Kendrion Classic Line 77600 A00 Series User manual

KENDRION INDUSTRIAL BRAKES
Classic Line
Spring-applied single-disc brake
Operating Instructions 77 600..A00
Types: 77 600..A00 77 600..K00 77 600..K01
77 600..A20

Operating Instructions BA 77 600..A00 // Last updated: 13/03/2020 // Page 2 of 33
Contents
1. General information .............................................................................................................................. 3
1.1 Introduction ............................................................................................................................................ 3
1.2 Standards and directives ....................................................................................................................... 3
1.3 Declaration of Incorporation (in accordance with Annex II, part 1, Section B of Machinery Directive
2006/42/EC)........................................................................................................................................... 3
1.4 Declaration of Conformity ...................................................................................................................... 4
1.5 Manufacturer's liability ........................................................................................................................... 4
1.6 Brake versions ....................................................................................................................................... 4
2. Product description............................................................................................................................... 5
2.1 Operating principle................................................................................................................................. 5
2.2 Design.................................................................................................................................................... 5
3. Installation.............................................................................................................................................. 8
3.1 Mechanical installation........................................................................................................................... 8
3.2 Installation of accessories...................................................................................................................... 9
3.3 Electrical connection and operation..................................................................................................... 10
3.3.1 DC power supply ............................................................................................................................. 11
3.3.2 AC power supply.............................................................................................................................. 11
3.3.3 Microswitch (19) connection ............................................................................................................ 13
3.4 Electromagnetic compatibility .............................................................................................................. 15
3.5 Set-up and start-up .............................................................................................................................. 18
3.5.1 Functional checks ............................................................................................................................ 18
3.5.2 Manual brake release ...................................................................................................................... 19
3.6 M2rated torque adjustments................................................................................................................ 19
4. Maintenance......................................................................................................................................... 20
4.1 Checks and service ............................................................................................................................. 20
4.2 Microswitch (19) adjustment (only applicable to brakes with microswitch (19)).................................. 21
4.3 Spare parts and accessories ............................................................................................................... 22
5. Condition at delivery........................................................................................................................... 22
6. Emissions............................................................................................................................................. 22
6.1 Noise.................................................................................................................................................... 22
6.2 Heat ..................................................................................................................................................... 23
7. Troubleshooting .................................................................................................................................. 23
8. Safety.................................................................................................................................................... 24
8.1 Intended use ........................................................................................................................................ 24
8.2 General safety information................................................................................................................... 24
8.2.1 Set-up .............................................................................................................................................. 25
8.2.2 Set-up and start-up .......................................................................................................................... 25
8.2.3 Installation........................................................................................................................................ 25
8.2.4 Operation ......................................................................................................................................... 25
8.2.5 Maintenance, repair and replacement ............................................................................................. 26
8.3 Warning symbols ................................................................................................................................. 26
9. Definitions ............................................................................................................................................ 27
10. Technical specifications..................................................................................................................... 29
11. Product number / type number / version number............................................................................ 32
12. Specialist repair shops ....................................................................................................................... 32
13. Revision history................................................................................................................................... 32
Document information:
Issued by: Kendrion (Villingen) GmbH Last updated: 13/03/2020
Replaces document: - Replaces the issue dated: 30/12/2009
Document type:translation of original German operating Document status: released
instructions BA 77 600..A00
Document title: BA 77 600..A00 Englisch

Operating Instructions BA 77 600..A00 // Last updated: 13/03/2020 // Page 3 of 33
1. General information
1.1 Introduction
These Operating Instructions describe the operating principle and features of spring-applied single-disc brake
types 77 600..A00, 77 600..A20, 77 600..K00 and 77 600..K01. 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.
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
(Villingen) and ask for clarification before starting to use the brake. Spring-applied single-disc brakes are not
ready-to-use devices, but are intended to be incorporated into or assembled with other equipment.
Consequently, they will be referred to as components in the following sections.
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 brakes are also subject to the Low Voltage
Directive 2014/35/EU. The user is required to employ suitable switching devices and controls to ensure use of
the brakes in accordance with EMC Directive 2014/30/EU.
1.3 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 and 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.
Manufacturer: Kendrion (Villingen) GmbH Person authorized Dominik Hettich
Wilhelm-Binder-Str. 4-6 to compile the Kendrion (Villingen) GmbH
78048 Villingen-Schwenningen documentation: Wilhelm-Binder-Str. 4-6
Germany 78048 Villingen-Schwenningen
Germany
Applied harmonized standards and other technical standards and regulations:
EN 60529 Enclosure protection ratings
DIN VDE 0580 Electromagnetic devices and components
Product: Electromagnetically released spring-applied single-disc brake
Types:77 600..A00 77 600..K00
77 600..A20 77 600..K01
The “..“ wildcard stands for the different brake sizes.
Kendrion (Villingen) GmbH Villingen Authorized signatory: .......................................................
13/03/2020 Dominik Hettich
(Head of Development)

