThe following sections lists the various operating supplies and auxiliary materials thatare required for correct maintenance.

Use Manufacturer Operatingsupply/auxili-ary material

Part num-ber

Quan-tity

Usedfor

Relevant for

Sealing com-pound

Marston-Domstel SEW‑L-Spezial 09112286 80 g [1259] BF11 – 30,

BF11(FS) – BF30(FS)

Lubricant Klüber Petamo

GHY 133

04963458 10 g [95] BF11,

BF11(FS),

BT11(FS)

BLR 46 – 122 03252663 6 g [95] BF20 – 30,

BF20(FS) – BF30(FS),

BT20(FS) – BT30(FS)

Thread lock-ing com-pound

Henkel Loctite 241 On request - [13]

[19]

[56]

[1189]

[1193]

DR..112/132

DR..160

HR, HT (all)

HR, HT (all)

HR, HT (all)

Loctite 243 On request - [19] DR..180

Anti-corrosionagent

SEW‑EURODRIVE NOCO® fluid 09107819 5.5 g [48]

[70]

All designs

For lubrication of the oil seal on the output end of the motor and the motor rolling bear-ings, observe the "DR..71 – 315, DRN80 – 315" operating instructions.

8.3 Inspection and maintenance intervalsInspect and service the double brake designed as holding brake according to the pro-jected inspection and maintenance intervals or every 0.5 to 2 years depending on theload conditions.If a diagnostic unit /DUE is used, the wear output of the evaluation unit indicateswhether brake maintenance is required. You may use the analog signal which is pro-portional to the air gap to plan brake maintenance.If the double brake is used for entertainment technology, observe the additional re-quirements e.g. stipulated by the accident prevention regulations BGV C1. They re-quire, among others, a yearly check of the safety-related and machine-relevant devi-ces.

INFORMATIONThe amount of wear depends on many factors and may therefore be high. The sys-tem manufacturer must determine the required inspection/maintenance intervals indi-vidually in accordance with the project planning documents.

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8Inspection/maintenanceSetting the working air gap of the double brake


8.4 Setting the working air gap of the double brake

WARNINGRisk of crushing if the drive starts up unintentionally.


• Isolate the motor, double brake, and forced cooling fan, if installed, from the pow-er supply before starting work, safeguarding them against unintentional re-start.

• Carefully observe the steps described below.


1. Remove forced cooling fan and rotary encoder, if installed. See chapter "Prelimina-ry work prior to maintaining and replacing the double brake" (→ 2 44).

2. First, remove the actuator elements [1191] from designs with HT manual brake re-lease.

3. Remove the fan guard [35] or the forced cooling fan [170] by loosening the retain-ing screws [22].

4. Move sealing strips [66], if necessary loosen existing clamping straps [157]. Suc-tion brake abrasion.

5. Check the thickness of both brake disks [68]. Required minimum thickness, seechapter "Technical Data" (→ 2 68).

6. If necessary, replace the brake disk. See chapter "Replacing brake disk/pressureplate of the double brake (→ 2 48)".

7. Check the working air gap of both partial brakes using a feeler gauge. If possible,check near the 4 retaining screws [60] and [1259]:

ð For BF11 – BF30 and BF11(FS) – BF30(FS): Between pressure plate [49] and[1258] and damping plate [718] and [1645]

ð For BT11(FS) – BT30(FS): Between pressure plate [49] and [1258] and magnetbody plate [54] and [1257]

8. Loosen the setting sleeves [67] and [1261] of both partial brakes and insert theminto the respective magnet body.

9. Set the working air gap of partial brake I first:

ð Tighten the retaining screws [60] manually until an even working air gap is setat the partial brake.

ð Note: The set gap should be approx. 0.1 mm smaller than the required targetvalue (e.g.: target value 0.4 mm, presetting 0.3 mm).

ð Insert 2 opposite setting sleeves [65] manually and then tighten them one afterthe other with the specified torque. Afterwards, check the working air gap again(it should match the target value now) and if necessary, repeat the procedure.Tightening torques:BF11, BF11(FS) and BT11(FS) → 27,3 Nm ±10%BF20, BF20(FS) and BT20(FS) → 54 Nm ±10%BF30, BF30(FS) and BT30(FS) → 93 Nm ±10%

ð Tighten the remaining setting sleeves in the same way, first manually, then withtightening torque.

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8 Inspection/maintenanceReplacing brake disk/pressure plate of the double brake


ð Afterwards, check pretension of the screws (see above mentioned tighteningtorques).

10.Set the working air gap for partial brake II. Repeat the steps for retaining screws[1259] and setting sleeves [1261].

11.For designs with HR or HT manual brake release: Reset the floating clearance ac-cording to chapter "Retrofitting HR or HT manual brake release" (→ 2 54).

12.For designs with diagnostic unit /DUE: If the sensors were not removed during thesetting of the working air gap, no further measures are required. If the sensors[1151] and [1152] were removed, recalibrate the zero value. See chapter "Calibra-tion of zero value" (→ 2 64).

13.Reinstall the sealing strips [66] and, if necessary, the clamping straps. For driveswith KS corrosion protection, replace the seal of the screws [1259] by reapplyingsealing compound SEW-L-Spezial, see chapter "Order information for operatingsupplies and auxiliary materials for maintenance" (→ 2 46).

14.Insert the plug connector [698] again and tighten it. Tighten the locking screws.

15.If required, install the fan wheel [36] and retaining ring [32].

16.Install the fan guard [35] and the forced cooling fan [170]. If necessary, screw inthe actuator elements [1191] of the HT manual brake release.

17.If necessary, install the rotary encoder according to the operating instructions.

8.5 Replacing brake disk/pressure plate of the double brake



• Isolate the motor, brake, and forced cooling fan, if installed, from the power sup-ply before starting work, safeguarding them against unintentional re-start.




2. For designs with HT manual brake release, first remove the actuator elements[1191].


4. If applicable: Remove the retaining ring [32] and the fan wheel [36] using a suitabletool.

5. Loosen the safety screws of the plug connector [698] and remove plug connector.

6. Move sealing strips [66], if necessary loosen existing clamping straps [157]. Suc-tion brake abrasion.

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8Inspection/maintenanceReplacing brake disk/pressure plate of the double brake


7. For designs with HR or HT manual brake release: Remove the entire releasing lev-er [53]. See chapter "HR and HT manual brake release" (→ 2 52).

8. For designs with diagnostic unit /DUE: Remove the sensors [1151] [1152] from thedouble brake. The wiring of the sensors in the terminal box must not be disconnec-ted. For further information, refer to chapter "Disassembling diagnostic unit /DUE" (→ 2 53).

9. First disassemble partial brake II:

ð Loosen hex head screws [1259].

ð Remove the magnet body [1257] with the pressure plate [1258] and sealing ring[95]. Make sure that no springs or damping parts fall out.

ð Remove the brake disk from partial brake II.

10.Then disassemble partial brake I:

ð Loosen hex head screws [60].

ð Remove the magnet body [54] and the pressure plate [49]. Make sure that nosprings or damping parts fall out.

ð Replace the brake disk of partial brake I with a spare part. Ensure that the circu-lar spring [69] is inserted correctly.

11.Reinstall partial brake I and reset the working air gap. See chapter "Setting theworking air gap" (→ 2 47).

12.If the pressure plates [49] and [1258] must be replaced, first insert the set screw[1265] for BF20 – 30 and BT20 – 30.

ð Tightening torque for set screw: 5 Nm (±20%)

13.Install the new brake disk for partial brake II. Ensure that the circular spring [69] isinserted correctly. Insert the prepared new pressure plate [1258] if necessary.

