Operating Instructions Brake Module

BGL-S20K275
EGL-S20K275

Number: A08 070 500 - 956

Creation code: 249
Date of issue: 26.09.2005
Modification status: B/4-Vaj05015
Number of pages: 11
Edited by: I.Vajic

Release date: _______________________

Signature: _______________________

PINTSCH BAMAG Antriebs- und Verkehrstechnik GmbH

Postfach 10 04 20 • D-46524 Dinslaken • Telephone (0 20 64) 6 02-0
Operating Manual No.: A08 070 500 - 956
Brake Module Date of issue: 26.09.2005

Contents

CONTENTS .................................................................................................................... 2

1 GENERAL ................................................................................................................ 2

2 THESE OPERATING INSTRUCTIONS … ............................................................... 3

3 GENERAL NOTES ON THE PRODUCT .................................................................. 3

4 GENERAL SAFETY NOTES .................................................................................... 3

4.1 MECHANICAL STRUCTURE ............................................................................. 5
4.1.1 CORRECT USE ............................................................................................ 5
4.1.1.1 PARALLEL OPERATION OF SEVERAL BRAKES............................... 8
4.1.1.2 ASSEMBLY ............................................................................................ 8
4.1.1.3 TYPICAL APPLICATIONS ..................................................................... 9
4.1.2 INCORRECT USE ........................................................................................ 9

5 NUMBER OF SWITCHING OPERATIONS .............................................................. 9

6 TECHNICAL DATA ................................................................................................ 11

1 General
These Operating Instructions apply to the following products:
Brake module BGL – S20K275 008 070 501 – 249
EGL – S20K275 008 070 511 – 249

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Drive Engineering
Operating Manual No.: A08 070 500 - 956
Brake Module Date of issue: 26.09.2005

2 These Operating Instructions …

... explain how to use the brake modules. Here, you will find information on safe
• assembly,
• commissioning and
• maintenance.
The Safety Notes for using the brake modules have been brought together in a
separate chapter.
In your own interest, familiarise yourself with these Instructions before assembling the
brake modules. Find out about possible dangers when handling the brake modules and
pay particular attention to the valid safety regulations.

... address:
• fitters
• maintenance personnel
• operators

... work with the following symbols:

∆ Safety Notes are Highlighted by a Light Triangle
• indicate lists
 stand for work stages to be done by you


3 General Notes on the Product

The brake modules are components of systems that work with electromagnetic spring-
loaded brakes designed for installation in switching cabinets and are used
• To generate the direct current needed by the brake
• To connect the contactor relay
• To limit the braking voltage when disengaging
• To connect the brake
The brake modules are suitable for all sizes and type of brakes available from Pintsch
Bamag and all conventional coil voltages.

The a.c. input voltage is rectified either with a one-way rectifier (EGL) or with a two
way rectifier (BGL). The choice of the form of rectification depends on the coil voltage
of the brake and the level of the a.c. input voltage.

4 General Safety Notes

The safety notes at this point are general safety notes. Specific safety notes
can be found at the beginning of each Chapter or at the appropriate point in
the text. Observing all safety notes helps you to avoid accidents and to
prevent damage to the brake module.
Observe the safety regulations even if you are under pressure of time. Accidents cannot
be undone.

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Operating Manual No.: A08 070 500 - 956
Brake Module Date of issue: 26.09.2005

∆ Don’t act negligently

Avoid any action that impairs the safety of the brake module.

∆ Electrician only
Only an electrician may connect the brake module and check its workings while
respecting all safety measures.

∆ Use intact devices

Devices that have visible damage may not be used.

∆ Isolate
All work on the electrics may only be carried out when the equipment has been
disconnected.
Disconnecting one of the cables conducting the braking electricity may cause
hazardous voltage due to the coil inductivity, even though the rated voltage of the coil
is low (24V)!

∆ Do not connect

Disconnect the electricity supply to the brake before you connect the brake
module.

 Post the notice “Do Not Connect” on the control points.

 Make the electrical connection.
 Remove notice.

∆ Pass on documents
When the brake module is handed on, these Operating Instructions must also be made
available to the recipient.

