Kendrion 77 500 B Series User manual

MODULE LINE
Operating Instructions 77 500..B..
Spring-applied single-disc brake module
Types: 77 50013B16 77 50019B15
77 50024B15 77 50029B15

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 2
Contents
1.General information .............................................................................................................................. 3
1.1Introduction............................................................................................................................................ 3
1.2Standards and directives....................................................................................................................... 3
1.3Manufacturer’s liability........................................................................................................................... 3
1.4Declaration of Incorporation (in accordance with Annex II, part 1, Section B of Machinery Directive
2006/42/EC)........................................................................................................................................... 4
2.Safety...................................................................................................................................................... 5
2.1Safety and warning symbols / Safety information ................................................................................. 5
2.2Intended use.......................................................................................................................................... 5
2.3General safety information..................................................................................................................... 6
2.3.1Installation.......................................................................................................................................... 6
2.3.2Start-up.............................................................................................................................................. 6
2.3.3Operation........................................................................................................................................... 6
2.3.4Maintenance and repair..................................................................................................................... 7
3.Emissions............................................................................................................................................... 7
3.1Noise...................................................................................................................................................... 7
3.2Heat ....................................................................................................................................................... 7
3.3Electromagnetic compatibility................................................................................................................ 7
4.Product description ............................................................................................................................ 10
4.1Operating principle............................................................................................................................... 10
4.2Design.................................................................................................................................................. 10
5.Installation............................................................................................................................................ 12
5.1Mechanical installation......................................................................................................................... 12
5.1.1Brake shaft (13) installation............................................................................................................. 12
5.1.2Mounting the brake module to the motor......................................................................................... 13
5.2Installation of accessories (not applicable to the brake shaft (13)) ..................................................... 14
5.3Electrical connection and operation..................................................................................................... 15
5.3.1DC power supply ............................................................................................................................. 17
5.3.2AC power supply.............................................................................................................................. 17
5.3.3Electrical connection of brake modules with microswitch (27)........................................................ 18
5.4Set-up and start-up.............................................................................................................................. 18
5.4.1Manual brake release...................................................................................................................... 19
5.5M4transmissible torque adjustments................................................................................................... 20
6.Maintenance......................................................................................................................................... 21
6.1Checks and service ............................................................................................................................. 21
6.2Brake module removal from motor and replacement of component parts.......................................... 22
6.3Microswitch (27) adjustment (only applicable to brake modules with microswitch (27))..................... 23
6.4Brake shaft (13) removal ..................................................................................................................... 24
7.Motor design........................................................................................................................................ 25
8.Driven components, balancing.......................................................................................................... 26
9.Condition at delivery........................................................................................................................... 26
10.Troubleshooting.................................................................................................................................. 27
11.Definitions............................................................................................................................................ 28
12.Technical specifications..................................................................................................................... 28
13.Revision history .................................................................................................................................. 29
Document information:
Issued by: Kendrion (Villingen) GmbH Division: Industrial Drive Systems
Replacement for document: - Replaces the issue dated: 2 July 2012
Type of document: Translation of German operating Document status: Released
instructions BA 77 500..B..
Designation of document: BA 77 500..B.. Englisch

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 3
1. General information
1.1 Introduction
These Operating Instructions describe the operating principle and features of Kendrion Binder spring-applied
single-disc brake modules type 77 500..B...
The safety information provided in this manual must be strictly observed during the set-up of the machine
(e.g. motor) and during the start-up, operation and maintenance of the spring-applied brake module.
Should any queries arise with respect to torques, torque variations, installation position, wear, wear reserve,
switching work, break-in conditions, release range, ambient conditions and the like, please contact Kendrion
Binder and ask for clarification before starting to use the brake.
Kendrion Binder spring-applied single-disc brake modules type 77 500..B.. are not ready-to-use devices, but
are intended to be incorporated into or assembled with other equipment. Consequently, these brakes will be
referred to as components in the following sections. The output side of the spring-applied single-disc brake
modules has the same fitting dimensions as the motor end shield. As a result, the brakes are designed as
fail-safe holding brakes with emergency stop function for attachment to electric motors.
1.2 Standards and directives
The state-of-the-art spring-applied brakes have been designed, built and tested in accordance with the
requirements of DIN VDE 0580 concerning electromagnetic devices and components. Being classified as
"electromagnetic components", spring-applied single-disc brake modules are not subject to the Low Voltage
Directive and must not bear a CE mark of conformity. The user is required to employ suitable switching
devices and controls to ensure use of the brakes in accordance with EMC Directive 2004/108/EC.
1.3 Manufacturer’s liability
The manufacturer will not assume any responsibility for damage caused by failure to use the products in
accordance with their intended use or by failure to observe safety information and other instructions provided
in this manual. The information in this manual was correct and up-to-date before going to print. The
information contained herein shall not entitle users to raise claims with respect to components purchased at
an earlier date.