14.Reinstall partial brake II and reset the working air gap. See chapter "Setting theworking air gap" (→ 2 47).

15.Install new sealing parts such as sealing ring [95] and, if necessary, O-rings [47] ofthe manual brake release.

16.For designs with diagnostic unit /DUE: Reinstall the sensors [1151] and [1152].See chapter "Installing the sensors" (→ 2 62).

17.For design with manual brake release: Install the entire releasing lever [53]. Resetthe floating clearance. Use the adjusting nut [58] for this.






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8 Inspection/maintenanceReplacing double brake


8.6 Replacing double brake







2. For designs with HT manual brake release: First remove the actuator elements[1191].



5. Loosen the safety screws of the plug connector [698] and remove plug connector.

6. For designs with HR or HT manual brake release: Remove the entire releasing lev-er [53]. See chapter "HR and HT manual brake release" (→ 2 52).

7. For designs with diagnostic unit /DUE: Remove the sensors [1151] [1152] from thedouble brake. The wiring of the sensors in the terminal box must not be disconnec-ted. See chapter "Disassembling diagnostic unit /DUE" (→ 2 53).

8. Loosen the retaining screws of the double brake at the stator:

ð For DR..112/132: Tie rods [13]

ð For DR..160/180: Retaining screws [19] and nuts [17]

9. Remove the double brake [550] from the motor. For easier disassembly, the doublebrake is equipped with 2 tapped holes for eyebolts (not included in the delivery) atthe magnet body of partial brake II [1257].

10.Check B-side motor bearing [44] and driver [70] for wear and replace if necessary:

ð Remove the retaining ring [62] from the driver.

ð Remove driver with suitable tool. The driver has a tapped hole on the face endthat can be used during the removal procedure.

ð For bearing replacement [44]: Remove spacer ring [48] and key [71]. Then re-move bearing.

ð Join the new bearing correctly. Then insert the new key [71].

ð Install spacer ring [48] and new driver [70]. For easier assembly, it is recom-mended to heat both parts prior to assembly.

ð Reinsert retaining ring [62].

11.Insert the new double brake. Ensure proper positioning of the brake disk [66] to thegearing of the driver [70].

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8Inspection/maintenanceChanging the double brake braking torque


12.Install the double brake with the new retaining parts [13] or [19] + [17] at the stator.For tightening torques, refer to the following table:

ð 25.5 Nm ±10% for BF11 and BT11



13.Install new sealing parts such as sealing ring [95] and, if necessary, O-rings [47] ofthe manual brake release.

14.For designs with diagnostic unit /DUE: Reinstall the sensors [1151] and [1152].See chapter "Installing the sensors" (→ 2 62).

15.For design with manual brake release: Install the entire releasing lever [53]. Resetthe floating clearance. Use the adjusting nut [58] for this.






8.7 Changing the double brake braking torqueThe braking torque can be altered in steps by:• Replacing the double brake• Type and number of brake springs.For the possible braking torque steps, please refer to chapter "Technicaldata" (→ 2 66).

8.7.1 Replacing the brake spring for BF.., BF..(FS) and BT..(FS) double brake






1. Perform steps 1 to 10 as described in chapter "Replacing brake disk/pressure plateof the double brake (→ 2 48)".

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8 Inspection/maintenanceDisassembling optional equipment


2. First, change the spring pack of the magnet body of partial brake I [54].

ð Remove the pressure plate [49].

ð With BT11 – 30, make sure that no damping element [1252] or [1253] is dam-aged or lost.

ð Remove the used springs [50/276/1312] and replace them with the new ones.Ensure symmetrical positioning. See chapter "Technical data" (→ 2 66).

ð For BF: If necessary, replace the damping plate [718] depending on the brakingtorque.

ð For BT: Replace the pressure plate [49] depending on the braking torque. Inserta set screw [1256] at the new pressure plate. Tightening torque for set screw:5 Nm ±20%

ð Place pressure plate on magnet body. For BT.. double brakes, observe the cor-rect position of the damping elements [1252] and [1253].

3. Install partial brake I and set the working air gap. See chapter "Setting the workingair gap of double brakes" (→ 2 47).

4. Repeat the procedure of step 2 for partial brake II.

5. Install partial brake II and set the working air gap. See chapter "Setting the workingair gap of double brakes" (→ 2 47).

6. Perform steps 15 to 20 of chapter "Replacing brake disk/pressure plate of the dou-ble brake (→ 2 48)".

WARNINGNo braking due to incorrectly set floating clearance "S".


• Set the floating clearance "S" correctly according to the following figures and ta-ble so that the pressure plate can move up as the brake lining wears. See chap-ter "Retrofitting HR or HT manual brake release" (→ 2 54).

8.8 Disassembling optional equipment

8.8.1 Disassembling HR and HT manual brake release


1. Remove the forced cooling fan and rotary encoder, if installed, see chapter "Pre-liminary work prior to maintaining and replacing the double brake" (→ 2 44).

2. For designs with HT manual brake release: First remove the actuator elements[1191].



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8Inspection/maintenanceDisassembling optional equipment


5. Remove the hex nuts [58].

6. Loosen screw [1193] and compression spring [1195] and remove the entire releas-ing lever [53] from the magnet body [1257].

8.8.2 Disassembling the diagnostic unit /DUE

[1151]

[1154]

[112]

[1119]

[1153]

[1152]

[1758]

[1757] [379]

[698]

13243704587

[112] Terminal box lower part [1152] Distance sensor 1[379] Screw plug [1153] Clamp[698] Complete connector [1154] Flat head screw[1119] Screw fitting [1757] Evaluation unit[1151] Distance sensor 2 [1758] Retaining screw



2. First, remove the actuator elements [1191] from designs with HT manual brake re-lease.



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8 Inspection/maintenanceRetrofitting optional equipment


5. Loosen the screw [1154] for the cable fixture clamp [1153].

6. Loosen the union nut of the sensor screw fitting. The sensor cable is free.

7. Loosen the sensors [1151] and [1152] from the mounting flange. Remove the sen-sors completely.

8.9 Retrofitting optional equipment8.9.1 Retrofitting HR or HT manual brake release





Proceed as follows for retrofitting:



3. If applicable: Remove the retaining ring [32] and the fan wheel [36].

4. Remove the closing caps [28] and [1273] from the magnet body of partial brake II[1257].

5. First insert O-rings [47] into the prepared countersinks of the magnet body of parti-al brake II [1257]. Insert studs [56] and [1189] and screw them to the double brake.NOTICE! Observe the mounting position and direction.

ð Insert the longer studs into the outer bores.

ð For all studs, insert the short threaded end into the pressure plate.

6. Stick the spacers [1188] on the studs.

7. Place the entire releasing lever [53] on the double brake. Mount the releasing leverto the magnet body of partial brake II [1257] using the screw [1193] and the com-pression spring [1195].

8. Set the floating clearance "S" between releasing lever and hex nut using the hexnut [58] (see following figure). First set the inner adjusting nuts, afterwards set theouter adjusting nuts.

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8Inspection/maintenanceRetrofitting optional equipment


S

14403893643

S

14403896331

Type of double brake Floating clearance Smm

BF11, BF11(FS), BT11(FS)2.2

(+0.6/-0.2)BF20, BF20(FS), BT20(FS)

BF30, BF30(FS), BT30(FS)

9. Check the function of the double brake by activating the manual brake release.You should be able to manually turn the motor shaft. If this is not possible the re-leasing lever must be put against the hex nut [58] that it first touches without force.The distance between the contact surface of the releasing lever must not exceed0.05 mm for all remaining hex nuts [58] (check with feeler gauge thickness of0.05 mm). Floating clearance "S" is required so that the pressure plate can moveup as the brake lining wears. Otherwise, reliable braking is not guaranteed.


