Kendrion 76..P..B00 Series User manual

EEX LINE
Operating Instructions 76 ..P..B00
Spring-applied single-disc brake
with dust and firedamp protection I
Types: 76 14P10B00 76 16P10B00 76 24P10B00 76 26P10B00
76 14P11B00 76 16P10B00 76 24P11B00 76 26P11B00
76 14P13B00 76 16P13B00 76 24P13B00 76 26P13B00
76 14P16B00 76 16P16B00 76 24P16B00 76 26P16B00
76 14P19B00 76 16P19B00 76 24P19B00 76 26P19B00
76 14P24B00 76 16P24B00 76 24P24B00 76 26P24B00

Kendrion Binder Magnete GmbH Operating Instructions 76 ..P..B00 Last updated: 30 Dec. 2009 Page 2
Contents
1. General information .............................................................................................................................. 3
1.1 Introduction ............................................................................................................................................ 3
1.2 Standards and directives ....................................................................................................................... 3
1.3 EC Declaration of Conformity ................................................................................................................ 3
1.4 Declaration of Incorporation
(in accordance with Annex II, part 1, Section B of Machinery Directive 2006/42/EC)........................... 4
1.5 Manufacturer's liability ........................................................................................................................... 4
2. Product description .............................................................................................................................. 5
2.1 Operating principle................................................................................................................................. 5
2.2 Structure ................................................................................................................................................ 5
3. Installation.............................................................................................................................................. 7
3.1 Mechanical installation........................................................................................................................... 7
3.2 Installation of the hand release (29) (brakes types with hand release)................................................. 8
3.3 Electrical connection and operation....................................................................................................... 9
3.3.1 AC power supply ......................................................................................................................... 10
3.3.2 Microswitch (13) and thermoswitch (11 and 12) connection....................................................... 12
3.4 Electromagnetic compatibility .............................................................................................................. 14
3.5 Set-up and start-up .............................................................................................................................. 16
3.6 M2 rated torque adjustments ................................................................................................................ 17
4. Maintenance......................................................................................................................................... 18
4.1 Checks and service ............................................................................................................................. 18
4.2 Spare parts and accessories ............................................................................................................... 21
5. Condition at delivery........................................................................................................................... 21
6. Emissions............................................................................................................................................. 21
6.1 Noise.................................................................................................................................................... 21
6.2 Heat ..................................................................................................................................................... 21
7. Troubleshooting.................................................................................................................................. 22
8. Safety.................................................................................................................................................... 23
8.1 Intended use ........................................................................................................................................ 23
8.2 General safety information................................................................................................................... 23
8.2.1 Set-up.......................................................................................................................................... 23
8.2.2 Set-up and start-up ..................................................................................................................... 24
8.2.3 Installation ................................................................................................................................... 24
8.2.4 Operation..................................................................................................................................... 24
8.2.5 Maintenance and repair .............................................................................................................. 24
8.3 Warning symbols ................................................................................................................................. 25
9. Definitions............................................................................................................................................ 26
10. Technical specifications..................................................................................................................... 28
11. Product versions (types).................................................................................................................... 30
12. Authorised repair shops for maintenance work .............................................................................. 30
Issued by: Kendrion Binder Magnete GmbH
Industrial Drive Systems
Replaces the issue dated: 10 June 2008
Translation of original German operating instructions issue dated: 30 December 2009

Kendrion Binder Magnete GmbH Operating Instructions 76 ..P..B00 Last updated: 30 Dec. 2009 Page 3
1. General information
1.1 Introduction
These Operating Instructions describe the operating principle and features of the 76 ..P..B00 series of
Kendrion Binder spring-applied brakes. 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 Binder and ask for clarification before starting to use the brake. Kendrion
Binder spring-applied brakes in the 76 ..P..B00 series are not ready-to-use devices, but are intended to be
incorporated into or assembled with other equipment.
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. The brakes are
intended for use in dust hazardous atmospheres and areas that are susceptible to firedamp. Brake versions
protected to IP 56 are only designed for use in atmospheres susceptible to firedamp. The brakes are
approved to the ATEX Directive (94/9/EC).
Approvals: dust and firedamp protection I Option: firedamp protection I
I M2; Ex de I I M2; Ex de I
II 2D Ex tD A21 IP67 T100°C IP56
DMT 02 ATEX E 122 X DMT 02 ATEX E 122 X
Being classified as "electromagnetic components", spring-applied brakes 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. A CE
mark in accordance with the ATEX Directive (94/9/EC) is affixed to the brakes.
1.3 EC Declaration of Conformity
in accordance with Directive 94/9/EC:
We hereby declare that the products specified below have been developed and manufactured in accordance
with the requirements of Directive 94/9/EC.
Certification authority: DEKRA EXAM GmbH EC type approval
Dinnendahlstr. 9 certificate: DMT 02 ATEX E 122 X
44809 Bochum
Germany
Manufacturer: Kendrion Binder Magnete GmbH
Industrial Drive Systems
Mönchweilerstr. 1
78048 Villingen-Schwenningen
Germany
Applied standards and directives:
EN 60529 Enclosure protection ratings
DIN VDE 0580 Electromagnetic devices and components
EN 60079-0:2006 Electrical apparatus for explosive gas atmospheres (General requirements)
EN 60079-1:2004 Electrical apparatus for explosive gas atmospheres (Flameproof enclosures "d")
EN 60079-7:2007 Electrical apparatus for explosive gas atmospheres (Increased safety "e")
EN 61241-0:2006 Electrical apparatus for use in the presence of combustible dust
(General requirements)
EN 61241-1:2004 Electrical apparatus for use in the presence of combustible dust
(Protection by enclosures "tD")