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 4
1.4 Declaration of Incorporation
(in accordance with Annex II, part 1, Section B of Machinery Directive 2006/42/EC)
We hereby declare that the products below comply with the essential health and safety requirements
specified in Annex I of Machinery Directive 2006/42/EC:
Annex I General Principles, Annex I Sections 1.1.2, 1.1.3, 1.1.5, 1.3.2, 1.5.1
The partly completed machinery must not be put into service until the final machinery into which it is to be
incorporated has been declared in conformity with the provisions of Machinery Directive 2006/42/EC. The
relevant technical documentation required for the partly completed machinery has been compiled in
accordance with Annex VII, part B of Machinery Directive 2006/42/EC. The manufacturer undertakes to
submit an electronic copy of the relevant technical documentation compiled for the partly completed
machinery if reasonably requested by national authorities.
Standards and directives:
EN 60529 Enclosure protection ratings
DIN VDE 0580 Electromagnetic devices and components
Products: Electromagnetically released spring-applied single-disc brake module
77 50013B16
77 50019B15
77 50024B15
77 50029B15
Manufacturer: Kendrion (Villingen) GmbH
Industrial Drive Systems
Wilhelm-Binder-Straße 4-6
78048 Villingen-Schwenningen
Germany
Person authorized Dr Uwe Gnauert
to compile the Kendrion (Villingen) GmbH
documentation: Industrial Drive Systems
Wilhelm-Binder-Straße 4-6
78048 Villingen-Schwenningen
Germany
Kendrion (Villingen) GmbH
Industrial Drive Systems Villingen Authorized signatory: ....................................................
12 Dec. 2013 (Dr Uwe Gnauert)
(Head of Development at IDS)

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 5
2. Safety
2.1 Safety and warning symbols / Safety information
Personal injury or equipment damage
Symbol / Signal word Warns against ... Potential risks and hazards
Danger imminent personal injury fatal accidents or serious injury
Warning potential risk of serious
personal injury fatal accidents or serious injury
Caution potential risk of personal injury minor injury
Attention potential risk of equipment
damage damage to components or other equipment
Information
Symbol / Signal word Provides information on …
Note the safe use and operation of the product
The brakes described in these Operating Instructions have been designed and built on the basis of an
analysis of hazards and in accordance with the requirements of the applicable harmonized standards and
technical specifications. They correspond to the state of the art and provide maximum safety. However,
safety hazards can only be avoided if the user of the equipment takes adequate precautions and makes sure
that safety instructions are strictly adhered to. It is the duty of the user of the machine to plan these
measures and to check their implementation.
The user is required to ensure that:
the brakes are only used in accordance with their intended use (see "Product description" section).
the brakes are in perfect working order and checked at regular intervals.
a complete copy of these Operating Instructions is kept available at the place of use of the brakes at
all times.
all applicable local and machinery-specific regulations and requirements are followed.
start-up, maintenance and repair work is only done by authorized and suitably qualified personnel.
such personnel are kept informed on all relevant occupational safety and environmental protection
issues and familiar with these Operating Instructions and with the safety information contained
herein.
brake functionality is not interfered with by an external magnetic field.
2.2 Intended use
The brake modules described in these Operating Instructions are intended to be assembled with electric
machines, in particular electric motors, for use on industrial equipment. Operation in potentially explosive or
firedamp atmospheres is not allowed. The brake modules must be used in accordance with the operating
requirements detailed in this manual. The rated power limits specified herein must not be exceeded. Use of
the brake modules as service brakes or safety brakes is not permitted.

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 6
2.3 General safety information
Brakes fitted to motors feature hazardous live components and rotating parts and may exhibit hot surfaces.
Any work associated with the transport, connection, start-up and periodical maintenance of the brakes must
be carried out by authorized and qualified specialist personnel (in accordance with VDE 0105; IEC 364).
Failure to observe safety, operating and maintenance instructions may cause serious personal injury and
severe damage to the equipment. Whenever special measures are required in accordance with the
instructions contained herein, such measures should be agreed with the brake manufacturer before the
machinery into which the brake is to be incorporated is set up.
Should any queries arise with respect to torques, torque variations, installation positions, wear, wear reserve,
switching work, break-in conditions, release range, ambient conditions and the like, please contact Kendrion
Binder and ask for clarification before using the brake.
Retrofitting or modification work to be carried out on the brake is subject to the approval from Kendrion
Binder.
Accident prevention regulations applying to the specific field of application of the brake must be strictly
observed.
The brakes described in this manual are not designed for use as "safety brakes". This means that torque
reductions caused by factors beyond the user's control cannot be excluded.
2.3.1 Installation
When connecting the brakes described in these Operating Instructions check that the voltage and voltage
type comply with the specifications on the rating plate. Sufficient heat dissipation must be ensured when the
brake is fitted to or incorporated into other equipment.
Adequate precautions must be taken to avoid overvoltage during disconnection or voltage peaks. The
magnetic field of the products may cause interference outside the brake or even feedback to the brake in
case of adverse installation conditions. Should you have queries concerning mounting and fitting conditions,
please contact the brake manufacturer and ask for clarification.
Adequate safety measures (DIN VDE 0848, part 4; DIN 31000/VDE 1000; DIN VDE 0100, part 0420) must
be taken by the brake user to avoid hazards to persons or damage to equipment caused by:
direct or indirect effects of electromagnetic fields,
heated components,
moving parts.
2.3.2 Start-up
The brakes must not be started up when:
power supply cables/wires or connections are damaged.
the solenoid housing or coil sheath is damaged.
other defects are suspected.
2.3.3 Operation
Make sure that live components such as plug contacts or the field coil are not exposed to water.
The brake cable connections must not be crushed, squeezed or exposed to mechanical loads.
Check that the friction surfaces of the friction elements are not contaminated with grease, oil or other fluids to
avoid substantial torque reduction. Bear in mind that the original torque cannot be restored even if the friction
surfaces are cleaned after contact with fluids.
The gradual brake wear towards the end of the brake service life may cause an approximately 10% torque
reduction. This must be taken into consideration in the set-up of the machine or overall system.
Due to the diverse ambient conditions in which the brakes may be used, always check that the brake module
is in perfect working order before start-up.
Torque reductions cannot be excluded if the brake module is used for applications where only minimum
friction work is required. In such cases, the user should ensure that the brake occasionally performs
sufficient friction work.