11.Install the fan guard [35] and the forced cooling fan [170].

12.Remove the closing piece of the manual brake release [1187] by loosening the re-taining screws [1186]. Replace the used closed closing piece with the new onecompatible to the HR or HT design.

13.Install the closing piece at the fan guard. For the HT design, screw in the actuatorelements [1191] in addition.


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8.9.2 Retrofitting diagnostic unit /DUE for function and wear monitoring

DANGERRisk of crushing if the drive starts up unintentionally.


• Disconnect the motor from the power supply and safeguard it against accidentalstartup before starting work!

For the component designation of the evaluation unit, refer to chapter "Componentdesignation" (→ 2 40).

Setting and installing the evaluation unit

The evaluation unit has a 5-pin DIP switch that is labeled with the numbers 1 to 5. Useit to set the measuring range and the maximum permitted wear limit (maximum work-ing air gap). The set maximum permitted wear limit and the measuring range apply toboth partial brakes.To activate a DIP switch ≙1, push the switch upwards. To deactivate a DIP switch ≙0,push the switch downwards.The following table shows the DIP switch settings of the evaluation unit for the maxi-mum working air gap.

1. Set the wear limit using the DIP switches.

INFORMATIONSet the DIP switch only in a de-energized state.

S1 S2 S3 S4 S5 Wear limitmm

BF11 – 30BF11 – 30(FS)

BT11 – 30(FS)

Sensor Ø 8 mm

1 0 0 0 0 1.2

1 0 0 0 1 1.1

1 0 0 1 0 1.0

1 0 0 1 1 0.9 X

1 0 1 0 0 0.8 X

1 0 1 0 1 0.7

1 0 1 1 0 0.6

1 0 1 1 1 0.5

X = Factory setting

Setting permitted

2. Screw the evaluation unit to the designated position in the terminal box, see drive-specific terminal assignment diagram. For information regarding the correct termi-nal assignment, contact SEW‑EURODRIVE.

3. Connect the sensors. See chapter "Connecting the sensors" (→ 2 58).

4. Calibrate the infinite value. See chapter "Calibration of infinite value" (→ 2 61).

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5. Install the sensors in the double brake. See chapter "Installing the sen-sors" (→ 2 62).

6. Route the cable. See chapter "Cable routing" (→ 2 63).

7. Calibrate the zero value. See chapter "Calibration of zero value" (→ 2 64).

8. To check function 1 and 2, measure the voltage via terminal FCT1 (5k) and FTC2(2k) to GND (10k). Switch the double brake and check if 24 V are applied.

9. To check the working air gap, measure the current between the terminals OUT1(4k) and OUT2 (1k) and GND (10k). Calculate the working air gap x in mm, seechapter "Output signals for the function and wear monitoring" (→ 2 60). Comparethe value to the set working air gap.

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Connecting electronics

The function and wear monitoring is connected according to the following wiring dia-gram. The maximum permitted cable cross section at the terminals "k" is 1.5 mm2 withconductor end sleeve without plastic collar, 0.75 mm2 with conductor end sleeve. Therequired cable cross section at the terminal "k" is 0.5 mm2 with conductor end sleevewithout plastic collar.

INFORMATIONSEW‑EURODRIVE recommends to use a shielded line during wiring.

In especially interference-intensive environments, SEW‑EURODRIVE recommendsto use a shielded cable to the evaluation unit for monitoring the analog signal. Con-nect the shield at one end to the GND (10k).

(BN)

(BK)

(WH)

(BN)

(BK)

(WH)

A C

B1 B2

1s

2s

3s

4k

5k

6k

7k

8k

9k

10k

11k

4s

5s

6s

1k

2k

3k

13258016907

[A] Double brake [1k] Analog output wear 2[B1] Sensor partial brake 1 [2k] Digital output function 2[B2] Sensor partial brake 2 [3k] Digital output wear 2[C] Evaluation unit [4k] Analog output wear 1

[5k] Digital output function 1[1s] Connection sensor A2 (brown cable) [6k] Digital output wear 1[2s] Connection sensor GND2 (black cable) [7k] Input calibration zero value[3s] Connection sensor B2 (white cable) [8k] Input calibration infinite value[4s] Connection sensor A1 (brown cable) [9k] Signal ground AGND[5s] Connection sensor GND1 (black cable) [10k] Ground potential GND[6s] Connection sensor B1 (white cable) [11k] DC 24 V supply

The evaluation unit is supplied with DC 24 V via the terminals GND [10k] and DC 24V[11k].

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The following digital signals are available for 24 V supply [11k] regarding the groundpotential GND [10k]:• The function FCT1 [5k] and the wear WEAR1 [6k] of the partial brake 1 and• The function FCT2 [2k] and the wear WEAR2 [3k] of the partial brake 2.The working air gap can be monitored continuously via the analog signal (4 – 20 mA)regarding the signal ground AGND [9k]:• Terminal OUT1 [4k] for partial brake 1 and• Terminal OUT2 [1k] for partial brake 2.

INFORMATIONIf values deviate from the factory setting, the wear point setting must be adjusted.See chapter "Setting and installing the evaluation unit" (→ 2 56).

Connecting the sensors

DUE-2K-00 21195536

OF

F

1

BN WH

BN WH

[1]

[2]

s 2s3s 4s5s6s

GN

D2

A2

B2

GN

D1

A1

B1

1k 2k 3k 4k 5k 6k 7k 8k 9k 10k 11k

OU

T1

ZE

RO

AG

ND

GN

D

DC

24

V

INF

FC

T2

FC

T1

WE

AR

2

WE

AR

1

OU

T2

13243680011

[1] Sensor partial brake 2[2] Sensor partial brake 1

The connection cross section of the sensor is 0.14 mm². The litz wires of the sensorcables must be equipped with conductor end sleeves. The cable shield must be isola-ted against other potentials using a heat shrink tubing. The litz wires can be pushedinto the terminals without using tools. Put the sensor cables in the provided line clip,see figure in chapter "Calibration of infinite value" (→ 2 61). To remove the sensorcables, use an insulated screwdriver to disengage the clips.

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Output signals for function and wear monitoring

The diagnostic unit /DUE is equipped with the following (for each partial brake):• 2 digital outputs (DC 24 V) for function and wear• 1 analog output (4 – 20 mA) for the currently measured working air gapExample:

FCT

WEAR

2,00x [mm]

IOut

[mA]

[1]

U [V]

24

[4] [3]

0,9

[5]

0

4

10

11,2

20

[2]

U [V]

24

0

x

14745059339

[1] FCT: Digital output function (DC 24 V, DIN EN 61131-2)[2] WEAR: Digital output wear (DC 24 V, DIN EN 61131-2)[3] Maximum measuring range of the sensor (2.0 mm for sensor

Ø8 mm)[4] Set maximum working air gap of double brake (DIP switch)[5] Set measured working air gap x (exemplary)

The current working air gap x of the previous example is calculated as follows via themeasured output current IOut:

xI mA

mAmm

mA mA

mAmm

Out

.

. .=

−

× =−

× =

4

162 0

10 4

162 0 0 755 mm

14973351435

The possible maximum output current IOut varies depending on the set maximum work-ing air gap (DIP switch setting). For the previous example:

Imax workingairgap mA

mmmA

mmOut =

×+ =

×

.

.