Kendrion Binder Magnete GmbH Operating Instructions 76 ..P..B00 Last updated: 30 Dec. 2009 Page 4
Products: Electromagnetically released spring-applied single-disc brake
76 14P10B00 76 16P10B00 76 24P10B00 76 26P10B00 76 14P11B00
76 16P11B00 76 24P11B00 76 26P11B00 76 14P13B00 76 16P13B00
76 24P13B00 76 26P13B00 76 14P16B00 76 16P16B00 76 24P16B00
76 26P16B00 76 14P19B00 76 16P19B00 76 24P19B00 76 26P19B00
76 14P24B00 76 16P24B00 76 24P24B00 76 26P24B00
Kendrion Binder Magnete GmbH
Industrial Drive Systems Villingen, 30 Dec. 2009 by proxy ..................................................
Dr. Matthias Dannemann
(Head of Development at IDS)
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.
Manufacturer: Kendrion Binder Magnete GmbH Person authorised Dr. Matthias Dannemann
Industrial Drive Systems to compile the Kendrion Binder Magnete GmbH
Mönchweilerstr. 1 documentation: Industrial Drive Systems
78048 Villingen-Schwenningen Mönchweilerstr. 1
Germany 78048 Villingen-Schwenningen
Germany
Applied standards and regulations:
EN 60529 Enclosure protection ratings
DIN VDE 0580 Electromagnetic devices and components
EN 60079-0:2006 Electrical apparatus for explosive gas atmospheres (General requirements)
EN 60079-1:2004 Electrical apparatus for explosive gas atmospheres (Flameproof enclosures "d")
EN 60079-7:2007 Electrical apparatus for explosive gas atmospheres (Increased safety "e")
EN 61241-0:2006 Electrical apparatus for use in the presence of combustible dust
(General requirements)
EN 61241-1:2004 Electrical apparatus for use in the presence of combustible dust
(Protection by enclosures "tD")
Products: Electromagnetically released spring-applied single-disc brake
76 14P10B00 76 16P10B00 76 24P10B00 76 26P10B00 76 14P11B00
76 16P11B00 76 24P11B00 76 26P11B00 76 14P13B00 76 16P13B00
76 24P13B00 76 26P13B00 76 14P16B00 76 16P16B00 76 24P16B00
76 26P16B00 76 14P19B00 76 16P19B00 76 24P19B00 76 26P19B00
76 14P24B00 76 16P24B00 76 24P24B00 76 26P24B00
Kendrion Binder Magnete GmbH
Industrial Drive Systems Villingen, 30 Dec. 2009 by proxy ....................................................
Dr. Matthias Dannemann
(Head of Development at IDS)
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.

