KEBCO COMBISTOP 38 User manual

COMBISTOP TYPE 38
INSTRUCTIONS FOR USE | INSTALLATION TYPE 38 SIZE 2...11
Translation of the original manual
Document 20228574 EN 04

3
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.
There are safety informations in the documentation in front of these operations. Security
signs are located on the device or machine. A warning contains signal words which are
explained in the following table:
DANGER Dangerous situation, which will cause death or serious injury in case of
non-observance of this safety instruction.
WARNING Dangerous situation, which may cause death or serious injury in case of
non-observance of this safety instruction.
CAUTION Dangerous situation, which may cause minor injury in case of non-ob-
servance of this safety instruction.
NOTICE Situation, which can cause damage to property in case of non-obser-
vance.
RESTRICTION
Is used when certain conditions must meet the validity of statements or the result is
limited to a certain validity range.
Is used when the result will be better, more economic or trouble-free by following
these procedures.
More symbols
 
• / - Enumerations are marked with dots or indents.
=> Cross reference to another chapter or another page.
Note to further documentation.
www.keb.de/service/downloads

4
PREFACE
Laws and guidelines

the device nameplate or the signing that it complies with the essential safety require-
ments.
The EC declaration of conformity can be downloaded on demand via our website.
Warranty and liability
The warranty and liability on design, material or workmanship for the acquired device is
given in the general sales conditions.

www.keb.de/terms-and-conditions

Support
Through multiple applications not every imaginable case has been taken into ac-
count. If you require further information or if problems occur which are not treated de-
tailed in the documentation, you can request the necessary information via the local
KEB Automation KG agency.
The use of our units in the target products is outside of our control and therefore
lies exclusively in the area of responsibility of the customer.

advice in spoken and written and through tests, are made to best of our knowledge and
information about the intended use. However, they are regarded as being only informal
and changes are expressly reserved, in particular due to technical changes. This also
applies to any violation of industrial property rights of a third-party. Selection of our units
in view of their suitability for the intended use must be done generally by the user.
Tests can only be done within the intended end use of the product (application) by
the customer. They must be repeated, even if only parts of hardware, software or

Copyright
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
respective owners.

5
TABLE OF CONTENTS
Table of Contents
Preface ....................................................................................................................................................3
Signal words and symbols .............................................................................................................3
More symbols.................................................................................................................................3
Laws and guidelines.......................................................................................................................4
Warranty and liability......................................................................................................................4
Support ........................................................................................................................................4
Copyright........................................................................................................................................4
Table of Contents ...................................................................................................................................5
List of Figures.........................................................................................................................................7
List of Tables ..........................................................................................................................................8
Glossary ..................................................................................................................................................9
Standards for mechanical components .............................................................................................10
1 Basic safety instructions .............................................11
1.1 Target group................................................................................................................................... 11
1.2 Transport, storage and proper use.............................................................................................. 11
1.3 Installation and mounting.............................................................................................................12
1.4 Electrical connection .................................................................................................................... 12
1.5 Start-up and operation ..................................................................................................................12
1.6 Maintenance...................................................................................................................................13
2 Product description..................................................... 14
2.1 Intended use .................................................................................................................................. 14
2.2 Residual risks ................................................................................................................................ 14
2.3 Improper use..................................................................................................................................14
2.4 Type code .......................................................................................................................................15
2.5 Type code magnet and magnet system.......................................................................................16
2.6 Overview COMBISTOP Type 38....................................................................................................17
2.7 Functional description .................................................................................................................. 17
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 ..................................................................................................21
3.3.3 Version with double brake ..................................................................................................22
3.4 Accessories ...................................................................................................................................24
3.4.1 Flange, friction disc ............................................................................................................24
3.4.2 Dust protection ring ............................................................................................................25

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.................................................................................................29
4.2.3 Step 3: Mounting the magnetic system ..............................................................................30
4.2.3.1 Check air gap X...............................................................................................................30
4.3 Microswitch (option) ..................................................................................................................... 31
4.3.1 Microswitch as armature position monitoring (default setting) ...........................................31
4.3.1.1 Checking the microswitch setting for armature position monitoring ................................ 31
4.3.2 Microswitch as wear control ...............................................................................................31
4.3.3 Adjustment and change of the microswitch........................................................................32
4.3.3.1 Dismounting ....................................................................................................................33
4.3.3.2 Mounting..........................................................................................................................33
4.3.3.3 Connecting the microswitch ............................................................................................33
4.3.3.4 Adjustment of the microswitch.........................................................................................34
5 Electrical connection................................................... 35
5.1 Connection of the brake ............................................................................................................... 35
5.1.1 AC side switching ...............................................................................................................36
5.1.1.1 Connection for AC side switching....................................................................................36
5.1.1.2 Connection in the terminal box for AC side switching .....................................................37
5.1.2 DC side switching...............................................................................................................38
5.1.3 DC and AC side switching .................................................................................................39
5.1.4 Protective earth ..................................................................................................................39
6 Start-up......................................................................... 40
6.1 Inspections prior to start-up of the brake ...................................................................................40
6.1.1 Visual inspection ................................................................................................................40
6.1.2 Load-free testing ................................................................................................................40
6.1.3 Run in of the brake.............................................................................................................40
6.1.3.1 Friction work switching frequency type N, H, D...............................................................41
7 Operation...................................................................... 42
7.1 Hand release (option)....................................................................................................................42
8 Troubleshooting........................................................... 43