. 16

2 04

0 9 16mmA

mmmA mA

2 04 11 2

. . + =

14975337867

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Calibration of infinite value

Before you can install the sensors in the double brake, the electronics must be calibra-ted to the actual cable length. During calibration of the infinite value, electronics is ad-justed to the sensor cable length. Electronics is reset and previous settings are over-written.The sensors must be removed from the double brake for the following steps.Procedure to calibrate the infinite value for both sensors at the same time:

1. Make sure that no metallic objects, such as the second sensor, are within a 10 cmradius from the sensor head. The spacer bushings may be in contact with the backof the sensor heads during calibration.

2. Apply supply voltage to INF (8k) and AGND (9k) for 5 seconds. GND (10k) can beused as reference potential instead of AGND (9k). The evaluation unit is suppliedvia the calibration input during calibration.

Calibration of the infinite value was successful if the red LED flashes every seconds.The corresponding wiring figure for the calibration process:

+24 V GND

DUE-2K-00 21195536

OF

F

1

s 2s3s 4s5s6s

GN

D2

A2

B2

GN

D1

A1

B1

1k 2k 3k 4k 5k 6k 7k 8k 9k 10k 11k

OU

T1

ZE

RO

AG

ND

GN

D

DC

24V

INF

FC

T2

FC

T1

WE

AR

2

WE

AR

1

OU

T2

13243677067

During calibration, the digital outputs WEAR1 (6k), WEAR2 (3k), FCT1 (5k), and FCT2(2k) send a 0 signal which may lead to error messages (wear limit reached).The analog outputs OUT1 (4k) and OUT2 (1k) show 0 mA during calibration. Aftersuccessful calibration, the outputs have 20 mA.

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Installing the sensors

After calibration, the eddy current sensors can be installed in the magnet body of thedouble brake. When installing the sensor, make sure that the sensor head can be in-serted in the stepped bore without pressure being applied.First install the lower part of the cable gland. Then mount the upper part of the cablegland.

INFORMATIONTo ensure that the sensor is correctly inserted in the stepped bore, twist the sensorcarefully with the cable before screwing in the cable gland. Protect the sensor cableagainst damage.

[2]

[1]

B2

B1

13243698699

[1] Sensor partial brake I[2] Sensor partial brake II

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Cable routing

To avoid the fan touching the cable, route the cable as shown below using a clampand a screw.

13951061387

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Calibration zero value

During calibration of the zero value, the current working air gap with released (open)double brake is written in the evaluation unit. The electronics is reset and previous set-tings are overwritten. You can save the zero value at any time without changing theinfinite value.Procedure to calibrate the zero value for both sensors at the same time:

1. Open the double brake.

2. Apply the supply voltage to ZERO (7k) and AGND (9k) for approx. 3 seconds. Elec-tronics is in calibration mode. You can use GND (10k) as reference potential in-stead of AGND (9k). The evaluation unit is supplied via the calibration input duringcalibration.

The evaluation unit saves the smallest working air gap of the double brake. Each writeprocess is indicated by a brief flashing of the red LED.The activated calibration mode is indicated by the following LED state:

LED State

Green [7] Off

Red [7] Flashing (2 Hz)

Green [6] Off

Red [6] Flashing (2 Hz)

+24 V GND

DUE-2K-00 21195536

OF

F

1

s 2s3s 4s5s6s

GN

D2

A2

B2

GN

D1

A1

B1

1k 2k 3k 4k 5k 6k 7k 8k 9k 10k 11k

OU

T1

ZE

RO

AG

ND

GN

D

DC

24V

INF

FC

T2

FC

T1

WE

AR

2

WE

AR

1

OU

T2

13258012555

During calibration, the digital outputs WEAR1 (6k), WEAR2 (3k), FCT1 (5k), and FCT2(2k) send a 0 signal which may lead to error messages (wear limit reached).The analog outputs OUT1 (4k) and OUT2 (1k) show 0 mA during calibration. Aftersuccessful calibration, the value is saved. The outputs have 4 mA with released dou-ble brake. If a better value is available within 3 seconds, the last value is deleted andthe new value is saved. The 4 mA at each output remain unchanged.

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Status messages of the evaluation unit

The LEDs of the evaluation unit can be used for diagnostic purposes as shown in thefollowing table:

Brake Sensor Calibration LEDs and outputsState

ZERO INF Green Red Green Red FCT WEAR OUT

Open Instal-led

- - To Off To Off HI HI 3.6 –5.6 mA

Brake open, no wear

Closed

Instal-led

- - Off Off Off Off LO HI 6 –20 mA

Brake closed, nowear

Closed

Instal-led

- - Off To Off To LO LO 6 –20 mA

Brake closed, setwear limit of brakereached

- - - - Off To Off To LO LO >20 mA Measuring range ex-ceeded or sensornot connected cor-rectly

- Not in-stalled

- HI Off Blink-ing

1 Hz

Off Blink-ing

1 Hz

LO LO 0 mA Calibration of infinitevalue active

- Not in-stalled

- HI Off Flashing

1 Hz

Off Flashing

1 Hz

LO LO 20 mA Infinite calibrationsuccessful

- - - - Blink-ing

1 Hz

Blink-ing

1 Hz

Blink-ing

1 Hz

Blink-ing

1 Hz

Clock1 Hz

Clock1 Hz

0 mA Not completely cali-brated:• Zero calibration

missing• Delivery state

(both calibrationsmissing)

Open Instal-led

HI - Off Blink-ing

2 Hz

Off Blink-ing

2 Hz

LO LO 0 mA Calibration of zerovalue active

Open Instal-led

HI - Off Blink-ing

2 Hz

Off Blink-ing

2 Hz

LO LO 4 mA First zero value suc-cessful

Open Instal-led

HI - Off Flick-ering

Off Flick-ering

LO LO 4 mA Smaller zero valuedetected and saved

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9 Technical dataBraking torques and brake springs


9 Technical data9.1 Braking torques and brake springs

The braking torque settings for both partial brakes are always identical. It is not permit-ted to have deviating values.

Braketype

Braking torque settings

Nominaltorque MB

Type and number ofsprings per partial

brake

Damping plateBF.. and BF..(FS)

Pressure plateBT..(FS)

Nm Nor-mal

blue white Part numberPartialbrake 1

Part numberPartialbrake 2



BF11,BF11(FS),BT11(FS)

2×110 6 – – 18477100 18477119 18477380 18477372

2×80 2 4 –

2×55 2 4 –

2×40 – 4 – 20681437 20681526 21196508 21196494

2×28 – 3 –

2×20 – – 4 2× 18477100 2× 18477119


2×200 8 – – 18477089 18477097 18477143 18477151

2×150 6 – –

2×110 2 4 –

2×80 – 6 – 20681585 20681534 18476015 18476023

2×55 – 2 4

2×40 – – 6 2× 18477089 2× 18477097


2×300 8 – – 20681704 20681720 18477240 18477232

2×200 4 4 –

2×150 4 – –

2×100 – 8 – 20682166 20682174 18476562 18476570

2×75 – 6 –

INFORMATIONEnsure a symmetrical arrangement of the brake springs, see the example in the fol-lowing figure.