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 7
Note!
The maximum air gap smax (see Table 28/1: air gap snom and smax) must not be exceeded throughout the
entire brake module service life. (Please refer to Section 6 “Maintenance” for details.)
2.3.4 Maintenance and repair
Repair work must only be carried out by qualified specialist personnel (definition to IEC 364). Failure to
perform repairs according to requirements may cause serious personal injury or equipment damage.
Make sure that no voltage is applied to the brakes when carrying out maintenance work.
3. Emissions
3.1 Noise
The spring-applied single-disc brake module produces switching noise during engagement and release. The
noise level is determined by the installation conditions, circuitry and air gap. Depending on the mounting
position, operating conditions and state of the friction surfaces, audible vibrations (squealing) may be
produced during braking.
3.2 Heat
Braking operations and gradual heating of the field coil cause the solenoid housing temperature to increase
substantially. Under adverse conditions, the surface temperature may rise to well over 100°C.
Caution!
Risk of burns in case of contact with hot surfaces! Suitable covers and hand guards must be installed to
provide protection against accidental contact.
3.3 Electromagnetic compatibility
As required by the German Electromagnetic Compatibility Act (EMVG), electromagnetic compatibility must
be guaranteed to ensure immunity to external electromagnetic fields and conducted interference.
Furthermore, the emission of electromagnetic fields and line-conducted interference during brake operation
must be minimized. Since the brake features depend on the circuitry and operation, a declaration of
conformity with the applicable EMC standard can only be furnished for the wiring type, but not for a specific
brake.
The spring-applied single-disc brake modules type 77 500..B.. are designed for industrial applications to
which the following EMC standards apply: Generic Immunity Standard EN 61000-6-2 and Generic Emission
Standard EN 61000-6-3 / EN 61000-6-4.
Other applications may be subject to different generic standards which must be considered by the
manufacturer of the overall system. The requirements in terms of electromagnetic compatibility of devices
and components are determined by basic standards derived from the generic standards. Brake wiring
recommendations will be provided in the following sections to ensure compliance with the individual basic
standards that are relevant for industrial use of the brake and some other applications.
For additional information on electromagnetic compatibility, especially with respect to the recommended
electronic rectifiers specified in Section 5.3, please refer to the applicable data sheets.

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 8
Immunity according to EN 61000-4:
EN 61000-4-2 Electrostatic discharge:
The spring-applied single-disc brake modules comply at least with severity level 3 without requiring
additional measures. The recommended rectifiers specified in Section 5.3 conform to severity level 3 without
additional measures.
EN 61000-4-3 Electromagnetic fields:
The spring-applied single-disc brake modules comply at least with severity level 3 without requiring
additional measures. The recommended rectifiers conform to severity level 3 without additional measures.
EN 61000-4-4 Fast transients (burst):
The spring-applied single-disc brake modules comply at least with severity level 3 without requiring
additional measures. The recommended rectifiers conform to severity level 3.
EN 61000-4-5 Surge:
The spring-applied single-disc brake modules comply at least with severity level 3 without requiring
additional measures. The recommended rectifiers conform to severity level 3.
EN 61000-4-9 Pulse magnetic fields, EN 61000-4-10 Damped oscillatory magnetic fields:
Since the operating magnetic fields of the electromagnetic brakes are stronger many times over than
interference fields, the brake function will remain unaffected. The spring-applied single-disc brake modules
comply at least with severity level 4. The recommended rectifiers conform at least to severity level 3.
EN 61000-4-11 Voltage dips, short interruptions, and short supply voltage variations:
a) Voltage interruptions:
Spring-applied single-disc brake modules that comply with the requirements of DIN VDE 0580 are de-
energized after the specified switching times at the latest. The switching time depends on the control
and mains conditions (e.g. generator effect of running down motors). Voltage interruptions of shorter
duration than the response delay specified by DIN VDE 0580 will not cause any malfunctions. The user
must ensure that any consequential damage is avoided (e.g. motor start-up before the brake has been
released caused by phase failure in the case of two-phase energized motors or by the slipping of an
electromagnetically engaged system due to torque drop). The functional reliability of the
electromagnetic brake and its electronic accessories remains unaffected provided that the
aforementioned consequential damage is avoided.
b) Voltage dips and short supply voltage variations:
Electromagnetically released systems:
Voltage dips and supply voltage variations to below 60% of the rated voltage and lasting longer than the
response delay specified by DIN VDE 0580 may cause the brake to be de-energized temporarily.
Consequential damage as described under a) above must be avoided by the user by taking adequate
precautions.
Electromagnetically engaged systems:
Voltage dips and supply voltage variations to below the minimum tolerance threshold will cause torque
reductions. The user is required to take adequate precautions to avoid consequential damage.