Operating Instructions BA 77 600..A00 // Last updated: 13/03/2020 // Page 4 of 33
1.4 Declaration of Conformity
This Declaration of Conformity applies to products that have a CE mark on their rating plate.
We hereby declare that the products below, specifically the product versions brought into circulation, have
been designed and built in accordance with the requirements of Directives 2014/35/EU (Low Voltage Directive)
and 2011/65/EU (RoHS Directive). The products are classified as category 11 equipment subject to Directive
2011/65/EU (RoHS Directive). This declaration will cease to be valid if modifications are made to the product
without prior permission from the manufacturer.
Manufacturer: Kendrion (Villingen) GmbH Person authorized: Dominik Hettich
Wilhelm-Binder-Str. 4-6 Kendrion (Villingen) GmbH
78048 Villingen-Schwenningen Wilhelm-Binder-Str. 4-6
Germany 78048 Villingen-Schwenningen
Germany
Applied harmonized standards and other technical standards and regulations:
EN 60529 Enclosure protection ratings
DIN VDE 0580 Electromagnetic devices and components
Product: Electromagnetically released spring-applied single-disc brake
Types: 77 600..A00 77 600..K00
77 600..A20 77 600..K01
The “..“ wildcard stands for the different brake sizes.
Kendrion (Villingen) GmbH Villingen Authorized signatory: .......................................................
13/03/2020 Dominik Hettich
(Head of Development)
1.5 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.
1.6 Brake versions
Typ Ausführung
77 600..A00 Basic brake component
77 600..A20 Brake component with special friction lining for enhanced switching energy Wmax and reduced rated
torque M2compared to basic brake component 77 600..A00
77 600..K00 Brake component with enhanced corrosion protection
77 600..K01 Brake component with enhanced corrosion protection and halogen-free connection cable
Tab. 4/1: Brake versions of spring-applied single-disc brakes (Classic Line).
The “..“ wildcard stands for the different brake sizes.

Operating Instructions BA 77 600..A00 // Last updated: 13/03/2020 // Page 5 of 33
2. Product description
2.1 Operating principle
The spring-applied single-disc brake is designed to operate dry. The force generated by an electromagnetic
field is utilised to overcome the braking effect produced by the spring force. The spring-applied single-disc
brake engages in unpowered condition and releases when DC voltage is applied. Brakes equipped with a built-
in rectifier (half-wave or bridge rectifier) can be connected directly to an AC power source. The form-fit
connection between the friction disc and hub and the connection of the hub with the machine shaft (e.g. motor
shaft) ensure that the torque generated by the spring-applied single-disc brake (brake torque) is reliably
transmitted to the machine (motor). The brake can also be equipped with an optional hand release to allow the
brake to be released manually.
2.2 Design
The solenoid housing (1.1) of the spring-applied single-disc brake accommodates the firmly fitted field coil
(1.2) with the connecting cable resp. at brakes with a connector box (25) whose connecting terminals are
located in the connector box (25). The solenoid housing (1.1) also includes the compression springs (3) which
press the friction disc (5) over the armature (2) against the friction plate 1) (10) and flange (11) to generate the
braking effect of the spring-applied brake. The air gap 's' is determined by the position of the intermediate ring
(6). The friction disc (5) features a square socket and can be moved on the hub (17) in axial direction. The
customer-specific connecting cable can be fed into the connector box (25) through a cable gland (14) (PG 11).
When DC voltage is applied to the field coil (1.2) of the spring-applied single-disc brake, the spring force is
overcome by the electromagnetic field force. This causes the armature (2) to be released and the braking
effect to be neutralised. The shaft to be braked is not subjected to any axial force by the brake. When using
brakes with hand release (21), openings must be provided in the part enclosing the brake (e.g. fan cover) so
that the hand release lever can be installed. The hand release (21) allows the brake to be released manually
(e.g. in case of power failure). When the brake is equipped with a microswitch (19), the microswitch prevents
any start-up of the machine (e.g. motor) before the brake has been released. Thanks to the centring diameters
on the flange and housing sides (diameters d2and d7), the spring-applied single-disc brake is ideal for
applications with mounted transmitters (e.g. tachometer generators, encoders, etc.) after the cover (9) has
been removed.
1) Size 10 to 16 brakes.

