SEW Brakes

Service and Maintenance

 Objectives

 Upon completion of this presentation, you will be able to accomplish

the following –

- Describe the purpose of the SEW brake

- Explain the operation of the SEW brake
- Identify the components of an SEW brake
- Apply basic troubleshooting procedures

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 Brake Purpose

 To Stop Motion
- The brake engages when power is removed from the motor
- The brake applies force to an object in motion until friction
either slows or stops the motion
- Motor slows and finally stops
 To Prevent Motion
- Brake engages after motor has come to complete stop
- Brake merely holds motor to prevent rotation.

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 Brake Features

 SEW Brake Features –

- Fail-safe operation
- Rectifier for conversion of AC into DC current
- DC controlled brake coil

Fail-safe operation refers to the brake preventing rotation of the

motor despite loss of power

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 Brake Operation

 The coil functions like an electro magnet when energized

Brake Coil

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 Brake Operation
De-energized Energized

When the coil is de-energized, the springs When the coil is energized, its magnetic field
apply force to the stationary plate. pulls the plate towards the coil.

This force presses against the brake disc to The magnetic force compresses the springs.
create friction.
The motor can now rotate freely.
Friction stops the motor and/or prevents it
from rotating.

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 Brake Operation

 The brake coil consists of two separate parts –

1. Accelerator coil (BS)
2. Fractional holding coil (TS)

Fractional

Accelerator

Brake Coil

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 Brake Operation

 Step 1 – The rectifier energizes the Accelerator (BS) coil very quickly
due to its low resistance

- Low resistance = High current

- High current = Strong electromagnetism
- Strong electromagnetism = Fast reaction

Brake
Motor

Input
Power
Rectifier

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 Brake Operation

 Step 2 – After 120 ms, the rectifier energizes both coils. The
combined coils have a higher resistance, allowing the coils to de-
energize faster when the power is removed

- High resistance = Low current

- Low current = Weak electromagnetism
- Weak electromagnetism = Quick coil collapse
Brake
Motor

Input
Power
Rectifier

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 Brake Operation

 Step 1

 Step 2 – 120ms

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 Brake Operation

 Starting
1. The rectifier energizes the brake coil
2. The brake coil attracts the stationary disc, removing pressure between
the stationary disc and brake disc
3. Motor rotates freely

 Stopping
1. Rectifier de-energizes the brake coil
2. Brake springs create pressure between stationary disc and brake disc
3. Friction stops the motor and prevents it from rotating

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 Brake Components
1 3 5
2 4 6
1. Pressure plate
2. Brake spring
3. Magnet (Coil)
4. Coil body
5. Motor rotor shaft
6. Dampening plate
7. Brake disc
8. Friction disc
9. Brake carrier
10. Brake air gap

8
7 9 10

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 Brake Components

Disc

Disc Coil Spring

Coil

Spring
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 Brake Components

 Rectifiers and relays that mount in Motor Conduit Box

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 Brake Components

 Rectifiers that mount in Control Panel

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 Brake Components

 Typical brake wiring configuration

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 Troubleshooting

 Troubleshooting SEW brakes

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 Troubleshooting

 Always follow the proper lockout/tagout procedures

 Always use the proper safety equipment and PPE

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 Troubleshooting

 Resources needed

- Nameplate data from motor

- Motor/Brakemotor operating instructions
- Motor/Brakemotor parts list
- Digital multi-meter
- Metric nutdrivers
- Metric feeler gauge

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 Troubleshooting

 Common faults

- Rectifier is damaged.
- Rectifier is wired incorrectly.
- AC brake voltage is incorrect or not applied.
- Brake coil is damaged or malfunctioning.
- Brake is mechanically locked.
- Air gap is outside of tolerance.
- Brake disc is worn or damaged.

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 Troubleshooting - Rectifier

 Damaged rectifier
- Incorrect voltage or wiring causes internal damage to rectifier
- Check the rectifier in a de-energized state using the diode checker on
your digital multi-meter
- All power to diode must be OFF. Diode should be isolated from other
components (all wires disconnected!)
- Multi-meter must be in (diode checker mode) with the meter’s black
lead in the jack and the meter’s red lead in the jack.
- See chart on following page

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 Troubleshooting - Rectifier

Brake Rectifier Diode Check Chart

Black Lead to Red Lead to

Type Good Reading
Terminal Terminal
BGE 1.5 / 3.0 1 5 ≈ 0.5 V dc
2 5 ≈ 2.9 V dc
BG 1.5 / 3.0 1 5 ≈ 0.5 V dc
2 5 ≈ 0.5 V dc
BSG 2 5 ≈ 0.2 V dc
4 5 ≈ 0.7 V dc
4 1 ≈ 0.5 V dc
4 2 ≈ 0.5 V dc
BMK 3 4 ≈ 1.8 V dc
1 13 0.0 V dc
BME 1.5 / 3.0 2 3 ≈ 2.9 V dc
13 1 0.0 V dc
14 3 ≈ 0.5 V dc
15 4 0.0 V dc

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 Troubleshooting - Wiring

 Incorrect wiring
- Refer to wiring diagram paperwork supplied with motor
- Verify proper wiring using the sticker supplied with motor
conduit box lid
- Refer to the motor nameplate for the correct brake voltage

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 Troubleshooting - Wiring

 Check voltage at brake contactor

- If rectifier power does not come from motor terminals, measure
the voltage at the brake contactor

 Check the activation of the brake contactor

- Verify that the brake contactor functions properly and changes
position when energized

