KEBCO COMBISTOP 38 User manual

INSTRUCTION MANUAL
COMBISTOP Type 38
Karl E. Brinkmann GmbH
Försterweg 36 - 38
D-32683 Barntrup
Phone [phone]
Telefax [phone]
E-Mail [e-mail]
Internet www.keb.de

01.09.2011 Rev. 01 COMBISTOP Type 38

01.09.2011 Rev. 01 COMBISTOP Type 38
Version 01
Date: September 2011
© Karl E. Brinkmann GmbH
This instruction manual and all figures contained therein are protected by copyright. Without the
prior written consent of the publisher, any use of this manual which infringes the copyright
provisions is not permitted and will lead to legal prosecution. This particularly applies to the
reproduction, translation, digital storage, and processing in electronic systems.

Table of Contents
01.09.2011 Rev. 01 COMBISTOP Type 38 Page I
Table of Contents
1Introduction ...................................................................................................................1
1.1 Means of Representation.................................................................................................2
1.2 Safety Instructions...........................................................................................................2
1.2.1 General Safety Instructions .............................................................................................3
1.2.2 Safety Instructions for Operation .....................................................................................4
1.2.3 Safety Instructions for Maintenance.................................................................................4
1.2.4 Permissible Friction Work ................................................................................................4
1.2.5 Special Risks when Using the Brake ...............................................................................4
1.2.6 Risks Caused by Electric Power ......................................................................................5
1.2.7 Personal Protective Equipment .......................................................................................5
1.3 Obligation of the Operating Company..............................................................................5
1.4 Obligation of the Personnel .............................................................................................6
1.5 Specified Application .......................................................................................................6
1.6 Guarantee and Liability....................................................................................................7
2Product Description ......................................................................................................8
2.1 Overview/Parts List..........................................................................................................8
2.2 Functional Description .....................................................................................................9
2.3 Safety Devices ................................................................................................................9
2.3.1 Micro Switch (Option) ......................................................................................................9
3Transport and Storage ................................................................................................10
3.1 Inspections on Acceptance by the Recipient .................................................................10
3.2 Notes on Transport........................................................................................................10
3.3 Packaging .....................................................................................................................10
3.4 Storage Instructions for Temporary Storage ..................................................................10
4Mounting and Start-up ................................................................................................11
4.1 Mounting .......................................................................................................................11
4.1.1 Notes on Mounting ........................................................................................................11
4.1.2 Mounting the Brake .......................................................................................................12
4.1.3 Mounting the Hand Release (Option) ............................................................................14
4.1.4 Micro Switch (Option) ....................................................................................................17
4.1.4.1 Replacing the Micro Switch ...........................................................................................18
4.1.4.2 Checking the Micro Switch Settings...............................................................................19
4.1.4.3 Readjusting the Micro Switch ........................................................................................20
4.1.5 Electrical Connection.....................................................................................................21
4.1.5.1 Connecting the Brake ....................................................................................................22
4.2 Initial Start-up ................................................................................................................24
4.2.1 Inspections prior to Start-up of Brake ............................................................................24
4.2.2 Notes on Running-in Process ........................................................................................24
5Operation .....................................................................................................................25
5.1 Actuating the Hand Release ..........................................................................................25
6Malfunctions ................................................................................................................26

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6.1 Safety Instructions.........................................................................................................26
6.2 Troubleshooting.............................................................................................................27
7Maintenance and Cleaning .........................................................................................28
7.1 Safety Instructions.........................................................................................................28
7.2 Maintenance Intervals ...................................................................................................28
7.3 Maintenance Work.........................................................................................................29
7.3.1 Checking the Air Gap ....................................................................................................29
7.3.2 Readjusting the Air Gap ................................................................................................30
7.3.3 Replacing the Lining ......................................................................................................31
7.4 Notes on Cleaning.........................................................................................................33
8Dismounting and Disposal .........................................................................................34
8.1 Dismounting ..................................................................................................................34
8.2 Disposal ........................................................................................................................34
9Annex ...........................................................................................................................35
9.1 Technical Data ..............................................................................................................35