Operating Instructions BA 77 600..A00 // Last updated: 13/03/2020 // Page 6 of 33
Reference sign list to Fig. 6/1:
1.1 Solenoid housing 18 Fixing surface
1.2 Field coil 19 Microswitch
2 Armature 19.1 Cable gland
3 Compression spring 19.2 Microswitch cap
4 Stud 19.3 Locknut
5 Friction disc 19.4 Hexagon head cap screw
6 Intermediate ring 19.5 Machine screw
7 Adjusting ring 20 Protective cover
8 Set screw 20.1 Machine screws for protective cover
9 Cover hood 21 Hand release
10 Friction plate 21.1 Lever
11 Flange 21.2 Cam with threaded bush
12 Sealing ring 22 Fixing screws
13 Machine screw 23 Screw plug
14 Cable gland 25 Connector box
15 Sleeve (only size 24 brakes)s 25.1 Connector box cover
16 Rating plate 25.2 Connecting terminal or rectifier
17 Hub with labyrinth seal 25.3 Machine screw
Table 6/1: Reference sign list for spring-applied single-disc brake

Operating Instructions BA 77 600..A00 // Last updated: 13/03/2020 // Page 7 of 33
Fig. 7/1: Spring-applied single-disc brake 77 600..A..00
Rated air gap

Operating Instructions BA 77 600..A00 // Last updated: 13/03/2020 // Page 8 of 33
3. Installation
3.1 Mechanical installation
The hub (17) must be slipped onto a shaft provided with a feather key to DIN 6885,
sheet 1. The hub must be axially secured (by means of a shaft collar, circlip or the like).
Make sure that the front face of the hub (17) is at the same height as the front face of
the flange (11). The friction disc (5) must be slipped onto the hub (17) with the complete
brake assembly and centred using centring diameter d2(see Fig. 6/1 and Classic Line
specification sheet) of the flange (11). Make sure that the friction disc (5) can be easily
moved along the hub (17).
Size
10
11
13
16
19
24
L [mm] 20,5 20,5 24 26,5 30 45
L1[mm] 0-0.8 0-0.8 0-1 0-1 0-1 0-1.2
MA[Nm] 5.5 5.5 5.5 9.5 9.5 22
MAZ [Nm] 1.5 1.5 3 5 5 11
Table 8/1: Hub dimensions (17); tightening torques of fixing screws (22)
and machine screws (13)
Check that the fixing surface (18) meets the following requirements before installing the brake:
•Axial runout relative to the shaft <0.1mm (measuring radius = reference diameter)
•Surface roughness max. Rz16
•Surface hardness min. 100HB
•Material: steel, aluminium, cast iron – with excellent thermal conductivity
•Absence of oil and grease
•Permitted mismatch of centring diameter (fixing surface (18)) relative to shaft <0.2mm
The spring-applied single-disc brake must be screwed to the fixing surface (18) by tightening the fixing screws
(22) to the MAtightening torques specified in Table 8/1. The factory-adjusted rated air gap 's' cannot be
changed.
Note!
If the friction disc (5) and/or hub (13) are equipped with rubber buffers for noise reduction, the buffers must be
slightly greased before installation to reduce fitting forces during brake mounting. Check that the friction disc
(5) can be easily moved along the hub (13) by hand. The fitted components (especially the friction surfaces)
must be free from grease.
Attention!
The MAtightening torque specified for the fixing screws (22) must be strictly observed. The screws (22) must
be tightened evenly in diametrically opposite sequence.
Note!
The centring diameter d7(see Fig. 6/1) is factory-aligned relative to the centring diameter d2on the flange (11)
with a maximum 0.2mm radial runout. This enables easy attachment of a tachometer generator to the solenoid
housing (1.1).
Hub position