Kendrion Binder Magnete GmbH Operating Instructions 76 ..P..B00 Last updated: 30 Dec. 2009 Page 5
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 AC voltage is
applied. 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). Spring-applied single-disc brakes with firedamp
protection are characterised by the fact that all components that may ignite explosive mixtures are placed in
an enclosure. This enclosure is designed to withstand the specified test pressure in case the mixture
explodes inside the enclosure. It also ensures that mixtures outside the enclosure are not affected by the
explosion. To ensure reliable firedamp protection, the cable entry of the spring-applied single-disc brake is
equipped with a special threaded entry sleeve.
2.2 Structure
The solenoid housing (1.1) of the spring-applied single-disc brake accommodates the firmly fitted field coil
(1.2) with flying leads. The flying leads are connected to the connecting terminal (19) inside the connector
box (25). The flange (3) and friction plate (33) are screwed to the solenoid housing (1.1) by means of
machine screws (22). The cover (7) is fixed to the solenoid housing (1.1) by means of machine screws (20)
to obtain a pressure-sealed assembly. Owing to the spring force generated by the compression springs (4
and 35), the friction disc (5) is pressed over the armature (2) against the friction plate (33) and flange (3) to
generate the braking effect of the spring-applied brake. The friction disc (5) and hub (17), which constitute
the rotating part of the spring-applied brake, are connected with the shaft to be braked. The friction disc (5)
features a square socket and can be moved on the hub (17) in axial direction. Spacer sleeves (6) are
provided to allow the air gap 's' to be adjusted. The customer-specific connecting cable can be fed into the
connector box (25) through a cable entry sleeve (30). When AC voltage is applied to the built-in bridge
rectifier of the spring-applied single-disc brake, the spring force is overcome by the dynamic effect of the
electromagnetic field. This causes the armature (2) to be released and the braking effect to be neutralised.
The shaft to be braked is not exposed to any axial force by the brake. The spring-applied single-disc brake is
equipped with a redundant thermoswitch system (2x2 thermoswitches) (11 and 12) and with a microswitch
(13) 1). The microswitch (13) is provided to prevent machine (e.g. motor) start-up before the brake has been
released. The four (2x2) thermoswitches (11 and 12) are connected in series with the microswitch (13) and
interrupt the control circuit of the machine (e.g. motor) as soon as the maximum permitted brake temperature
is exceeded. When using brakes with hand release (29), openings must be provided in the part enclosing the
brake (e.g. fan cover) to allow the hand release lever to be installed. The hand release (29)
2) allows the
brake to be released manually (e.g. in case of power failure).
1) brake types with microswitch
2) brake types with hand release
Key to figures:
1.1 Solenoid housing 13.3 Angle 25 Connector box
1.2 Field coil 13.4 Countersunk screw 26 Cover
2 Armature 13.5 Plate 27 Machine screw
3 Flange 13.6 Machine screw 28 Spring washer
4 Compression spring 13.7 Connecting cable (microswitch) 29 Hand release
5 Friction disc 14 Circlip (outer ring) 29.1 Cam
6 Spacer sleeve 15 Circlip (inner ring) 30 Cable entry sleeve assembly
7 Cover 16 O-ring 30.1 Threaded cable entry sleeve
8 Fixing surface 17 Hub 30.2 Sealing ring
9 Flat seal 18 Deep groove ball bearing 30.3 Machine screw
10 Fixing screw 19 Connecting terminal 30.4 Clamping strap
11 Thermoswitch (2 switches) 20 Machine screw 31 Locknut
12 Thermoswitch (2 switches) 21 Spring washer 32 Machine screw
13 Microswitch 22 Machine screw 33 Friction plate
13.1 Locknut 23 Spring washer 34 Rating plate
13.2 Set screw 24 O-ring 35 Compression spring
36 Duct

Kendrion Binder Magnete GmbH Operating Instructions 76 ..P..B00 Last updated: 30 Dec. 2009 Page 6
Fig. 6/1: Spring-applied single disc brake 76 26P..B00
Rated air gap

Kendrion Binder Magnete GmbH Operating Instructions 76 ..P..B00 Last updated: 30 Dec. 2009 Page 7
3. Installation
3.1 Mechanical installation
The spring-applied single-disc brake must be slipped with its hub (17) onto a
shaft (tolerance h6) provided with a feather key to DIN 6885, sheet 1. As the
hub (17) is firmly fitted to the brake, it need not be axially secured on the
machine shaft (e.g. motor shaft). Make sure that no radial forces act on the
deep groove ball bearing (18) during installation and operation (vertical
installation, if possible) and that the hub (17) is not exposed to any
permanent axial force (e.g. exerted by shaft shoulder) after installation has
been completed. The spring-applied brake is centred by means of the deep
groove ball bearing (18) of the hub (17). Fixing screws (10) are provided to
allow the spring-applied single-disc brake to be screwed to the fixing surface
(8) of the machine (e.g. motor). Before starting installation work, the O-ring
(16) must be inserted into the corresponding groove provided in the solenoid
housing (1.1). Make sure the fixing screws (10) are tightened evenly in
diametrically opposite sequence and that the specified tightening torques
(see Table 7/1) are not exceeded.
Note!
Make sure that the deep groove ball bearing (18) is not distorted during installation of the spring-applied
single-disc brake and that the shaft rotates easily when the brake is released. Check that no grinding sounds
can be heard.
Size
10 11 13 16 19 24
L [mm] 70 70 90 90 100 100
MA[Nm] 9.7 9.7 24 24 45 45
Table 7/1: Hub dimensions (17); tightening torques of fixing screws (10)
Check that the fixing surface (8) meets the following requirements before installing the brake:
•Axial runout relative to the shaft end to DIN 42955-N (measuring radius = reference circle)
•Material: steel, cast iron, aluminium – with excellent thermal conductivity
•Absence of oil and grease
Radial runout of the shaft end relative to the fixing surface (8) to DIN 42955-N
Attention!
The specified axial runout of the fixing surface (8) relative to the shaft end and the specified radial runout of
the shaft end relative to the fixing surface (8) must be strictly observed in order not to reduce the reliability
and service life of the spring-applied single-disc brake. Before installing the brake, the shaft end must be
slightly brushed with a high temperature grease (e.g. Copaslip). This is essential to allow the brake to be
easily removed if maintenance work needs to be carried out at a later date.
Attention!
The MAtightening torque specified for the fixing screws (10) must be strictly observed. The screws (10) must
be tightened evenly in diametrically opposite sequence.

