Maxcess Global Series User manual

Global Series Brake
Instruction Manual
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Global Brake Series
MI 850A169 1 L
Page 1 of 14
Models GBA, GBAM, GBB, GBBM, GBC, GBCM, GBD, GBDM, GBE, GBEM, GBF, GBFM
All of the information herein is the exclusive proprietary property of Maxcess International and is disclosed with
the understanding that it will be retained in confidence and will neither be duplicated nor copied in whole or in part
nor be used for any purpose other than for which disclosed.
Copyright 2011, 2018, all rights reserved.
Periodically there will be updates to this manual. The latest version is available on our website or by calling your
regional office listed on the back page of this publication.
These brake devices must not be installed or used in a machine or system which does not comply with the
machinery directive 2006/42/EC.
These brake devices were designed and manufactured to be installed as Partly Completed Machinery into a
machine or partly completed machine.
The instructions must be read and used by all persons who have the responsibility of installing and maintaining
these brake devices.
These instructions must be retained and incorporated in the technical documentation for the machine or partly
completed machinery into which the brake device is installed.
These are the original instructions, written in English.

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Global Brake Series
MI 850A169 1 L
Page 2 of 14
CE MARKING
These brake devices are marked with the CE sign according to the low voltage directive 2006/95/EC for the 90
volt coil models. The 24 volt coil models do not carry the CE sign. The air hoods are marked with the CE sign
according to the low voltage directive 2006/95/EC.
Electromagnetic Compatibility (EMC)
The brake device is inherently benign in terms of electromagnetic compatibility and the EMC directive has not
been applied. The electromagnetic compatibility of the brake device can only be assessed in connection with the
entire electrical installation including the control. The machine builder who installs this partly completed
machinery into a machine is responsible for compliance with the EMC directive.
MODEL NUMBER KEY
Global brakes purchased with/without attached air hood blower cooling
Format: Series –Size –CoilVolt –Bore –Cooling –Sxx
Series:
GB –Global Brake
Size:
A, B, C, D, E, F
CoilVolt:
24 = 24 volt coil
90 = 90 volt coil
Bore:
Blank = English dimension bore diameter
M = Metric dimension bore diameter
Cooling:
Blank = No Cooling
A115 = Air Hood with 115 VAC blower motor
A230 = Air Hood with 230 VAC blower motor
Sxx:
Specials: Other coil voltages, bore diameters, etc.
Example model number:
GBE90A115 = Global brake, size E with 90 volt coil, English dimension bore diameter and 115 VAC
fan cooling.
Air Hood Blower kits purchased separately to be installed by customer on a global brake.
Format: BlowerKit –Series –Size - Voltage
BlowerKit:
BK –Blower kit
Series:
GB –Global Brake
Size:
A, B, C, D, E, F
Voltage:
115 = 115 VAC blower motor
230 = 230 VAC blower motor
Example model number:
BKGBA230 = Air hood blower kit for GBA brake with 230 VAC blower motor.

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Global Brake Series
MI 850A169 1 L
Page 3 of 14
SAFETY INSTRUCTIONS
To ensure safe and problem free installation of the magnetic particle brake device, the brake must be properly
transported and stored, professionally installed and placed in operation. Proper operation and maintenance will
ensure a long service life of the device. Only persons who are acquainted with the installation, commissioning,
operation and maintenance of the system and who possess the necessary qualifications for their activities may
work on the magnetic particle brake. Note: The safety information may not be comprehensive.
The content of these instructions must be read and followed.
All national, state, and local requirements for installation, accident prevention and environmental
protection must be followed.
The safety instructions and symbols described in this section are used to avoid possible dangers for users and to
prevent material damage.
SIGNAL WORD
Source of danger and its results.
Avoiding dangers.
The signal word WARNING refers to the danger of moderate to severe bodily injuries or death.
The signal word CAUTION refers to the danger of slight to moderate bodily injuries or material damage.