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9Technical dataBraking torques and brake springs


The following table shows the number, designs and position of the brake springs in thecoil body:

BF11, BF11(FS), BT11(FS)

6 springs 4 + 2 springs 2 + 2 springs 4 springs 3 springs

BF20 – 30, BF20 – 30(FS), BT20 – 30(FS)

8 springs 4 + 2 springs 4 + 4 springs 6 springs 4 springs

No spring (empty spring bore)

Spring color 1 (see table (→ 2 66))

Spring color 2 (see table (→ 2 66))

Technical data of the brake springs:d

L0

De

14222057355

Braketype

Spring col-or

Part number Dimensions

Length Outer diameter Wire diameter Number ofturns

L0mm

Demm

dmm

nt-

BF11BF11(FS)BT11(FS)

Normal 13741837 50.7

13.3

2.9

12.5Blue (BU) 13741845 51.3 2.6

White (WH) 13747789 52.9 2.2


Normal 18476791 46.1

15.2

3.2 10

Blue (BU) 18476805 46.2 2.8 10.5

White (WH) 21196753 46.5 2.5 11


Normal 01874551 5219.2

3.6 10

Blue (BU) 13744356 51.7 3.0 11

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9 Technical dataWork done, working air gap, brake disk thickness


9.2 Work done, working air gap, brake disk thickness

Brake type Braking workdone until

maintenance

Working air gap Brake disk thick-ness

min.1) max. min.

MJ mm mm

BF11, BF11(FS) 2×425 0.3 0.9 10

BF20, BF20(FS) 2×670 0.3 0.9 10

BF30, BF30(FS) 2×1000 0.3 0.9 10

BT11(FS) 2×285 0.4 0.8 10

BT20(FS) 2×445 0.4 0.8 10

BT30(FS) 2×670 0.4 0.8 101) When checking the working air gap, note: Parallelism tolerances on the brake disk may give rise to devi-ations of ± 0.15 mm after a test run.

9.3 Possible brake control systems

INFORMATIONOperation without brake control at AC or DC voltage is not permitted.

Controllers for control cabinet installation are available for the BF.., BF..(FS), andBT..(FS) double brake. Use the same brake controllers for the partial brakes I and II.

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9Technical dataPossible brake control systems


9.3.1 Permitted combinationsThe following table shows the standard and optional combinations of double brakeand brake rectifier.

Type des-ignation

Voltage rangeV

BF11,BF11(FS)

BF20,BF20(FS)

BF30,BF30(FS)

BT11(FS) BT20(FS) BT30(FS)

BME 1.4 AC 230 – 575 • • • − − −

BME 1.5 AC 150 – 500 X X X − − −

BME 3.0 AC 42 – 150 • • • − − −

BMH 1.4 AC 230 – 575 • • • − − −

BMH 1.5 AC 150 – 500 • • • − − −

BMH 3.0 AC 42 – 150 • • • − − −

BMP 1.4 AC 230 – 575 • • • − − −

BMP 1.5 AC 150 – 500 • • • − − −

BMP 3.0 AC 42 – 150 • • • − − −

BMK 1.4 AC 230 – 575 • • • − − −

BMK 1.5 AC 150 – 500 • • • − − −

BMK 3.0 AC 42 – 150 • • • − − −

BMT 2.2 AC 230 – 500 − − − o o o

BMV 5.0 DC 24 • • − − − −

BST 0.6S AC 460 • • • − − −

BST 0.7S AC 400 • • • − − −

BST 1.2S AC 230 • • • − − −

X Standard design

• Can be selected

o Only for BT..(FS)

– Not permitted

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9 Technical dataPossible brake control systems


9.3.2 Brake control for BF.. and BF..(FS) double brakeBF.. and BF..(FS) double brakes are compatible to the current portfolio of brake con-trol systems of single brakes.The following table lists the technical data of brake control systems for installation inthe control cabinet, and the assignment regarding the motor size and connection tech-nology. The different housings have different colors (= color code) to make them eas-ier to distinguish.

Type Function Voltage rangeV

Holdingcurrent

IHmax in A

Type desig-nation

Part num-ber

Colorcode

BME Half-wave rectifier withelectronic switching for

fast release of the doublebrake

AC 230 – 575 1.0 BME 1.4 08298319 Red

AC 150 – 500 1.5 BME 1.5 08257221 Red

AC 42 – 150 3.0 BME 3.0 0825723X blue

BMH Half-wave rectifier withelectronic switching and

heating function

AC 230 – 575 1.0 BMH 1.4 08298343 green

AC 150 – 500 1.5 BMH 1.5 0825818X green

AC 42 – 150 3.0 BMH 3.0 08258198 Yellow

BMP Half-wave rectifier withelectronic switching, inte-grated voltage relay forcut-off in the DC circuit

AC 230 – 575 1.0 BMP 1.4 08298327 white

AC 150 – 500 1.5 BMP 1.5 08256853 white

AC 42 – 150 3.0 BMP 3.0 08265666 Lightblue

BMK One-way rectifier withelectronic switching, 24

VDC control input and cut-off in the DC circuit

AC 230 – 575 1.0 BMK 1.4 08298335 Waterblue

AC 150 – 500 1.5 BMK 1.5 08264635 Waterblue

AC 42 – 150 3.0 BMK 3.0 08265674 Brightred

BMV Brake control unit withelectronic switching,

24 VDC control input andfast cut-off

DC 24 5.0 BMV 5.0 13000063 white

BST Safety-related brake con-trol with electronic switch-

ing and DC link supply

AC 460 0.6 BST 0.6S 08299714 -

AC 400 0.7 BST 0.7S 13000772 -

AC 230 1.2 BST 1.2S 13001337 -

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9Technical dataPossible brake control systems


9.3.3 Brake control for the BT..(FS) double brakeIn combination with the BT..(FS) double brake, SEW‑EURODRIVE stipulates that thefollowing brake control exclusively for control cabinet installation:

Type Function Voltage rangeVAC

Holdingcurrent

IHmax in A

Type desig-nation

Part num-ber

Color

BMT Bridge/one-way rectifierwith automatic switching

200 – 500 2.8 BMT 2.2 28215036 Orange

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9 Technical dataOperating currents for the BF.., BF..(FS), and BT..(FS) double brake


9.4 Operating currents for the BF.., BF..(FS), and BT..(FS) double brakeThe following table shows the operating currents of the double brake for different con-nection voltages. The power and current values specified in the table apply to an am-bient temperature of +20 °C and per partial brake.The specified holding currents IH are r.m.s. values in the brake control supply cable.Only use current measurement units that are designed to measure r.m.s. values.Observe that the high-speed excitation of the brake controllers fromSEW‑EURODRIVE may result in an increased current (accelerator current IB) flowingfor a short time during switch-on:• Approx. 160 ms for BF.. and BF..(FS)• Approx. 500 ms for BT..(FS)The amount of acceleration current IB can be calculated using the inrush current ratioESV and the relevant holding current IH. It must be considered during the dimension-ing of the power supply cables.

Operating currents BF11,BF11(FS)

BF20,BF20(FS)

BF30,BF30(FS)


Nominal power per brake coilin W

65 85 105 75 95 120

Inrush current ratio (ESV) 7.5 8 7.7 2 2 2

Nominal voltage (nominalvoltage range)

BF11,BF11(FS)

BF20,BF20(FS)

BF30,BF30(FS)


VNV

IH AAC

IHAAC

DC 24 (23 – 26) - - - - - -

AC 120 (111 – 123) 0.87 1.08 1.42 - - -

AC 230 (218 – 243) 0.44 0.54 0.71 0.66 0.80 0.66

AC 360 (344 – 379) 0.28 0.34 0.45 0.41 0.51 0.41

AC 400 (380 – 431) 0.25 0.30 0.45 0.37 0.45 0.37

AC 460 (432 – 484) 0.22 0.27 0.36 0.33 0.40 0.33

AC 500 (485 – 542) 0.20 0.24 0.32 0.29 0.36 0.29

AC 575 (543 – 600) 0.17 0.22 0.28 - - -

ESV Inrush current ratio IB/IH

IB Acceleration current in Ampere (AC or DC) when operated with SEW‑EURODRIVE brake controlfor high-speed excitation

