Emerson 9055E Automobile Parts User Manual

Emerson Industrial Automation
Installation and
Maintenance Manual
for FCR Equipped Motors
and Gearmotors
Browning, Emerson, Emerson Industrial Automation and Intelligear are trademarks of Emerson Electric
Co. or one of its affiliated companies.
©2008, 2009, 2013 Emerson Power Transmission Corps., All Rights Reserved.
MCIM13005E • Form# 9055E • Printed in USA
7120 New Buffington Road
Florence, KY 41042
Application Engineering: 800 626 2093
www.emerson-ept.com
FORM
9055E
Revised
May 2013
Installation Instructions
•
Read and follow all instructions carefully.
•
•
Disconnect and lock-out power before installation and
maintenance. Working on or near energized equipment
can result in severe injury or death.
Periodic inspections should be performed. Failure to perform proper maintenance can result in premature product
failure and personal injury.
•
All electrical work should be performed by qualified personnel and compliant with local and national electrical codes.
•
Do not operate equipment without guards in place.
Exposed equipment can result in severe injury or death.
1Receipt Inspection
Upon receipt, check the condition of the brake - should the motor or brake or even the packaging be damaged in any way, inform the carrier. Check the brakemotor and gear nameplate to make sure it conforms with the order specifications (mounting arrangements, etc.)
1.1 Brakemotor Nameplate
3
5
4
2
9
1
10
6
8
7
2
Item #
1
2
3
4
5
Nameplate details
Motor frame
Motor/brake type
Motor speed in rpm
Motor HP
Motor voltage
Item #
6
7
8
9
10
Nameplate details
Manufacturing ID #
Braking torque (ft.lbs.)
Brake coil voltage (VDC)
Duty cycle
Brake Enclosure
Installation Instructions
2Storage
Store the equipment in a clean, dry place that is protected from shocks, vibration and temperature fluctuations and with relative humidity levels of less
than 90%.
3Installation
3.1 Mechanical Installation
Allow a minimum of 8.3 inches of clearance between
the fan cover guard of the brakemotor and any surface
to allow room for removing the fan cover guard and
servicing or adjusting the brake.
3.2 Electrical Installation
Make all electrical and grounding connections in accordance with all national, and local codes. When
these motors are supplied with normally closed thermostats, they should be wired to the holding coil
of a motor starter and are not designed for power input.
NOTICE: When the motor is started with reduced
voltage or variable frequency power, the brake must
be supplied with power separate from the motor. The
reduced voltage will likely not release the brake, and
thus cause motor and brake damage.
Brakemotors designed specifically for operation from
VFD power sources will have a 100 VDC brake coil
and the rectifier. These 100 VDC brakes require a separate fixed frequency 115 or 230 VAC power source.
For shorter brakes set times to prevent coasting potentials, it's necessary to use an auxiliary contact from
the motor start and connect it to the rectifier as shown
in the wiring diagrams as location "A".
3.3 Brakes with manual release lever
To manually release the brake, exert pressure on the
manual release handle towards the non-drive end of
the motor.
Power Supply (see connection diagrams on page 4)
Make sure to re-set it after maintenance is complete.
Brake motors with built-in power supply can be connected in the same way as a standard motor. They
are fitted with a 180V DC coil. The brake is directly
supplied from the motor stator (230/460, 575V) via a
brake power supply unit with the rectifier mounted in
the terminal box.
The terminal box on a brakemotor or brake gearmotor
is supplied with two (2) threaded openings on side 1
and 3. See diagram below.
Each of these openings are supplied with a threaded
plug allowing removal of any or all plugs for required
cable entry. Keeping plugs in unused locations preserves the enclosure integrity of the motor and brake.
Side 1
Rectifier
(2) 3/4-14 NPT
(2) 1/2-14 NPT
Side 3
3
Installation Instructions
3.4 Electro-magnetic characteristics @ 20°C + 5%
180 VDC Brake Coil
Motor Frame
100 VDC Brake Coil
Current
Resistance
Power
Current
Resistance
Power
A
Ω
W
A
Ω
W
56 or 56C
0.31
572
57
0.54
186
54
140T or 140TC
0.31
572
57
0.54
186
54
180T or 180TC
0.35
510
64
0.65
155
65
3.5 Wiring diagrams
3.5.1 Fixed Frequency
Three phase brake motors operated from a fixed frequency power supply are supplied with onboard rectifiers in the
conduit box to allow powering the brake rectifier directly from the motor. Two versions of rectifiers ( SO6 and SO8 )
can be used interchangeably. Note the rectifier in the motor being wired.