WARNING/CAUTION –General danger or important note
Reference to general hazards that may result in bodily injuries or damage to device or material.
WARNING/CAUTION –danger due to crushing
Reference to danger of injury caused by crushing.
WARNING/CAUTION –danger due to cutting
Reference to danger of injury caused by cutting.
WARNING/CAUTION –danger due to voltage, electric shock
Reference to danger of injury caused by electric shock due to voltage.
WARNING/CAUTION –danger due to hot surfaces
Reference to risk of injury caused by burning.
BASIC SAFETY INFORMATION
PROPER USE:
The brake devices are intended to be used on machines or systems to control the braking torque of a
device connected to the shaft of the brake device.
Indoor operation, see environmental specifications
IMPROPER USE:
Operation outside the technical specifications
Operation in an Ex-area or intrinsically safe area
Operation as a safety component or safety brake. The brake does not produce torque if the control
current fails.
Outdoor operation
Any other use than the proper use shall be deemed inappropriate

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Global Brake Series
MI 850A169 1 L
Page 4 of 14
Safety information continued
INSTALLATION AND COMMISSIONING:
Any brake device which is damaged must not be installed or put into operation.
Only perform installation, maintenance or repair tasks on the brake device when the machine has been
stopped and is secured from being turned on.
Only perform installation, maintenance or repair tasks on the brake device when there is no electrical
power in the system.
The brake device must be securely mounted before being placed in operation.
Only replacement parts obtained from Fife may be used.
No modifications may be made to the brake device.
Do not place electrical cables under mechanical strain.
Do not bring this brake device into contact with water or other fluids. Grease or oil on the internal brake
parts will cause a loss of torque.
WARNING –The brake device contains rotating parts which could cause injury due to crushing.
Appropriate protective guards must be installed by the user according to his use of this product.
WARNING –Death or injury can result from electric shocks.
Protect against electric shocks by installing a conductive connection between the terminal marked with
the PE symbol on the brake device and air hood and the PE circuit of the building or machine.
WARNING –Danger of falling down or muscle or skeletal injury during installation.
The brake devices, especially the larger designs, are heavy. Appropriate equipment is to be used and
the safety rules of the company must be observed.
OPERATION:
CAUTION –Burns can result from touching the brake surface during operation.
The brake device converts mechanical motion into heat and the surface of the brake will become hot
during operation. Appropriate guards must be installed by the user according to his use of the product.
WARNING –The brake device contains rotating parts which could cause injury due to crushing.
Do not touch anything on or in the vicinity of the moving or rotating parts. Appropriate protective
guards must be installed by the user according to his use of this product.
MAINTENANCE AND REPAIR:
WARNING –Death or injury can result from electric shocks.
Maintenance and repair tasks on the brake device must be performed when there is no electrical
power in the system.
WARNING –Danger of injury from crushing.
Maintenance and repair tasks on the brake device must be performed only when the machine has
been stopped and has been secured from being turned on again.
WARNING –Danger of falling down or muscle or skeletal injury during maintenance and repair.
The brake devices, especially the larger designs, are heavy. Appropriate equipment is to be used and
the safety rules of the company must be observed.
DECOMMISSIONING:
The brake must be disposed of in accordance with all the applicable national, state and local regulations.

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Global Brake Series
MI 850A169 1 L
Page 5 of 14
THEORY OF OPERATION
The brake construction consists of two stators, a rotor, a coil assembly, magnetic powder, and two bearings. The
bearings support and align the rotor with the stators, and allow the rotor to rotate within the brake assembly. The
magnetic powder occupies the space between the stators and the rotor, and represents a key element in the
operation of the brake.
The stators are connected to the machine frame through a torque arm and remain stationary. The rotor is
connected to a rotating machine shaft, which supports the weight of the brake. The magnetic powder functions as
the adjustable bond or link between the stators and the rotor. It is the medium for the transmission of torque.
