KEBCO COMBISTOP 38 User manual

COMBISTOP type 38
Instruction Manual | Theater Load Brake Size 10
Original Manual
Theater Load Brake Size 10
Document 20243555 000 00

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©
2020 KEB America, Inc.

Preface
©
2020 KEB America, Inc.
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1 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.
1.1 Warning Signs and Key Symbols
Certain procedures within this document can cause safety hazards during the installation or
operation of the device. Refer to the safety warnings in this document when performing these
procedures. Safety signs are also located on the device where applicable. A safety warning is
marked by one of the following warning signs:
DANGER
Dangerous situation which will cause death or serious injury if this
safety warning is ignored.
WARNING
Hazardous situation which may cause death or serious injury if
this safety warning is ignored.
CAUTION
Hazardous situation which may cause minor or moderate injury if
this safety warning is ignored.
NOTICE
Situation which may cause property damage if this safety warning
is ignored.
RESTRICTION Used when the following statements depend on certain conditions or
are only valid for certain ranges of values.
i
Used for informational messages or recommended procedures.
1.2 More Symbols
1. Numbered lists begin action steps.
•Enumerations are marked with dots.
→Thin arrows indicate cross references to another chapter or another page.
Further documentation can be found at
https://www.kebamerica.com
Document search on www.kebamerica.com/em-
documents/

Preface
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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.
The UL, CSA and CE marks are located on the name plate when applicable. The EC
declaration of conformity can be downloaded on demand via our website.
→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.
1.5 Support and Liability
It is not possible to cover every potential application of our device in a single manual. If
you require further information or if problems occur which are not covered in this
document, you can request the necessary information via KEB America, Inc. or the local
KEB Automation KG agency.
The use of our products in the target application is beyond our control and
therefore exclusively the responsibility of the machine manufacturer, system
integrator or customer.
The information contained in this document, as well as any user-specific advice in spoken
or written form or generated through testing, is provided to best of our knowledge and is
considered for informational purposes only. KEB America, Inc. bears no responsibility or
liability for the accuracy of the information listed above, nor for any violation of industrial
property rights committed by a third-party in relation to this information.
Selection of the most suitable product for any given application is the
responsibility of the machine manufacturer, system integrator or customer.
Evaluation of the product can only be performed by the machine manufacturer in
combination with the application. Any tests performed must be repeated every time any
part of the hardware or software is modified, or any time the unit adjustment is changed.
1.6 Copyright
The customer may use the information contained within this document for internal
purposes only. Copyright of this document is held by KEB America, Inc. and remains
valid in its entirety.
Other wordmarks or/and logos are trademarks (™) or registered trademarks (®) of their
respective owners and are listed in a footnote at the first occurrence.

Table of Contents
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Table of Contents
1Preface ...................................................................................................3
1.1 Warning Signs and Key Symbols ................................................................... 3
1.2 More Symbols................................................................................................... 3
1.3 Laws and Requirements .................................................................................. 4
1.4 Warranty............................................................................................................ 4
1.5 Support and Liability ....................................................................................... 4
1.6 Copyright .......................................................................................................... 4
Table of Contents ....................................................................................................... 5
List of Figures............................................................................................................. 7
List of Tables .............................................................................................................. 8
Glossary...................................................................................................................... 9
Standards for COMBISTOP type 38 Theater Load Brake...................................... 11
2Safety Instructions..............................................................................12
2.1 Target Audience ............................................................................................. 12
2.2 Specified Application..................................................................................... 13
2.3 General Safety Guidelines............................................................................. 13
2.4 Electrical Safety Guidelines .......................................................................... 13
2.5 Installation and Operation Safety Guidelines .............................................. 14
2.6 Maintenance Safety Guidelines .................................................................... 14
2.7 Personal Protective Equipment .................................................................... 15
3Product Description............................................................................16
3.1 Scope of this Manual ..................................................................................... 16
3.2 Description ..................................................................................................... 16
3.2.1 Brake Components ............................................................................................................... 16
3.2.2 Brake Assembly Numbering Scheme ................................................................................. 18
3.3 Brake Specifications...................................................................................... 20
4Installation ...........................................................................................21
4.1 Required Tools ............................................................................................... 21
4.2 Unpacking the Brake ..................................................................................... 22