Operating Instructions BA 77 600..A00 // Last updated: 13/03/2020 // Page 9 of 33
3.2 Installation of accessories
Hand release (21):
The two screw plugs (23) fitted opposite each other to the circumference of
the intermediate ring (6) must be screwed out. The cams (21.2) with
threaded bush must be screwed into the bores provided in the screw plugs
(23) making sure that they are in the right position (see figure). Secure the
cams with Loctite 601. The hand release lever (21.1) must be fixed to the
square socket provided in the cams (21.2). The release forces F and the
maximum permitted release forces (actuation forces) Fmax are specified in
Table 7/1.
Note!
Machinery-specific regulations and requirements (e.g. for hoists, cranes and
elevators) must be observed when using brakes with hand release (21).
Size
10
11
13
16
19
24
MAtightening torque of threaded bush [Nm] 20 20 20 26 26 35
Release force F 2) [N] 4 7 20 60 70 110
Max. permitted release force (actuation force) Fmax [N] 11 18 50 150 155 230
Table 9/1: Release force F and maximum permitted release force (actuation force) Fmax of hand release (21);
MAtightening torque of threaded bush of cams (21.2)
Note!
When installing the cams (21.2) make sure that the cam surface points towards the armature (2).
Caution!
The brake torque can be neutralised manually by means of the hand release (21). Consequently, the brake
must be installed in such a way that any unintentional actuation of the hand release (21) is excluded.
Warning!
Check that the mechanical hand release (21) is in a central position (see Fig. 6/1) when not in use. This is
crucial to ensure reliable brake engagement. Otherwise, the full braking effect of the spring-applied single-disc
brake 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 (21) and automatic return of the hand release lever in
its central position (see Fig. 6/1) has been ensured.
2) Release force F (approx.) at the highest rated (standard) torque.
Installation of cams
with threaded bush

Operating Instructions BA 77 600..A00 // Last updated: 13/03/2020 // Page 10 of 33
3.3 Electrical connection and operation
The spring-applied single-disc brake must be supplied with
DC voltage. Connection to an AC power source is via a
half-wave, bridge or overexcitation rectifier (25.2). Brakes
with connector box (25) and built-in rectifier (25.2) can be
connected directly to the AC mains. The contact
assignment is shown in Fig. 10/1. Brakes equipped with
connector box (25) and connecting terminal (25.2) resp.
connecting cable must be connected directly to DC
voltage. The customer-specific connecting cable must be
connected to the terminals (25.2) or built-in rectifier (25.2)
by means of a cable gland (14) (PG 11, clamping range 7.5
to 10 mm). Remove the cover (25.1) of the connector box
(25) so that the individual strands of the connecting cable
can be connected to the terminals (25.2) or to the contacts
of the built-in rectifier (25.2).
Brake versions with flying leads or connecting cable do not
have a connector box (25). The wire ends of the flying
leads or cable must be connected directly to the DC power
source.
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 07.22B.0 half-wave 0-500 (±10%) U1•0.445 1.6 2.0
32 07.23B.0 bridge 0-400 (±10%) U1•0.890 1.6 2.0
32 17350E.. overexcitation
bridge⇒half-wave
48-120 (±10%)
220-415 (±10%)
480-525 (±10%)
U1•0.890 / U1•0.445 2.3 3
32 17.2.B.. overexcitation
bridge⇒half-wave
110-230 (±10%)
220-415 (±10%) U1•0.890 / U1•0.445 1.2
0.8
1.5
1.0
Specific rectifier specification sheets must be observed!
Table 10/1: Recommended rectifiers for single-phase AC voltage supply and for connection via terminal (25.2)
Attention!
When fixing the cover (25.1) to the connector box (25), the MAtightening torques of the machine screws
specified in Table 14/1 must be strictly observed. Damage to the flat seal between the connector box (25) and
cover (25.1) must be avoided.
When using brakes with built-in rectifier (25.2), the supply voltage is rectified by means of a half-wave rectifier
(25.2). The built-in rectifier (25.2) 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. 10/1). Various Kendrion rectifiers are available
(see Table 8/1, list not exhaustive) for direct brake connection to an AC power source via the built-in connecting
terminal (25.2). 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.
Fig. 10/1:Connector box (25) with terminal
(25.2) or rectifier (25.2)