An electric current in the coil creates a magnetic field (flux), which passes through the stators, magnetic powder,
and the rotor. The flux aligns the powder particles, forming a bond or link between the stators and the rotor. The
strength of the bonding action (torque) is proportional to the amount of current in the coil. The torque is transmitted
to the rotating shaft through the rotor. See figure 1 for a cross-sectional view of the brake.
MECHANICAL INSTALLATION
WARNING –The brake device contains rotating parts which could cause injury due to crushing.
Appropriate protective guards must be installed by the user according to his use of this product.
WARNING –Death or injury can result from electric shocks.
Installation of the brake device must be performed when there is no electrical power in the system.
WARNING –Danger of injury from crushing.
Installation of the brake device must be performed only when the machine has been stopped and has
been secured from being turned on again.
WARNING –Danger of falling down or muscle or skeletal injury during maintenance and repair.
The brake devices, especially the larger designs, are heavy. Appropriate equipment is to be used and
the safety rules of the company must be observed.
1. Unpack the brake, check for completeness and transport damages and verify the nameplate. The GBE/M and
GBF/M models should be packed with 2 eye bolts to facilitate lifting and positioning of the brake.
2. The rotor shaft centerline must be mounted within 30° of the horizontal plane.
3. Prior to installation, manually check the rotation of the rotor to observe that it is smooth and free of binding or
scraping.
4. Mount the brake on the shaft and tighten the two set screws in the collar using the torque from table 1. This will
prevent axial movement of the brake. The GBE/M and GBF/M models have eye bolts which may be installed in
the threaded holes to facilitate lifting and positioning of the brake. After installation of the brake on the shaft,
remove the eye bolts and store in a safe place for use when removing the brake from the shaft for repair.
WARNING –Danger due to falling or flying objects.
Do not leave the lifting eye bolts installed during operation of the brake. These could come loose and
fall or be projected from the brake during operation.
lb-in
N-m
GBA
28
3.2
GBB
48
5.4
GBC
48
5.4
GBD
116
13.1
GBE
229
25.9
GBF
229
25.9
Table 1. Collar Set Screw Tightening Torque

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Global Brake Series
MI 850A169 1 L
Page 6 of 14
5. Attach a torque arm between the extension bolt(s) and the machine frame with a “loose” or “floating” mount to
prevent binding forces on the brake bearings. The torque arm will prevent the rotation of the brake stators.
Tighten the mounting bolts to the torque specified in table 2.
lb-in
N-m
GBA
30
3.4
GBB
30
3.4
GBC
51
5.8
GBD
124
14
GBE
249
28.1
GBF
860
97.2
Table 2. Mounting Bolt Tightening Torque
CAUTION –Damage to the fan on blower models can result from the shaft extending past the end of
the brake and hitting the fan blades. On blower models ensure the shaft does not extend past the end
of the brake.
ELECTRICAL INSTALLATION
WARNING –Death or injury can result from electric shocks.
Installation of the brake device must be performed when there is no electrical power in the system.
Never break the electrical connection to the device with a switch or similar component while the brake
device is energized. The inductive voltage generated by breaking the current flow may breakdown the
coil insulation system and may pose a shock hazard. Destruction of the electronics of the power
amplifier or control unit may also occur.
Never place electrical cables under mechanical strain. Always route wiring in either flexible or rigid
conduit.
Protection class 1: Protection class 1 is based on an intact basic insulation and when all conductive parts are
connected to the PE (Protective Earth) conductor on the permanent installation.
All wiring must comply with the essential requirements of the appropriate standard(s) and is the responsibility of
the installer.
Wiring to the brake and blower kit must be insulated copper wire with a temperature rating of at least 105 ⁰C. The
wire size should be 0.52 or 0.82 mm2(20 or 18 AWG).
The tightening torque for the terminals is 0.4 N-m (3.5 lb-in).
For both 24 VDC and 90 VDC devices:
1. Mount a conduit fitting in one of the junction box knock-outs.
2. Connect DC (direct current) power source to the terminals marked 1 and 2.
3. Connect the protective grounding circuit to the terminal marked with the P.E. symbol.
WARNING –Death or injury can result from electric shocks.
