1. Manuals
  2. Brands
  3. KEB Manuals
  4. Spring Applied Brakes
  5. COMBISTOP 38
  6. Instruction manual

KEB COMBISTOP 38 Instruction Manual

Load brake size 9
Hide thumbs Also See for COMBISTOP 38:
Table of Contents

Advertisement

Quick Links

Download this manual
COMBISTOP type 38
Instruction Manual | Load Brake Size 9
Original Manual
Load Brake Size 9
Document 20139598 000 01
Material No. 0938TUM-K001

Advertisement

Table of Contents
loading

Related Manuals for KEB COMBISTOP 38

Summary of Contents for KEB COMBISTOP 38

  • Page 1 COMBISTOP type 38 Instruction Manual | Load Brake Size 9 Original Manual Load Brake Size 9 Document 20139598 000 01 Material No. 0938TUM-K001...
  • Page 2 2021 KEB America, Inc. ©...

  • Page 3: Preface

    The hardware and software described in this document are products of KEB America, Inc. The information contained in this document is valid at the time of publishing. KEB reserves the right to update this document in response to misprints, mistakes or technical changes.

  • Page 4: Laws And Requirements

    → Further information is provided in Appendix 1: Certification. 1.4 Warranty KEB Automation KG provides a limited warranty on all products. This warranty can be found in the terms and conditions at our website. KEB America, Inc. Terms and Conditions Terms and Conditions Further agreements or specifications require written confirmation from KEB America, Inc.

  • Page 5: Table Of Contents

    Scope of this Manual ..................16 Description ..................... 17 3.2.1 Brake Components ....................... 17 3.2.2 Brake Assembly Numbering Scheme ................. 18 Brake Specifications ..................20 4 Installation ..................21 Required Tools ....................21 Unpacking the Brake ..................22 2021 KEB America, Inc. ©...
  • Page 6 Example Wiring Diagrams ................38 7.1.1 AC Side Switching......................... 38 7.1.2 DC Side Switching......................... 40 7.1.3 OEX Switch Wiring Diagrams ....................42 8 Appendix .................... 44 Appendix 1: Certification ................44 9 Revision History ................45 2021 KEB America, Inc. ©...

  • Page 7: List Of Figures

    Phase to Phase ............................41 Figure 27 OEX Wiring AC Side Switching - Independent Contactor Switching - Phase to Phase ..... 42 Figure 28 OEX Wiring DC Side Switching - Independent Contactor Switching - Phase to Phase ..... 43 2021 KEB America, Inc. ©...

  • Page 8: List Of Tables

    Table 1 Part Numbers ..........................19 Table 2 Coil Specifications .......................... 20 Table 3 Resistance Ranges ........................20 Table 4 Optional Accessories ........................30 Table 5 Hand Release Components ......................30 Table 6 Microswitch Components ....................... 33 2021 KEB America, Inc. ©...

  • Page 9: Glossary

    If the air gap is too narrow, the brake may drag continuously. Application The machine/system in which the KEB device is to be used. For brakes the application is typically the motor to which the brake is attached.
  • Page 10 An external flat rim or ridge for attaching an external object to the device. KEB Automation KG Parent company of KEB America, Inc. Also referred to as KEB. Machine Manufacturer The manufacturer of the application in which the COMBISTOP brake is installed. Not KEB America, Inc.

  • Page 11: Standards For Combistop Type 38 Load Brake

    OSHA 1910.137 • Region: US Personal safety code detailing appropriate personal protective equipment for working on electrical installations. • OSHA 1910.269 Region: US Occupational safety code detailing safety standards for electrical power generation, transmission, and distribution. 2021 KEB America, Inc. ©...

  • Page 12: Safety Instructions

    The following safety instructions have been created by KEB America, Inc. for the Load Brake. These instructions can be supplemented by local, country- or application-specific safety instructions where relevant.

  • Page 13: Specified Application

    • to operation. Never use the brake in potentially explosive environments. • • The brake may not be modified or altered in any way not intended by KEB America, Inc. 2.4 Electrical Safety Guidelines DANGER Rick of electrical shock!  Turn off the power supply and secure it against switching on prior to any work on the device.

  • Page 14: Installation And Operation Safety Guidelines

    Hot Surfaces!  The heat generated during the operation of the brake may cause burns on contact with skin. Always wear appropriate protective equipment. Carefully observe the following safety guidelines before performing maintenance on the brake. 2021 KEB America, Inc. ©...

  • Page 15: Personal Protective Equipment

    Long-sleeved protective clothing • Safety gloves • Safety shoes • • Safety goggles The personal protective equipment must be provided by the operating company and must comply with any applicable safety regulations. 2021 KEB America, Inc. ©...

