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KTR-Group KTR-STOP XS F B Series Operating & Assembly Instructions

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XS-xx-F B-xx is a spring-actuated brake in a floating calliper design serving to
generate a brake force on a brake disk in order to decelerate a plant's movement
or stop it, respectively, or keep it at standstill.
Please observe protection
note ISO 16016.
KTR-STOP
Operating/Assembly instructions
KTR-STOP
Drawn:
2020-03-26 Shg/Wie
Verified:
2020-03-26 Shg
®
XS-xx-F B-xx
®
XS-xx-F B-xx
Replacing:
Replaced by:
KTR-N
44536 EN
Sheet:
1 of 25
Edition:
3
KTR-N dated 2017-12-19

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Summary of Contents for KTR-Group KTR-STOP XS F B Series

  • Page 1 KTR-N 44536 EN ® KTR-STOP XS-xx-F B-xx Sheet: 1 of 25 Operating/Assembly instructions Edition: ® KTR-STOP XS-xx-F B-xx XS-xx-F B-xx is a spring-actuated brake in a floating calliper design serving to generate a brake force on a brake disk in order to decelerate a plant’s movement or stop it, respectively, or keep it at standstill.

  • Page 2: Table Of Contents

    KTR-N 44536 EN ® KTR-STOP XS-xx-F B-xx Sheet: 2 of 25 Operating/Assembly instructions Edition: The KTR brake system was designed to operate as a service brake/emergency stop brake on rotating brake disks. For any other applications please consult with KTR. Table of contents Technical data Advice...

  • Page 3: Technical Data

    KTR-N 44536 EN ® KTR-STOP XS-xx-F B-xx Sheet: 3 of 25 Operating/Assembly instructions Edition: Technical data Illustration 1: Dimensional drawing Table 1: Technical data XS-xx-F B-xx Weight [kg] Approx. 19 Width of brake pad [mm] organic 8000 Surface of each brake pad Powder metal 5800 Max.
  • Page 4 KTR-N 44536 EN ® KTR-STOP XS-xx-F B-xx Sheet: 4 of 25 Operating/Assembly instructions Edition: Technical data Table 2: Clamping force, loss of preload force, opening pressure and weight Braking torque [Nm] with Clamping force Loss of power Opening Brake type brake disk Ø...

  • Page 5: Advice

    KTR-N 44536 EN ® KTR-STOP XS-xx-F B-xx Sheet: 5 of 25 Operating/Assembly instructions Edition: Technical data Connection dimensions of brake Illustration 3: Connection dimensions Advice 2.1 General advice Please read through these operating/assembly instructions carefully before you start up the brake. Please pay special attention to the safety instructions! The operating/assembly instructions are part of your product.

  • Page 6: General Hazard Warnings

    KTR-N 44536 EN ® KTR-STOP XS-xx-F B-xx Sheet: 6 of 25 Operating/Assembly instructions Edition: Advice 2.3 General hazard warnings With assembly, operation and maintenance of the brake it has to be made sure that the STOP entire drive train is secured against accidental switch-on. You may be seriously hurt by rotating parts.

  • Page 7: Assembly

    KTR-N 44536 EN ® KTR-STOP XS-xx-F B-xx Sheet: 7 of 25 Operating/Assembly instructions Edition: Assembly The brake is supplied in pre-assembled condition. Before assembly the brake has to be inspected for completeness.  The brake is generally supplied with the transport lock mounted. The screw plug (component 1.9) is attached to the brake in bulk.
  • Page 8 KTR-N 44536 EN ® KTR-STOP XS-xx-F B-xx Sheet: 8 of 25 Operating/Assembly instructions Edition: Assembly 4.1 Components of the brake Component assembly 3: Base plate with guide pin Component Quantity Description Base plate Guide pin Illustration 6: Base plate with guide pin Component assembly 4: Centering system Component Quantity...

  • Page 9: Preparation Of Assembly

    KTR-N 44536 EN ® KTR-STOP XS-xx-F B-xx Sheet: 9 of 25 Operating/Assembly instructions Edition: Assembly 4.1 Components of the brake Component assembly 8: Pad retraction set for housing Component Quantity Description Pressure spring Illustration 8: Pad retraction set for housing 4.2 Preparation of assembly ...

  • Page 10: Brake Pads

    KTR-N 44536 EN ® KTR-STOP XS-xx-F B-xx Sheet: 10 of 25 Operating/Assembly instructions Edition: Assembly 4.3 Brake pads  KTR supplies brake pads free from asbestos and lead only. If requested, we will provide you with the respective certificates. The brake pads are each adapted to the application and delivered accordingly. They can be distinguished as follows: •...
  • Page 11 KTR-N 44536 EN ® KTR-STOP XS-xx-F B-xx Sheet: 11 of 25 Operating/Assembly instructions Edition: Assembly 4.4 Assembly of the brake  Secure the screw connection (component 8.1) on the brake pad additionally against working loose, e. g. conglutinating with Loctite (average strength). •...

  • Page 12: Setting/Resetting Of The Centering System

    KTR-N 44536 EN ® KTR-STOP XS-xx-F B-xx Sheet: 12 of 25 Operating/Assembly instructions Edition: Assembly 4.5 Setting/resetting of the centering system  The centering system needs to be reset with initial assembly or after having replaced brake pads or single parts, respectively. Only in this way it is ensured that the gap between the brake disk and the brake pad on the bottom side is set to the right value and the pad does not touch on any side.