3.5.1.1 Three phase 230/460, 190/380V
SO8 Rectifier
T1
T2
T3
T1
T2
T3
Lo-Volts
(A)
B2
B1
230V AC
HI-Volts
180V DC
180V DC
*Disconnect B1 and B2 for separate
power supply to Brake Rectifier (S06)
380/460V AC
(A) Break DC: faster response time.
Remove jumper and add contact.
C
LR57008
T4
T5
T6
T4
T5
T6
T7
T8
T9
T7
T8
T9
T1
T2
T3
T1
T2
T3
_
+
-
++
15%
T6
T9
SO8 Rectifier
~
~
+-
T5
T8
15%
T4
T7
+-
T6
T9
(A)
B1 B2
Lo-Volts
HI-Volts
*Disconnect B1 and B2 for separate
power supply to Brake Rectifier (S08)
Brake Connection Diagram
Separate Power Supply Required
Brake Connection Diagram
230V AC
180V DC
(A) Break DC: faster response time.
Remove jumper and add contact.
IMPORTANT
T5
T8
+
IMPORTANT
T4
T7
-
_
~
*S08 Brake
Rectifier
B1
B2
CAUTION: DISCONNECT THE RECTIFIER CELL WHEN
TESTING FOR CURRENT INSULATION OR DIELECTRIC.
SO6 Rectifier
~
*S08 Brake
Rectifier
B1
B2
230v or 460v or 380v
230v
SO6 Rectifier
+
*Disconnect B1 and B2 for separate
power supply to Brake Rectifier (S06)
! Insulate ends of B1 and B2 if
separate power supply used
for Brake.
15%
T3
(A)
+-
Single Voltage
C
LR57008
-
B1
B2
230V AC
180V DC
(A) Break DC: faster response time.
Remove jumper and add contact.
IMPORTANT
T2
_
~
CAUTION: DISCONNECT THE RECTIFIER CELL WHEN
TESTING FOR CURRENT INSULATION OR DIELECTRIC.
SO6 Rectifier
~
T1
SO8 Rectifier
Brake Connection Diagram
B2
FN0419
IntelliGear® wiring with ESFR card (see IntelliGear Plus™ Manual Form 9112).
4
+
-
++
(A)
180V DC
380/460V AC
(A) Break DC: faster response time.
Remove jumper and add contact.
460v or 380v
3.5.3 Three phase 575V
B1
_
C
LR57008
FN0416
*S06 Brake
Rectifier
SO8 Rectifier
~
~
15%
Brake Connection Diagram
*S06 Brake
Rectifier
B1
B2
CAUTION: DISCONNECT THE RECTIFIER CELL WHEN
TESTING FOR CURRENT INSULATION OR DIELECTRIC.
*S06 Brake
Rectifier
B1
B2
+-
SO6 Rectifier
Installation Instructions
3.5.2 Variable Frequency
Three phase brake motors operated from a variable frequency power supply are designed with onboard rectifiers
in the conduit box to allow powering the brake rectifier from a 115V or 230V fixed frequency single phase power
separate from the motor/VFD but interlocked with that power source such that both motor and brake get powered
simultaneously. Two versions of rectifiers ( SO6 and SO8 ) can be use inter-changeably. Note the rectifier in the
motor being wired. 3.5.2.1 SO6 Rectifier
SO6 Rectifier
_
~
-
+
IMPORTANT
+-
15%
~
115V AC
(A)
100V DC
100V DC
230V AC
(A) Break DC: faster response time.
Remove jumper and add contact.
C
LR 57008
C A UT ION: DIS C ONNE C T T HE R E C T IF IE R C E L L WHE N
T E S T ING F OR C UR R E NT INS UL AT ION OR DIE L E C T R IC .
Brake Connection Diagram
Separate Power Supply Required
FN0438
3.5.2.2 SO8 Rectifier
Brake Connection Diagram
Separate Power Supply Required
Brake Connection Diagram
Separate Power Supply Required
SO8 Rectifier
SO8 Rectifier
_
+
-
++
+-
15%
+-
_
~
~
+
-
++
15%
~
~
(A)
100V DC
115V AC
(A)
100V DC
230V AC
(A) Break DC: faster response time.