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 9
Radio interference suppression in accordance with EN 55011:
The brake modules and the recommended electronic rectifiers are classified as Group 1 equipment in
accordance with EN 55011. As far as the emissions from this equipment are concerned, one distinguishes
between field guided radiated interference and line-conducted interference.
a) Radiated interference:
When operated with DC voltage or rectified 50/60 Hz AC
voltage, all brakes comply with the limit values
applicable to Class B equipment.
b) Conducted interference:
When connected to a DC power source, the
electromagnetic brakes meet the limit values applicable
to Class A equipment. If the brakes are connected to a
50/60 Hz AC power source and equipped with electronic
rectifiers or other electronic controls, interference
suppression measures as shown in Fig. 9/1 must be
taken to ensure compliance with the limit values
applicable to Class A equipment.
Interference suppression capacitors should be used which must be dimensioned to suit the connection
data of the electromagnetic components and the specific mains conditions. The recommended rectifiers
specified in Section 5.3 are CE mark certified in accordance with the EMC Directive. They have built-in
interference suppression components and comply at least with the requirements of EN 55011 for Class
A equipment, unless otherwise specified in the specification sheets. When brakes are used with the
specified rectifiers or with other types of rectifiers, the recommended values listed in Table 9/1 should
be observed.
Interference suppression components should be installed as close as possible to the consumer.
Interference caused during switching operations of the electromagnetic component is generally
attributable to the inductive load.
Where necessary, assemblies designed to limit the disconnection voltage (e.g. anti-parallel diode) or
voltage limiting components (e.g. varistors, suppressor diodes, resistance diodes and the like) can be
installed. However, such components will inevitably change the switching times of the brake and
increase the generated noise level. The rectifiers specified in Section 5.3 are equipped with free-wheel
diodes and/or varistors to limit the disconnection voltage.
In case of DC side switching, a varistor rated for the type-specific maximum operating voltage and
connected in parallel with the field coil (1.2) limits the peak voltage to the values specified in Table 9/2.
Note!
If the brake is used in connection with other electronic accessories, the user is responsible to ensure
compliance with EMC requirements. Compliance with applicable standards concerning the design and
operation of components, sub-assemblies or equipment employed shall not relieve the user and
manufacturer of the overall system from their obligation to furnish proof of conformity of the overall system
with such standards.
Rectifier type Rated input voltage range
U1/VAC (40-60 Hz) DC at L-load
(ADC) Capacitor (nF/VAC)
Half-wave rectifier
32 07332B40 up to 500 (10%) up to 2.0 no additional
interference suppression
measures required
Table 9/1
Max. rectifier operating voltage
(VAC) Recommended disconnection voltage for DC side switching (V)
250 700
Table 9/2
U
R
C
L
Fig. 9/1

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 10
4. Product description
4.1 Operating principle
The brake module is an electromagnetic component with built-in electromagnetically released spring-applied
single-disc brake designed to operate dry. The braking effect is produced by the spring force and neutralized
electromagnetically. The brake module with ball bearing supported brake shaft should preferably be mounted
to the A-face end shield of electric motors. The brake can also be equipped with an optional hand release so
that it can be released manually.
4.2 Design
The solenoid housing (1.1) with the encapsulated field coil (1.2) accommodates the armature (2), friction disc
(4) and flange (3). The flange is fixed by means of the cheese head screws (10). The compression springs
(7) located in the solenoid housing (1.1) are supported on the adjusting ring (9) and solenoid housing (1.1)
by the studs (8) (size 13 brakes: compression springs (7) only). These compression springs generate an
axial force that is transmitted to the friction disc (4) through the armature (2). As a result, the friction disc (4)
is clamped between the firmly fixed flange (3) and the armature (2) and the braking effect (torque) is
produced. Straight pins (5) are provided which act as tangential torque supports for the armature (2) relative
to the solenoid housing (1.1).
When DC voltage is applied to the field coil (1.2), the electromagnetic force thus generated causes the
armature (2) to be attracted, overcoming the force of the compression springs (7). The friction disc (4) is thus
released and the braking effect is neutralized.
As the brake module is a closed system, no forces are transmitted outwards away from the brake.
Transmission of the braking force from the axially moveable friction disc (4) to the brake shaft (13) is
achieved through the form-fit connection of the square socket in the friction disc with the brake shaft (13),
with the brake shaft being rigidly connected with the motor shaft. This applies to size 13, 19 and 24 brakes.
When a size 29 brake is used, the friction disc is connected with the brake shaft by means of the teeth
provided on the disc and shaft. The ball bearing (15) located between the solenoid housing (1.1) and brake
shaft (13) ensures that the brake can be centred relative to the brake shaft (13) and motor shaft when it is
mounted to the motor flange. The bearing also absorbs transverse forces that act radially on the brake shaft
(13). The ball bearing is factory-sealed.
An additional sealing ring (6) is provided which protects the friction disc (4) against dirt, grease or oil ingress
in case the factory-installed ball bearing sealing rings are damaged and ensures that abrasive grit and dust
produced by the friction disc cannot escape.
On the drive side, the flange (3) and brake shaft (13) are sealed by the sealing ring (11). The optional hand
release (24) allows the spring-applied single-disc brake module to be released manually (e.g. in case of
power failure). The brake must be connected directly to the terminals in the connector box (19).
The transmissible torque of the brake module can be changed with the adjusting ring (9). Rubber bolts (18)
and an O-ring (26) are provided to reduce the noise and vibration produced by the friction disc (4).
Key to Fig. 11/1:
1.1 Solenoid housing 15 Ball bearing
1.2 Field coil 16 Circlip
2 Armature 17 Screw plug
1)
3 Flange 18 Rubber bolt
2)
4 Friction disc 19 Connector box
5 Straight pin 20 Feather key
6 Sealing ring
7 Compression spring 22 Sealing washer
8 Stud (not used in size 13 brakes) 23 Cover (2 x arranged at 180°)
3)
9 Adjusting ring (not used in size 13 brakes) 24 Hand release (accessories)
10 Cheese head screw 25 Set screw
1)
11 Sealing ring 26 O-ring
4)
12 Disc E Adjusting ring clearance
13 Brake shaft A Contact surface motor side
14 Spring washer B Contact surface brake shaft (13)
1) bonded with Loctite 243; installed in brake shaft (13)
2) accessories for size 19 and 24 brakes; included as standard parts of friction disc (4) in size 13 brakes
3) only used in brakes without hand release (24)
4) only in size 29 brakes