Introduction
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1 Introduction
This instruction manual provides all information required to properly operate the KEB
brake and applies to the following brake types:
–COMBISTOP Type 38
COMBISTOP Type 38.11N
without hand release for dynamic applications (regular rated torque)
COMBISTOP Type 38.13N / DEN
with hand release for dynamic applications (regular rated torque)
COMBISTOP Type 38.11H
without hand release for static applications (enhanced rated torque)
COMBISTOP Type 38.13H / DEH
with hand release for static applications (enhanced rated torque)
The type designation can be found on the type plate and/or the code number.
The instruction manual must be read, understood and applied by all persons
responsible for the operation of the brake. This particularly applies to the safety
instructions herein.
After reading the instruction manual, you can
–operate the brake safely,
–perform maintenance work according to regulations,
–take the corresponding measure in case of a malfunction.
Before starting to install the COMBISTOP type 38 brake, carefully read this instruction
manual.
The following sections describe the functional principle, the mounting and the basic
operation of the brake.
The information contained in the technical documentation, as well as any user-specific
advice in spoken and written form and through tests, are made to best of our
knowledge and information about the application. However, they are considered for
information only without responsibility. This also applies to any violation of industrial
property rights of a third party.
Inspection of our units in view of their suitability for the intended use must be done
generally by the user.
Application and use of our units in the target products is outside of our control and
therefore exclusively in the area of responsibility of the user.
In addition to this instruction manual, observe all applicable legal regulations and other
mandatory requirements applying to accident prevention as well as environmental
protection in the country of utilisation.
Always keep the instruction manual at the site where the brake is used.

Introduction
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1.1 Means of Representation
For information purposes as well as to directly warn the operator of dangers, any
information given in this instruction manual which needs to be strictly observed is
marked as follows:
Note!
This symbol is used to indicate notes on a function and/or setting or
on the importance of being cautious when working.
This symbol in connection with the respective signal word is used to
indicate the following important instructions:
–Caution!
Is used to indicate a hazardous situation with a low level of risk
which could result in minor or moderate bodily injuries or material
damages if the warning is ignored.
–Warning!
Is used to indicate a possibly hazardous situation with a medium
level of risk which may result in death or (severe) bodily injuries if
the warning is ignored.
–Danger!
Is used to indicate an imminently hazardous situation with a high
level of risk which will result in death or (severe) bodily injuries if the
warning is ignored.
Caution!
Warning!
Danger!
Warning - Dangerous Electrical Voltage!
This symbol is used to indicate electrical hazards.
Only qualified and authorised electricians may work on electrical
equipment!
Danger!
In addition, the following means of representation are used:
–Any text following this marking is considered a list.
Any text following this marking describes the actions which need to be executed in
the specified order or which are automatically executed.
"..." Any text marked by quotation marks refers to other chapters or sections.
1.2 Safety Instructions
Note!
Carefully read the safety instructions and hazard warnings outlined in
this section prior to mounting and start-up of the brake!

Introduction
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1.2.1 General Safety Instructions
Prior to mounting and start-up, carefully read the instruction manual, particularly
observing the safety instructions and recommendations therein. Failure to comply with
these instructions may result in personal injury and material damages. Furthermore,
observe the state of the art as well as all applicable safety regulations and standards of
the respective countries.
The spring-applied brake corresponds to the state of the art at the time of delivery and
is generally safe to operate.
Only qualified personnel may transport, mount, start up, operate and maintain the
brake.
Qualified personnel in the context of these general safety instructions refers to persons
who are familiar with the transport, mounting, installation and commissioning of the
brake as well as with the relevant standards, and who are sufficiently qualified in their
field of expertise.
–Only trained personnel may commission the brake.
–Immediately put the brake out of operation in case of malfunctions. Have
appropriately trained personnel or the manufacturer correct the malfunctions.
–Do not exceed the technical performance data (see section "9.1 Technical Data").
–Never use the brake in potentially explosive or aggressive atmospheres!
–The brake must not be converted, modified or misused.

