Lenze M Series Istruzioni operative

.Z!z

Ä.Z!zä

Supplement to Operating Instructions

M... MCA19, MCA21

Asynchronous servo motors with spring−applied

brake mounted on the B−bearing side



Please read these instructions before you start working!

Follow the safety instructions enclosed.

Important notes

This supplement is only valid together with the general motor operating instructions, see Inter-

net!

Invalid chapters of the motor operating instructions: none

Additions to the "Maintenance and repair" section:

Stop!

When replacing the brake, complete rotor or the hub, the spare part from the

corresponding Lenze repair kit must always be used.

Characteristics and maintenance of the BFK457−16 R and BFK458−18 spring−applied brakes.

Encoder dismounting and mounting.

0Abb. 0Tab. 0

Contents i

Lenze ¯ MA 33.0012 ¯ 1.0

1 Mechanical installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Important notes 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Spring−applied brake − holding brake 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.1 Characteristics 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.2 BFK457−16R design − non−adjustable 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.3 BFK458−18 design − adjustable 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Maintenance/repair 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Spring−applied brake − holding brake 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.1 Wear on spring−applied brakes 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.2 Maintenance 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.3 Dismounting the MCA19 and 21 fan cover 9. . . . . . . . . . . . . . . . . . . . . . . .

2.1.4 BFK457−16R air gap 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.5 Checking and re−adjusting the BFK458−18 air gap 11. . . . . . . . . . . . . . . . . .

2.2 Replacing the brake 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.1 Dismounting the MCA 19 and 21 encoder 12. . . . . . . . . . . . . . . . . . . . . . . . .

2.3 BFK457−16R 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.1 Dismounting and mounting 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 BFK458−18 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.1 Dismounting and mounting 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.2 Encoder mounting 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical installation

Important notes

4 Lenze ¯ MA 33.0012 ¯ 1.0

1 Mechanical installation

1.1 Important notes

The brake that is mounted here is specially adapted to the use on the MCA 19 and 21.

Stop!

If the wear air gap of a spring−applied brake is reached, the brake will no

longer be released. In this case, the complete rotor of the brake must be

replaced.

Note!

¯ BFK457−16R: It is not possible to re−adjust the brake. The complete

rotor must be replaced.

¯ BFK458−18: When the wear limit has been reached, the brake must be

re−adjusted, or the complete rotor must be replaced.

Safety system

Stop!

If a safety encoder is used, all maintenance and installation work must be

performed at the Lenze site.

Otherwise any warranty will expire and Lenze GmbH will not accept any

liability for consequential damage.

The IG2048−5V−V3 safety encoder can be mounted on the brakes described here and must

not be dismounted and mounted. This service work is performed by Lenze.

Mechanical installation

Spring−applied brake − holding brake

Characteristics

Lenze ¯ MA 33.0012 ¯ 1.0

1.2 Spring−applied brake − holding brake

1.2.1 Characteristics

Motor type Type of brake sLrated

+0.1 / −0.05

sLmax.

holding brake

Max.

adjustment,

permissible

wear path

Rotor thickness Tightening

torque of the

fixing screws

Fixing screws

[mm] [mm] [mm] min. [mm] max. [mm] [Nm] No. of pieces

MCA19 BFK457−16R 0.3 0.6 −−− −−− −−− 24.6 4

MCA21 BFK458−18 0.4 0.6 3.0 10.0 13.0 24.6 6

1.2.2 BFK457−16R design − non−adjustable

Fig. 1 Design of an INTORQ BFK457−16 Compact spring−applied brake, fully mounted rotor and flange

1 Stator 3 Rotor with friction lining 6 Fixing screws

2 Armature plate 4 Spacer bush 7 Screws of the emergency manual

release

5 Flange sLAir gap

1.2.3 BFK458−18 design − adjustable

Fig. 2 Design of an INTORQ BFK458 spring−applied brake: basic module E (complete stator) + rotor + hub + flange

1 Stator 3 Rotor with friction lining 6 Fixing screws

2 Armature plate 5 Flange 8 Sleeve bolts

sLAir gap

Maintenance/repair

Spring−applied brake − holding brake

6 Lenze ¯ MA 33.0012 ¯ 1.0

2 Maintenance/repair

2.1 Spring−applied brake − holding brake

The brakes need to be checked on a regular basis to ensure safe and trouble−free

operation.

The necessary maintenance intervals primarily depend on the stress to which the brake

is subjected in an application. When a maintenance interval is being calculated, all

causes of wear must be taken into account (see notes "Wear on spring−applied brakes").

In the case of brakes which are subjected to low levels of stress, e.g. holding brakes with

emergency stop function, regular inspections at a fixed time interval are recommended.

In order to reduce the amount of work involved in maintenance, perform the inspection

at the same time as other maintenance work carried out cyclically on the machine if

possible.

If the brakes are not properly serviced, operating faults, production outages or damage

to machinery can occur. A maintenance concept adapted to the operating conditions

and the stresses to which the brakes are subjected must therefore be drawn up for every

application. For brakes, the maintenance intervals and servicing work listed in the

following table are necessary.