Remove jumper and add contact.
230V
230V
(A) Break DC: faster response time.
Remove jumper and add contact.
115V
115V
5
Installation Instructions
16
24
8
14
0.4mm
23
Figure 1
11
40
50
4Maintenance*
4.1Adjustments
Adjusting the air gap: (Figure 1)
The air gap needs to be adjusted when the
mechanical release mechanism no longer functions
normally.
• Unscrew the manual release handle(16) when it is supplied.
• Unscrew the 4 cover screws (40) which are securing
the fan cover guard (23) on the motor.
* See page 7 for exploded view and parts lists.
6
• Remove the fan cover guard (23). Remove manual
release (14) and remove the sealing o-ring (50).
Clean the parts by removing the friction lining dust.
Insert a 0.4 mm (0.016 in.) shim between the brake
housing (8) and the armature (11). Tighten the brake
nut (24) so as to obtain a working gap of 0.4 mm distance between the armature (11) and the brake housing (8). The shim should slip slightly.
• Remove shim.
• Replace the sealing o-ring (50).
Replace the fan cover guard (23) and tighten the fan
cover screws (40).
• Replace the manual release handle (16) (if
supplied).
Installation Instructions
4.2 Disassembly and reassembly of the brake
manual release (default option) (Figure 2)
Disassembly of the brake manual release:
• Unscrew the handle (16) of the manual release (14)
(if supplied).
• Remove the fan cover screws (40) which are
securing the fan cover (23) in place.
• Remove the two screws (12) on the manual release
(14) and release the spring (13).
• Remove the manual release (14).
Reassembling the brake manual release:
• Position the brake manual release (14) around the
brake housing (8).
• Install screw (12) on the left to affix the manual
release (14).
• Install screw (12) with spring on right with large end
of spring engaged into hole in housing (8) (see Figure
2). Tighten screw (12). Once screw is tightened, set
short end of spring under manual release notch (see
Figure 2).
• Assemble the fan cover guard (23) with screws (40).
• Remove the rubber plug in the fan guard and
assemble the handle (16) (if required) to release the
brake manually.
4.3 Changing brakemotor on modular gear
Removing brakemotor from gear:
• Remove fan cover guard (23) from motor.
• Remove brake nut (24) while holding fan (15
stationary. Remove washer (20).
• Disassemble manual release per 4.2 above.
• Remove the motor stud nut (25) and motor stud
(61).
• Use bearing puller to remove fan (15) and brake
armature (11) together.
• Follow "Modular Motor Disassembly" instructions,
which are supplied with the replacement brakemotor,
to now remove the motor rotor and stator.
Figure 2
Reinstalling new brakemotor onto gear with
modular tapered input connection:
•Clean female taper of new motor's shaft completely
with petroleum solvent.
NOTICE: Do not lubricate the female taper end of the
motor shaft or the male taper of the reducer shaft.
Lubrication could cause the connection to slip in
service
•Keeping rotor (2) and stator (1) together, rotate
rotor/brake until pair of tapped holes in brake housing
(8) are at 90 degrees from where manual release
handle (16) is desired.
•Install the 4 stator bolts (5) through brake housing
(8) and stator assembly and engage them into gear
input bracket. Tighten in alternating rotating pattern.
•Install and tighten rotor stud nut per "Modular Motor
Assembly" instructions supplied with replacement
brakemotor.
•Hold brake fan with an adjustable wrench to prevent
rotation, insert 0.4 mm shim between brake housing
(8) and armature plate (11). Tighten brake nut (24) to
just before shim is captive but less than .50 mm shim.
•Replace the sealing o-ring (50).
•Reassemble the brake manual release components
per 4.2 above if required to original orientation.
•Assemble the brake fan cover guard (23) using 4
screws (40).
•Replace manual release handle (16) (if required).
4.4 Braking torque (ft. lbs.)
The table below defines the standard braking torque rating for the FCR brakemotor or gearmotor designs:
Motor
HP / Poles
Frame
Brake Rating
Springs
(FT. Lbs.)