Introduction
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1.2.2 Safety Instructions for Operation
Protective measures to be taken by the user:
–Protection against the ingress of foreign particles into the air gap. These particles
may impede the movement of the armature.
–Protection against dangerous temperatures at the magnet of the brake.
High temperatures may cause the torque to decrease.
–Protection against accidental contact with rotating or moving parts, i. e., protection
against being crushed or caught.
–Never use the brake in potentially explosive or aggressive atmospheres!
–Protection against electric shock by installing a protective earth conductor between
the magnet and the fixed installation incl. standardised inspection of the protective
earth conductor connection to all exposed metal parts.
–Measures against freezing and/or formation of ice on the friction surfaces and the
resulting loss of torque.
–The movement of the armature must not be impeded by the ingress of foreign
particles into the air gap. If necessary, dust protection rings (accessories) are to be
used or other protective measures are to be taken.
–Air humidity, aggressive vapours/liquids or the like may lead to corrosion and cause
the lining to stick. In this case, the user needs to provide appropriate measures!
1.2.3 Safety Instructions for Maintenance
Protective measures to be taken by the user:
–Secure the brake against being switched on accidentally during maintenance work.
–When working on the brake, disconnect the brake from load to avoid uncontrolled
movements!
–Protection against the ingress of foreign particles into the air gap. These particles
may impede the movement of the armature.
–When carrying out maintenance and repair work, the brake must not be energised!
–The lining must not come into contact with cleaning agents or solvents.
1.2.4 Permissible Friction Work
When operating the brakes, adhere to the friction work values specified in the KEB
catalogue "Electromagnetic Technology" taking the frequency of operation and the
speed into account. Exceeding these specifications may result in thermal overload of
the lining and a strong decrease in braking torque.
1.2.5 Special Risks when Using the Brake
The brake has been designed and built in accordance with the state-of-the-art
technology and recognised safety regulations. Nevertheless, the following residual
risks exist when using the brake:

Introduction
01.09.2011 Rev. 01 COMBISTOP Type 38 Page 5
Danger - Rotating Parts!
The brake is used to decelerate rotating axes.
There is a risk of body parts being caught or crushed. Depending on
installation, provide safety measures against being caught or crushed!
Warning!
Warning - Hot Surface!
The heat generated during the operation of the brake causes the
surfaces to heat up!
Due to the risks arising therefrom, always use appropriate personal
protective equipment when operating the brake (see section
"1.2.7 Personal Protective Equipment").
Caution!
Always observe the safety information and/or warnings on the brake and in this
instruction manual!
1.2.6 Risks Caused by Electric Power
–Only an electrician may work on the electrical power supply.
–The electrical equipment of the brake (connecting cable, upstream rectifier) needs to
be checked by an electrician for proper functioning and defects such as, for
example, loose connections or burned cables, at regular intervals. Have the defects
remedied immediately.
–If work needs to be done on live parts, ask a second person to switch off the main
power supply switch in case of emergency. Cordon off the working area with a red-
white safety chain and put up warning signs. Only use insulated tools.
1.2.7 Personal Protective Equipment
When using the brake, use the following personal protective equipment:
–long-sleeved protective clothing,
–safety gloves,
–safety shoes,
–safety goggles.
The personal protective equipment is to be provided by the operating company and
must comply with the applicable requirements.
1.3 Obligation of the Operating Company
The operating company shall be obliged to
–only have personnel working on the brake who are familiar with the basic regulations
applying to occupational health and safety as well as accident prevention and who
have been instructed on the operation of the brake,
–instruct the personnel on the safe operation of the brake at regular intervals,
–provide the personal protective equipment required to operate the brake.