∆ Do Not Open Device

The device must not be opened. For this reason, the device is fitted with a seal that is
destroyed when attempts are made to open it. The seal cannot be removed without
damage. If the seal is damaged, all claims against the manufacturer shall become
void.

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Operating Manual No.: A08 070 500 - 956
Brake Module Date of issue: 26.09.2005

Fig. 1: Quality Seal

The quality seal may be of various colours. The colour is of no significance for the user.

∆ Abnormal Device Behaviour

Devices that behave abnormally must be stopped immediately and replaced.

4.1 Mechanical Structure

The electrics are housed in a 22,5mm narrow plastic housing for top-hat-rail mounting,
with a total length of around 80mm and a height of around 80mm. The terminals are
screw terminals and are located on the top and bottom. The terminals can take wire
cross-sections of 0.25 -2.5mm². The wiring plan is printed on the left-hand side of the
housing.

4.1.1 Correct Use

After the supply voltage has been switched off, the coil current does not abruptly stop
flowing. The coil inductivity drives the coil current further by building up a
correspondingly high back-e.m.f.
Therefore, in addition to the rectification function on the a.c. input voltage, the brake
modules are fitted with an internal suppressor circuit.
The suppressor circuit in the brake modules limits the high back-e.m.f. that arises while
the brake coil is being disengaged and quickly depletes the coil current.
The brake modules BGL-S20K275 and EGL-S20K275 each contain a suppressor circuit
with a mean continuous output of 1W.

(Fig. 2) and (Fig.3) shows the brake modules in block diagrams.

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Operating Manual No.: A08 070 500 - 956
Brake Module Date of issue: 26.09.2005

Fig. 2: Block Diagram with Direct Current Connection of the Brakes for BGL-S20K275

Fig. 3: Block Diagram with Direct Current Connection of the Brakes for EGL-S20K275

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Operating Manual No.: A08 070 500 - 956
Brake Module Date of issue: 26.09.2005

From the block diagram it can be seen that provision has been made between terminals
3 and 4 for a d.c. contactor to activate the brake.
The brake can also be activated by an a.c. contactor; in this case connecting terminals
1 and 2 must be wired to the a.c. contactors in addition to terminals 3 and 4.
Activation of the brake by means of an a.c. contactor is illustrated in (Fig. 4). This
connection version offers the advantage that the d.c. contactor can be replaced by a
cheaper a.c. contactor.

If the mean continuous output of the internal suppressor circuit is not adhered to for a
certain application due to exceeding a permitted number of switching operations
(Section 5), the suppressor circuit may become ineffective and consequential damage
may arise. There is also premature ageing if the max. permitted coil current is
exceeded.
This means that the technical specifications of the brake module must be adhered to
accordingly in dimensioning for the application in question in order to ensure reliable
operation.

Fig. 4: Block Diagram with Connection of the Brake with a.c. Contactor for BGL-S20K275

This wiring can be transferred analogously to brake modules EGL-S20K275

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Operating Manual No.: A08 070 500 - 956
Brake Module Date of issue: 26.09.2005

4.1.1.1 Parallel Operation of Several Brakes

When operating several brakes in parallel, it is also necessary to review the application.
In this connection, the total current of the parallel connection must be considered.

Fig. 5: Parallel Operation

4.1.1.2 Assembly
The wiring plan for the brake module is printed on the housing.

 The brake module must be assembled in a switching cabinet or something similar on

top-hat rails NS 35 in accordance with EN 50022 so that connecting terminal 1 is at
the top. The mounting rail must be grounded according to the local regulations.
 When wiring the braking circuit, cables with an electric strength of at least 700 V,
even though the braking voltage is only 24 V.
 The cable cross-section must be adapted to the braking current.
 The terminals must be tightened to 0.4 Nm.

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Operating Manual No.: A08 070 500 - 956
Brake Module Date of issue: 26.09.2005

4.1.1.3 Typical Applications

• Container crane systems
• Winches
• Automatic Stacking Shelves
• Conveyor Belts

In cases of doubt, contact Pintsch Bamag to check whether the brake module is suitable
for your application.

