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KEB COMBISTOP 38M Instruction Manual
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KEB COMBISTOP 38M Instruction Manual

KEB COMBISTOP 38M Instruction Manual

Load brake size 9
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COMBISTOP TYPE 38M
INSTRUCTION MANUAL | LOAD BRAKE SIZE 9
Original Manual
Document 20139598 US 03

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Summary of Contents for KEB COMBISTOP 38M

  • Page 1 COMBISTOP TYPE 38M INSTRUCTION MANUAL | LOAD BRAKE SIZE 9 Original Manual Document 20139598 US 03...
  • Page 3 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 Warning: Hot surface 1.3 Laws and Requirements KEB Automation KG has certified the product against the US, Canadian and European standards. Additionally, KEB Automation KG provides the EC declaration of conformity that the product complies with the essential safety requirements.
  • Page 5 1.6 Copyright The customer may use the information contained within this document for internal purposes only. The copyright of this document is held by KEB America, Inc. and remains valid in its entirety. This KEB product or parts thereof may contain third-party software, including free and/ or open-source software.
  • Page 6 3 Product Description ................17 Scope of this Manual ..................17 Description ....................18 3.2.1 Brake Components ......................18 3.2.2 Brake Assembly Model Number ..................19 Brake Specifications ..................20 4 Installation ..................21 Required Tools ....................21 2025 KEB America, Inc. ©...
  • Page 7 Example Wiring Diagrams ................39 7.1.1 AC Side Switching ....................... 39 7.1.2 DC Side Switching ....................... 42 7.1.3 OEX Switch Wiring Diagrams ..................... 44 8 Appendix .................... 46 Appendix 1: Certification ................46 9 Revision History ................47 2025 KEB America, Inc. ©...
  • Page 8 43 Figure 7.6 OEX wiring AC side switching - independent contactor switching - phase to phase ....44 Figure 7.7 OEX wiring DC side switching - independent contactor switching - phase to phase ....45 2025 KEB America, Inc. ©...
  • Page 9 List of Tables List of Tables Table 3.1 Coil specifications ........................20 Table 3.2 Resistance ranges ........................20 Table 5.1 Optional accessories ........................31 Table 5.2 Hand release components ......................31 Table 5.3 Microswitch components ......................34 2025 KEB America, Inc. ©...
  • Page 10 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 11 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 12 Region: US o Personal safety code detailing appropriate personal protective equipment for working on electrical installations. • OSHA 1910.269 o Region: US o Occupational safety code detailing safety standards for electrical power generation, transmission, and distribution. 2025 KEB America, Inc. ©...
  • Page 13 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 14 • Malfunctions should be corrected by trained personnel before returning the brake 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...
  • Page 15 • Ensure there is protection against accidental contact with rotating or moving parts. • Ensure there is sufficient protection from environmental factors such as moisture or aggressive gases that may compromise the integrity of the friction surface or armature. 2025 KEB America, Inc. ©...
  • Page 16 • 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. 2025 KEB America, Inc. ©...
  • Page 17 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 18 3 (1 per stud) M10 nylon lock-nuts 3 (1 per stud) Microswitch (optional) Hand release lever (optional) Spherical Washer (included with Hand Release) Spherical Bolts (included with Hand Release) Dust protection ring Figure 3.1 Brake Components 2025 KEB America, Inc. ©...
  • Page 19 2: SEW 57/67 B 3: Torque Arm Disk Code (fixed) M: Multi-disk Brake (fixed) Type Code (fixed) 38: Spring Set Brake (fixed) Brake Size 09: The only size described in this manual (fixed) Figure 3.2 Model number 2025 KEB America, Inc. ©...
  • Page 20 Resistance Range Coil Voltage Resistance (Ω) 3.9 – 4.5 24 VDC 76 – 87 105 VDC 199 – 229 170 VDC 275 – 317 205 VDC 502 – 578 270 VDC Table 3.2 Resistance ranges 2025 KEB America, Inc. ©...
  • Page 21 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 • 17 mm wrench • Feeler gauge Brake with Hand Release: •...
  • Page 22 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 (customer supplied). 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. 6. Proceed to Checking the Air Gap.
  • Page 24 Do not loosen or remove the two black manual release bolts (if included) as they hold the magnet together. 2. Lift the magnet assembly (2) off the mounting studs (3) and set it aside. Figure 4.4 Magnet removal Design B 2025 KEB America, Inc. ©...