IH Holding current in Ampere, r.m.s. value of the braking current in the supply cable to theSEW‑EURODRIVE brake control

VN Nominal voltage (nominal voltage range) of the double brake in V (AC or DC)

Permitted tolerances for nominal voltage: Nominal voltage range ± 5%

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9Technical dataSwitching times


9.5 Switching timesThe switching times of the double brake depend on the used brake control.The switching times of the double brake depend on various factors, e.g. operatingtemperature of the brake and state of wear. The set braking torque and the usedbrake control are particularly decisive for the switching times. Depending on the brak-ing torque, the following table shows the response times (t1) and the applications timesfor cut-off in the AC circuit (t2I) and cut-off in the DC and AC circuits (t2II).The following table gives guide values for the switching times of the double brakes.The following indexes show the distinction between:

• t1I: Response time without high-speed excitation

• t1II: Response time with high-speed excitation• t2I: Application time cut-off in the AC circuit (AC)• t2II: Application time cut-off in the DC and AC circuits (AC/DC)

Observe the wiring diagrams in chapter Brake control wiring diagrams (→ 2 82) tocorrectly determine the application time for your application. The relevant connectiontype is displayed with icons.

AC

Use of t2I

DC Use of t2II

AC

DC Use of t2II

9.5.1 BF11, BF11(FS) double brake

Brakingtorque

Nm

Response timet1Ims

Response timet1IIms

Applicationtime t2I

ms

Applicationtime t2II

ms

110 - 55 120 35

80 - 55 120 35

55 - 55 240 50

40 - 55 240 50

28 - 55 450 65

20 - 55 450 65

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9 Technical dataSwitching times



Brakingtorque

Nm

Response timet1Ims

Response timet1IIms

Applicationtime t2I

ms


ms

200 - 70 165 35

150 - 70 165 35

110 - 70 300 65

80 - 70 300 65

55 - 70 420 100

40 - 70 420 100


Brakingtorque

Nm

Response timet1Ims

Response timet1IIms

Applicationtime t2I

ms


ms

300 - 125 280 65

200 - 125 280 65

150 - 125 460 110

100 - 125 460 110

75 - 125 660 170

9.5.4 BT11(FS) double brake

Brakingtorque

Nm

Response timet1Ims

Response timet1IIms

Applicationtime t2I

ms


ms

110 - 110 190 60

80 - 110 190 60

55 - 110 190 60

40 - 110 190 60

28 - 110 190 60

20 - 110 190 60

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9Technical dataSwitching times



Brakingtorque

Nm

Response timet1Ims

Response timet1IIms

Applicationtime t2I

ms


ms

200 - 210 270 80

150 - 210 270 80

110 - 210 270 80

80 - 210 270 80

55 - 210 270 80

40 - 210 270 80


Brakingtorque

Nm

Response timet1Ims

Response timet1IIms

Applicationtime t2I

ms


ms

300 - 290 390 100

200 - 290 390 100

150 - 290 390 100

100 - 290 390 100

75 - 290 390 100

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9 Technical dataPermitted braking work


9.6 Permitted braking workThe maximum permitted braking work WMax of the double brake for emergency stopbraking depends on the operating speed and the application. For information on proj-ect planning, refer to the "Gearmotors with BF../BT.. Double Brake" catalog.The limits of the permitted maximum braking work must not be exceeded, not even foremergency stop braking.

INFORMATIONDouble brakes are not approved as service brakes but as holding brakes with emer-gency stop properties.

Emergency stop braking may negatively influence the braking effect. This is whySEW‑EURODRIVE recommends performing brake diagnostics after an emergencystop braking.

Double brakes for vertical direction of movementIn lifting applications, the limits of the permitted maximum braking work may not be ex-ceeded, not even for emergency stop braking (standard range, limit curve S).

Double brakes for horizontal direction of movementFor horizontal movements, such as travel drive applications, increased braking work inemergency stop situations is permitted under the following conditions (overload range,limit curve A to D).

• A maximum of 75% of the maximum nominal braking torque is permitted.• The specific wear of the brake lining with increased braking work increases signifi-

cantly in case of emergency stops. It can reach factor 100 under certain circum-stances. This additional wear must be considered when determining the mainte-nance cycle.

• During the braking process, the effective dynamic braking torque can be reduceddue to the heating of the brake lining during braking. In extreme cases, the effec-tive braking torque can be reduced to 60% of the rated value. Take this into ac-count when you determine the braking distance.

9.6.1 Terms and definitions

Description

nemergency_stop The actual speed at the moment of the emergency stop brak-ing. This value is used for calculating the situational permittedmaximum braking work.

nbase The lower base speed for calculating the minimum value of thepermitted braking work.

nMax The maximum permitted emergency stop speed.

Wper The speed-dependent permitted braking work. For determiningthe braking work, the actual speed at the time of the emergen-cy stop braking is decisive.

KWper An additional calculation value for determining the speed-de-pendent maximum permitted braking work.

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9Technical dataPermitted braking work


9.6.2 Determining the maximum permitted braking workIn the catalog in chapter "Project planning", you will find information on how to calcu-late the actual braking work Wact. Compare Wact to the permitted braking work Wper.The following basic correlations apply to determining the maximum permitted brakingwork Wper:

nbase ≤ nemergency_stop ≤ nMax

The following applies to speeds in the range between the lower base speed nEck andthe upper maximum speed nMax:

W nK

nper emergency_stop

Wper

emergency_stop( ) =

nemergency_stop < nbase

For speeds nemergency_stop < nbase, the work is limited to the following maximum value:

W n nK

nper emergency_stop base

Wper≤( ) =

base

nNot-Halt > nMax

For speeds nemergency_stop > nbase, no emergency stop braking operations are permitted:

W n nper emergency_stop Max( )> = 0

INFORMATIONRefer to the following tables for the required values.

Depending on the application, the following values apply to the factor KWper:For vertical applications or applications with lifting parts, the standard values must beused.For horizontal applications, the values from the overload ranges A to D can additional-ly be considered.

Type Factor KWperkJ/min

Standard S Overload A Overload B Overload C Overload D

BF11, BF11(FS),BT11(FS)

22 600 32 600 53 400 77 100 88 900


30 800 47 500 77 700 112 000 130 000


46 900 55 700 91 200 130 000 153 000

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The following values apply to the speed limits:

Type Lower base speednbase1/min

Max. speed nMax forstandard range1/min

Max. speed nMax foroverload range Ato D1/min


1 250 3 600 3 600


1 250 3 600 3 600


1 250 1 800 3 600

9.6.3 Overload ranges"Standard S" always applies to vertical applications. Refer to column "Standard S" forthe values for calculating the permitted braking work.For horizontal approved, refer to the column "Standard S" and also the columns"Overload range A to D" for the values for calculating the maximum permitted brakingwork.

INFORMATIONUsing the values from the overload ranges A to D leads to further restrictions for cal-culating the permitted braking work for horizontal applications.

On the one hand, the permitted braking work increases in the overload ranges A toD. On the other hand, the values for brake wear change. This is first achieved by lim-iting the permitted braking torque steps. The lower tolerance of the braking torque ex-pands as follows:

• Increase brake wear from overload range A to D.

• Lowered tolerance limit of the braking torque fMmin from overload range A to D.