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 11
Fig. 11/1: Spring-applied single-disc brake module 77 500..B15
Fig. 11/2: Microswitch installation on spring-applied single-disc brake module 77 500..B15
Release direction
Output side Drive side
Rated air gap
turned
by 45°
Microswitch Direction
Brake with microswitch

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 12
Key to Fig. 11/2:
27 Microswitch 31 Stud
28 Strap 32 Straight pin
29 Cheese head screw (2x) 33 Bellows
30 Oval head screw (2x) 34 Hexagon head cap screw M2.5x8 (not supplied)
5. Installation
Attention!
Every time the spring-applied single-disc brake module is reassembled, the fixing screws and cheese head
screws (10) must be tightened to the MAtightening torques specified in Table 13/1 and Table 22/1. The
adjusting ring (9) must be secured with the set screw (25) (tightening torque MA= 3 Nm). Loctite 243 must be
applied to the set screw (25). When maintenance work is carried out on the connector box (19) (see Section
5.3), the cheese head screws (19.3) must be tightened to MA= 1.6 Nm when installing the cover (19.1) with
the connector box (19). Damage to the seal between the connector box (19) and cover (19.1) must be
avoided.
5.1 Mechanical installation
5.1.1 Brake shaft (13) installation
The press-fit connection of the brake shaft (13) with the motor shaft provides reliable transmission of the
brake torque. An additional form-fit connection in the form of a feather key, for example, is not allowed. The
motor shaft must not have a feather key groove.
Attention!
The fits and surface roughness required for the motor shaft must be chosen by the brake user according to
the adjusted transmissible brake torque and must be suitable to ensure reliable transmission of the
generated brake torques.
1. Before heating the brake shaft (13), make sure that both the brake shaft (13) and the motor shaft end are
dry and free from grease and that the following parts have been removed:
screw plug (17) – any brake size,
rubber bolts (18) (accessories) – sizes 19 + 24,
O-ring (26) (accessories) – size 29.
2. Check the position of the motor shaft contact shoulder relative to the contact surface of the brake on the
motor flange and correct it by installing shim rings, if necessary. The permitted tolerance is 0.5 mm.
3. Before mounting the brake shaft (13), check the radial runout on the motor shaft end and mark the
maximum runout angle on the front face of the motor shaft.
4. After completion of the above operations, the brake shaft (13) must be evenly heated in an electric oven
or by means of an inductive heating system until it has reached a temperature of 280°C to 300°C. Once
heated, the brake shaft (13) must be slipped onto the motor shaft end until it touches the contact
shoulder and secured in axial direction until is has cooled down. Make sure that the brake shaft (13) is
mounted in such a way that the radial runout mark is offset by 180° relative to the runout mark on the
motor shaft.
5. After the brake shaft has cooled down, screw the screw plug (17) into the brake shaft (13) and secure it
with Loctite type 222. This applies to all brake sizes.
6. When rubber bolts (18) are used (size 19 and 24 brakes), insert the bolts (18) into the bores provided in
the brake shaft (13) (see Fig. 11/1) after the shaft has cooled down.
7. When using a size 29 brake, insert the O-ring (26) into the groove in the brake shaft (13) (see Fig. 11/1).
8. If rubber bolts (18) (size 19 + 24 brakes) or an O-ring (26) (size 29 brakes) are used, check that they are
correctly positioned (rubber bolts (18): rounded end pointing outwards in the bores of the brake shaft
(13) square socket; O-ring (26): located in the groove near the brake shaft teeth).
9. During brake mounting, apply talc to the projecting surface of the rubber bolts (18) or O-ring (26) to
reduce slip-on forces.