Table of Contents
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4.3 Installing the Brake ........................................................................................ 22
4.3.1 Mounting the Brake Hub....................................................................................................... 22
4.3.2 Removing the Magnet Assembly from the Friction Basket .............................................. 23
4.3.3 Mounting the Friction Basket Assembly to the Hub.......................................................... 24
4.3.4 Mounting the Magnet Assembly to the Friction Basket Assembly.................................. 25
4.3.5 Adjusting the Air Gap ........................................................................................................... 26
4.3.6 Replacing the Dust Protection Ring and Enclosure.......................................................... 26
4.4 Testing the Brake Function ........................................................................... 27
5Optional Components and Accessories ...........................................28
5.1 Hand Release Lever ....................................................................................... 28
5.2 Installation ...................................................................................................... 29
5.3 Microswitch .................................................................................................... 31
5.3.1 Installation ............................................................................................................................. 32
5.4 Enclosure Retrofit .......................................................................................... 34
5.4.1 Installation ............................................................................................................................. 35
6Operation .............................................................................................38
6.1 Normal Operation........................................................................................... 38
6.2 Manual Operation........................................................................................... 38
7Rectifiers..............................................................................................39
7.1 Part Numbers.................................................................................................. 39
7.2 Example Wiring Diagrams ............................................................................. 40
7.2.1 Rectifier Wiring Diagrams. ................................................................................................... 40
7.2.2 230VAC OEX Switch Wiring Diagrams................................................................................ 41
7.2.3 460 VAC OEX Switch Wiring Diagrams............................................................................... 42
8Appendix..............................................................................................43
8.1 Appendix 1: Certification............................................................................... 43
9Revision History..................................................................................44

List of Figures
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List of Figures
Figure 1 Theater Load Brake with optional Hand Release Lever and Microswitch.................................... 21
Figure 2 Mounting Surface Clearance ........................................................................................................ 22
Figure 3 Hub Mounted to Mounting Surface............................................................................................... 22
Figure 4 Removing the Enclosure (if present) ............................................................................................ 23
Figure 5 Removing Magnet Assembly from Friction Basket....................................................................... 23
Figure 6 Spring Washer Orientation ........................................................................................................... 24
Figure 7 Mounting the Friction Basket Assembly ....................................................................................... 24
Figure 8 Mounting the Magnet Assembly ................................................................................................... 25
Figure 9 Adjusting the Air Gap.................................................................................................................... 26
Figure 10 Lifting Tab in Storage Position.................................................................................................... 26
Figure 11 Removing the Manual Release Bolts.......................................................................................... 29
Figure 12 Mounting the Hand Release Yoke.............................................................................................. 29
Figure 13 Attaching the Hand Release Handle........................................................................................... 30
Figure 14 Microswitch Assembly ................................................................................................................ 32
Figure 15 Plunger Location......................................................................................................................... 32
Figure 16 Installing the Microswitch Assembly ........................................................................................... 32
Figure 17 Adjusting the Microswitch Plunger.............................................................................................. 33
Figure 18 Returning the Manual Release Bolts to Normal Operation ........................................................ 33
Figure 19 Enclosure Assembly ................................................................................................................... 35
Figure 20 Gasket Installation ...................................................................................................................... 35
Figure 21 Gasket End ................................................................................................................................. 35
Figure 22 Mounting the Enclosure Studs.................................................................................................... 36
Figure 23 Enclosure Plugs.......................................................................................................................... 36
Figure 24 Enclosure Installation.................................................................................................................. 37
Figure 25 Example Rectifier Wiring Diagrams............................................................................................ 40
Figure 26 Example OEX Switch 230VAC Wiring Diagrams ....................................................................... 41
Figure 27 Example OEX Switch 460VAC Wiring Diagram ......................................................................... 42

List of Tables
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List of Tables
No table of figures entries found.

