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KTR-Group KTR-STOP XS A Series Operating & Assembly Instructions

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XS-xx A-xx-xx is a spring-actuated brake in a fixed calliper design serving to ge-
nerate a brake force onto 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:
2020-04-09 Shg/Wie
Verified:
2020-08-11 Shg
®
XS-xx A-xx-xx
®
XS-xx A-xx-xx
Replacing:
Replaced by:
KTR-N
45126 EN
Sheet:
1 of 22
Edition:
1
---

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Summary of Contents for KTR-Group KTR-STOP XS A Series

  • Page 1 KTR-N 45126 EN ® KTR-STOP XS-xx A-xx-xx Sheet: 1 of 22 Operating/Assembly instructions Edition: ® KTR-STOP XS-xx A-xx-xx XS-xx A-xx-xx is a spring-actuated brake in a fixed calliper design serving to ge- nerate a brake force onto 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 45126 EN ® KTR-STOP XS-xx A-xx-xx Sheet: 2 of 22 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 45126 EN ® KTR-STOP XS-xx A-xx-xx Sheet: 3 of 22 Operating/Assembly instructions Edition: Technical data Illustration 1: Dimen- sional drawing Table 1: Technical data XS-xx A-xx-xx Weight [kg] Approx. 20 Width of brake pad [mm] organic 8,000 Surface of each brake pad powder 5,800 metal...
  • Page 4 KTR-N 45126 EN ® KTR-STOP XS-xx A-xx-xx Sheet: 4 of 22 Operating/Assembly instructions Edition: Technical data Table 2: Clamping force, loss of preload force and opening pressure Braking torque [Nm] with Clamping Loss of power Opening pres- Brake type force brake disk Ø...

  • Page 5: Advice

    KTR-N 45126 EN ® KTR-STOP XS-xx A-xx-xx Sheet: 5 of 22 Operating/Assembly instructions Edition: Advice 2.1 General advice Please read carefully through these operating/assembly instructions before you start up the brake. Please pay special attention to the safety instructions! The operating/assembly instructions are part of your product. Please store them carefully. The copyright for these operating/assembly instructions remains with KTR.

  • Page 6: Storage, Transport And Packaging

    KTR-N 45126 EN ® KTR-STOP XS-xx A-xx-xx Sheet: 6 of 22 Operating/Assembly instructions Edition: Storage, transport and packaging 3.1 Storage The brake is delivered in preserved condition and can be stored in a closed, dry place during 12 months. With favourable storage conditions its properties remain unchanged for up to 12 months. If the brake is stored over a longer period exceeding 12 months as well as after each transport the corrosion pro- tection needs to be renewed and the brake has to be activated over the full braking distance in order to prevent the gaskets from sticking together.

  • Page 7: Components Of The Brake

    KTR-N 45126 EN ® KTR-STOP XS-xx A-xx-xx Sheet: 7 of 22 Operating/Assembly instructions Edition: Assembly 4.1 Components of the brake Components/subassemblies of brake – Type XS-xx A-xx-xx Compo- nent/suba Quantity Description ssembly Housing with components Pad retraction set Brake pad Sensor 1) Optionally available Illustration 3: Components/subassemblies of brake...

  • Page 8: Preparation Of Assembly

    KTR-N 45126 EN ® KTR-STOP XS-xx A-xx-xx Sheet: 8 of 22 Operating/Assembly instructions Edition: Assembly 4.1 Components of the brake Subassembly 2: Pad retraction sets Compo- Quantity Description nent Pressure spring Disk Illustration 5: Pad retraction set 4.2 Preparation of assembly ...

  • Page 9: Assembly Of The Brake

    KTR-N 45126 EN ® KTR-STOP XS-xx A-xx-xx Sheet: 9 of 22 Operating/Assembly instructions Edition: Assembly 4.4 Assembly of the brake If one half of the brake has to be mounted under pressure (without transport lock) for reasons of space, please consult with KTR. In order to avoid any injuries please always make use of proper lifting equipment.

