KEB COMBISTOP 38 Instructions For Use Manual
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- Page 1 COMBISTOP T YPE 38 INSTRUCTIONS FOR USE | INSTALLATION TYPE 38 SIZE 2...11 Translation of the original manual Document 20228574 EN 04...
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Page 3: Preface
PrEfAcE Preface The described devices or add-on parts are products of the KEB Automation KG. The enclosed documents correspond to conditions valid at printing. Misprint, mistakes and technical changes reserved. Signal words and symbols Certain operations can cause hazards during the installation, operation or thereafter. -
Page 4: Laws And Guidelines
The customer may use the instructions for use as well as further documents or parts from it for internal purposes. Copyrights are with KEB Automation KG and remain valid in its entirety. Other wordmarks or/and logos are trademarks (™) or registered trademarks (®) of their... -
Page 5: Table Of Contents
3 Technical data .............. 18 3.1 Operating conditions ........................18 3.1.1 Climatic environmental conditions ..................18 3.1.2 Electrical operating conditions .................... 18 3.2 Device data cOMbISTOP 38 ......................19 3.2.1 Overview ..........................19 3.3 Dimensions and weights ......................20 3.3.1 Version without options ...................... 20 3.3.2 Version with hand release .................... - Page 6 TAbLE Of cONTENTS 4 Mounting ............... 26 4.1 Notes on mounting ........................26 4.1.1 Checks before mounting the brake ..................26 4.1.2 Observe during mounting ....................27 4.2 Mount brake ........................... 27 4.2.1 Step 1: Mounting the hub ....................28 4.2.2 Step 2: Mounting the lining ....................
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Page 7: List Of Figures
TAbLE Of cONTENTS 9 Maintenance and service ..........44 9.1 Maintenance intervals ........................44 9.2 Service ............................44 9.2.1 Dismount the brake ......................44 9.2.2 Check air gap ........................45 9.2.2.1 Checking the air gap X ....................46 9.2.3 Readjust air gap .........................47 9.2.4 Replacing the lining ...................... -
Page 8: List Of Tables
LIST Of fIGUrES List of figures Figure 1: Overview COMBISTOP Type 38 ..................17 Figure 2: Dimensions COMBISTOP Type 38 without options ............20 Figure 3: Dimensions COMBISTOP Type 38 hand release ............21 Figure 4: Dimensions COMBISTOP Type 38 double brake ............22 Figure 5: Dimensions COMBISTOP Type 38 friction disc / flange .......... -
Page 9: Glossary
Functional earth Reference potential, ground International standard IP xx Degree of protection (xx for level) KEB product The KEB product is subject of this manual. Manufacturer The manufacturer is KEB, unless otherwise specified (e.g. as ma- nufacturer of machines, engines, vehicles or adhesives). -
Page 10: Standards For Mechanical Components
STANDArDS fOr MEcHANIcAL cOMPONENTS Standards for mechanical components VDE 0580 Electro magnetic devices and components DGUV regulation 3 Electrical installations and equipment DIN 46228-1 Tubular end-sleeves without plastic sleeve DIN 46228-4 Tubular end-sleeves with plastic sleeve DIN IEC 60364-5-54 Low-voltage electrical installations - Part 5-54: Selection and erection of electrical equipment - Earthing arrangements, protective conductors and protec- tive bonding conductors EN 60204-1... -
Page 11: Basic Safety Instructions
NOTICE Hazards and risks due to ignorance. ► Read the instructions for use! ► Observe the safety and warning instructions! ► If anything is unclear, please contact KEB! 1.1 Target group This manual is determined exclusively for technical staff. Technical staff for the purpose of this manual must have the following qualifications: •... -
Page 12: Installation And Mounting