Protect against electric shocks by installing a conductive connection between the terminal marked with
the PE symbol on the brake device and the PE circuit of the building or machine.
4. Connect the appropriate AC (alternating current) power source to the terminals marked 1 and 2 of the blower
if it exists.
5. Connect the protective grounding circuit to the terminal marked with the PE symbol of the blower if the blower
exists.

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Global Brake Series
MI 850A169 1 L
Page 7 of 14
SPECIFICATIONS
WARNING –Do not use the devices outside of their rated specifications.
Temperature Range:
Operating 0°C to 40°C
Storage -30° to +80°C
Relative Humidity: 5% to 85%
Pollution Degree: 2 (IEC664-1)
Altitude: 0 to 2000 meters
Maximum RPM: 1800 RPM
NOTE: All rated current and resistance is for Class F coils.
Models
(also applies to
metric models)
Rated
Torque
Heat
Dissipation
(Watts)
Non-Excited
Drag Torque
Inertia (WR2) of
Rotating
Members
Weight
Coil Data
Fan Current
(Amps)
Time Constants
(Seconds)
lb-ft
N-m
lb-ft
N-m
lb-ft2
kg-m2
Lb
kg
Rated
Current
(Amps)
Ohms
@
20⁰C
115
VAC
230
VAC
Current
Torque
GBA-90
5.5
7.5
88
0.07
0.09
0.013
5.5e-4
11
5
0.16
361
—
—
0.06
0.22
GBA-90 AIR
295
14
7
0.19
0.09
GBA-24
88
11
5
0.76
20.8
—
—
0.06
0.22
GBA-24 AIR
295
14
7
0.19
0.09
GBB-90
11
14.9
85
0.07
0.09
0.030
1.3e-3
15
7
0.21
278
—
—
0.09
0.18
GBB-90 AIR
351
17
8
0.19
0.09
GBB-24
85
15
7
1.00
15.7
—
—
0.09
0.18
GBB-24 AIR
351
17
8
0.19
0.09
GBC-90
26
35.2
155
0.23
0.31
0.08
3.4e-3
25
11
0.32
186
—
—
0.10
0.28
GBC-90 AIR
556
28
13
0.19
0.09
GBC-24
155
25
11
1.18
13.2
—
—
0.10
0.28
GBC-24 AIR
556
28
13
0.19
0.09
GBD-90
56
75.9
195
0.56
0.76
0.30
0.013
38
17
0.39
150
—
—
0.16
0.36
GBD-90 AIR
657
42
19
0.19
0.09
GBD-24
195
38
17
1.54
10.2
—
—
0.16
0.36
GBD-24 AIR
657
42
19
0.19
0.09
GBE-90
100
135
320
3.5
4.75
0.33
0.014
75
34
0.45
129
—
—
0.56
1.38
GBE-90 AIR
1230
86
39
0.23
0.11
GBE-24
320
75
34
1.58
9.95
—
—
0.56
1.38
GBE-24 AIR
1230
86
39
0.23
0.11
GBF-90
325
441
595
10.0
13.5
1.97
0.083
180
81.6
0.53
111
—
—
1.12
1.88
GBF-90 AIR
1930
191
86.6
0.34
0.17
GBF-24
595
180
81.6
1.61
9.21
—
—
1.12
1.88
GBF-24 AIR
1930
191
86.6
0.34
0.17

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Global Brake Series
MI 850A169 1 L
Page 8 of 14
Note: Mounting bolts are reversed on fan cooled units.