The following applications are distinguished according to the project planning guide-line:

Area Standard S Overload rangeA

Overload rangeB

Overload rangeC

Overload rangeD

Permitted for All applica-tions

Trolleys Trolleys Trolleys Trolleys

Permitted brak-ing torque steps

All steps Maximum 75%MBmax

Maximum 75%MBmax

Maximum 75%MBmax

Maximum 75%MBmax

Wear factor

fV

Normal Normal Slightly increased Significantly in-creased

Massively in-creased

1 1 10 50 100

Tolerance forMB

Min. (fMmin)Max. (fMmax)

Normal Normal Slightly expanded Significantly ex-panded

Extremely expan-ded

0.9 0.9 0.8 0.7 0.6

1.5 1.5 1.5 1.5 1.5

The following diagrams show the permitted braking work depending on the speed. Thelower base speed nbase is defined as 1250 1/min.

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Permitted braking work Wper of the BF11, BF11(FS), and BT11(FS) double brake:

D

C

B

A

S

0

10

20

30

40

50

60

70

80

1000 1600 2100 2600 3100 3600

Wper(kJ)

(rpm)

14664282507

A Overload limit curve AB Overload limit curve BC Overload limit curve CD Overload limit curve DS Standard limit curve S

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Permitted braking work Wper of the BF20, BF20(FS), and BT20(FS) double brake:Wper(kJ)

(rpm)

D

C

B

A

S

0

20

40

60

80

100

120

1000 1600 2100 2600 3100 3600

14664873739


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Permitted braking work Wper of the BF30, BF30(FS), and BT30(FS) double brake:Wper(kJ)

(rpm)

D

C

B

A

S

0

20

40

60

80

100

120

140

1000 1600 2100 2600 3100 3600

14664876171


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9 Technical dataBrake control wiring diagrams


9.7 Brake control wiring diagrams9.7.1 BME brake control

AC

1

2

3

13

14

15

BME

BMS

4

RD BUWH

[1]

1

2

3

13

14

15

4 BME

BMS

RD BUWH

[1]

AC

DC

[2]

3L 4L 5L 3M 5M4M[3] 3L 4L 5L 3M 5M4M[3]

RD BUWH

[2]

RD BUWH

1

2

3

13

14

15

BME

BMS

4

1

2

3

13

14

15

BME

BMS

4

UE (AC) UE (AC)

UE (AC)UE (AC)

14785359243

CustomerFactory

AC

Cut-off in the AC circuit (standard application of the brake)

AC

DC Cut-off in the DC and AC circuits (rapid application of the brake)

[1] Brake coil partial brake I[2] Brake coil partial brake II[3] Terminal stripVI (AC) Input voltage power supply

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9Technical dataBrake control wiring diagrams


9.7.2 BMH brake control

1

2

3

13

14

15

4 BMH

1

2

3

13

14

15

4 BMH

[1]

RD BUWH

[2]

3L 4L 5L 3M 5M4M[3]

RD BUWH

[1]

RD BUWH

[2]

3L 4L 5L 3M 5M4M[3]

RD BUWH

AC

1

2

3

13

14

15

4 BMH

K12

1

2

3

13

14

15

4 BMH

AC

DC

K12

UE (AC)

UE (AC)

UE (AC)

UE (AC)

14785364107

CustomerFactory

AC


AC



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9.7.3 BMP brake control

RD BUWH

[1]

BMPBMP

AC

1

2

3

13

14

15

4

BMP

1

2

3

13

14

15

4 BMP

RD BUWH

[2]

1

2

3

13

14

15

4

1

2

3

13

14

15

4

3L 4L 5L 3M 5M4M[3]

DC

AC

RD BUWH

[1] [2]

3L 4L 5L 3M 5M4M[3]

RD BUWH

UE (AC)

UE (AC)

UE (AC)

UE (AC)

14785361675

CustomerFactory

AC


AC



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9.7.4 BMK 3.0, BMK 1.5 brake control

1

2

3

13

14

15

4

+

-BMK3.0

BMK1.5

BMKB1.5

RD BUWH

[1] [2]

3L 4L 5L 3M 5M4M[3]

RD BUWH

1

2

3

13

14

15

UE (AC)

4

+

-BMK3.0

BMK1.5

BMKB1.5

UE (AC)

Uin (DC 24V)

AC

DC

Uin (DC 24V)

14785368971

CustomerFactory

AC


[1] Brake coil partial brake I[2] Brake coil partial brake II[3] Terminal stripVI (AC) Input voltage power supplyVIN (DC24V) Functional control voltage

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9.7.5 BMK 1.4 brake control

RD BUWH

[1]

AC

DC

3L 4L 5L 3M 5M4M [3]

[2]

RD BUWH

1

2

3

13

14

15

4

+

-

BMK

1.4

1

2

3

13

14

15

4

+

-

BMK

1.4

Ui n(DC 24V)

UE (AC)

Ui n(DC 24V)

UE (AC)

14785373835

CustomerFactory

AC



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9.7.6 BMT 2.2 brake control

RD BUWH

[1] [2]

3L 4L 5L 3M 5M4M[3]

RD BUWH

[4][4]

AC

1

2

3

13

14

15

4

BMT

1

2

3

13

14

15

4

BMT

K12

[5]

UE (AC)

UE (AC)

RD BUWH

[1] [2]

3L 4L 5L 3M 5M4M[3]

RD BUWH

[4][4]

1

2

3

13

14

15

4

BMT

1

2

3

13

14

15

4

BMT

K12

[5]

AC

DC

K13

[6]

UE (AC)

UE (AC)

AC

14785376267

CustomerFactory

AC


AC


[1] Brake coil partial brake I[2] Brake coil partial brake II[3] Terminal strip[4] Litz wire not connected to brake coil[5] Operating contactor AC cut-off[6] Emergency switching off contactor AC-DC cut-offVI (AC) Input voltage power supply

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INFORMATIONBMT 2.2 brake control is only approved for the BT..(FS) double brake.

The connection example in the wiring diagram on the right side allows for applyingthe double brake fast in case of emergency. The functional control is carried out withnoise reduction via K12 [5] (cut-off in the AC circuit). In case of emergency, safe con-trol via K13 [6] (cut-off in the DC and AC circuit) for fast disconnection. Observe theresulting reduced noise reduction when the double brake is used.

Safe disconnection in case of emergency (safety function SBC) via contactors mustmeet the requirements of the required performance level of the double brake. Usual-ly, 2 contactors (redundancy) with contactor monitoring via a safety controller is re-quired.

9.7.7 BMV brake control

1

2

3

13

14

15

4 BMV

+

-

+

-

RD BUWH

[1] [2]

3L 4L 5L 3M 5M4M[3]

RD BUWH

1

2

3

13

14

15

4 BMV

+

-

+

-UE (DC 24V)

Uin (DC 24V)

UE (DC 24V)

Uin (DC 24V)

DC

14785366539

CustomerFactory

DC Cut-off in the DC circuit (fast application of the brake)


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9.7.8 BST brake control

13

14

15

BST

+

-

3

4-

-

+

+

UZ

PE

RD BUWH

[1] [2]

3L 4L 5L 3M 5M4M[3]

RD BUWH

14

BST

+

- 2

4-

-

+

+

UZ

PE

3Uin (DC24V)

Usafe (DC24V)

Uin (DC24V)

Usafe (DC24V)

1

NC

6

5

NC

1

NC

2

6

5

NC

13

15

AC

14785371403

CustomerFactory

AC

Fast disconnection (cut-off in the DC circuit) of the brake by the BSTmodule is not part of the safety function (SBC). The brake applicationtime for cut-off in the AC circuit must be consulted.

[1] Brake coil partial brake I[2] Brake coil partial brake II[3] Terminal stripVsafe (DC24V) Safe control voltageVIN (DC24V) Functional control voltageVZ DC link voltage frequency inverter

Observe the "Safety-Related BST Brake Module for Control Cabinet Installation" oper-ating instructions.

