Ortlinghaus TPI 215 EN Operation manual

Ortlinghaus-Werke GmbH
Postfach 50 14 40
42907 Wermelskirchen
Kenkhauser Str. 125
42929 Wermelskirchen
Germany
Tel. [phone]
Fax [phone]
Email [email protected]
Website www.ortlinghaus.com
Version: 03.2012
450 series
Keep for future use
Translation of
original operating manual
Technical product information
TPI 215 EN
Pneumatically released
brake

Ortlinghaus-Werke GmbH Operating instructions TPI 215 EN
2 03.2012
Table of contents
1. Notes regarding use of the operating manual 3
1.1. Who are the operating instructions aimed at? 3
1.2. What can be found in the operating instructions? 4
1.3. Use of these instructions 4
1.4. Notes on the symbols used in the text 4
1.4.1. Personal injury 4
1.4.2. Product / machinery / plant system damage 5
1.5. Personnel qualifications and training 5
1.6. The Ortlinghaus numbering system 5
2. Technical data / intended purpose 6
2.1. Intended Use 6
2.2. Appropriate use 6
2.3. Improper use 7
2.4. Functional description 8
2.4.1. Braking 8
2.4.2. Engaging the clutch (optional version) 8
2.5. Variants 9
2.5.1. Different ways in which the plates are
suspended 9
2.5.2. Different friction linings 9
2.5.3. Special versions 9
3. Transport, packaging 10
3.1. Hazard notes on transport, packaging 10
3.2. Condition on delivery 10
3.3. Transport 11
4. Installation and assembly instructions 12
4.1. Installation conditions 12
4.2. Fundamental installation variants 13
4.3. Installation with twelve-point suspension of
the plates 13
4.4. Installation with twelve-point housing plate
mounting (friction block version) 14
4.5. Installation with two-point plate suspension 15
4.6. Installation with combined suspension of the
plates 15
5. Commissioning 16
5.1. Hazard notes on commissioning 16
5.2. Function test 18
6. Operation 19
6.1. Hazard notes for operation 19
6.2. Inspection while the machine is in operation 21
6.3. Setting the oiler 21
7. Troubleshooting 22
8. Maintenance 24
8.1. Hazard notes on maintenance 24
8.2. Checking wear by measuring the air gap 25
8.3. Wear compensation at friction lining half-
wear point (from size 61 and upwards)) 26
8.3.1. Setting of the wear indicator (with reduced
cylinder volume) 27
8.4. Removing and fitting the plates/housing plates 27
8.4.1. Twelve-point suspension of the plate 28
8.4.2. Twelve-point suspension of the housing
plates (friction block version) 28
8.4.3. Two-point suspension of the plates 28
8.5. Maintenance intervals 28
8.5.1. Changing the seals (elastomer) 29
8.5.2. Changing the springs 29
8.6. Care 29
9. Servicing and repair, modification 30
9.1. Hazard notes on servicing and repairs 30
9.2. Dismantling of the brake 31
9.3. Assembly of the dismantled brake 32
9.4. Hazard notes on modification 34
10. Spare parts 35
10.1. Spare parts list for brake 0450- . . . -23- 36
10.2. Isometric diagram for brake 0450-...-23- 37
10.3. Replacement parts list for brake 0450-...-
29- to 0450-...-61- 38
10.4. Isometric diagram for brake 0450-...-29- to
0450-...-61- 39
10.5. Replacement parts list for brake 0450-...-
62- to 0450-...-93- 40
10.6. Isometric diagram for brake 0450-...-62- to
0450-...-93- 41
11. Storage, de-commissioning 42
11.1. Hazard notes on storage, de-commissioning 42
11.2. Storage 43
11.3. De-commissioning 43
12. Disposal 44
12.1. Hazard notes on disposal 44
13. Annex 45
13.1. Declaration of Conformity 45
Table 1: List of amendments
Amendment Edition date
BA rev. no. 215.002 03.2012