Glossary
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Glossary
AC
Alternating current.
Aggressive Fumes/Liquids Gasses or liquids that are chemically reactive and may cause
corrosion in exposed machine parts.
Air Gap The gap between the armature and the magnet. This air gap must
be precisely adjusted to a specific width, denoted as X. If the air
gap is too wide, the brake may not release torque. 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.
Armature
The component of the brake connected to the magnet which
moves across the air gap to engage or disengage the brake.
When powered off the armature is pressed against the friction
brake assembly by springs causing braking torque. When
powered on the armature is pulled across the air gap by the
magnet and the brake releases.
AWG / Wire Gauge
American Wire Gauge. A measure of the thickness of a wire using
standardized sizes.
Branch Circuit Protection
Circuit protection for the portion of the electrical distribution
system that extends beyond the final branch circuit protection
device. A branch circuit is used to run motors or other appliances,
and is what is commonly found inside a building.
CE
European safety standards for products in the European
Economic Area. Manufacturers self-test products against these
standards to maintain CE certification. The CE mark indicates a
product meets EEA safety standards.
CEC
Canadian Electric Code. Safety standard for electrical installations
used in Canada.
Control Device/Interface
The COMBISTOP brake is controlled electronically by a control
device. This can be as simple as a switch, or as complex as a full
suite of control software.
CSA Canadian Standards Authority, also known as CSA Group.
Organization that tests and certifies products according to
Canadian safety standards. The CSA mark indicates a product
meets Canadian safety standards.
Customer The corporation or individual who purchased the COMBISTOP
brake.
DC Direct current.
Device / KEB Device
The COMBISTOP brake described in this manual.
Drive Shaft A mechanical component for transmitting torque and rotation from
a motor to other parts of a mechanical system.
Dry running Operation in dry environments with no danger of dripping or
splashing liquids.

Glossary
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EC Declaration of
Conformity
Declaration that the device conforms to EU standards of safety.
Enclosure
A metal covering installed to protect the brake from airborn
particles or moisture, and to prevent accidental contact with the
brake that may result in injury.
Equipotential Bonding A practice of intentionally electrically connecting all exposed metal
items not designed to carry electricity in a room as protection from
electric shock.
Flange 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.
Magnet The component of the brake which contains the magnetic
components.
Mounting Surface A surface to which the COMBISTOP device is physically
attached.
NEC US National Electric Code. Safety standard for electrical
installations used in the United States.
Product / KEB Product
See Device.
Recommended tightening
torque
The torque required to fully screw a socket head screw into a
mounting surface. The recommended tightening torque depends
on the type of screw used as well as the material, thread depth
and locking components (if any) used in the mounting surface.
Refer to the machine manufacturer for details on recommended
tightening torques for specific mounting surfaces.
Run-out An inacuracy of rotating mechanical systems whereby the shaft
does not rotate precisely in line with the main axis. Always
present but must be minimized.
Specified Application The specific application for which the COMBISTOP device was
ordered, is usually (but not always) the same as the Application in
which the device is being used.
System Integrator The technician installing the COMBISTOP brake into the
application.
UL Independent Standardization Company that tests and certifies
products according to defined and industry leading safety
standards. The UL mark indicates a product meets UL safety
standards.

Glossary
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Standards for COMBISTOP type 38 Theater Load Brake
The COMBISTOP type 38 Theater Load Brake installation must comply with all relevant
safety standards. The following standards are relevant to the installation and operation of
the Theater Load Brake.
•Directive 2006/42/EC (annex I)
oRegion: EU
oEssential health and safety requirements for the design and construction of
machinery.
•C22.1-18: Canadian Electric Code, Part 1 (CEC)
oRegion: Canada
oElectric safety code detailing safety standards for electric installations in
Canada.
•NFPA 70: National Electric Code (NEC)
oRegion: US
oElectric safety code detailing safety standards for electric installations in the
United States.
•NFPA 79: Electrical Standard for Industrial Machinery
oRegion: US
oIndustrial safety code detailing safety standards for industrial machinery to
protect against fire and electrical hazards.
•OSHA 1910.137
oRegion: US
oPersonal safety code detailing appropriate personal protective equipment for
working on electrical installations.
•OSHA 1910.269
oRegion: US
oOccupational safety code detailing safety standards for electrical power
generation, transmission, and distribution.