English Model Dimensions (Inches)
Model
Number
A
B
C
D
-0.000
Keyway
Set
Screws
(mm)
E
(mm)
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
GBA
—
2.25
6.81
0.500
+0.001
NONE
M5x0.8
M5x0.8
4.81
1.38
0.38
0.12
0.75
0.46
1.75
1.75
0.88
0.81
0.12
0.88
—
THRU
5.31
—
GBA-AIR
6.84
4.56
0.69
8.34
2.63
2.36
GBB
—
2.28
7.45
0.625
+0.001
3/16x3/32
M6x1.0
M5x0.8
5.50
1.75
0.44
0.12
0.72
0.46
THRU
5.94
—
GBB-AIR
6.84
4.59
0.66
8.34
2.72
2.37
GBC
—
2.50
9.03
0.750
+0.001
3/16x3/32
M6x1.0
M6x1.0
6.94
1.88
0.44
0.16
1.00
0.57
THRU
7.50
—
GBC-AIR
8.13
4.56
0.94
9.66
2.94
2.19
GBD
—
2.81
10.42
1.000
+0.001
1/4x1/8
M8x1.25
M8x1.25
8.25
2.38
0.50
0.20
0.94
0.73
THRU
8.88
—
GBD-AIR
9.50
4.87
0.88
10.91
3.31
2.36
GBE
—
3.29
13.38
1.375
+0.002
5/16x5/16
M10x1.5
M8x1.25
11.13
2.75
0.80
0.24
1.22
1.06
—
THRU
11.88
—
GBE-AIR
12.50
5.59
1.16
14.00
4.37
3.40
GBF
—
4.66
17.29
1.750
+0.002
3/8 SQ.
M10 x 1.5
M12x1.5
14.72
3.50
0.86
0.35
1.64
1.65
—
THRU
15.75
—
GBF-AIR
16.75
8.28
1.58
18.45
6.69
6.08
Metric Model Dimensions (Millimeters)
Model
Number
A
B
C
D
-0.000
Keyway
Set
Screws
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
GBAM
—
57
173
14 H8
+0.025
NONE
M5x0.8
M5x0.8
122.2
35
10
3
19
11
44
44
22
21
3
22
—
THRU
135
—
GBAM-AIR
174
116
18
212
67
60
GBBM
—
58
189
17 H8
+0.025
5 x 2.5
M6x1.0
M5x0.8
139.7
44
11
3
18
12
THRU
151
—
GBBM-AIR
174
117
17
212
69
60
GBCM
—
64
229
19 H8
+0.025
6 x 3
M6x1.0
M6x1.0
176.2
48
11
4
25
14
THRU
190
—
GBCM-AIR
207
116
24
245
75
56
GBDM
—
71
265
25 H8
+0.025
8 x 3.5
M8x1.25
M8x1.25
209.6
60
13
5
24
19
THRU
226
—
GBDM-AIR
241
124
22
277
84
60
GBEM
—
83
340
35 H8
+0.051
10 x 8
M10x1.5
M8x1.25
282.6
70
20
5
37
27
—
THRU
302
—
GBEM-AIR
318
142
35
356
111
86
GBFM
—
118
439
45 H8
+0.051
14 x 9
M10x1.5
M12x1.5
373.8
89
22
9
42
42
—
THRU
400
—
GBFM-AIR
425
210
40
469
170
154

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Global Brake Series
MI 850A169 1 L
Page 9 of 14
RATED COIL CURRENTS
NOTE: The coil system has changed from Class A to Class F. Refer to the nameplate on your unit to determine
which insulation class you have. If you have Class F insulation, the nameplate will denote Class F. If you have
Class A, there will be no notation on the nameplate. All new brake products have Class F coils.
Rated Current, Amp DC
Coil Voltage, VDC
24
90
Model
Class F
Class F
GBA, GBAM
0.76
0.16
GBB, GBBM
1.00
0.21
GBC, GBCM
1.18
0.32
GBD, GBDM
1.54
0.39
GBE, GBEM
1.58
0.46
GBF, GBFM
1.61
0.53
Legacy
Models
(Before 2003)
Rated Current, Amp DC
Coil Voltage, VDC
24
90
Model
Class A
Class A
GBA, GBAM
0.60
0.15
GBB, GBBM
0.88
0.19
GBC, GBCM
1.25
0.28
GBD, GBDM
1.36
0.37
MAXIMUM COIL CURRENTS AT 0⁰C
This table shows the maximum current draw at rated voltage when the coil is at 0⁰C.
