CP 18 Skip Motor Air gap adjusting procedure

Motor Details
Make
Type
IP
Hz

: Bonfiglioli
: 3 BN 132 MA_FD
IMB : 5
: 55
Volt : _ y 400
: 50
A : ( _ y) 16.1 KW : 7.5

Main components in brake assembly

1 Brake hub
2 Stainless steel disc IP55
3 Brake disc
4 D.C. brake type FD
5 Rectifier (Inside the terminal box)
6 Brake release tow (Manual brake release lever)
7 V ring (IP 55)

1 - Brake hub

2 Stainless steel disc IP55

3 - Brake Disc

Brake disc Positions

Projection step in one side

Difference in other side

4 - D.C. brake type FD, Brake coil assembly

6 Brake release tow (Manual brake release lever)

Assembling procedure of brake unit

Step 1 - Ensure the condition of
circlip lock in brake hub

Step 2 - Fix steel disc

(fasteners not required)

Step 3 Fix Brake Disc on Hub

(ensure that the projection step
facing towards cooler fan)

Step 4 Fix brake coil assembly

with manual release lever, Allen
bolts with back nut. Nuts should
kept free while fixing

Shown bolts are spring loaded also for manual release two bolts in addition to
that three more tension springs located inner side of the coil assay (shown in
next slide)
Note: Even tightening is required for all six bolts in 360* circle cycling manner
hence the air gap will become very accurate in all sides. So the tightening of
this six bolts has to be taken care sensitively

Inner spring 3nos

These back nuts requires free while fixing

Step 5 - Even tightening is required for all six bolts in 360* circle cycling
manner hence the air gap will become very accurate in all sides. So the
tightening of this six bolts has to be taken care sensitively

3
5
4
Start tightening from 1 to 6 repeatedly until the reach of required air gap 0.4mm

Step 6 - While tightening of six Allen bolts ensure back side nut in
the allen bolts should not holding in too tight. Unless nuts free air
gap clearance cant be set right, also the manual release bolts
tightness and positions are must be same like shown here.

Air gap needs to measure in

this gap it should be equal in
all areas

Step 7 - Once the right air gap has been set lock the Allen bolt tightness by back side
nuts i.e. tighten all nuts to the gear box side or view from cooler fan tight clockwise
direction

Step 8 - Tight the both side bolts of Manual release lever.

Note : Too tightening of these bolts results poor release. Check the braking
release manually during tighten of those bolts.

Step 9 - Insert the V ring (IP 55) before fixing the cooler fan. Start the plant check the
brake alone by giving 440V supply to the rectifier and remove the skip motor
incoming lines

7 V ring (IP 55)

Step 10 - Its necessary to measure the motor load during operation. After one
hour operation again check the air gap and lock nuts tightening, also check
manual release function. Fix the dust cover rubber ring

Dismantling is Vice Versa after removing the coil wire

Details of Air Gap for FD and FDR Brakes, Braking torque, Brake
timings and brake voltage from Bonfiglioli
BRAKE
DESC

MOTOR SIZES
4 POLE MOTORS

Minimum
AIR
GAP

Maximum
AIR GAP

MANUAL
LEVER
PLAY(only
for brake
with release
lever)

No: of
springs

torque
NM

torque
NM

No: of
springs

No: of
Springs

Braking
Time in
Milli
seconds

Rectifier
Brake
Release time

torque
NM

t2

t2
c

NB
(ms)

SB
(ms)

FD 02

BN 63

0.20mm

0.40mm

0.60mm

3.5

1.75

65

30

15

FD 03

BN 71

0.20mm

0.40mm

0.60mm

3.5

1.75

80

12

50

20

FD 53

BN 71

0.20mm

0.40mm

0.80mm

7.5

2.5

80

12

60

30

FD 04

BN 80

0.30mm

0.45mm

1.00mm

15

10

120

16

80

35

FD 14

BN 90

0.30mm

0.45mm

1.00mm

15

10

120

16

80

35

FD 05

BN 90

0.30mm

0.45mm

1.00mm

40

26

13

170

21

150

65

FD 15

BN 100

0.30mm

0.45mm

1.00mm

40

26

13

170

21

150

65

FD 55

BN 100

0.30mm

0.45mm

1.00mm

55

37

18

170

23

65

FD 06 S

BN 112

0.40mm

0.55mm

1.20mm

60

40

20

180

23

70

FD 56

BN 132

0.40mm

0.55mm

1.20mm

75

37

190

19

90

FD 06

BN 132

0.40mm

0.55mm

1.20mm

100

50

170

26

100

FD 07

BN 132

0.40mm

0.60mm

1.20mm

150

100

50

250

38

120

FD 08

BN 160

0.50mm

0.70mm

1.30mm

250

200

170

350

50

140

9springs

7springs

6springs

Notes from Bonfiglioli:

t2 = brake supply as drawing no: C20 and C21 in BN catalogue page no:18
t2c = brake supply as drawing no: C22 and C23 in BN catalogue page no:18

The air gap value must be checked periodically and the value must be between the
min and max.
Airgap higher than the max value may prevent from braking and increase the brake
noise.
Excessive air gap may affect the brake torque.
Always it is better to the set the air gap in MIN value for effective braking.
If the brake coil is for 100 volt DC, the AC volt to rectifier should be 230 volt AC.( for
sizes BN63 TO BN132 )
If the brake coil is for 180 volt DC, the AC volt to rectifier should be 440 volt AC.( for
size BN160 )
The voltage to the rectifier is always mentioned in the motor name plate.
The brake torque and the type of rectifier is always mentioned in the motor name
plate.
The SB rectifiers are used in high number of start and stops and short brake
release time.
Separate power supply to be given in case of 24 VOLT brake coil