Safety Instructions
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2 Safety Instructions
The COMBISTOP type 38 Theater Load Brake is designed and constructed with state-of-
the-art technology in accordance with recognized safety rules and regulations. Improper
use of this device may cause hazards to life and limb of the user or third-parties, or
damage to the application and other material property.
The following safety instructions have been created by KEB America, Inc. for the Theater
Load Brake. These instructions can be supplemented by local, country- or application-
specific safety instructions where relevant.
Violation of the safety instructions in this manual will result in the loss of any liability
claims.
NOTICE
Stay Safe! Stay Informed!
Read the instruction manual prior to operating the device!
Follow all safety and warning instructions!
If you are unsure of any part of these instructions, please contact
KEB prior to operating the device!
2.1 Target Audience
This manual is intended exclusively for the use of qualified electrical/mechanical
technicians. Qualified technicians for the purpose of this document must meet the
following:
•Must have fully read and understood the safety instructions contained in this
manual.
•Must be familiar with the installation and assembly of electrical products.
•Must be familiar with the installation and operation of the product as specified in
this manual.
→See the Installation and Operation chapters for details.
•Must fully understand the specified application of the product.
→See the Specified Application section for details.
•Must be familiar with the hazards and risks of mechanical braking technology.
•Must be familiar with appropriate electrical and safety codes:
oUS: NFPA 70 National Electric Code (NEC)
oCanada: Canadian Electric Code, C22 Part 1 (CEC)
•Must be familiar with national safety regulations (e.g. OSHA Title 29 CFR):
→See the Standards for COMBISTOP type 38 Theater Load Brake section
for details.

Safety Instructions
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2.2 Specified Application
The operational reliability of the brake is only guaranteed when the device is used for the
specified application. In this context, specified application means the purpose for which
the brake was ordered and configured.
Any use of the brake outside of this specified application is considered at the user’s own
risk. Such unintended uses may pose unforeseeable risks or hazards. KEB America, Inc.
retains no liability for any damage or injury resulting from the use of a COMBISTOP
brake outside of the specified application.
2.3 General Safety Guidelines
Carefully observe the following safety guidelines before installation or operation of the
device.
•Only trained personnel should operate the brake.
•Immediately remove the brake from operation in case of a malfunction.
•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
DANGER
Rick of electrical shock!
Turn off the power supply and secure it against switching on prior
to any work on the device.
Never bridge branch circuit protection devices.
Carefully observe the following safety guidelines during the electrical installation.
•Observe all relevant safety standards for the device.
→See the Standards for COMBISTOP type 38 Theater Load Brake section
for details specific to the product.
•Use only wire gauges and fuses rated for the power requirements of the device.
•Ensure new or existing circuits meet NEC or applicable local requirements.
•The device must be appropriately grounded by a connector from the magnet and
the fixed installation.
•When using components without isolated inputs/outputs, equipotential bonding
must be used between the connected components to prevent damage to the
device.
•Do not exceed specified electrical voltage and currant limits.

Safety Instructions
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2.5 Installation and Operation Safety Guidelines
WARNING
Moving parts can crush and cut!
Contact with rotating or moving parts may cause serious injury.
Ensure adequate protection around the brake to prevent
accidental contact!
CAUTION
Hot Surfaces!
The heat generated during the operation of the brake may cause
burns on contact with skin. Always wear appropriate protective
equipment!
Do not start the device until you have confirmed that the installation complies with the
following safety standards.
•Ensure there is sufficient protection against foreign particles entering the air gap.
These particles may impede the motion of the armature.
•Ensure there is sufficient thermal protection such that the brake or clutch does
not exceed or fall below the listed temperature limits for the device.
•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.
2.6 Maintenance Safety Guidelines
DANGER
Risk of electrical shock!
Turn off the power supply and secure it against switching on prior
to any maintenance on the brake.
WARNING
Moving parts can crush and cut!
Contact with rotation or moving parts may cause serious injury.
Wait until the drive has come to a complete stop before
performing any maintenance.
Secure the drive against accidental movement prior to
performing any maintenance.
CAUTION
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.

Safety Instructions
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•Ensure the device is powered off and has come to a complete stop before
performing any maintenance.
•Secure the brake so it cannot be switched on accidentally during maintenance.
•Disconnect the brake from the load before maintenance to avoid uncontrolled
movements.
•Ensure there is sufficient protection against foreign particles entering the air gap
during maintenance.
•Ensure there is sufficient protection against moisture or aggressive gasses that
may compromise the integrity of the friction surface or armature.
2.7 Personal Protective Equipment
When installing or performing maintenance on the brake or clutch, use the following
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.