Kendrion Binder Magnete GmbH Operating Instructions 76 ..P..B00 Last updated: 30 Dec. 2009 Page 8
3.2 Installation of the hand release (29) (brakes types with hand release)
The lever of the hand release (29) must be inserted into the square socket of the two cams (29.1) which are
firmly fitted to the circumference of the solenoid housing (1.1). Make sure the lever is correctly positioned.
The mechanical release forces F and the maximum permitted release forces (actuation forces) Fmax are
specified in Table 8/1.
Note!
Machinery-specific regulations and requirements (e.g. for hoists, cranes and elevators) must be observed
when using brakes with hand release (29). The hand release (29) must not be used to release the brake
during normal operation.
Caution!
The brake torque can be neutralised manually by means of the hand release feature (29). Consequently, the
brake must be installed in such a way that any unintentional actuation of the hand release (29) is excluded
and reliable brake operation is ensured.
Size
10 11 13 16 19 24
Release force F [N] approx. 18 approx. 35 approx. 45 approx. 90 approx. 85 approx. 170
Max. permitted release force Fmax [N] 50 50 125 125 240 240
Table 8/1: Release force F, max. permitted release force Fmax of hand release (29)
Warning!
Check that the mechanical hand release (29) 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 (29) and automatic return of the hand
release lever in its central position (see Fig. 6/1) has been ensured.

Kendrion Binder Magnete GmbH Operating Instructions 76 ..P..B00 Last updated: 30 Dec. 2009 Page 9
3.3 Electrical connection and operation
The spring-applied brake
must be connected to an
AC power source via
jumpers 1 (BA1) and 2
(BA2) on the connecting
terminal (19) (see Fig.
9/2). The customer-
specific connecting cable
must be connected to the
terminal (19) by means of
a special cable entry
sleeve (30). Remove the cover (26) of the connector box
(25) so that the individual strands of the connecting cable
can be connected to the terminal. The threaded cable
entry sleeve (30.1) of the sleeve assembly (30) is factory-
fitted to the solenoid housing (1.1) (see Fig. 9/1). Tighten
the threaded entry sleeve (30.1) to secure the customer-
specific connecting cable. The sealing ring (30.2) seals the cable entry. Tighten the machine screws (30.3) to
strain-relieve the connecting cable (cable diameter 17…19 mm). The clamping strap (30.4) locks the
threaded cable entry sleeve (30.1) in its position so that it cannot rotate. After completion of these steps, the
cover (26) of the connector box (25) must be reinstalled.
Attention!
When fixing the cover (26) to the connector box (25), the MAtightening torques of the machine screws
specified in Table 13/1 must be strictly observed. The flat seal (9) and spring washer (28) must be installed
as shown in Fig. 6/1.
The supply voltage is rectified by the built-in bridge rectifier. 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. 9/1
Fi
g
.9
/
2
Connecting terminal
contact assignment
Thermo-
switch (11)
Thermo-
switch (12)
Safety
switches
Microswitch (13)
Jumper
Bridge
rectifier
Brake