Qty and Color
0.33 HP / 4
56/56C
2.2
4 blue
0.50 HP / 4
56/56C
2.5
6 blue
0.75 HP / 4
56/56C
4.4
3 green
1.00 HP / 4
143T/56C/143TC
5.9
4 green
1.50 HP / 4
145T/145TC
7.4
5 green
2.00 HP / 4
145T/145TC
8.85
6 green
3.00 HP / 4
182T/182TC
15
4 grey
5.00 HP / 4
184T/184TC
23
5 grey
16
14
12 and 13
Manual
Release
Notch
12 and 13
12
13
Hole in
Housing (8)
7
Installation Instructions
5 Exploded View and Parts List For FCR Brake Motors
23 40 25
24
20
15
16
14
12
11
28
50
5
8
7
1
13
60
2
45
Figure 3
61
43
41 49
47 44
46 52 53
5.2 FCR parts list
Ref.
1
2
5
7
8
11
12
13
14
15
Description
Qty
Wound stator assembly
1
Rotor assembly
1
Motor stator bolts
4
Non-drive bearing
1
Brake housing
1
Brake armature
1
Manual release screws 2
Manual release spring
1
Manual release
1
Brake fan/lining
1
Ref.
16
20
23
24
25
28
40
41
43
44
Description
Qty
Manual release handle 1
Brake washer
1
Fan cover guard
1
Brake nut
1
Rotor stud nut
1
Brake Springs
3 to 6
Fan screws
4
Terminal lid screws
4
Terminal box mtg. bolts
2
1/2-14 NPT plugs
2
Ref.
45
46
47
49
50
52
53
60
61
Description
3/4-14 NPT plugs
Brake power rectifier
Terminal lid gasket
Terminal box lid
Sealing o-ring
Terminal box
Terminal box gasket
Rotor shaft keys
Rotor stud
6 Replacement brakemotors and Repair Parts
6.1Procedure
All orders or quotes for replacement parts must be accompanied by:
• The complete motor type, number of units and the complete nameplate information.
• Reference # and their descriptions per 5 and 5.2 above.
All request for quotes for replacement motors or gearmotors must be accompanied by:
• Complete nameplate information from the motorand the gear nameplates.
8
Qty
1
1
1
1
1
1
1
2
1
Installation Instructions
7 Troubleshooting Guide
Symptom
Probable Cause(s)
Abnormal Noise
Originating from motor or driven machine?
Noisy Motor
Mechanical causes: if noise persists after
switching off the electrical power supply.
- Bearing noise
- Mechanical friction: ventilation, brake disc, coupling
Electrical cause: if noise stops after
switching off the electrical power supply.
- Normal voltage and 3 phases are balanced
- Abnormal voltage
- Phase imbalance
Motor heating up abnormally
- Faulty ventilation
- Faulty power supply
- Terminal connection fault
-Overload
- Partial short-circuit
Motor will not start
- Phase imbalance
No load:
- Mechanical locking
- Broken supply line
With load:
- Phase imbalance
Brake does not release
Brake releases but is very noisy
Brake releases but braking is insufficient
Insufficient supply voltage:
Defective coil:
Air gap is irregular, or is too large:
Foreign body in air gap.
Insufficient pressure on springs.
If spring pressure is correct.
Action Recommended
*Uncouple motor from machinery and
run test motor/gearmotor alone.
*Test the brake release system.
*Check the bearings for damage.
*Check.
*Check the power supply at the motor’
leads.
*Check tightness of power connections
in the conduit box.
*Check the power supply line.
*Check the winding resistance and the
supply (voltage) balance.
*Monitor ambient.
*Clean the fan cover guard grill and
cooling fan.
*Check the fan for correct mounting on
shaft.
*Check.
*Check.
*Check the current consumption against
the nameplate current rating.
*Check the electrical continuity of the
windings and/or the insulation.
*Check the winding resistance.
Release the brake and with the motor
switched off:
*Check motor shaft rotates freely by hand.
*Check fuses, electrical protection,
starting device and electrical continuity.
When switched off:
*Check the direction of rotation (phase order).
*Check resistance and the continuity of the motor windings.
*Check electrical protection.
The maximum permissible voltage drop is
15% of the rated voltage.
Replace the coil.
Dismantle and clean.
Clean the parts.
*Check spring quantity and color.
*Check air gap.
*Check surface condition of the friction
lining and the brake armature.
*Blow away any friction dust.
9
Browning, Emerson, Emerson Industrial Automation and Intelligear are trademarks of Emerson Electric
Co. or one of its affiliated companies.
©2008, 2009, 2013 Emerson Power Transmission Corps., All Rights Reserved.
MCIM13005E • Form# 9055E • Printed in USA
10