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 13
5.1.2 Mounting the brake module to the motor
Attention!
The friction surfaces of the friction disc (4), the guide surfaces of the square socket (size 13, 19, 24 brakes)
or the teeth of the friction disc (4) (size 29 brakes) must be free from grease or oil. Do not use any lubricant
to improve the axial guide properties of the friction disc (4) and make sure to avoid damage to the sealing
rings (6 and 11).
1. Mount the brake module in vertical position with the motor shaft pointing upwards.
2. Close the oil supply bore in the brake shaft (13) with the screw plug (17). Apply Loctite 222.
3. Mount the brake module to the motor by slipping it onto the brake shaft (13) until it makes contact with
the motor flange. Ensure that the brake is parallel to the motor shaft and that a form-fit connection is
established between the brake shaft (13) and the square socket (size 13, 19, 24 brakes) or with the
internal teeth (size 29 brakes) of the friction disc (4).
4. The friction disc (4) is factory-centred in the spring-applied single-disc brake module to ensure easy
installation.
5. Slightly tighten the fixing screws after having taken the preliminary assembly steps described above.
Ensure that the brake is released electromagnetically after the spring-applied single-disc brake module
has been connected (see Section 5.3).
6. Manual brake release by means of an attached hand release (24), for example, is not allowed. To
complete brake mounting, use the ball bearing set (accessories).
7. The spring washers (14) must be placed into the solenoid housing (1.1) as shown in Fig. 11/1. Size 13
and 19 brakes require only one spring washer each, whereas size 24 and 29 brakes must be equipped
with two spring washers.
Attention!
The brake shaft and ball bearing must not be exposed to any axial shocks. The disc (12) is essential to the
correct operation of the brake module and must only be replaced by an original spare part.
8. In order to install the ball bearing (15), pressure must be evenly applied both to the inner and outer rings
of the bearing (15) to force it onto the motor shaft until it touches the shaft shoulder of the brake shaft
(13). The necessary pressure is generated through a mounting sleeve and the thread provided at the
front end of the brake shaft (13).
9. The solenoid housing (1.1) is thus centred through the ball bearing. Proceed to install the disc (12) and
circlip (16).
Attention!
The MAtightening torque (Table 13/1) specified for the fixing screws must be strictly observed. The screws
must be tightened evenly in diametrically opposite sequence.
10. Tighten the fixing screws to the MAtightening torques specified in Table 13/1.
Size
13 19 24 29
MAtightening
torque (fixing
screws) [Nm] 42 70 165 165
Table 13/1: MAtightening torques for fixing screws

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 14
5.2 Installation of accessories (not applicable to the brake shaft (13))
Hand release (24) (only applicable to retrofitted hand release):
1. Remove the two covers (23) located opposite each other
on the circumference of the solenoid housing (1.1) (see
Fig. 14/1).
2. Screw the cams (24.1) with the threaded bush into the
bores of the covers (23), making sure they are correctly
positioned (see figure to the right). Apply Loctite 243 to
secure the cams.
3. Insert the hand release lever (24.2) into the square
socket provided in the cams (24.1). The hand release
can be operated by pushing the lever (24.2) in one
direction (see Fig. 14/1).
4. The mechanical release forces F required to release the
brake and the maximum permitted release forces
(actuation forces) Fmax are specified in Table 14/1. The
release forces F are based on the highest transmissible
(standard) torque (see "Technical specifications").
Key to Fig. 14/1:
1.1 Solenoid housing 4 Friction disc
1.3 Bore for air gap measurement 24.1 Cam (complete)
2 Armature 24.2 Hand release lever
3 Flange s Air gap
Size
13 19 24 29
Threaded bush tightening torque MA[Nm] 20 26 35 35
Release force F [Nm] 80 130 200 240
Max. permitted release force (actuation force) Fma
x
[N] 120 180 280 330
Table 14/1: Release force F, max. permitted release force (actuation force) Fmax of hand release (24),
MAtightening torque of threaded bush of cams (24.1)
Warning!
Check that the mechanical hand release (24) is in a central position (see Fig. 11/1) when not in use. This is
crucial to ensure reliable brake engagement. Otherwise, the full braking effect of the spring-applied single-
disc brake module may not be reached. In this case, the machine (e.g. motor) must be stopped immediately
and must not be restarted until correct operation of the hand release (24) and automatic return of the hand
release lever in its central position (see Fig. 11/1) has been ensured.
Caution!
The brake torque can be neutralized manually by means of an attached hand release (24). Consequently,
the brake must be mounted in such a way that any unintentional actuation of the hand release (24), e.g. by
removing the hand release lever, is excluded.
Note!
Machinery-specific regulations and requirements (e.g. for hoists, cranes and elevators) must be observed
when using brakes with hand release (24).
Fig. 14/1: Hand release and air gap control

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 15
Fig. 15/1: Connector box (19)
with terminal (19.2)
or rectifier (19.2)
Ball bearing set (ball bearing (15), spring washer (14), circlip (16)):
The ball bearing set is required as a second bearing for the motor shaft. The complete ball bearing set must
be installed as described in Section 5.1.1.
Rubber bolts (18) (size 19 and 24 brakes), O-ring (26) (size 29 brakes):
To reduce the noise produced by the brake module during operation, rubber bolts (18) (size 19 and 24
brakes) or an O-ring (26) (size 29 brakes) can be installed in the brake shaft (13) as described in Section
5.1.1.
5.3 Electrical connection and operation
Warning!
The brake module is a DC operated system. Permanent voltage variations on the power source of the
electromagnetic brake must be limited to +/-10% of the rated voltage.
The following checks must be carried out when connecting the brake:
Check that the connecting cables are suitable for the intended use and for the voltage and amperage of
the brake.
Check that the connecting cables are secured with screws, clamps or other suitable fixtures to avoid
interruptions in the power supply.
Check that the connecting cables are long enough for the intended use and that suitable torsion, strain
and shear relief features as well as bending protections are provided.
Check that the PE conductor (only for protection class I) is connected to the earthing point.
Check that no foreign matter, dirt or humidity is trapped inside the terminal box.
Check that unused cable entries and the terminal box are suitably sealed to ensure compliance with the
protection class requirements to EN 60529.
The spring-applied single-disc brake module must be
supplied with DC voltage.
Connection to an AC power source is via a half-wave
rectifier (19.2). Brakes equipped with a built-in rectifier
(19.2) can be connected directly to the AC power source.
The contact assignment is shown in Fig. 16/1.
Brakes equipped with connecting terminal (19.2) must be
connected directly to DC voltage. The customer-specific
connecting cable must be connected to the terminal
(19.2) or built-in rectifier (19.2) by means of a cable
gland (M16x1.5 for cross-sections of between 5 and
10 mm.
Remove the cover (19.1) of the connector box (19) so
that the individual strands of the connecting cable can be
connected to the terminal (19.2) or to the contacts of the
built-in rectifier (19.2).