Kendrion Binder Magnete GmbH Operating Instructions 76 ..P..B00 Last updated: 30 Dec. 2009 Page 10
3.3.1 AC power supply
Direct connection of the spring-applied single-disc brake to an AC power source is only possible if a rectifier
is used. Wiring of the brake in case of single-phase AC power supply must be performed in the same way as
with three-phase voltage. The coupling times vary depending on the switching type (DC side switching or AC
side switching).
Bridge rectification:
Bridge rectifiers provide voltage with minimum residual ripple. This allows brake humming to be avoided
even if small size brakes are used. In case of bridge rectification, the U2coil voltage is lower by factor 0.89
than the rectifier input voltage.
AC side switching:
In case of AC side switching, the switching contact for the spring-applied single-disc brake is provided on the
AC voltage side directly before the bridge rectifier. It must be considered, however, that the bridge rectifier
with its free-wheel diode may extend the coupling time significantly (by factor 5 or over) after AC voltage has
DC side switching:
In case of DC side brake switching, an auxiliary contact is provided on the brake contactor, for example. This
auxiliary contact is designed to interrupt the power supply on the DC side. The jumper on the connecting
terminal (19) (see Fig. 9/2) must be replaced by the auxiliary contact. In case of DC side switching, AC side
switching is also required.

Kendrion Binder Magnete GmbH Operating Instructions 76 ..P..B00 Last updated: 30 Dec. 2009 Page 11
DC side switching
AC side switching
- ~ ~ +
N
M
3~
2
1
4
3
5
L1 L2 L3
Fig. 11/1: Suggested wiring of brake and safety switches (circuit diagram)
2
3
4
6
5-~~+
N
M
3~
L1 L2 L3
U

Kendrion Binder Magnete GmbH Operating Instructions 76 ..P..B00 Last updated: 30 Dec. 2009 Page 12
Attention!
In case of DC side switching, additional protective elements (e.g. varistors, spark arresters, etc.) must be
installed to avoid damage such as burns or welded contacts.
Warning!
Work on the brake must only be carried out by suitably qualified 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.
Warning!
The brake 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.
3.3.2 Microswitch (13) and thermoswitch (11 and 12) connection
The four (2x2) thermoswitches (11 and 12) and the microswitch (13) provided to control the release status of
the spring-applied single-disc brake are factory-connected in series. These safety switches (microswitch (13)
and thermoswitches (11 and 12)) must be tied into the control circuit of the machine (e.g. motor) (see Fig.
Fig. 11/1). This is to ensure that the microswitch (13) prevents any start-up of the machine (e.g. motor)
before the spring-applied single-disc brake has been released. The four (2x2) thermoswitches (11 and 12)
connected in series with the microswitch (13) interrupt the control circuit of the machine (e.g. motor) as soon
as the temperature measured at the individual measuring points of the thermoswitches (field coil (1.2) and
flange (3)) exceeds the maximum permitted temperature. The cover (26) of the connector box (25) must be
removed to allow the connecting cable of the safety switches (microswitch (13) and thermoswitches (11 and
12)) to be installed. The customer-specific connecting cable for the safety switches can be fed into the
connector box (25) of the spring-applied single-disc brake through the cable entry sleeve (30) (M20x1.5)
(see Section 3.3). The cable strands must be connected with the connecting terminal (19) (see Section 3.3,
Fig. 9/2). After completion of these steps, the cover (26) of the connector box (25) must be reinstalled.
Attention!
When fixing the cover (26) to the connector box (25), the MAtightening torques of the machine screws
specified in Table 13/1 must be strictly observed.

Kendrion Binder Magnete GmbH Operating Instructions 76 ..P..B00 Last updated: 30 Dec. 2009 Page 13
Size
10 11 13 16 19 24
MA tightening torque [Nm] of machine screws (20) for
cover (7) 5.6 5.6 24 24 45 45
MA tightening torque [Nm] of machine screws (22) for
flange (3) 7.6 7.6 9.7 9.7 24 24
MA tightening torque [Nm] of machine screws (27) for
cover (26) of connector box (25) 3 3 3 3 3 3
Table 13/1: Tightening torques of machine screws
Note!
Machinery-specific regulations and requirements (e.g. for hoists, cranes and elevators) must be observed
when using brakes with microswitches (13).
Warning!
The motor circuit must be protected in such a way that no accidental motor start-up can occur when the
microswitch (13) contact closes.
Note!
The suggested wiring of the spring-applied single-disc brake with microswitch (13) shown in Fig. 11/1 is
based on the generally accepted recommendations for the connection of electromagnetic components used
in electric machinery (e.g. motors) without load torque impact. 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 (13) and spring-applied single-disc brake.