bASIc SAfETY INSTrUcTIONS 1.3 Installation and mounting NOTICE Squeezing and pinching of fingers by self-rotation. ► Before installation, make sure that the drive is load-free. ► Secure drive against rotation. Consider the following installation measures to prevent faults ► Do not operate the brake in an explosive environment. ►... -
Page 13: Maintenance
bASIc SAfETY INSTrUcTIONS cAUTION High temperatures due to braking burning of the skin! ► Cover hot surfaces safe-to-touch. ► If necessary, attach warning signs on the system. ► Check the temperature and let the brake cool down if necessary. cAUTION rotating Parts Shock or crushing of body parts! ►... -
Page 14: Product Description
Any use beyond the technical specifications is also considered as not specified. The actual use of the brake in the target products is beyond KEB Automation KG's con- trol and, therefore, shall be exclusively within the operating company's responsibility. -
Page 15: Type Code
PrODUcT DEScrIPTION 2.4 Type code The type designation and the version can be taken from the nameplate or the marking. x x 3 8 x x x - x x x x Variant Customer versions N / DEN: Dynamic application H / DEH: Static application Design DDN /... -
Page 16: Type Code Magnet And Magnet System
PrODUcT DEScrIPTION 2.5 Type code magnet and magnet system Magnet designation can be taken from the signing. x x 0 3 x x x - x x x x Strands Material and length Voltage e.g. DC 24 V 100 / 0NN: Dynamic application Version 10H / 00H: Static application Type... -
Page 17: Overview Combistop Type 38
PrODUcT DEScrIPTION 2.6 Overview cOMbISTOP Type 38 ➀ Legend Size 02 to 06 2a / 2b Hub Size 07 to 11 3a / 3b Lining Magnet system Friction disc (optional) Magnet Flange (optional) E-piece (adjusting piece) Hand release (optional) Armature Dust protection ring (optional) Figure 1: Overview COMBISTOP Type 38... -
Page 18: Technical Data
TEcHNIcAL DATA 3 Technical data 3.1 Operating conditions 3.1.1 climatic environmental conditions Operation Standard class Notes - 5...35°C (standard) Ambient temperature – VDE 0580 - 40...35°C (CCV: Cold Climate Version) IP40 Standard Construction and degree of EN 60529 protection IP44 With dust protection ring Table 3: Climatic environmental conditions... -
Page 19: Device Data Combistop 38
DEvIcE DATA cOMbISTOP 38 3.2 Device data cOMbISTOP 38 3.2.1 Overview Device size Rated torque after running-in at 20 °C / Nm 1000 N version Rated torque after running-in at 20 °C / Nm 1500 H version Rated power N version... -
Page 20: Dimensions And Weights
DIMENSIONS AND WEIGHTS 3.3 Dimensions and weights 3.3.1 version without options 02…1138N/H-xxxx Dimensions / mm Weight / kg Size 3811N/H max. 34.2 1-1.5 37.7 3x4.2 37.2 2-2.5 41.7 3x5.3 47.2 2-2.5 51.7 3x6.5 52.7 2.5-3 57.7 3x6.5 59.8 2.5-3 68.8 3x8.5 75.5 3x8.5... -
Page 21: Version With Hand Release
DIMENSIONS AND WEIGHTS 3.3.2 version with hand release 02…113813N/DEN-xxxx 02…113813H/DEH-xxxx Dimensions / mm Size 105.5 53.5 25.5 26.2 30.5 39.5 46.5 1000 Figure 3: Dimensions COMBISTOP Type 38 hand release Mechanical release with hexagon head screw. -
Page 22: Version With Double Brake
DIMENSIONS AND WEIGHTS 3.3.3 version with double brake Hub variant 1 Hub variant 2 continued on the next page Figure 4: Dimensions COMBISTOP Type 38 double brake... -
Page 23: Table 6: Dimensions Combistop Type 38 Double Brake
DIMENSIONS AND WEIGHTS Dimensions / mm Size Weight / kg 105.5 53.5 34.2 39.4 45.5 22.5 37.2 47.5 47.2 51.4 52.7 55.9 59.8 64.6 77.1 79.9 82.1 88.9 94.9 98.6 Dimensions / mm Size D1/D2 max. 12.5 12.5 18.5 57/76 19.5 14.5 16.5... -
Page 24: Accessories
AccESSOrIES 3.4 Accessories 3.4.1 flange, friction disc Flange with collar for dust protection ring Größe 10-11 6x 60° 00…1138510-xxxx Friction disc 02…0638515-xxxx continued on the next page Figure 5: Dimensions COMBISTOP Type 38 friction disc / flange... -
Page 25: Dust Protection Ring