  • Page 16: Product Description

    3 Product Description 3.1 Scope of this Manual This manual describes the installation and operation of the KEB size 09 COMBISTOP Type 38 Load Brake. The Load Brake is a specialized version of the COMBISTOP spring set brake designed for quiet running and heavy loads.

  • Page 17: Description

    3 (1 per stud) M10 nylon lock-nuts 3 (1 per stud) Hand release lever (optional) Microswitch (optional) Spherical Washer (included with Hand Release) Spherical Bolts (included with Hand Release) Dust protection ring Figure 1 Brake Components 2021 KEB America, Inc. ©...

  • Page 18: Brake Assembly Numbering Scheme

    Flange Type Generic Flange KEB F4/K4 SEW 57/67 B Torque Arm Torque Rating 250 Nm 500 Nm 750 Nm 1000 Nm 1250 Nm 1500 Nm Coil Voltage 24 VDC 105 VDC 170 VDC 205 VDC 2021 KEB America, Inc. ©...

  • Page 19: Table 1 Part Numbers

    2.00‘‘ 2.375‘‘ 2.50‘‘ Options Bolt release, no microswitch Hand release, no microswitch Bolt release with microswitch Hand release with microswitch Special Standard Designation Special, number C, D and E are randomized Table 1 Part Numbers 2021 KEB America, Inc. ©...

  • Page 20: Brake Specifications

    Resistance Range Coil Voltage Resistance (Ω) 24 VDC 3.9 – 4.5 105 VDC 76 – 87 170 VDC 199 – 229 205 VDC 275 – 317 270 VDC 502 – 578 Table 3 Resistance Ranges 2021 KEB America, Inc. ©...

  • Page 21: Installation

    You will need the following tools before you begin the Load Brake installation. • Customer supplied hex head key (Design A) • 6mm or 8mm hex head key (Design B) KEB Alignment Tool (Design B, Optional): Part number 0938007-007U • 17mm wrench • Feeler gauge •...

  • Page 22: Unpacking The Brake

    2. Inspect the complete brake assembly for damage or defect.  Report any shipping damage to the device or packing to the shipping company and to KEB America, Inc. 3. Remove the rubber dust ring, if installed. 4. Remove cardboard packaging strips holding the hub in place.

  • Page 23: Install The Brake On The Hub

    Start the bolts using the appropriate hex head key. 5. Tighten the bolts equally in two stages until the brake assembly is securely fastened to the mounting surface. KEB recommends a tightening torque of 60 – 80 Nm. Proceed to Checking the Air Gap.

  • Page 24: Design B Installation

    2. Lift the magnet assembly (2) off the mounting studs (3) and set it aside. Figure 5 Magnet Removal 3. Remove the hub (4) from the brake assembly (5) and set it aside. Figure 6 Hub Removal 2021 KEB America, Inc. ©...

  • Page 25: Mount The Brake Assembly

    3. Fasten the brake assembly to the gear motor using the mounting bolts (2). 4. Tighten the bolts equally in two stages until the brake assembly is securely fixed to the motor. KEB recommends a tightening torque of 60 – 80 Nm. 2021 KEB America, Inc.

  • Page 26: Mount The Hub

    Figure 9 Hub Alignment 4. Align the hub axially on the shaft per the brake specifications. 5. Tighten set screws, clamping color or snap rings to secure the hub in place. 2021 KEB America, Inc. ©...

  • Page 27: Mount The Magnet

    3. Slide the washers (10) onto the M10 mounting studs (8) and fasten a nylon lock-nut (11) to each stud. 4. Tighten the lock-nuts equally in stages to compress the pressure springs and reduce the air gap between the magnet and armature. Proceed to Checking the Air Gap 2021 KEB America, Inc. ©...

  • Page 28: Checking The Air Gap

    After checking the air gap, re-install the dust protection ring (1) over the lead wire cable, ensuring the ring fits into the groves in the brake to ensure a tight seal. Figure 12 Dust Protection Ring 2021 KEB America, Inc. ©...

  • Page 29: Testing The Brake Function

    4. Check for free rotation of the shaft while the brake is powered off. The shaft should not rotate with the brake engaged. WARNING  After performing an emergency stop inspect the brake components and test the brake performance before continued use. 2021 KEB America, Inc. ©...

  • Page 30: Optional Components And Accessories

    To use the Hand Release Lever, pull directly away from the mounting surface with at least 70lbs of force. The handle of the Hand Release Lever can optionally be replaced by a lifting eyebolt as needed for the specific application. 2021 KEB America, Inc. ©...

  • Page 31: Installation

    Figure 14 Hand Release Yoke Attachment 3. Tighten the bolts to 60Nm with a 13mm wrench/socket. 4. Screw the hand release handle (3) to the yoke, ensuring a tight fit. 2021 KEB America, Inc. ©...