Kendrion Binder Magnete GmbH Operating Instructions 76 ..P..B00 Last updated: 30 Dec. 2009 Page 14
3.4 Electromagnetic compatibility
As required by the German Electromagnetic Compatibility Act (EMVG), electromagnetic compatibility is
essential 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
minimised. 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
76 ..P..B00 series of spring-applied single-disc brakes are designed for industrial applications to which the
following EMC standards apply: Generic Immunity Standard VKE 0839, part 6-2 (EN 61000-6-2), and
Generic Emission Standard VDE 0839, part 81-2 (EN 50081-2). 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
brake use and other applications. Please refer to the specification sheets for additional information on
electromagnetic compatibility, especially with respect to the recommended electronic rectifiers specified in
Section 3.3.
Immunity according to EN 61000-4:
EN 61000-4-2 Electrostatic discharge:
The spring-applied single-disc brakes in the 76 ..P..B00 series comply at least with severity level 3 without
requiring additional measures. The built-in rectifier conforms to severity level 3 without additional measures.
EN 61000-4-3 Electromagnetic fields:
The brakes comply at least with severity level 3 without requiring additional measures. The built-in rectifier
conforms to severity level 3 without additional measures.
EN 61000-4-4 Fast transients (burst):
The brakes comply at least with severity level 3 without requiring additional measures. The built-in rectifier
conforms to severity level 3 without additional measures.
EN 61000-4-5 Surge:
The brakes comply at least with severity level 3 without requiring additional measures. The built-in rectifier
conforms to severity level 3 without additional measures.
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 brakes comply at least with severity level 4.
The built-in rectifier conforms to severity level 3 without additional measures.
EN 61000-4-11 Voltage dips, short interruptions, and short supply voltage variations:
a) Voltage interruptions:
Brakes that comply with the requirements of DIN VDE 0580 are de-energised 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
damage is avoided (e.g. motor start-up before the brake has been released caused by phase failure in
the case of two-phase energised 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 any 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-energised temporarily.
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 Binder Magnete GmbH Operating Instructions 76 ..P..B00 Last updated: 30 Dec. 2009 Page 15
Radio interference suppression in accordance with EN 55011:
The brakes and the built-in electronic rectifier 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:
The built-in rectifier is equipped with interference suppression components. This means that if the
brakes are connected to a 50/60 Hz AC power source, no additional interference suppression measures
are required to ensure compliance with the limit values applicable to Class A equipment. 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 built-in rectifier is equipped with free-wheel diodes
and/or varistors to limit the disconnection voltage.
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.

Kendrion Binder Magnete GmbH Operating Instructions 76 ..P..B00 Last updated: 30 Dec. 2009 Page 16
50
230
P
3.5 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 and secured against accidental or unintentional start-up.
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. Provided that the fixing surface (mounting side) (8) for the spring-applied single-disc
brake is closed, no further measures need to be taken to ensure compliance with the required protection
class. If the fixing surface (mounting side) (8) is open, adequate sealing must be provided in accordance with
the Kendrion Binder recommended installation procedure E76 00A0030 000. In this case, the maximum
possible protection rating is IP 56. After connection of the brake, an operational test must be performed to
check that the friction disc (5) runs smoothly. For this purpose, turn the shaft (while the brake is energised
and the machine (e.g. motor) is unpowered). Install the required guards and protections after completion of
installation.
Specifications on rating plates (example):
Zone 1: occasional explosion hazard
Zone 2: occasional explosion hazard for short periods
Zone 21: occasional explosion hazard caused by combustible dust in normal operation
Zone 22: explosion hazard caused by combustible dust unlikely to occur in normal operation;
if it does only for short periods
Certification codes:
(to EN 60079-0)
I M2 group I equipment;
category M2 (for use in underground
parts of mines as well as those parts
of surface installations of such mines
endangered by firedamp and/or
combustible dust); zones 1 and 2
II 2D group II equipment;
category 2D (for use in combustible
dust atmospheres)
tD A21 protection by enclosures for use in
the presence of combustible dust
according to method A for zones 21
and 22
IP 67 T100°C IP 67 protection; max. surface
temperature 100°C
Ex de I flameproof enclosure;
increased safety;
group I equipment (electrical
apparatus intended for use in mines
susceptible to firedamp)
DMT 02 certification authority and certification
year
ATEX E 122 X certification number