  • Page 13: Pressure Port Of A Brake

    KTR-N 44536 EN ® KTR-STOP XS-xx-F B-xx Sheet: 13 of 25 Operating/Assembly instructions Edition: Assembly 4.6 Pressure port of a brake • Connect the pressure oil line to one of the pressure ports of the brake (see illustration 12 and 13). For that purpose remove the screw plug beforehand.

  • Page 14: Pressure Port Of Several Brakes

    KTR-N 44536 EN ® KTR-STOP XS-xx-F B-xx Sheet: 14 of 25 Operating/Assembly instructions Edition: Assembly 4.7 Pressure port of several brakes  If several brakes are assembled we recommend to connect the pressure port for each brake individually (in parallel) (see illustration 14). Please note, if several brakes are connected in a series (see illustration 15), the braking effect of all following brakes may become effective slightly delayed.

  • Page 15: Start-Up Of The Brake

    KTR-N 44536 EN ® KTR-STOP XS-xx-F B-xx Sheet: 15 of 25 Operating/Assembly instructions Edition: Assembly 4.8 Start-up of the brake  Before start-up and after each operation on the brake the hydraulic system has to be generally vented. Repeat bleeding the brake several times a year, since any air in the hydraulic system may affect the operation of the brake and the plant.

  • Page 16: Setting/Resetting Of The Brake

    KTR-N 44536 EN ® KTR-STOP XS-xx-F B-xx Sheet: 16 of 25 Operating/Assembly instructions Edition: Assembly 4.9 Setting/Resetting of the brake  The brake needs to be set with the initial assembly or after having replaced the brake pads or single parts, respectively. Only in this way it is ensured that the brake has the clamping force specified.

  • Page 17: Recommendation Of Fluids To Be Used

    KTR-N 44536 EN ® KTR-STOP XS-xx-F B-xx Sheet: 17 of 25 Operating/Assembly instructions Edition: Assembly 4.10 Recommendation of fluids to be used You may only use mineral hydraulic fluids meeting the demands of DIN 51524. KTR recommends those fluids corresponding to DIN 51524-3. KTR recommends the following fluids (other manufacturers may be selected): Manufacturer Standard...

  • Page 18: Disassembly Of The Brake

    KTR-N 44536 EN ® KTR-STOP XS-xx-F B-xx Sheet: 18 of 25 Operating/Assembly instructions Edition: Assembly 4.11 Disassembly of the brake In order to avoid any personal injuries, protect the brake by means of the assembly lock. STOP • Remove the screw plug (component 1.9) or the sensor (component 9) from the setting nut (component 1.7). •...

  • Page 19: Disposal

    KTR-N 44536 EN ® KTR-STOP XS-xx-F B-xx Sheet: 19 of 25 Operating/Assembly instructions Edition: Assembly 4.13 Disposal In respect of environmental protection we would ask you to dispose of the products on termination of their service life in accordance with the legal regulations and standards that apply, respectively. •...

  • Page 20: Maintenance Of The Brake / Replacement Of Single Parts

    KTR-N 44536 EN ® KTR-STOP XS-xx-F B-xx Sheet: 20 of 25 Operating/Assembly instructions Edition: Maintenance 5.1 Replacement of brake pads • Secure the brake pad on the fixed side via the spring clamps (component 6) and the cap screws (component 7). •...
  • Page 21 KTR-N 44536 EN ® KTR-STOP XS-xx-F B-xx Sheet: 21 of 25 Operating/Assembly instructions Edition: Maintenance 5.2 Maintenance of the brake / replacement of single parts • Remove the O-ring (component 1.8). • Put the opening pressure (see table 2) onto the hydraulic system. •...
  • Page 22 KTR-N 44536 EN ® KTR-STOP XS-xx-F B-xx Sheet: 22 of 25 Operating/Assembly instructions Edition: Maintenance 5.2 Maintenance of the brake / replacement of single parts Illustration 20: Assembly of gasket and scraper Illustration 21 Inspect the surfaces of the brake piston and the hole of the housing to make sure that they are neither scratched nor damaged, since the surfaces are either ground or polished.

  • Page 23: Maintenance And Service

    KTR-N 44536 EN ® KTR-STOP XS-xx-F B-xx Sheet: 23 of 25 Operating/Assembly instructions Edition: Maintenance 5.2 Maintenance of the brake / replacement of single parts • Set the gap between brake disk and brake pad to 0.5 mm or the requested value x (see illustration 22) by screwing the hexagon nut marked with 1 in illustration 23 upwards or downwards.

  • Page 24: Accessories - Sensor

    KTR-N 44536 EN ® KTR-STOP XS-xx-F B-xx Sheet: 24 of 25 Operating/Assembly instructions Edition: Accessories - Sensor 6.1 Technical Data „State/wear sensor“ Operation of sensor There are two micro switches in the housing of the sensor. The distance pin activates the switches in two different positions.

  • Page 25: Assembly / Start-Up

    KTR-N 44536 EN ® KTR-STOP XS-xx-F B-xx Sheet: 25 of 25 Operating/Assembly instructions Edition: Accessories - Sensor 6.1 Technical Data „State/wear sensor“ Technical data: Operating temperature - 40 °C to + 85 °C Max. voltage 30 V DC/AC Switching current 100 mA Protection class IP 65 (mounted)

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