  • Page 32: Figure 15 Hand Release Lever Attachment

    Figure 15 Hand Release Lever Attachment 5. Test the Hand Release Lever before returning the brake to operation.  A pull force of 70lbs is required to release the Load Brake via the hand release lever. 2021 KEB America, Inc. ©...

  • Page 33: Microswitch

    1. Install the anti-rotation wire (1) onto the magnet, fitting both ends of the wire into the guide holes (2). This wire keeps the plunger from rotating out of alignment. Figure 16 Anti-rotation Wire Attachment 2021 KEB America, Inc. ©...

  • Page 34: Figure 17 Plunger Attachment

    Figure 18 Plunger Position 4. Fasten the microswitch wire to the magnet housing via the pipe clip (5). Tighten the bolt with a 4mm hex head key. 2021 KEB America, Inc. ©...

  • Page 35: Figure 19 Microswitch Wire Attachment

    7. Attach the brake power leads to the power supply and power the brake on. 8. Using an 8mm wrench, rotate the plunger upward until it contacts the microswitch and the multimeter shows the switch is closed. 2021 KEB America, Inc. ©...

  • Page 36: Figure 21 Plunger Adjustment

    9. Rotate the plunger outward 1/6 turn further. The microswitch is now set. 10. Test the microswitch functionality by power cycling the brake several times to verify the microswitch triggers when the brake is powered on. 2021 KEB America, Inc. ©...

  • Page 37: Operation

    The Hand Release Lever is intended for emergency release of the brake in power failure situations, and should not be used as the standard method of operation of the Load Brake. 2021 KEB America, Inc. ©...

  • Page 38: Rectifiers

    Rectifiers 7 Rectifiers Several rectifiers are available for the COMBISTOP Load Brake. Size 04 KEB rectifiers can be used on the AC side or for simultaneous AC and DC side switching. An over- excitation or OEX switch is also available for simultaneous AC and DC side switching.

  • Page 39: Figure 23 Rectifier Wiring Ac Side Switching - Independent Contactor Switching - Phase To Phase

    Line Voltage: 480VAC Input Voltage: 480VAC Coil Voltage: 205VDC = Class CC fuse max. 5A Motor Contactor sized for motor, min 5A Figure 24 Rectifier Wiring AC Side Switching - Motor Contactor Switching - Phase to Phase 2021 KEB America, Inc. ©...

  • Page 40: Dc Side Switching

    = Class CC fuse max. 5A = min 300VDC 9A AC3 brk_dc Optional redundant contactor for safety = min 300VAC 5A AC1 brk_ac Figure 25 Rectifier Wiring DC Side Switching - Independent Contactor Switching - Phase to Phase 2021 KEB America, Inc. ©...

  • Page 41: Figure 26 Rectifier Wiring Dc Side Switching - Independent Contactor Switching With External Mov - Phase To Phase

    MOV: 625Vrms / 1000Vpk / 500J brk_dc Installed at the brake Optional redundant contactor for safety = min 600VAC 5A AC1 brk_ac Figure 26 Rectifier Wiring DC Side Switching - Independent Contactor Switching with External MOV - Phase to Phase 2021 KEB America, Inc. ©...

  • Page 42: Oex Switch Wiring Diagrams

    Line Voltage: 230VAC Input Voltage: 230VAC Coil Voltage: 205VDC = Class CC fuse max. 5A Independent Contactor rated 300VAC, min 5A AC1 Figure 27 OEX Wiring AC Side Switching - Independent Contactor Switching - Phase to Phase 2021 KEB America, Inc. ©...

  • Page 43: Figure 28 Oex Wiring Dc Side Switching - Independent Contactor Switching - Phase To Phase

    = Class CC fuse max. 5A = min 300VDC 9A AC3 brk_dc Optional redundant contactor for safety = min 300VAC 5A AC1 brk_ac Figure 28 OEX Wiring DC Side Switching - Independent Contactor Switching - Phase to Phase 2021 KEB America, Inc. ©...

  • Page 44: Appendix

    Appendix 8 Appendix 8.1 Appendix 1: Certification 2021 KEB America, Inc. ©...

  • Page 45: Revision History

    Revision History 9 Revision History Chapter Change Date Instruction Manual Initial Publication 07/2021 2021 KEB America, Inc. ©...
  • Page 46 Revision History 2021 KEB America, Inc. ©...
  • Page 47 Internet: www.keb.jp Belgium | KEB America, Inc. P.R. China | KEB Power Transmission Technology (Shanghai) Herenveld 2 9500 Geraardsbergen Belgium Co. Ltd. No. 435 QianPu Road Chedun Town Songjiang District Tel: +32 544 37860 Fax: +32 544 37898 201611 Shanghai P.R. China E-Mail: vb.belgien@keb.de...

Table of Contents