AccESSOrIES Dimensions / mm Size Weight / kg ─ ─ ─ ─ ─ 0.08 3xM4 3xM5 0.35 3xM6 131.5 0.75 3xM6 3xM8 ─ 3xM8 ─ ─ ─ 2.10 ─ 3xM8 ─ ─ ─ 2.70 ─ 3xM10 ─ ─ ─ 3.70 ─... -
Page 26: Mounting
NOTES ON MOUNTING 4 Mounting Unless otherwise stated, the numbers mentioned in this chapter refer to => „Figure 1: Overview COMBISTOP Type 38“. 4.1 Notes on mounting 4.1.1 checks before mounting the brake Before mounting the brake, check the following: ► Compliance of the ordered voltage and performance data with the type plate data. ►... -
Page 27: Observe During Mounting
► The movement of the armature must not be impeded by the ingress of foreign parti- cles into the air gap. Take appropriate safety measures as required. ► The eccentricity of the mounting hole circle relative to the shaft end must not ex- ceed the following values: cOMbISTOP 38 03…06 07…10 Eccentricity / mm ►... -
Page 28: Step 1: Mounting The Hub
MOUNT brAKE 4.2.1 Step 1: Mounting the hub ► Mount the hub on the motor shaft. ► Secure the hub axially on the motor shaft. ► The hub and the linings must not be damaged! ① ② ③ ④ Legend Motor shaft Locking ring Lining... -
Page 29: Step 2: Mounting The Lining
MOUNT brAKE 4.2.2 Step 2: Mounting the lining ► Slide the lining onto the hub. ► While doing so, be careful not to damage the lining by misaligned or tilted positioning. ► The lining must be easily movable on the hub. ①... -
Page 30: Step 3: Mounting The Magnetic System
MOUNT brAKE 4.2.3 Step 3: Mounting the magnetic system ► Slide the fully assembled magnetic system over the hub and the lining. ► While doing so, make sure that the lining is easily movable ► Fix the magnet system with three socket head screws without defined torque. ► Apply rated voltage. Thus the armature is pulled towards the housing in the oppo- site direction to the spring forces. -
Page 31: Microswitch (Option)
MIcrOSWITcH (OPTION) 4.3 Microswitch (option) A microswitch can only be retrofitted if the brake is prepared for it. That is why the variant must be ordered already ex factory. The microswitch can be used for armature position monitoring or as wear control. 4.3.1 Microswitch as armature position monitoring (default setting) A microswitch can be used to monitor the switching state of the armature (brake open/ closed). -
Page 32: Adjustment And Change Of The Microswitch
MIcrOSWITcH (OPTION) 4.3.3 Adjustment and change of the microswitch NOTICE Unauthorized exchange, repair and modifications! Adjustment and change of the microswitch may only be carried out by qualified personnel ! cAUTION Loss of braking efficiency ! Before replacing the microswitch, mechanically secure the load against unintended movements and disconnect the brake from load! Legend Microswitch... -
Page 33: Dismounting
MIcrOSWITcH (OPTION) 4.3.3.1 Dismounting ► Remove the two socket head screws. ► Remove the microswitch. 4.3.3.2 Mounting ► The microswitch is mounted in reverse order. ► Connect the microswitch according to the following connection diagram: 4.3.3.3 Connecting the microswitch Connect the microswitch as a normally open contact (terminal 1 and 4). Legend Ground (black) NC contact (brown) -
Page 34: Adjustment Of The Microswitch
MIcrOSWITcH (OPTION) 4.3.3.4 Adjustment of the microswitch cAUTION Loss of braking efficiency! Before checking the microswitch settings, mechanically secure the load against unintended movements and disconnect the brake from load! ① ④ ② ③ Legend Microswitch Socket head screw Hexagon head screw Hexagon nut Figure 13: Adjustment of the microswitch... -
Page 35: Electrical Connection
► Compare with existing voltage source. ► The maximum input voltage U must not be exceeded. ► Only connect if the values match. If no suitable DC voltage is available, the following KEB accessories can be used: • Half and full-wave rectifier (COMBITRON 91) •... -
Page 36: Ac Side Switching
