Brake module

BGL-PE400/150/3
EGL-PE400/150/5

Assembly and operating instructions

Number: A08 099 100 - 956

Creation code: 249
Date of issue: 11.05.2005
Modification status: A/4-Vaj05006
No. of pages: 13
Revised 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 instructions Number: A08 099 100 - 956
Brake module Date of issue: 11.05.2005

List of contents

1 General information ………………………………………………….……………….4

2 These operating instructions..............................................................................4
3 General product information…………………………………………………..........4
4 General safety information........……………………………………………………..5
5 Mechanical structure.…………………………………………………………………6
6 Correct use……………………………………………………………………………...6
7 Use of the brake module in parallel operation of brakes……………….………8
8 Assembly……………………………………………………………………………...11
9 Typical applications..........………………………………………….……………….11
10 Incorrect use…………………………………………………………………………..11
11 Technical data....……………………………………………………………………...12

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Drive Engineering
Operating instructions Number: A08 099 100 - 956
Brake module Date of issue: 11.05.2005

Notes on these assembly and operating instructions

Instruction obligation

These operating instructions must be read carefully by persons working with or on the
brake module BGL-PE400/150/3 and EGL-PE400/150/5 before the BGL-PE400/150/3
and EGL-PE400/150/5 are assembled and used for the first time.
The user or operator of this device is under obligation to make these operating
instructions available in full to all persons using, maintaining or carrying out any other
work on this device.
These operating instructions form an integral part of the brake module BGL-
PE400/150/3 or EGL-PE400/150/5

Validity

These operating instructions are in accordance with the technical state of the art of the
brake module BGL-PE400/150/3 or EGL-PE400/150/5 at the time of issue. The
contents do not constitute part of the contract but serve as information.
Pintsch Bamag reserves the right to amend the contents and carry out technical
modifications with regard to the details set out in these operating instructions without
prior notification. Pintsch Bamag cannot be held liable for any inaccuracies or
inappropriate information contained in these operating instructions as there is no
obligation to constantly update these operating instructions.

Loss of guarantee

Our deliveries and services are based on our general conditions of sale (AVB) for
deliveries and services. However, we reserve the right to amend the details in these
operating instructions, in particular the technical data, operation, the dimensions and
weights. Complaints about delivered goods must be submitted within two weeks of
receipt of the goods accompanied by the delivery note. Subsequent complaints cannot
be taken into consideration. Opening the housing or damaging the inspection seal result
in immediate loss of guarantee.

Use

These operating instructions for the brake module BGL-PE400/150/3 or EGL-

PE400/150/3 have been drawn up so that all the working stages required for assembly,
operation and maintenance are described and can be carried out by trained electro-
technical specialist personnel. The safety instructions must be observed.

Service

Our service information department is at your disposal in the even of any questions
relating to the assembly, operation and maintenance of the brake module BGL-
PE400/150/3 or EGL-PE400/150/5.The contact numbers and address are set out on the
last page.

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Drive Engineering
Operating instructions Number: A08 099 100 - 956
Brake module Date of issue: 11.05.2005

1 General points
These operating instructions apply to the following products:
Brake module BGL-PE400/150/3 PB-No.:008 099 100 – 249
EGL-PE400/150/5 PB-No.:008 099 101 – 249

2 These operating instructions...

... ... explain the procedures for operating the brake modules and contain information on
safe

• Installation
• Commissioning
• Maintenance

The safety information for using the brake modules is summarised in a separate
chapter.

These instructions should be read prior to installation of the brake modules. Familiarise
yourself with the operation of the brake modules and carefully observe the safety
regulations

… address :
• Workshop fitters
• Maintenance personnel
• Operators

… use the following symbols:

∆ Safety information is emphasised by a light triangle
• indicates lists
- stands for working steps to be carried out 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 reduce the arc occurring during the disconnection process
• 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 AC 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 AC input voltage.

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Drive Engineering
Operating instructions Number: A08 099 100 - 956
Brake module Date of issue: 11.05.2005

4 General safety information

The safety information provided here is of a general nature. Special safety
information is provided at the start of a chapter or appropriate point in the
text. All safety information should be observed in order to prevent accidents
and damage to the BCU 2001.
The safety requirements must also be observed under pressure. Accidents cannot be
reversed.