  • Page 25 If the washers do fall off the mounting studs, replace them with the first washer cone up and then alternating directions (<><>). A piece of tape or similar measure may be used to secure washers to the mounting studs if the brake must be moved before reassembly. 2025 KEB America, Inc. ©...
  • Page 26 3. Fasten the brake basket to the gear motor using the internal 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. 2025 KEB America, Inc.
  • Page 27 (if used). Some rotation of the hub may be necessary to align all of the friction disks if the optional alignment tool is not used. Figure 4.8 Hub alignment Design B 4. Align the hub axially on the shaft per the brake specifications. 2025 KEB America, Inc. ©...
  • Page 28 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. 5. Proceed to Checking the Air Gap. 2025 KEB America, Inc. ©...
  • Page 29 After checking the air gap, re-install the dust protection ring (1) over the lead wire cable, ensuring the ring fits into the grooves in the brake to ensure a tight seal. Figure 4.11 Dust protection ring 2025 KEB America, Inc. ©...
  • Page 30 2. Using the M10 (17mm socket) bolts, tighten the bolts until there is a 3.5 mm gap between the bottom of the square nut and the armature slot ( Refer to Figure 6.1 Load brake "m" dimension). 2025 KEB America, Inc. ©...
  • Page 31 To use the hand release lever, pull directly away from the mounting surface with at least 70 lbs. of force. The handle of the hand release lever can optionally be replaced by a lifting eyebolt as needed for the specific application. 2025 KEB America, Inc. ©...
  • Page 32 Figure 5.2 Hand release yoke attachment 3. Tighten the bolts to 14 Nm with a 13 mm wrench/socket. 4. Screw the hand release handle (3) to the yoke, ensuring a tight fit. 2025 KEB America, Inc. ©...
  • Page 33 Figure 5.3 Hand release lever attachment 5. Test the Hand Release Lever before returning the brake to operation. A pull force of 70 lbs. is required to release the load brake via the hand release lever. 2025 KEB America, Inc. ©...
  • Page 34 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 5.4 Anti-rotation wire attachment 2025 KEB America, Inc. ©...
  • Page 35 Figure 5.5 Plunger attachment 3. Tighten the plunger with an 8 mm wrench until there is at least a one-inch gap from the plunger tip to the top of the magnet. Figure 5.6 Plunger position 2025 KEB America, Inc. ©...
  • Page 36 The multimeter should read “OL”, indicating there the microswitch is open. 7. Attach the brake power leads to the power supply and power the brake on. 2025 KEB America, Inc. ©...
  • Page 37 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. 2025 KEB America, Inc. ©...
  • Page 38 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. The “m” dimension is nominally 3.5 mm. Figure 6.1 Load brake "m" dimension 2025 KEB America, Inc. ©...
  • Page 39 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 40 Coil Voltage: 205 VDC = Class CC fuse max. 5 A Independent Contactor rated 300 VAC, min 5 A AC1 Figure 7.2 Rectifier wiring AC side switching - independent contactor switching - phase to phase 2025 KEB America, Inc. ©...
  • Page 41 Input Voltage: 480 VAC Coil Voltage: 205 VDC = Class CC fuse max. 5 A Motor Contactor sized for motor, min 5 A Figure 7.3 Rectifier wiring AC side switching - motor contactor switching - phase to phase 2025 KEB America, Inc. ©...
  • Page 42 = min 300VDC 9 A AC3 brk_dc Optional redundant contactor for safety = min 300 VAC 5 A AC1 brk_ac Figure 7.4 Rectifier wiring DC side switching - independent contactor switching - phase to phase 2025 KEB America, Inc. ©...
  • Page 43 Installed at the brake Optional redundant contactor for safety = min 600 VAC 5 A AC1 brk_ac Figure 7.5 Rectifier wiring DC side switching - independent contactor switching with external MOV - phase to phase 2025 KEB America, Inc. ©...
  • Page 44 Coil Voltage: 205 VDC = Class CC fuse max. 5 A Independent Contactor rated 300 VAC, min 5 A AC1 Figure 7.6 OEX wiring AC side switching - independent contactor switching - phase to phase 2025 KEB America, Inc. ©...
  • Page 45 = min 300VDC 9 A AC3 brk_dc Optional redundant contactor for safety = min 300 VAC 5 A AC1 brk_ac Figure 7.7 OEX wiring DC side switching - independent contactor switching - phase to phase 2025 KEB America, Inc. ©...
  • Page 46 Appendix 8 Appendix 8.1 Appendix 1: Certification 2025 KEB America, Inc. ©...
  • Page 47 • Instances of “brake assembly” updated to “brake basket” in section 4.3.2 Design B Installation. • Load brake “m” dimension reference and figure added to section 6.2 Manual Operation. 06/2025 • Added section 4.6 Resetting Manual Brake Release. 2025 KEB America, Inc. ©...
  • Page 48 Belgium | KEB America, Inc. Herenveld 2 9500 Geraardsbergen Belgium P.R. China | KEB Power Transmission Technology (Shanghai) 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 Internet: www.keb.de...
  • Page 49 Automation with Drive www.kebamerica.com KEB America, Inc. 5100 Valley Industrial Blvd S Shakopee, MN 55379 Tel. +1 952-224-1400 E-Mail: info@kebamerica.com...