ELEcTrIcAL cONNEcTION NOTICE connection for drive controller operation. ► Rectifiers or power boxes are destroyed when operated on drive controllers. ► Rectifiers or power boxes may only be connected directly to the mains. Influence on the engaging time! The brake can be switched off on the DC or AC side. Switching off on the DC side reduces the engaging time, i.e. the time until the torque is built up for braking. 5.1.1 Ac side switching 5.1.1.1 Connection for AC side switching ①... -
Page 37: Connection In The Terminal Box For Ac Side Switching
ELEcTrIcAL cONNEcTION 5.1.1.2 Connection in the terminal box for AC side switching ① Legend Jumper Figure 15: Connection in the terminal box for AC side switching • Not permitted for drive controller operation, since the power box or the rectifier would be destroyed. -
Page 38: Dc Side Switching
ELEcTrIcAL cONNEcTION 5.1.2 Dc side switching Switching occurs between rectifier and brake. KEB rectifiers and power boxes are pro- tected against the voltage peaks resulting from the switching. Figure 16: Connection for DC side switching • Not permitted for drive controller operation, since the power box or the rectifier would be destroyed.. -
Page 39: Dc And Ac Side Switching
ELEcTrIcAL cONNEcTION 5.1.3 Dc and Ac side switching Figure 17: Connection for DC and AC switching • Drive controller operation possible, because the power box or the rectifier is sup- plied from the mains. • For drive controller operation, switch the switch via digital output during ramp-up. • Enables the shortest switch-off times. • Reduces the contact erosion. 5.1.4 Protective earth The brake does not have its own PE connection. -
Page 40: Start-Up
INSPEcTIONS PrIOr TO STArT-UP Of THE brAKE 6 Start-up 6.1 Inspections prior to start-up of the brake 6.1.1 visual inspection • Do connection and rated voltage (magnet marking) agree? • Are external damages visible? • Are there impurities in the functional area or foreign bodies in the air gap of the brake? 6.1.2 Load-free testing •... -
Page 41: Friction Work Switching Frequency Type N, H, D
INSPEcTIONS PrIOr TO STArT-UP Of THE brAKE 6.1.3.1 Friction work switching frequency type N, H, D Rmax Switching frequency per hour Figure 18: Friction work switching frequency type N, H, D... -
Page 42: Operation
The max. „5.1 Connection of the number of switching cycles must not be exceeded => „3.2 Device data COMBISTOP 38“ 7.1 Hand release (option) As an option, the brake can be delivered with a hand release. In the event of malfunc- tions, the brake can be actuated using the hand release. -
Page 43: Troubleshooting
Remove the foreign particles. armature and lining Clean the brake. Magnet coil or connecting Replace the brake. cable defective Insert a quick switch (e.g. KEB Excessive heating Powerbox). Damaged toothing pre- vents the movement of the Replace the lining and the hub. -
Page 44: Maintenance And Service
MAINTENANcE AND SErvIcE 9 Maintenance and service ► Observe the general safety instructions. ► Disconnect the brake from the power supply during maintenance and repair work. ► Protect electrical and electronic components from splash water. 9.1 Maintenance intervals Due to its design, the COMBISTOP Type 38 brake can only be checked when it has been removed. -
Page 45: Check Air Gap
MAINTENANcE AND SErvIcE 9.2.2 check air gap The brakes are delivered ex works with pre-set air gap "X“ (nominal air gap) ready for installation. As a result of wear, the air gap increases. To ensure proper functioning, the air gap (distance between magnet housing and armature) must be checked in regular intervals in a de-energised state with feeler gauge. -
Page 46: Checking The Air Gap X
MAINTENANcE AND SErvIcE 9.2.2.1 Checking the air gap X Easy control of the air gap: ► Ensure that the brake is in a de-energised state. ► Check the air gap between the magnet housing and the armature with a feeler gauge. This is usually sufficient. -
Page 47: Readjust Air Gap