∆ Do not act negligently

Any actions that affect the safety of the brake module are forbidden.

∆ Only qualified electricians

Only qualified electricians may connect and test the functions of the brake module
BCU observing all safety measures.

∆ Use undamaged devices

Devices which exhibit visible damage must not be used.

∆ Isolate
Disconnection from the supply must be ensured before carrying out any work on the
electrical system.

When disconnecting a cable carrying brake current, a dangerous voltage can occur
on account of the high coil inductance, even with a low rated coil voltage (24V)!

∆ Do not switch on

Before connecting the brake module, the power supply must be

disconnected.

 Place “Do not switch on” sign at the switching points.

 Establish electrical connection.
 Remove sign.

∆ Passing on of documents
If the Brake module is transferred to others, these operating instructions must be
passed on to the recipient.

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Drive Engineering
Operating instructions Number: A08 099 100 - 956
Brake module Date of issue: 11.05.2005

∆ Do not open device

The device must not be opened. For this purpose, the device is provided with a seal
that is damaged if an attempt is made to open the device. The seal cannot be
removed without being damaged. If the seal is damaged, all claims against the
manufacturer will cease to apply

Fig. 1: Quality seal

The quality seal can be in various colours. The colour is of no significance to the user.

∆ Abnormal device behaviour

Devices that operate abnormally must be switched off and replaced.

5 Mechanical structure
The electronic circuitry is accommodated in a 22.5 mm narrow plastic housing for fixing
to mounting rails with an overall length of about 80 mm and a height of about 80 mm.
The terminals are screw-type terminals and are located on the top and bottom. The
terminals are able to accept wire cross-sections of 0.25-2.5mm2. The circuit diagram is
printed on the left-hand side of the housing.

6 Correct use

After disconnecting the supply voltage the coil current does not stop flowing abruptly.
The coil inductivity continues to drive the coil current with the build-up of a
correspondingly high countervoltage.
Therefore, in addition to the rectification function of the input alternating voltage, the
brake modules are also provided with an integrated protection element.
By way of the protective circuits (fig. 2) and (fig. 3), countervoltages occurring during the
disconnection process are limited in a defined manner and the arc is suppressed at the
contactor.

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Drive Engineering
Operating instructions Number: A08 099 100 - 956
Brake module Date of issue: 11.05.2005

Principal circuit diagrams:

Fig 2: Principal circuit diagram BGL-PE400/150/3 when switching with three-phase current contactor

Fig 3: Principal circuit diagram EGL-400/150/5 when switching with three-phase current contactor

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Drive Engineering
Operating instructions Number: A08 099 100 - 956
Brake module Date of issue: 11.05.2005

Figs. 2 and 3 show the principle of switching the brake modules from the alternating
current network for the BGL- and EGL-versions and this must be observed accordingly.
As switching can take place simultaneously on the alternating and direct current side, a
more cost-effective three-phase current contactor can be used for switching the brake
instead of the direct current contactor.

For choosing the right three-phase current contactor is the following

criterion to attend. The contactors have to be able to switch the 2,5
times DC-brake current. Otherwise, as a result of the arc effect at the
protective contactor, rapid ageing occurs which eventually leads to
destruction.

7 Use of the brake module in the parallel operation of brakes

In contrast to disconnecting one brake, when disconnecting several brakes a greater

current flows and the disconnection output is greater (fig. 4). The higher current and
higher disconnection power bring about an arc of great intensity and effect duration
which results in more rapid wear of the protective contactor. Suppression of the arc
occurring at the protective contactor during the disconnection process is achieved by
means of an integrated capacitor.

In the case of parallel operation of several brakes with the brake

module it must be ensured that the maximum permitted coil current
and the maximum permitted continuous output (see section 11) are
not exceeded.