4.1.2 Incorrect Use

The brake modules are not suitable for the following applications:

• Operation in rooms where there may be explosive or highly flammable gases,

vapours, solids, dust particles or liquids
• Operation in damp or wet rooms
• Operation in the open air
• Operation underground
• Operation in networks that are exposed to direct lightning without protection
• Operation in switchgear of low, medium or high voltage energy distribution systems
• Operation of mechanically damaged equipment
• Operation of open equipment
• Operation in rooms where there is electrically conductive dust
• Parallel operation of two brake modules
• Series connection of two brake modules

5 Number of Switching Operations

The possible number of switching operations of the brake depends on the breaking
energy of the brake and the permitted mean continuous output of the suppressor circuit
integrated in the brake module. It must be checked in each case.
The mean breaking power of the brake coil can be calculated via the breaking energy of
the coil and number of switching operations of the brake according to the following
formula.

n/h . E
P=
3600

n/h: max. No. of switching operations by the brake per hour

P: mean continuous output of the suppressor circuit in [W]
E: breaking energy of the brake in [J]

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Operating Manual No.: A08 070 500 - 956
Brake Module Date of issue: 26.09.2005

Table1 offer an overview of the maximum possible switching operations per hour
(number of switching operations) in terms of the Pintsch Bamag brake series SFB and
KFB. The values for the max. number of switching operations per hour listed in Table 1
refer to brake modules EGL-S20K275 and BGL-S20K275. The max. continuous output
of the internal suppressor circuit is 1W (Section 6).
If a higher number of switching operations per hour is needed for the brake type in
question, Pintsch Bamag brake modules BGL-PE400/150/3 or EGL-PE400/150/5 must
be fallen back as a function of application case.

An additional parallel connection of varistors for brake modules EGL-S20K275 and

BGL-S20K275 is not permitted.
Table1 for BGL-S20K275 and EGL-S20K275

Max. No. of Switching Operations

Brake Type Breaking Energy [J]
per Hour

SFB 6,3 6.9 522

SFB 10 12.5 288

SFB 16 15.5 232

SFB 25 21.9 164

SFB 40 24.4 148

SFB 63 35.3 102

SFB 100 46 78

SFB 160 65.9 55

SFB 250 88.3 41

KFB 10 10.6 340

KFB 16 12.5 288

KFB 25 15.5 232

KFB 30 28.1 128

KFB 40 22 164

KFB 63 24.6 146

KFB 100 65 55

KFB 160 75 48
Table 1: Values Apply to One Brake and a Breaking Power of 1W of the Internal Suppressor Circuit

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Drive Engineering
Operating Manual No.: A08 070 500 - 956
Brake Module Date of issue: 26.09.2005

6 Technical Data

BGL-S20K275
Max. voltage of the supplying AC 460V – 50/60Hz
a.c. system
.
Voltage of the brake coil 0,9 Urms
(coil voltage)
Permitted coil rated voltage DC 24V…390V
Max. coil current 1.5A
Max. energy absorption 150J
of a switching operation
Max. continuous output of the internal 1W
Suppressor circuit (mean value)
Breaking peak at max. coil current <600V
Ambient temperature -40°C…. +50°C
Degree of protection IP 20

EGL-S20K275
Max. voltage of the supplying AC 460V – 50/60Hz
a.c. system
.
Voltage of the brake coil 0,45 Urms
(coil voltage)
Permitted coil rated voltage DC 24V…200V
Max. coil current 1.5A
Max. energy absorption 150J
of a switching operation
Max. continuous output of the internal 1W
Suppressor circuit (mean value)
Breaking peak at max. coil current <600V
Ambient temperature -40°C…. +50°C
Degree of protection IP 20

Our Service department is available for questions on assembly, operation and maintenance of the
switching rectifier:
Fa. Pintsch Bamag
Hünxer Str. 149
D-46537 Dinslaken
Phone: +49(0)2064 602-242
-246
-305
Fax: +49(0)2064 602-283
Internet: http://www.pintschbamag.de
Copyright
Handing on, reproducing and/or adopting this service manual, including extracts thereof, requires the
express prior written approval of Pintsch Bamag.
© Copyright Pintsch Bamag. All rights reserved.

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