Kendrion Binder Magnete GmbH Operating Instructions 76 ..P..B00 Last updated: 30 Dec. 2009 Page 17
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-energised.
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! If the shaft
needs to be turned during set-up operations while the machine (e.g. motor) is switched off, the brake must
be released electromagnetically or by means of the hand release lever (29).
Caution!
High-voltage tests performed during brake installation 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.
Attention!
Check that the brake has been connected in accordance with the specifications provided on the rating plate
before it is put into operation. 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 3.4 will cause
damage to electronic rectifiers, electronic accessories, switching contacts and to the field coil (1.2).
3.6 M2 rated torque adjustments
The brakes are factory-adjusted to the M2rated torque (as
specified in the purchase order). The M2rated torque is specified
on the rating plate (33) of the brake. In case fine adjustment is
required, the M2rated torque can be continuously reduced.
However, it must not be increased. In order to adjust the torque,
proceed as follows: Loosen the machine screws (20) provided on
the cover (7) and remove the cover (7). Screw in the machine
screw (32) clockwise by means of a screwdriver, making sure to
secure the nut (31) in such a way that it cannot turn. Fine
adjustment must be carried out uniformly on all machine screws (32). Check that the requirements in terms
of the minimum length of projection xmin (see Table 17/1) of the machine screw (32) from the flange (3) are
met. The change in the M2rated torque resulting from these adjustments is specified in Table 17/1. The
factory-set nominal value (approximate value) of the length of projection xnom (see Table 17/1) is marked on
the flange.
Size
10 11 13 16 19 24
ΔM2/mm [Nm] 0.5 0.65 4 7.5 7.5 10
xnom [mm] 10.5 10.5 11.5 11 11 11
xmin [mm] 7.5 7.5 9 9 9 9
Table 17/1: Change in the M2rated torque from 1 mm axial adjustment of the machine screw (32);
permitted projection xmin
Warning!
Any adjustment of the rated torque must be performed by the manufacturer's authorised personnel.

Kendrion Binder Magnete GmbH Operating Instructions 76 ..P..B00 Last updated: 30 Dec. 2009 Page 18
4. Maintenance
4.1 Checks and service
The spring-applied single-disc brake does not require any particular maintenance except that the friction disc
(5) must be replaced when worn (see "Technical specifications" for information on the maximum air gap smax)
and that the safety switches (microswitch (13)
1) and thermoswitches (11 and 12)) must be checked at
regular intervals. These maintenance measures must be performed during the general inspection of the
electric machine (e.g. motor). Make sure that the spring-applied brake is unpowered and that the explosion
protection is not interfered with when carrying out maintenance work. When opening the flameproof enclosed
solenoid housing (1.1) to allow the friction disc (5) to be replaced, for example, the safety information
provided in this manual must be strictly observed. Always check that the flameproof gaps are in perfect
condition. Do not use spare parts other than original spares supplied by the manufacturer of the spring-
applied brake.
1) brake types with microswitch
Warning!
In case the explosion protection features of the spring-applied brake are damaged during maintenance or
repair work, the brake must be checked by an authorised expert. Any measures required to restore explosion
protection must be performed by the manufacturer or by authorised repair shops (see Section 12).
Brake removal from the machine (e.g. motor):
Loosen the machine screws (27) provided on the cover (26) of the connector box (25) and remove the cover
(26). Disconnect the strands of the connecting cables (field coil (1.2) and safety switches) from the
connecting terminal (19). Unscrew the machine screw (30.3) of the cable entry sleeve (30) and remove the
connecting cables from the connector box (25). Loosen the fixing screws (10). Remove the brake from the
shaft with the two pull-off threads provided on the solenoid housing (1.1) and by means of machine screws
(e.g. in accordance with ISO 4762).
Checking the air gap 's':
Loosen the machine screws (20) provided on the cover (7) and remove the cover (7). Place a measuring
bridge with dial gauge on the flange (3) to measure the air gap 's'. Position the measuring tip of the
micrometer screw on the friction disc (5).
Release the spring-applied brake so that the air gap 's' can be determined from the difference between the
values indicated by the dial gauge.
Attention!
Temporary electric release of the spring-applied brake is required to allow the air gap 's' to be measured. For
information on the electrical connection of the brake to the power source, please refer to Section 3.3.
Friction disc (5) replacement:
Remove the self-locking nut (31) from the machine screws (32). Loosen the machine screws (22) provided
on the flange (3) and remove the flange (3). Remove the friction disc (5) from the hub (17) and replace it by a
new one.
Attention!
Make sure that the connections of the four thermoswitches (11 and 12) are not damaged or loosened when
removing the flange (3).