  • Page 10: Pressure Port Of A Brake

    KTR-N 45126 EN ® KTR-STOP XS-xx A-xx-xx Sheet: 10 of 22 Operating/Assembly instructions Edition: Assembly 4.4 Assembly of the brake • Repeat this process withthe second half of brake.  To facilitate the assembly it is possible to fix the position of the brake by one connection screw only first.
  • Page 11 KTR-N 45126 EN ® KTR-STOP XS-xx A-xx-xx Sheet: 11 of 22 Operating/Assembly instructions Edition: Assembly 4.5 Pressure port of a brake • Connect the drain line to the brake (see illustration 7 and 8). For that purpose remove the sealing plugs befo- rehand.

  • Page 12: Pressure Port Of Several Brakes

    KTR-N 45126 EN ® KTR-STOP XS-xx A-xx-xx Sheet: 12 of 22 Operating/Assembly instructions Edition: Assembly 4.6 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 9). Please note, if several brakes are connected in a series (see illustration 10), the braking effect of all following brakes may set in slightly delayed.

  • Page 13: Start-Up Of The Brake

    KTR-N 45126 EN ® KTR-STOP XS-xx A-xx-xx Sheet: 13 of 22 Operating/Assembly instructions Edition: Assembly 4.6 Pressure port of several brakes Severe leakages have to be removed immediately. Oil which has escaped has to be comple- tely removed, since oil remains may vaporize on hot components and ignite. ...

  • Page 14: Setting/Re-Setting Of The Brake

    KTR-N 45126 EN ® KTR-STOP XS-xx A-xx-xx Sheet: 14 of 22 Operating/Assembly instructions Edition: Assembly 4.7 Start-up of the brake • Remove the screw with the disk (assembly lock, see illustration 11) on both sides from the from the brake piston (component 1.5).

  • Page 15: Recommendation Of Liquids To Be Used

    KTR-N 45126 EN ® KTR-STOP XS-xx A-xx-xx Sheet: 15 of 22 Operating/Assembly instructions Edition: Assembly 4.8 Setting/Re-setting of the brake • Screw the screw with the disk (assembly lock, see illustration 11) on both sides into the brake piston (component 1.5). •...

  • Page 16: Disassembly Of The Brake

    KTR-N 45126 EN ® KTR-STOP XS-xx A-xx-xx Sheet: 16 of 22 Operating/Assembly instructions Edition: Assembly 4.9 Recommendation of liquids to be used As a standard the KTR basic power packs are equipped with a 10 µm inline filter. In order to ensure the reliability of the system, only those oils originating from the following purity class are permit- ted: •...

  • Page 17: Spares Inventory, Customer Service Addresses

    KTR-N 45126 EN ® KTR-STOP XS-xx A-xx-xx Sheet: 17 of 22 Operating/Assembly instructions Edition: Assembly 4.11 Spares inventory, customer service addresses A basic requirement to ensure the readiness for use of the brake is a stock of the most important spare parts on site.

  • Page 18: Maintenance Of The Brake / Replacement Of Single Parts

    KTR-N 45126 EN ® KTR-STOP XS-xx A-xx-xx Sheet: 18 of 22 Operating/Assembly instructions Edition: Maintenance 5.1 Replacement of brake pads • Inspect the position of the setting nut (component 1.7) on both sides. If necessary, set it to the right dimension (see illustration 12).
  • Page 19 KTR-N 45126 EN ® KTR-STOP XS-xx A-xx-xx Sheet: 19 of 22 Operating/Assembly instructions Edition: Maintenance 5.2 Maintenance of the brake / replacement of single parts • Remove the O-ring (component 1.8) on both sides. • Put the opening pressure (see table 2) on the hydraulic system. •...

  • Page 20: Maintenance And Service

    KTR-N 45126 EN ® KTR-STOP XS-xx A-xx-xx Sheet: 20 of 22 Operating/Assembly instructions Edition: Maintenance 5.2 Maintenance of the brake / replacement of single parts Oils and greases containing molybdenum disulphite or zinc sulphite additives must not be used. Illustration 15: Assembly of gasket and scraper Illustration 16 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 21: Technical Data „State/Wear Sensor

    KTR-N 45126 EN ® KTR-STOP XS-xx A-xx-xx Sheet: 21 of 22 Operating/Assembly instructions Edition: 6.1 Technical Data „State/wear sensor“ Operation of sensor There are two micro switches in the housing of the sensor. The spacer pin activates the switches in two different positions.

  • Page 22: Assembly / Start-Up

    KTR-N 45126 EN ® KTR-STOP XS-xx A-xx-xx Sheet: 22 of 22 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) Width across flats...

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