Maintenance interval for holding brake with

emergency stop

Maintenance work

At least every 2 years Inspection of the brake integrated in the motor:

¯ Check ventilation function and

activation/deactivation

¯ Measure air gap (re−adjust air gap, if necessary),

2.1.4

After 1 million cycles at the latest

Shorter intervals in the case of frequent emergency

stops!

Maintenance/repair

Spring−applied brake − holding brake

Wear on spring−applied brakes

Lenze ¯ MA 33.0012 ¯ 1.0

2.1.1 Wear on spring−applied brakes

Causes of wear

Component Effect Influencing factors Cause

Friction lining Wear on the friction lining Applied friction energy Braking during operation

(impermissible, holding

brakes!)

Emergency stops

Overlapping wear when

the drive starts and stops

Active braking by the drive

motor with the help of the

brake (quick stop)

Number of start−stop

cycles

Starting wear if motor is

mounted in a position

with the shaft vertical,

even if the brake is open

Armature plate and

flange

Running−in of armature

plate and flange

Applied friction energy Friction between the brake

lining and the armature

plate or flange e.g. during

emergency braking or

service brake operation

Teeth of the brake

rotor

Teeth wear (primarily at

the rotor end)

Number of start−stop

cycles,

Level of the braking

torque,

Dynamics of the

application,

Speed fins in operation

Relative movement and

impacts between brake

rotor and brake hub

Armature plate

bracket

Armature plate, cap screws

and bolts are deflected

Number of start−stop

cycles,

Level of braking torque

Load changes and impacts

due to reversal error

during interaction

between armature plate,

cap screws and guide bolts

Springs Fatigue failure of the

springs

Number of switching

operations of the brake

Axial load cycle and

shearing stress on the

springs due to radial

reversing error of the

armature plate

Inspection of the individual parts

With a mounted brake ¯ Check release function and control

¯ Measure air gap (re−adjust, if necessary)

¯ Measure rotor thickness (replace rotor, if necessary)

¯ Thermal damage of armature plate or flange (tarnished

dark blue)

With a dismounted brake ¯ Check clearance of the rotor gear teeth (replace rotors that are damaged

by vibration)

¯ Damage by vibration of the torque support at the sleeve bolts, cylindrical

pins, and armature plate

¯ Check springs for damage

¯ Check armature plate and flange or end shield

– Max. run−in depth = rated air gap of the design size

Maintenance/repair

Spring−applied brake − holding brake

Maintenance

8 Lenze ¯ MA 33.0012 ¯ 1.0

2.1.2 Maintenance

Stop!

The brakes must not be actuated without blowers.

Danger!

¯ Only work on the drive system when it is in a deenergised state!

¯ Hot motor surfaces of up to 140 °C. Observe cooling times!

¯ Remove loads acting on motors or secure loads acting on the drive!

Note!

Always fully replace brakes with defective armature plates, cylinder head

screws, springs or counter friction faces.

¯ The brakes used are not fail−safe because interference factors which

cannot be influenced (e.g. oil ingress) may lead to a reduction in

torque.

¯ When the rotor has been replaced, the original braking torque is only

attained after the friction surfaces have run in. After the rotor

replacement, increased initial wear will occur if the armature plate and

counter friction faces are not run in.

Tools required

Type Torque key

Use for hexagon socket

screws

Open−jawed spanner width

across flats [mm]

Box spanner

for flange

mounting on

the outside

Feeler gauge

Measuring

range [Nm]

Width across

flats [mm]

Sleeve bolts Two−flat

lever

Width across

flats [mm]

BFK457−16 20 to 100 6 x 1/2"

square

−−−−− −−−−− −−−−−

BFK458−18 20 to 100 6 x 1/2"

square

15 10 13 x 1/2"

square

Maintenance/repair

Spring−applied brake − holding brake

Dismounting the MCA19 and 21 fan cover

Lenze ¯ MA 33.0012 ¯ 1.0

2.1.3 Dismounting the MCA19 and 21 fan cover

The brake is mounted to the N−end shield of the motor. Remove the fan cover to

check, maintain, or set the brake.

1. Disconnect the mains plug (1) of the fan.

2. Loosen the four screws (2) with which the fan is fitted onto the non−drive end

shield and remove the fan.

Maintenance/repair

BFK457−16R air gap

Dismounting the MCA19 and 21 fan cover

10 Lenze ¯ MA 33.0012 ¯ 1.0

2.1.4 BFK457−16R air gap

Stop!

¯ The motor must not run whilst the air gap is checked.

¯ Do not insert feeler gauge further than 10 mm between the armature

plate (2) and stator (1)!

1 Complete stator 6 Fixing screw

2 Armature plate ÀAir gap

1. Check air gap near the fixing screws (6) between the armature plate (2) and the

stator (1) using a feeler gauge and compare the values to the data "sLrated" in the

table, 5.

If the value measured, "sLrated", is outside the tolerance (5), the rotor must be

replaced (12).

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