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 Troubleshooting - Coil

 Brake coil is damaged or malfunctioning

- Wrong voltage applied to brake coil causes internal and
external damage

Coil received incorrect voltage

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 Troubleshooting - Coil

 Measure the actual resistances of accelerator coil and fractional coil

14

13-14 (accelerator coil)

14-15 (fractional coil)
13

13-15 (total coil)

15

Accelerator coil winding resistance = ¼ of winding resistance

Fractional coil winding resistance = ¾ of winding resistance
Total coil winding resistance = sum of accelerator and holding coil resistance
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 Troubleshooting - Coil
Brake Coil Resistance Values
BE05 / BE30 / BE60 / BE120 /
Nominal voltage VN BE2 BE5 BE11 BE20
BE1 BE32 BE62 BE122

VAC VDC RB RT RB RT RB RT RB RT RB RT RB RT RB RT RB RT

24 (23-26) 10 0.77 2.35 0.57 1.74 - - - - - - - - - - - -

60 (57-63) 24 4.85 14.8 3.60 11.0 2.20 10.5 1.20 7.6 1.1 7.1 - - - - - -

120 (111-123) 48 19.4 59.0 14.4 44.0 8.70 42.0 4.75 30.5 3.3 28.6 2.1 15.8 - - - -

147 (139-159) 60 31.0 94.0 23.0 69.0 13.8 66 7.7 43.5 5.4 36.0 3.7 27.5 - - - -

184 (174-193) 80 48.5 148 36.0 111 22.0 105 12.0 76.0 8.4 57 5.3 39.8 - - - -

208 (194-217) 90 61.0 187 45.5 139 27.5 132 15.1 96 10.6 71.7 6.7 50 3.95 32.5 - -

230 (218-243) 96 78.0 235 58.0 174 34.5 166 19.0 121 13.3 90.3 8.4 63 5.0 41.0 8.0 29.9

254 (244-273) 110 97.0 295 72.0 220 43.5 210 24.0 152 16.7 134 10.6 79.3 6.3 52.0 10.1 37.2

290 (274-306) 125 122 370 91 275 55.0 265 30.0 191 21.1 143 13.3 100 5.6 64.0 12.7 47.4

330 (307-343) 140 154 470 115 350 69.0 330 38.0 240 26.5 180 16.8 126 9.9 80.0 20.1 75.1

360 (344-379) 160 194 590 144 440 87.0 420 47.5 305 33.4 227 21.1 158 12.6 101 - -

400 (380-431) 180 245 740 182 550 110 530 60 380 42.1 286 26.6 199 15.8 128 25.3 94.6

460 (432-484) 200 310 940 230 690 138 660 76 480 52.9 360 33.4 251 19.9 163 31.8 119

500 (485-542) 220 385 1180 290 870 174 830 95 600 66.7 453 42.1 316 25.5 205 40.1 150

575 (543-600) 250 490 1480 365 1100 220 1050 120 760 83.9 570 53.0 398 31.5 260 50.5 189

RB accelerator coil resistance at 68°F in Ω

RT coil section resistance at 68°F in Ω
VN nominal voltage (nominal voltage range)

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 Troubleshooting – Hand Release

 Brake is mechanically locked

- Verify the free play on the release arm
- Adjust the locking nuts to achieve the correct floating clearance

Brake Floating clearance s [mm]

BE05, BE1, BE2, BE5 1.5
BE11, BE20, BE30/32, BE60/62, BE120/122 2

Caution!
There must always be clearance on the lever.
Note: The brake release mechanism is not used to
change the brake’s torque setting.
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 Troubleshooting – Air Gap

 Out of tolerance brake air gap

- Too much air gap and the brake will not release
- Insufficient air gap and the brake will not release

Air-gap

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 Troubleshooting – Air Gap

 Obtain correct value for air gap

Brake type Working air gap – in / [mm]

Look up the correct values in the
- Min. Max.
SEW Motor Operating Instructions
BE05/BE1/BE2 .01 / [0.25] .024 / [0.60]
BE5 .01 / [0.25] .035 / [0.90]
BE11/BE20/BE30/BE60 .012 / [0.30] .047 / [1.20]
BE32/BE62 .016 / [0.40] .047 / [1.20]
BE120 .024 / [0.60] .047 / [1.20]
BE122 .031 / [0.80] .047 / [1.20]

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 Troubleshooting – Air Gap

 Adjustment Method 1
1. Insert feeler gauge (minimum value set) between dampening
plate and coil or between pressure plate and coil
2. Adjust (3) hex nuts until the feeler gauge feels snug equally
around the brake

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 Troubleshooting – Air Gap

 Adjustment Method 2
1. Tighten the three adjustment nuts equally to establish zero air gap
2. Loosen the adjustment nuts equally ½ turn

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 Troubleshooting – Brake Disc

 Brake disc is worn or damaged

- Sliding friction cause carbon based brake disc to wear
- High cycle rates require more frequent disc replacement
- Overheating can cause pressure plate to warp

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 Troubleshooting – Brake Disc

 Check thickness of brake disc

1. Measure the thickness of the brake disc with calipers
2. Replace disc if out of tolerance
3. Reinstall new disc or current disc if within tolerance range

Brake type Thickness in / [mm]

BE05/BE1/BE2/BE5 .354 / [9]
BE11/BE20/BE30/BE32/BE60/BE62 .394 / [10]
BE120/BE122 .473 / [12]

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 Conclusion

This presentation provided a basic overview of SEW Brakes and should

enable you to achieve the following –

1. Describe the purpose of the SEW brake

2. Explain the operation of the SEW brake
3. Identify the components of an SEW brake
4. Apply basic troubleshooting procedures

For more detail information and maintenance of SEW mechanical

products please visit our website at –
http://www.seweurodrive.com/s_training/index.php5

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