MAINTENANCE
WARNING –Death or injury can result from electric shocks.
Maintenance and repair of the brake device must be performed when there is no electrical power in the
system.
WARNING –Danger of injury from crushing.
Maintenance and repair of the brake device must be performed only when the machine has been
stopped and has been secured from being turned on again.
WARNING –Danger of falling down or muscle or skeletal injury during maintenance and repair.
The brake devices, especially the larger designs, are heavy. Appropriate equipment is to be used and
the safety rules of the company must be observed.
Due to its small number of moving components and its basic design, maintenance of the brake is generally
necessary only after extended service. The main loss of function occurs by the magnetic powder eventually
deteriorating and manifests itself as the maximum torque of the brake slowly decreasing until it no longer
produces sufficient torque for the application. When a problem appears in the system, ensure that all couplings,
belts, etc., and the control device are functioning properly. Use the Troubleshooting guide below to determine the
cause of the problem. For general maintenance, the brakes can be rebuilt with a repair kit. A repair kit includes a
new powder charge and the appropriate bearings, seals and snap rings generally needed to rebuild the unit.
NOTE: When ordering parts not contained in the kit, provide the model number, serial number and parts list item
number and description from Figure 1.
Maximum Current @ 0°C, Amp DC
Coil Voltage, VDC
24
90
Model
Class A
Class F
Class A
Class F
GBA, GBAM
0.94
1.32
0.25
0.28
GBB, GBBM
1.06
1.75
0.28
0.37
GBC, GBCM
1.56
2.06
0.42
0.55
GBD, GBDM
2.03
2.68
0.54
0.69
GBE, GBEM
---
2.76
---
0.80
GBF, GBFM
---
2.98
---
0.93

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Global Brake Series
MI 850A169 1 L
Page 10 of 14
TROUBLESHOOTING
PROBLEM
POSSIBLE CAUSE
ACTION
Load is not controlled by brake
Power supply voltage output low
Magnetic powder has deteriorated
Coil is open
Replace or repair control
Overhaul the brake
Replace coil
Load operates in an intermittent
manner with proper voltage
Coil is intermittently open
Replace coil
Brake is noisy and has vibration
Bearings are worn
Overhaul brake using repair kit
DISASSEMBLY (Refer to Figure 1)
1. Remove the set screws and collar from the rotor shaft and remove the brake from the shaft. For the GBE/M
and GBF/M models use the supplied eye bolts to facilitate lifting and positioning of the brake.
2. Remove the external snap rings from both sides of the rotor shaft.
3. Remove the three (four) screws which hold the left and right stators together.
4. Separate the stator frames by tapping on the end of the rotor with a soft mallet (all models except
GBE/GBEM and GBF/GBFM). Tap on the right stator side first. The rotor will remain attached to the left
stator. For the GBE/GBEM/GBF/GBFM insert the 4 bolts removed in step 3 into the tapped holes in the left
stator frame and screw them in evenly to separate the stator halves.
NOTE: Removal of the junction box and cover are not required.
CAUTION –Damage to the stator halves may occur.
Do not attempt to pry the left and right stators apart with a screwdriver or wedge. This can damage the
mating surfaces and could result in a loss of torque.
5. Remove the coil and the coil gaskets from the stators.
6. Remove the rotor from the left stator by tapping on the rotor shaft with a soft mallet from the left stator side.
7. Remove the powder seals from the stators by prying around the inner lip with a screwdriver.
8. Remove the internal snap rings from both stators.
9. Press the bearing out of each stator.
10. Remove the powder fill screw (and washer for GBA, GBAM, GBB & GBBM only) from the right stator. For
all other models remove the blind rivet.
NOTE: Discard all bearings, powder seals, gaskets, snap rings and magnetic powder. These parts must
be replaced, and are included in the repair kit.