Bonfiglioli BXN/MXN Motor Installation and Brake Maintenance Complete Guide

Option B: The brake coil adopts an independent power supply (SA option), and the braking time does not depend on the motor time constant, which is suitable for applications that require precise control of the braking timing.

Option C: Simultaneously disconnect the AC and DC lines to achieve rapid braking (using NBR/SBR rectifiers).

Option D: Independent power supply and simultaneous disconnection of AC and DC to achieve the fastest braking response.

Important reminder: Due to the inductive load of the brake coil, the control contacts must be selected according to the use category of AC-3 (AC) or DC-13 (DC) that complies with IEC 60947-4-1, otherwise the contacts are prone to burning.

3.3 New Series FDD Brakes (for BXN/MXN)

The EVOX series motor adopts the FDD new brake, and its rectifier wiring is more complex, providing NR (standard performance) and SR (fast performance) rectifiers, and supporting multiple voltage combinations (WD1~WD12 configurations). The manual provides a detailed voltage/connection comparison table (such as WD1-50 applicable to 115/200/230/400V, etc.). For frequency converter power supply applications, the brake must use an independent power supply (SA) and ensure that the voltage is consistent with the motor nameplate.

3.4 Anti condensation heater (H1/NH1 options)

If the motor is equipped with an anti condensation heater, its power supply must be independent and must be cut off before the motor runs. This heater is used to prevent winding condensation during shutdown, especially suitable for humid environments.

3.5 Steering confirmation

When connected to the U-V-W terminal in phase sequence L1-L2-L3, it rotates clockwise when viewed from the drive end. Swap any two phases to reverse. For motors equipped with one-way anti reverse devices, the nameplate will clearly indicate the allowed direction and corresponding phase sequence, which must be strictly followed.

Start debugging: final check before loading

Before the first power on, complete the following checks one by one:

Confirm that all safety protection devices are installed in place.

No load power on, check if the rotation direction is consistent with the requirements.

Check if the independent fan (if any) is functioning properly.

Monitor the running sound to ensure no abnormal vibration or friction.

If equipped with a brake, repeatedly tap it several times to confirm that the brake can be properly engaged and released.

If there is excessive current, abnormal temperature rise, abnormal noise or severe vibration, immediately cut off the power and investigate the cause. Do not forcefully operate with load.

Daily maintenance and adjustment of brake air gap

The most critical maintenance item for the brake motor is the regular inspection and adjustment of the brake air gap (T). Excessive air gap can lead to increased braking noise, incomplete release, and in severe cases, a decrease in braking torque; If the air gap is too small, it may cause dragging and overheating.

5.1 FD brake air gap adjustment steps

Loosen the locking nut (ref.2).

Adjust the air gap to the minimum value specified in the table (e.g. Tmin=0.2mm, Tmax=0.5mm for FD02~FD53) by turning the hexagon socket bolt (ref.1) or nut (ref.3).

Secure the bolt and tighten the nut.

Check the empty stroke "X" of the manual release mechanism, which must be greater than the lower limit value in the table (such as X ≥ 0.8mm).

The thickness of the friction plate must always be greater than 1.5mm, otherwise the brake disc needs to be replaced.

5.2 FDD Brake Air Gap Adjustment (New Type)

Loosen the hexagonal socket bolt slightly (ref.1).

Use a wrench to rotate the socket bolt (ref.2) clockwise to increase the air gap and counterclockwise to decrease the air gap (about 1/6 turn to change by 0.15mm).

Adjust to Tmin (0.2 or 0.3mm) and tighten the bolt.

Also check the minimum thickness of X stroke and friction plate (see Table 1 and Table 2 in the manual).

5.3 Routine Maintenance Checklist

Check the operating current and temperature every month.

Clean the fan cover and motor surface every quarter to prevent dust blockage.

Check if the cable entry port and sealing ring are intact.

If there is a condensate drain hole (option), regularly unscrew the screw plug to drain the accumulated water.

Standard bearings require maintenance free grease lubrication, but it is recommended to check or replace the bearings every 3 years of operation.

Quick troubleshooting and spare parts management

When the brake shows slow response, abnormal noise, or insufficient braking force, first check the air gap and friction plate thickness, and then verify whether the rectifier input/output voltage is normal. For fast braking applications, it is essential to use SR series rectifiers to achieve strong excitation and fast shutdown.

Chapter 8 of the manual provides a detailed list of spare parts kits (kits), covering motor flanges, rotors, fans, bearings, brake discs, springs, rectifiers, etc. It is recommended that users pre stock commonly used vulnerable parts (such as brake discs, rectifiers, seals) according to the motor model to reduce downtime waiting time.

Scrapping and environmental disposal