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9 Technical dataSafety characteristics


9.8 Safety characteristicsDefinition of the safety architecture (category):The safety architecture (category) classifies safety-related components regarding theirresistance to errors and their response in the event of an error based on the reliabilityand/or the structural arrangement of the parts. A higher resistance to errors means ahigher potential to reduce risk.

9.8.1 BF.. double brake

Characteristic Characteristic to EN ISO 13849-1

Classification Category B

9.8.2 BF..(FS) and BT..(FS) double brake

Characteristic Characteristic to EN ISO 13849-1

Classification Category 31)

System structure 2 channels

Common Cause Failure (CCF) 80

Operating mode selection "High demand"

Probability of dangerous failureper hour (PFHd value)

Calculation by user via B10d value

Service life (depending on thestarting frequency)

20 years maximum, after which the componentmust be replaced with a new one.

Safe condition Supply voltage of BF..(FS) and BT..(FS) doublebrake is switched off. Double brake is applied.

Safety function2) • Safe brake hold (SBH)• Safe brake actuation (SBA)

1) According to the standard, category 3 requires brake diagnostics of the double brake. This is not part ofthe double brake and must be realized within the braking system.2) Take into account the possible system architectures, see "Safe Braking System" system manual.

INFORMATIONThe brake diagnostics of the double brake that is to be implemented in the systemmust meet the requirements according to the standard.

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9Technical dataCharacteristic safety values


9.9 Characteristic safety valuesDefinition of the characteristic safety value B10d:The value B10d specifies the number of switching cycles at which 10% of componentshave failed dangerously (definition according to standard EN ISO 13849-1). Faileddangerously means in this context that the double brake does not realize at least oneof the safety functions when required. This means the brake does not deliver the nec-essary braking torque.

Brake type B10d value

BF11 BF11(FS) BT11(FS) 8 000 000

BF20 BF20(FS) BT20(FS) 5 000 000

BF30 BF30(FS) BT30(FS) 3 000 000

9.10 Diagnostic unit /DUE

Sensor Ø 8 mm DUE-d8-00

Measuring range (MB) mm 2.0

Protection class IP66

Operating temperature (sensor and ca-ble)

-50 to +150 °C

Evaluation unit DUE-2K-00

Part number 21195536

Signal outputs (2 channels) Partial brake 1Out1: 4 – 20 mA

FCT1: DC 24 V (150 mA)

WEAR1: DC 24 V (150 mA)

Partial brake 2Out2: 4 – 20 mA

FCT2: DC 24 V (150 mA)

WEAR2: DC 24 V (150 mA)

Current consumption Max. mA 360

Min. mA 80

Supply voltage DC 24 V (± 15%)

Electromagnetic compatibility DIN EN 61800‑3Operating temperature (evaluation unit) -40 to +105 °C

Humidity ≤ 90% rF

Protection class IP20 (in the closed terminal box IP66)

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10 MalfunctionsMalfunction/malfunction load


10 Malfunctions

INFORMATIONIn the event of a failure of the safety-rated double brake, consult theSEW‑EURODRIVE Service.

If you contact S‑EURODRIVE Service, have the serial number of the motor and theidentification number of the double brake (ID) at hand.In the event of a failure of all other components, proceed as described in the corre-sponding operating instructions.

10.1 Malfunction/malfunction loadA malfunction load may occur due to e.g. a component failure, power failure or trig-gered safety function.The malfunction load may exceed twice the nominal load.During project planning of the double brake, it must be ensured that the double brakeis dimensioned for this malfunction load.

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Index

IndexB

Basic unit.............................................................. 24BF.., BT.. double brake

Functional safety............................................. 16Brake controls ...................................................... 68Brake rectifier combinations................................. 69Brake replacement

Traceability...................................................... 16Brake springs ....................................................... 66Brakemotor

with BF11 and BF/BT11(FS)........................... 25with BF20 and BF/BT20 – 30(FS)................... 26

Braking torques .................................................... 66Braking work ........................................................ 68

C

Changing the brake springBF and BT....................................................... 51

Changing the braking torque................................ 51Code table............................................................ 15Connecting diagnostic unit /DUE ......................... 58Copyright notice ..................................................... 8

D

Designated use .................................................... 11Diagnostic unit /DUE...................................... 35, 56Disassembly......................................................... 46

Diagnostic unit /DUE....................................... 53HR and HT manual brake release .................. 52

Double brakeBraking work ................................................... 68Working air gap............................................... 68

E

Electrical connection ............................................ 13Embedded safety notes ......................................... 7Exclusion of liability ................................................ 8Exploded view

BF.. and BF..(FS)............................................ 27BF11 and BF/BT11(FS) .................................. 25BF20 – 30 and BF/BT20 – 30(FS) .................. 26BT..(FS) .......................................................... 28

F

FS logo................................................................. 12Function and wear monitoring.............................. 35Functional safety ...................................... 12, 14, 15

BF.., BT.. double brake ................................... 16Code table....................................................... 15ID .................................................................... 15Knowledge ...................................................... 12

G

General safety notes .............................................. 9

H

Hazard symbolsMeaning ............................................................ 7

HR/HT manual brake release retrofit ................... 54

I

Inspection and maintenance work........................ 44Inspection intervals .............................................. 46Installation ............................................................ 13

Electrical ......................................................... 38Mechanical...................................................... 37

Intervals................................................................ 46

M

Maintenance intervals .......................................... 46Manual brake release HR/HT option.................... 32Mechanical installation

HR/HT manual brake release ......................... 37

N

Nameplate............................................................ 31Notes

Designation in the documentation..................... 6Meaning of the hazard symbols ........................ 7

O

Operating currents ............................................... 72Other applicable documentation .......................... 12

P

Permitted braking work ........................................ 76Preliminary work

Double brakes................................................. 44

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Index

Product names....................................................... 8

R

Retrofitting the HR/HT manual brake release ...... 54Right to claim under warranty ................................ 8

S

Safe Brake Actuation (SBA)................................. 21Safe Brake Hold (SBH) ........................................ 22Safety class.......................................................... 14Safety functions

Safe Brake Actuation (SBA)............................ 21Safe Brake Hold (SBH) ................................... 22SBC – Safe Brake Control .............................. 20

Safety notesElectrical connection ....................................... 13Designated use ............................................... 11Designation in the documentation..................... 6General ............................................................. 9Installation....................................................... 13Meaning of the hazard symbols ........................ 7Preliminary information ..................................... 9Structure of embedded ..................................... 7Structure of the section-related......................... 7Transport......................................................... 12

SBC – Safe Brake Control ................................... 20Section-related safety notes................................... 7Service ................................................................. 92Setting the working air gap

BF.. and BT..................................................... 47Signal words in the safety notes ............................ 6Standards............................................................. 14Startup.................................................................. 42Status message evaluation unit ........................... 65Structure

BF.. and BF..(FS)............................................ 27BT..(FS) .......................................................... 28

T

Test ...................................................................... 46Trademarks ............................................................ 8Transport.............................................................. 12Type designation.................................................. 30

V

Validity.................................................................. 14

W

Working air gap .................................................... 68

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SEW-EURODRIVE—Driving the world

SEW-EURODRIVE GmbH & Co KGP.O. Box 302376642 BRUCHSALGERMANYPhone +49 7251 75-0Fax +49 7251 [email protected]

www.sew-eurodrive.com

Instructions Addendum to the Operating - SEW … · 4.6 Overview of types ... 9.5.3 BF30, BF30(FS)...

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Transcript of Instructions Addendum to the Operating - SEW … · 4.6 Overview of types ... 9.5.3 BF30, BF30(FS)...