MAINTENANcE AND SErvIcE 9.2.3 readjust air gap NOTICE Wrong air gap! Damage of the brake! ► Check data sheet whether the air gap can be adjusted. ► Depending on the design, adjusting spacers can be fixed and im- movable. As a result of wear, the nominal air gap increases. In order to ensure a trouble-free func- tion, the air gap should be readjusted after reaching the air gap “X “... -
Page 48: Replacing The Lining
MAINTENANcE AND SErvIcE 9.2.4 replacing the lining cAUTION Worn or dirty linings! Loss of braking efficiency! ► Securing the load! ► Prevent damage to the hub by all means. ► Be careful not to damage the lining by misaligned or tilted positioning. ►... -
Page 49: Checking The Adjustment Dimension
MAINTENANcE AND SErvIcE 9.2.5.1 Checking the adjustment dimension The adjustment dimension "m" must be checked / adjusted with attracted armature!The adjustment dimension applies to rated torque and operation with rated voltage. Figure 22: Adjustment dimension "m" of the hand release... -
Page 50: Dismounting And Disposal
DISMOUNTING AND DISPOSAL 10 Dismounting and Disposal 10.1 Dismounting For dismounting the brake => „9.2.1 Dismount the brake“. 10.2 Disposal Separated according to the materials used, dispose of the electromagnetic brake components in compliance with the applicable local environmental regulations. The corresponding key numbers are subject to change depending on the disassembling process (metals, plastics and cables). -
Page 51: Certification
01 bis 14 Spannungsklassen 71...440Vdc / 50 … 690Vac Diese Konformitätserklärung ist unter alleiniger Verantwortung der KEB Automation KG erstellt worden Das bezeichnete Produkt stimmt mit den Vorschriften folgender Europäischer Richtlinien überein: Niederspannung : 2014 / 35 / EU Number:... -
Page 52: Figure 23: Eu Declaration Of Conformity
Zertifizierungsstelle des RWTÜV Steubenstrasse 53 D - 45138 Essen Nummer der Bescheinigung 041 004 500 Ausstelldatum: 20.10.94 Gültig durch Nachprüfung bis: 12.2024 KEB Automation KG, Südstr. 38, D-32683 Barntrup www.keb.de E-Mail: info@keb.de Tel.: +49 5263 401-0 Fax: -116 Seite: 2 von 2... -
Page 53: Csa Certificat
Project: Date Issued: 70199031 2018-10-05 Issued to: KEB Automation KG Suedstrasse 38 32683 Barntrup, GERMANY The products listed below are eligible to bear the CSA Mark shown with adjacent indicators 'C' and 'US' for Canada and US or with adjacent indicator 'US' for US only or without either indicator for Canada only. - Page 54 cErTIfIcATION Certificate: 70199031 Master Contract: 172220 Project: 70199031 Date Issued: 2018-10-05 Notes: 1. The first two figures define the size of the product. The next two figures describe the product type, e.g. COMBISTOP. The following three figures describe the design and the last four figures describe the layout of the product type.
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Page 55: Figure 24: Csa Certificat
cErTIfIcATION Supplement to Certificate of Compliance Certificate: 1267150 (LR49670) Master Contract: 172220 (049670_0_000) The products listed, including the latest revision described below, are eligible to be marked in accordance with the referenced Certificate. Product Certification History Project Date Description 70199031 2018-10-05 Update of report to cover correction of issued address and to update report in accordance with CSA-C22.2 No. -
Page 56: Revision History
rEvISION HISTOrY 12 revision history version Date Description 2011-09 First edition 2020-03 Complete editorial revision 2021-06 Adaptation of the air gap description, general revision 2023-04 Adaption of values, editorial revision... - Page 57 / Mitjer, Nave 8 - Pol. Ind. LA MASIA E-Mail: info@keb.cz Internet: www.keb.cz 08798 Sant Cugat Sesgarrigues (Barcelona) Spain Tel: +34 93 8970268 Fax: +34 93 8992035 E-Mail: vb.espana@keb.de Société Française KEB SASU france Z.I. de la Croix St. Nicolas 14, rue Gustave Eiffel...
- Page 58 Automation with Drive www.keb.de KEB Automation KG Suedstrasse 38 32683 Barntrup Tel. +49 5263 401-0 E-Mail: info@keb.de...
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