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 16
Rectifier series Rectifier type Rated input voltage range
U1/VAC (40-60 Hz) Output voltage U2/VDC
Max. output current
R-load
I/ADC L-load I/ADC
32 07332B40 half-wave 0-500 (10%) U10.445 1.6 2.0
Specific rectifier specification sheets must be observed!
Table 16/1: Rectifier for single-phase AC voltage supply via connecting terminal (19.2)
Attention!
When installing the cover (19.1) and connector box (19), the cheese
head screws (19.3) must be tightened to MA= 1.6 Nm. Damage to the
seal between the connector box (19) and cover (19.1) must be
avoided.
Brakes equipped with built-in rectifiers (19.2) use half-wave
rectification.
The built-in rectifier (19.2) can be wired in such a way that AC side
switching (normal coupling time t1) or DC side switching (short coupling
time t1) is possible (see Fig. 16/1).
Depending on the brake size and torque, voltage ripple due to
intermittent power supply may cause brake humming or incorrect brake
operation.
Perfect brake operation must be ensured by the user or system
manufacturer by providing suitable electrical controls.
Attention!
When connecting the rectifier (19.2), the terminals must be tightened to
a tightening torque of MA= 0.4 Nm.
Fig. 16/1: Rectifier
(contact assignment)
Normal coupling time t1:
Shorter coupling time t1:
brake coil
In case of DC side switching, AC
side switching is also required.

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 17
t
t
M
U
0,9 x
M
2
B
U
U
Vmax
t
t
11 1
1
M
5.3.1 DC power supply
The figure to the right shows the voltage curve after the field
coil (1.2) has been de-energized.
Attention!
The peak voltage UVmax during disconnection without protective
circuit may reach several thousand V in the millisecond
region. This may cause irreversible damage to the field coil
(1.2), switching contacts and electronic components.
Sparking will occur on the switch during disconnection.
Consequently, a protective circuit must be provided to reduce
the current during disconnection and to limit the voltage. The
maximum permitted overvoltage during disconnection is
1500 V.
If Kendrion Binder rectifiers are used (see Table 16/1), the
protective circuit required for the built-in electronic components
and field coil (1.2) is included in the rectifier and limits the
disconnection voltage to approx. 300 V. This also applies to
contacts S1 and S2 (DC side disconnection).
Attention!
In case of DC side switching and connection to a DC power source, the brake must be operated with a
protective circuit to avoid overvoltage. Additional protective elements (e.g. varistors, spark arresters, etc.)
must be installed to avoid damage such as burns or fusing of contacts.
Attention!
Sensitive electronic components (e.g. logical components) may also be damaged by the lower voltage.
5.3.2 AC power supply
Warning!
Work on the brake must only be carried out by qualified specialist personnel. Make sure that no voltage is
applied during brake connection. The specifications on the rating plate and the information provided in the
circuit diagram in the terminal box or in the Operating Instructions must be strictly observed.
Direct connection of the spring-applied single-disc brake to an AC power source is only possible if a rectifier
is used. The coupling times vary depending on the switching type (DC side switching or AC side switching)
(see Section 5.3).
Half-wave rectification:
In case of half-wave rectification, the U2coil voltage is lower by factor 0.445 than the rectifier input voltage.
Half-wave rectifiers produce voltage with high residual ripple which, depending on the brake size, may
slightly reduce the switching times when compared to bridge rectifiers. Due to the shorter switching times
and the lower coil voltage, half-wave rectifiers are generally preferred to bridge rectifiers. However, brake
humming may occur when small size brakes are used.
UBoperating voltage (coil voltage)
UVmax disconnection voltage

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 18
DC side switching:
In case of DC side brake switching, an auxiliary contact is provided on the motor contactor, for example. This
auxiliary contact is designed to interrupt the power supply on the DC side.
5.3.3 Electrical connection of brake modules with microswitch (27)
Note!
Machinery-specific regulations and requirements (e.g. for hoists, cranes and elevators) must be observed
when using brakes with microswitches (27).
When the brake is used for applications during which a load torque is generated, the system user is
responsible to ensure correct and safe wiring of the microswitch (27) and brake module.
Warning!
The motor circuit must be protected in such a way that no accidental motor start-up can occur when the
microswitch (27) contact closes.
If brakes are equipped with a microswitch (27) to control the release status (released/engaged) of the spring-
applied single-disc brake module, the microswitch (27) must be tied into the control circuit of the machine
(e.g. motor). This is crucial to ensure that the microswitch (27) prevents start-up of the machine (e.g. motor)
before the spring-applied single-disc brake module has been released. The optional microswitch (27) must
be ordered together with the brake as it cannot be retrofitted to the brake at a later date. The microswitch
(27) is factory-adjusted prior to shipment of the brake module.
5.4 Set-up and start-up
Warning!
The functional check of the brake must not be performed unless the machine (e.g. motor) has been switched
off (disconnected) and secured against accidental or unintentional start-up.
Attention!
When using machines (e.g. motors) with vertically upward directed shaft end, any ingress of fluids (water or
cooling lubricant) into the ball bearing (15) of the brake module must be avoided. The brake module must be
mounted in such a way that sufficient heat dissipation is ensured.
Attention!
Check that the brake has been connected in accordance with the specifications provided on the rating plate
before it is started. Even short-term operation outside the specified supply voltage limits may cause
irreversible damage to the brake or electronic accessories. Such damage may not be apparent immediately.
DC side brake switching without protective circuit as described in Section 3.3 will cause damage to electronic
rectifiers, electronic accessories, switching contacts and to the field coil (1.2).
Warning!
Before starting the machine (e.g. motor) test run without driven components, the feather key (if used) must
be secured in such a way that it cannot be hurled out. The shaft must not be exposed to load torques. Before
the machine (e.g. motor) is re-started, the brake must be de-energized.