The maximum continuous output of the parallel connection results from the number of
brakes and the required switching frequency. The maximum continuous output can be
calculated using the following formula. With regard to the Pintsch Bamag brake series
KFB and SFB, the values for the disconnection energy are set out in table 1. It should
be noted that in the parallel connection of brakes the individual disconnection energies
of each brake are added to each other.

n/h . E
Formula for calculating the max. continuous output : P=
3600

n/h: max. number of brake switchings per hour

P: max. continuous output of the parallel connection in in [W]
E: total disconnection energy of all brakes in [J]

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Drive Engineering
Operating instructions Number: A08 099 100 - 956
Brake module Date of issue: 11.05.2005

Fig 4: Parallel operation of several brakes with brake module

Page: 9 of 13
Drive Engineering
Operating instructions Number: A08 099 100 - 956
Brake module Date of issue: 11.05.2005

Table 1 shows an overview of the disconnection energies in relation to the Pintsch

Bamag brake series SFB und KFB.
Disconnection energy
Brake type
of one brake [J]

SFB 6.3 6.9

SFB 10 12.5

SFB 16 15.5

SFB 25 21.9

SFB 40 24.4

SFB 63 35.3

SFB 100 46

SFB 160 65.9

SFB 250 88.3

SFB 400 112

SFB 630 143

SFB 1000 271

KFB 10 10.6

KFB 16 12.5

KFB 25 15.5

KFB 30 28.1

KFB 40 22

KFB 63 24.6

KFB 100 65

KFB 160 75

Table 1

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Drive Engineering
Operating instructions Number: A08 099 100 - 956
Brake module Date of issue: 11.05.2005

8 Assembly
The circuit diagram of the brake module is printed on the side of the housing.
- The brake module must be installed in a control cabinet or similar on NS 35
mounting rails according to EN 50022 in such a way that the connection terminal 1 is
at the top
The mounting rail must be earthed in compliance with the locally applicable
regulations.
- For wiring the brake circuit, cables with a voltage strength of at least 700V must be
used, even when the braking voltage is only 24V.
- The cable cross-section must match the brake current.
- The terminals must be tightened with 0.4 Nm.

9 Typical applications

• Container crane systems

• Ships’ winches
• Automatic stacking shelves
• Conveyor belts
• General electrical drive systems

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

10 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 low, medium or high-voltage energy distribution switchgear
• Operation of mechanically damaged equipment
• Operation of open equipment
• Operation in rooms where there is electrically conductive dust
• The series connection of two or more brake modules

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Drive Engineering
Operating instructions Number: A08 099 100 - 956
Brake module Date of issue: 11.05.2005

11 Technical data

Terminal dimensions Length = approx. 80 mm

Height = approx. 80 mm (incl. mouting rail)
Width = approx 22.5 mm ( incl. cover plate)

BGL-PE400/150/3

Max. voltage of the supplying AC 460V – 50/60Hz

alternating current network
.
Brake coil voltage 0.9 Urms
(coil voltage)

Permissible coil rated voltage DC 24V…390V

Max. coil current 2.5A

Max. energy absorption of one disconnection 150J

Max. continuous output of the internal 3W

protective circuit (mean value)

Disconnection peak at max. coil current ≤450V

Ambient temperature -40°C…. +50°C

Protection type IP 20

EGL-PE/400/150/5

Max. voltage of the supplying AC 460V – 50/60Hz

alternating current network
.
Brake coil voltage 0.45 Urms
(coil voltage)

Permissible coil rated voltage DC 24V…220V

Max. coil current 5A

Max. energy absorption of one disconnection 150J

Max. continuous output of the internal 5W

protective circuit (mean value)

Disconnection peak at max. coil current ≤450V

Ambient temperature -40°C…. +50°C

Protection type IP 20

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Drive Engineering
Operating instructions Number: A08 099 100 - 956
Brake module Date of issue: 11.05.2005

Note:
Polarity must be observed. The built-in inverse diode only permits current flow
when disconnecting the coil.
Further technical data is set out in the data sheet.

Contakt: Pintsch Bamag

Antriebs- und Verkehrstechnik GmbH
Postfach 10 04 20
D-46524 Dinslaken
Telephone: +49(0) 20 64 602- 242
246
305
Fax: +49(0) 20 64 602-283
Internet: http://www.pintschbamag.de

Copyright

The passing on, reproduction and/or taking over of these operating instructions, even in the form of
excerpts, require the express prior written permission of Pintsch Bamag.

© Copyright Fa. Pintsch Bamag.

All rights reserved.

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Drive Engineering