Product Description
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3 Product Description
3.1 Scope of this Manual
This manual describes the installation and operation of the KEB size 10 COMBISTOP
Type 38 Theater Load Brake. The Theater Load Brake is a specialized version of the
COMBISTOP spring set brake designed for quiet running and loads optimized for the
theater industry.
The size 10 Theater Load Brake can be mounted to an adaptor flange on the gearbox, or
directly on the bulkhead of the machine.
This manual also covers the installation of a microswitch and hand release lever for the
brake, as well as explaining the different rectifiers available for the Theater Load Brake.
3.2 Description
3.2.1 Brake Components
Brake Components
Component
Name
Number Included
1 Brake basket assembly 1
2 Magnet assembly 1
3 Hub 1

Product Description
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Brake Components
Component
Name
Number Included
4
M10 spring washers
30 (5 per stud)
5 M10 nylon lock-nuts 6 (1 per stud)
6
M10 washers
6 (1 per stud)
7 Hand release lever (optional) 1
8 Microswitch (optional) 1
9
Customer supplied mounting bolts (M16 or 5/8‘‘)
4
10
Rubber dust ring
1
11 Hand release spherical washers (optional) 2
12
Hand release bolts (optional)
2
13 Metal enclosure (optional, cannot be used with hand
release lever)
1
14
Sealing Washer (optional)
4
15 Stud for enclosure mount (optional) 4
16 M8 nylon lock-nut for enclosure (optional) 4
17
Lifting eyebolt for hand release lever (optional)
1
18 Lifting tab for standard bolt release 1

Product Description
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3.2.2 Brake Assembly Numbering Scheme
The part number for a COMBISTOP brake describes the device type as well as options
specified for the device. It is important to order the correct brake for your specified
application. Consult the following table for a description of Theater Load Brake part
numbers and their meanings.
XX TY PA B C D E F
Part Number Component Descriptions
Number
Name
Options
Description
XX
Brake Size 10 The only size described in this manual (Fixed)
TY
Type Code 38 Spring Set Brake (Fixed)
P
Disc Code M Multi-Disk Brake (Fixed)
A
Flange Type 0 Generic Flange
1 Generic Flange with Enclosure (Bolt release only)
B
Torque Rating 3 1600 Nm
4 2133 Nm
5 2667 Nm
6 3200 Nm
C
Coil Voltage 0 24 VDC, 5.63 Amps
1 105 VDC, 1.29 Amps
2 170 VDC, 0.79 Amps
3 205 VDC, 0.67 Amps
4 270 VDC, 0.5 Amps
D
Hub Bore (Metric) 0 44 mm, T max: 1600 Nm
1 50 mm, T max: 1600 Nm
F: Special Designation
E: Options
D: Hub Bore
C: Coil Voltage
B: Torque Rating
A: Flange
P: Disk Code (fixed)
TY: Type Code (fixed)
XX: Brake Size

Product Description
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Part Number Component Descriptions
Number
Name
Options
Description
2
55 mm, T max: 2133 Nm
3 60 mm, T max: 2133 Nm
4
65 mm, T max: 2667 Nm
5 70 mm, T max: 3200 Nm
6 75 mm, T max: 3200 Nm
7
80 mm, T max: 3200 Nm
8
85 mm, T max: 3200 Nm
9 90 mm, T max: 3200 Nm
Hub Bore
(Inches)
B 1.875‘‘, T max: 2133 Nm
C 2.000‘‘, T max: 2133 Nm
D
2.125‘‘, T max: 2667 Nm
E 2.250‘‘, T max: 2667 Nm
F 2.375‘‘, T max: 3200 Nm
G
2.500‘‘, T max: 3200 Nm
H 2.625‘‘, T max: 3200 Nm
I 2.750‘‘, T max: 3200 Nm
J 2.875‘‘, T max: 3200 Nm
K 3.000 ‘‘, T max: 3200 Nm
L 3.125 ‘‘, T max: 3200 Nm
M
3.250 ‘‘, T max: 3200 Nm
E
Options 0 Bolt release, no microswitch
1 Hand release, no microswitch
2
Bolt release with microswitch
3 Hand release with microswitch
4 Bolt release with double microswitches
5 Hand release with double microswitches
F Special
Designation
0 Standard
X Special, number C, D and E are randomized

Product Description
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3.3 Brake Specifications
Coil Specifications
Specification
Value
Voltage Variable
Power 135W
Current 135W/Coil Voltage
Mounting Can be mounted vertically or horizontally
Max Operating Speed 200 RPM
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