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 19
Caution!
The brake surface temperature may rise to over 100°C. Heat-sensitive parts such as conventional cables or
electronic components must not be fixed to or be in contact with these surfaces. If necessary, suitable
protections and hand guards must be installed to avoid accidental contact with hot surfaces!
Attention!
High-voltage tests performed during brake mounting within an overall system or during start-up must be
carried out in such a way that damage to the built-in electronic accessories is avoided. The limits for high-
voltage tests and follow-up tests specified by DIN VDE 0580 must be observed.
The following checks must be carried out:
Check compliance with the specifications provided on the rating plate with respect to the mounting
position and protection class.
Ensure that power is supplied separately to the spring-applied single-disc brake module (and not to the
motor) and turn the motor shaft while the brake is released to check that the friction disc (4) and brake
shaft (13) move smoothly. Proceed to perform a functional test of the axial armature movement.
Check that the axial and radial runout is within the tolerance range specified in EN 50347-N.
Information on ball bearing break-in conditions, bearing lubrication intervals etc. is provided in the
specification sheets of the bearing manufacturers and in the motor manual.
After completion of mounting, all necessary covers and guards must be installed.
Specifications on rating plates (example):
5.4.1 Manual brake release
Warning!
Extreme caution is advised during manual release (jog mode) of the spring-applied single-disc brake module
(e.g. for maintenance work on the machine (e.g. motor) or in case of failure of the regular power supply and
use of a UPS system). If the drive system is unbalanced, the load torque may accelerate the drive. The
brake user is required to take adequate precautions to ensure that no hazardous situations are caused by
the load torque when the brake module is released and engaged in jog mode.
Transmissible torque
(factory-set)
Offer drawing index
Variant numbe
r
Rated current
Brake numbe
r
Coil voltage
Type numbe
r
Supply voltage
Production ID code

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 20
The spring-applied single-disc brake module can be released "manually" by means of a mechanical hand
release (24) (accessories). In case of failure of the regular power supply, it is also possible to use a
commercial UPS (e.g. UPS battery system) for the electrical release of the brake module. For this purpose,
the brake user is required to install a UPS system that complies with the voltage specifications given on the
brake module rating plate.
5.5 M4transmissible torque adjustments
Attention!
When adjusting the adjusting ring (9) on the basis of the values given in the offer drawing, make absolutely
sure that the M4transmissible torque is not below the minimum torque required.
The changed adjusting ring clearance "E" must be marked on the bottom of the solenoid housing. The
adjusted theoretical M4transmissible torque must be entered in the blank field provided on the rating plate of
the brake module (see rating plate example).
After adjustment of the M4transmissible torque, the brake user is required to ensure that the adjusting ring
(9) is secured with the set screw (25), applying a tightening torque of MA= 3 Nm.
The adjusting ring (9) must be turned in such a way that the set screw (25) can be located between the studs
(8). The M4torque tolerance is +15%/-5%.
1. The brake modules are factory-adjusted to the standard M4transmissible torque specified in the
specification sheet. The M4transmissible torque applicable at the time of shipment is specified on the
rating plate.
2. The torque can be adjusted by means of the adjusting ring (9). After completion of adjustment, the ring
must be locked by means of the set screw (25). The adjusting ring clearance "E" (see Fig. 11/1) is
marked on the bottom of the solenoid housing near the set screw (25). After having loosened the set
screw (25), the M4standard torque can be changed by changing the adjusting ring clearance "E" by
means of a pin spanner.
3. After having changed the torque, the new adjusting ring clearance "E" must be marked on the solenoid
housing. The adjusting ring must be locked by means of the set screw (25), making sure, however, that
the set screw is not within the reach of the studs (8).
4. Secure the set screw (25) with Loctite 243, for example.
5. While torque variations only have a minor impact on coupling times t1, the disconnection time t2is
reduced proportionally to the torque reduction.
Size
19 24 29
Transmissible torque change M4/mm [%] approx. 15 approx. 12 approx. 14
M4transmissible torque (standard value) [Nm] 150 310 500
Maximum transmissible torque M4 max. 150 310 500
Table 20/1: Change in the M4transmissible torque [%] from 1 mm axial adjustment of the adjusting ring (9);
M4transmissible torque (standard value) and maximum transmissible torque M4 max.
Note: Torque adjustments are not possible for size 13 brakes.