7
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............................................................................................................48
9.2.5 Check the function hand release (option)...........................................................................48
9.2.5.1 Checking the adjustment dimension ...............................................................................49
10 Dismounting and Disposal ....................................... 50
10.1 Dismounting.................................................................................................................................50
10.2 Disposal........................................................................................................................................50
 ................................................................ 51
11.1 EU declaration of conformity...................................................................................................... 51
 ...............................................................................................................................53
12 Revision history......................................................... 56

8
LIST OF FIGURES
List of Tables
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
  ..................................................24
Figure 6: Dimensions COMBISTOP Type 38 dust protection ring ..................................................25
Figure 7: Mounting the hub on the motor shaft ...............................................................................28
Figure 8: Consideration of the axial clearance of the motor shaft...................................................28
Figure 9: Mounting the lining...........................................................................................................29
Figure 10: Mounting the magnetic system ........................................................................................30
Figure 11: Changing the microswitch................................................................................................32
Figure 12: Strands for the microswitch..............................................................................................33
Figure 13: Adjustment of the microswitch .........................................................................................34
Figure 14: Connection for AC side switching ....................................................................................36
Figure 15: Connection in the terminal box for AC side switching......................................................37
Figure 16: Connection for DC side switching....................................................................................38
Figure 17: Connection for DC and AC switching...............................................................................39
Figure 18: Friction work switching frequency type N, H, D ...............................................................41
Figure 19: Operation of the hand release .........................................................................................42
Figure 20: Dismount the brake..........................................................................................................44
Figure 21: Checking the air gap........................................................................................................46
Figure 22: Adjustment dimension "m" of the hand release ...............................................................49
 ............................................................................................52
 ...................................................................................................................55
Table 1: Type code ........................................................................................................................15
Table 2: Type code magnet and magnet system...........................................................................16
Table 3: Climatic environmental conditions ...................................................................................18
 .........................................................................................................18
Table 5: Device data COMBISTOP Type 38..................................................................................19
Table 6: Dimensions COMBISTOP Type 38 double brake ............................................................23
  ..................................................25
Table 8: Pre-assembled connection cables...................................................................................35
Table 9: Run in of the brake...........................................................................................................40
Table 10: Troubleshooting ...............................................................................................................43
Table 11: Check air gap...................................................................................................................45
Table 12: Check the function hand release .....................................................................................48

9
GLOSSARY
Glossary
0V Earth-potential-free common point
1ph 1-phase mains
3ph 3-phase mains
AC AC current or voltage
Application The application is the intended use
of the KEB product.
AWG American wire gauge
B2B Business-to-business
Customer The customer has purchased a KEB
product from KEB and integrates the
KEB product into his product (cus-
tomer product) or resells the KEB
product (dealer)
DC DC current or voltage
DIN German Institut for standardization
EMC Electromagnetic compatibility
EN European standard
End customer The end customer is the user of the
customer product.
FE Functional earth
GND Reference potential, ground
IEC 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
-
nufacturer of machines, engines,
vehicles or adhesives).
MCM American unit for large wire cross
sections
MTTF Mean service life to failure
NN Sea level
PE Protective earth
PELV Protective Extra Low Voltage
SELV Safety Extra Low Voltage (<60 V)

10
STANDARDS FOR MECHANICAL COMPONENTS
Standards for mechanical components
VDE0580 Electro magnetic devices and components
 
DIN46228-1 Tubular end-sleeves without plastic sleeve
DIN46228-4 Tubular end-sleeves with plastic sleeve
DINIEC60364-5-54 Low-voltage electrical installations - Part 5-54: Selection and erection of
electrical equipment - Earthing arrangements, protective conductors and protec-
tive bonding conductors
EN60204-1 Safety of machinery - Electrical equipment of machines - Part 1: General requi-
rements (IEC 44/709/CDV)
EN60529 Degrees of protection provided by enclosures (IP Code) (IEC 60529)
EN60664-1 Insulation coordination for equipment within low-voltage systems - Part 1:
Principles, requirements and tests (IEC 60664-1)
 
environmental parameters and their severities - Section 1: Storage (IEC 104/648/CD)
 
environmental parameters and their severities - Section 2: Transportation and
handling (IEC 104/670/CD)
 
environmental parameters and their severities; section 3: Stationary use at
weatherprotected locations (IEC 60721-3-3)
DIN 748-3 Cylindrical shaft ends - Part 3: For rotating electrical machinery
 
frame size larger then 315 - Tolerances, test
DIN EN 50347 General purpose three-phase induction motors having standard dimensions and

DIN 6885-1 Drive type fastenings without taper action, parallel keys, keyways - Deep pattern
DIN 6885-3 Drive type fastenings without taper action, parallel keys, keyways - Low pattern
DIN 332-2 Center holes 60° with thread for shaft ends for rotating electrical machines