Kendrion Binder Magnete GmbH Operating Instructions 76 ..P..B00 Last updated: 30 Dec. 2009 Page 19
Deep groove ball bearing (18):
When performing maintenance and repair work, check that the deep groove ball bearing (18) rotates
smoothly. If the bearing (18) needs to be replaced, proceed as described above under "Brake removal from
the machine (e.g. motor)" and "Opening the solenoid housing (1.1)". After having removed the friction disc
(5), remove the circlips (14 and 15). Push the hub (17) and deep groove ball bearing (18) out of the solenoid
housing (1.1) and remove the bearing (18) from the hub (17). Before reassembling the spring-applied brake,
all components (except for the friction disc (5)) must be cleaned with grease-free cleaners. In order to
assemble the individual components, proceed in reverse order of removal. When fine adjusting the M2rated
torque, make sure that the machine screws (32) project from the flange (3) by the length xnom (approximate
value – see Table 17/1) marked on the flange (3). The self-locking nuts (31) (to ISO 10511-04-A2F; 140°C)
must be replaced before adjusting the screws.
Attention!
When the spring-applied single-disc brake is mounted to the machine, it is crucial that the fixing screws (10)
be tightened applying the MAtightening torque specified in Table 7/1. The machine screws (20) on the cover
(7) and the machine screws (22) must be tightened to the MAtorque specified in Table 13/1. The O-ring (24),
spring washer (21 and 28) and flat seal (9) must be installed as shown in Fig. 6/1.
Attention!
Depending on its operating condition, it may no longer be possible to release the spring-applied single-disc
brake when the maximum air gap smax (see "Technical specifications") has been exceeded. In this case, the
braking effect cannot be neutralised.
Warning!
If a hand release lever (29) is fitted to the brake and the maximum air gap smax (see "Technical
specifications") has been exceeded (especially in case of a reduced M2rated torque), the hand release lever
(29) may limit the axial movement of the armature (2). This would cause the torque to be reduced down to
zero. Whenever carrying out maintenance work, check the degree of wear of the friction disc (5) and the air
gap 's' and replace the friction disc (5) well before the maximum air gap smax (see "Technical specifications")
is reached.
Microswitch (13) adjustment or replacement (only brakes with microswitch):
The spring-applied single-disc brake must be released
electrically to allow the microswitch (13) to be adjusted.
Loosen the machine screws (20) provided on the cover
(7) and remove the cover (7). Unscrew the locknut
(13.1) and turn the set screw (13.2) clockwise until the
microswitch (13) switches (slight audible click or contact
closure between contacts 5 and 6 (see Section 3.3). If
the microswitch (13) is in ON position, it must be turned
anticlockwise to OFF. After the changeover position has
been reached, continue to turn the set screw (13.2) by
60° to 90°. Tighten the locknut (13.1). Make sure the set
screw (13.2) position remains unchanged when
tightening the locknut. Switch the brake on and off to
check that the microswitch is in perfect working order. If
the microswitch (13) needs to be replaced (e.g. when
the maximum service life (switching operations) has been reached) (see "Technical specifications"), such
work must be carried out by the manufacturer or by an authorised repair shop due to the difficult installation
of the microswitch with the four thermoswitches (11 and 12).
Fig. 19/1: Microswitch adjustment

Kendrion Binder Magnete GmbH Operating Instructions 76 ..P..B00 Last updated: 30 Dec. 2009 Page 20
Thermoswitch replacement (11 and 12)
The thermoswitches (11 and 12) must be replaced when the maximum service life (switching operations) has
been reached. Replacement must be carried out by the manufacturer or by an authorised repair shop due to
the difficult installation of the thermoswitches with the microswitch (13) 1). The thermoswitches (11 and 12)
will only interrupt the control circuit of the machine (e.g. motor) if the maximum permitted operating
temperatures (see "Technical specifications") on the measuring points of the thermoswitches (11 and 12) are
exceeded. Under normal conditions, the thermoswitches (11 and 12) remain closed during the entire
operation of the spring-applied single-disc brake.
1) brake types with microswitch
Attention!
The machine screws (20) provided on the cover (7) must be tightened to the MAtorque specified in Table
13/1. The O-ring (24) and spring washer (21) must be installed as shown in Fig. 6/1.
Information on flameproof gaps without thread and flameproof thread gaps
All flameproof gaps are factory-specified. The gap dimensions and surface specifications (Ra < 6.3 μm) must
be maintained. If gap surfaces are found to be damaged or if gap dimensions are different from those
specified, it is crucial that original spare parts are used when performing repair work or replacing individual
components. Repair work must be carried out by the manufacturer or by authorised specialists!
Flameproof gaps without thread:
hub (17) / solenoid housing (1.1)
cover (7) / solenoid housing (1.1)
cam (29.1) / sleeve (29.2)
Flameproof thread gaps:
sleeve (29.2) / solenoid housing (1.1)
duct (36) / solenoid housing (1.1)
Caution!
Whenever inspection and maintenance work is carried out, check that
•the machine (e.g. motor) is secured against accidental or unintentional start-up.
•no load torque is applied to the shaft.
•the lock provided to prevent accidental start-up of the machine (e.g. motor) is removed after completion
of inspection and maintenance work.
•all friction surfaces are free from grease and oil. An oily or greasy friction disc (5) cannot be cleaned.
•the friction lining has not swollen or turned vitreous.