Ortlinghaus-Werke GmbH Operating instructions TPI 215 EN
03.2012 3
1. Notes regarding use of the operating manual
These operating instructions, hereafter referred to as OI, are part of the
product and contain important information on how to safely and correctly
operate our product in machinery and plant systems as well as maintain,
repair, convert, store, decommission and dispose of the product.
In addition to these OI please also refer to the technical descriptions and
information provided in the product drawing as well as the application-
specific design data, e.g. design calculations. If these should not be
contained within the scope of documentation then please request these
immediately from Ortlinghaus.
Without the product drawing these OI are incomplete.
Keep these OI in a safe place, make them accessible to all users at all
times and pass them on to your customers! If necessary, you can down-
load our OI or TPI via the internet from the “Service” directory at www.
ortlinghaus.com. You are also free to make copies of this example. Always
keep the OI near to the machine or system in order to ensure direct acces-
sibility.
On delivery of the product, the attached OI represent the latest technical
development at the time of publication. Any supplements provided by us
should be added to the OI by you or future owners.
We reserve the right to make technical changes to these OI as part of tech-
nical further development. Please ensure that you have the most recent
version of the information.
This information can be requested by telephone (for telephone number see
front page) and obtained in text form or downloaded from the internet at
www.ortlinghaus.com under “Download”.
1.1. Who are the operating instructions aimed at?
These OI are aimed at qualified specialist personnel, especially:
➜assembly fitters of the machinery/plant system manufacturer;
➜industrial mechanics/fitters of the machinery operator;
➜other qualified and properly trained specialist personnel, responsible for
and thereby entrusted with project planning, assembly, commissioning,
operation, maintenance, decommissioning, storage and disposal of the
product.
Persons tasked with using the product must read the OI carefully before
conducting any work. If these prerequisites are not fulfilled, there is a risk
of the product being used incorrectly with severe damage to the product
and subsequent damage to other items as well as physical or fatal injury
and health hazards to the user or third parties. Reference is made in addi-
tion to paragraph 1.5 of the OI.

Ortlinghaus-Werke GmbH Operating instructions TPI 215 EN
4 03.2012
1.3. Use of these instructions
➜Read through these OI completely before working with the product.
➜The instructions in the OI must be complied with.
➜Consider the product drawing as well as any design calculations.
➜These OI are part of the product and should be kept accessible for all
users.
➜If the product is passed on to a third party then pass these OI on as
well.
1.2. What can be found in the operating instructions?
These OI with the product drawing contain all the necessary information
related to the product named on the cover page for the proper utilisation
throughout the various stages of operation.
Note the residual dangers and safety information provided for the stages
of operation.
1.4. Notes on the symbols used in the text
Our products are produced in accordance with our knowledge of latest
engineering practice at the time of design and are operationally safe
and are subject to constant product enhancement. Nonetheless there is
a danger to personnel and property if the following instructions are not
complied with. For hazard-free installation, function and operation the most
important passages in the following pages are highlighted with symbols.
These symbols mean:
NOTE!
➜Pay special attention to this text.
1.4.1. Personal injury
WARNING!
• Hazard while performing the described activity or as a result of hazards
during machine operation.
➜Potentially severe head injury.
WARNING!
• Hazard while performing the described activity or as a result of
hazardous electrical voltage during machine operation.
➜Potentially severe head injury.
ATTENTION!
• Hazard while performing the described activity or as a result of hazards
during machine operation.
➜Potential physical injury or risk to health.

Ortlinghaus-Werke GmbH Operating instructions TPI 215 EN
03.2012 5
1.5. Personnel qualifications and training
Work on our products may only be carried out by professionals (authorized
persons) who possess appropriate qualification or professional training
pertaining to the tasks to be carried out, and who acknowledge and under-
stand the content of these OI.
Professional personnel (authorized persons) must acknowledge and observe
the applicable safety standards.They must use appropriate safety equip-
ment. Furthermore, professional personnel (authorized persons) must be
able to detect possible hazards that could arise in the course of carrying out
their work.
The level of responsibility, expertise, qualification and monitoring of profes-
sional personnel (authorized persons) is the responsibility of the operator.
If personnel do not possess the requisite qualifications and knowledge then
they must be trained and instructed accordingly.
1.6. The Ortlinghaus numbering system
Example: 0 111 - 222 - 33 - 444 555
0 = Code digit for products
Code digits for series
Code digits for design characteristics
Design size
Serial no.
Further design characteristics
WARNING!
• Hazard while performing the described activity or as a result of non-
observance of explosion protection during machine operation.
➜Potentially severe head injury.
1.4.2. Product / machinery / plant system damage
CAUTION!
• Hazard while performing the described activity or as a result of mechan-
ical hazards during machine operation.
➜Potential material damage.
Non-observance of safety notices results in a loss of any claim for
compensation.

Ortlinghaus-Werke GmbH Operating instructions TPI 215 EN
6 03.2012
2. Technical data / intended purpose
2.1. Intended Use
The pneumatically released spring pressure brakes are suitable for appli-
cations with high torques and high heat loading, e.g. for slowing large iner-
tial masses. They find application above all in presses and shearing units.
WARNING!
• The brakes should not be used in atmospheres with high humidity or
which contain oil.
➜Otherwise, there is the danger of the plates slipping, causing braking
action to deteriorate significantly.
2.2. Appropriate use
Our products are intended exclusively for use in accordance with the tech-
nical data stipulated per the design shown on the product drawing
(0 . . . - . . . - . . - . . . . . .)
The order-specific design which was performed by Ortlinghaus may only
be used for the intended application.
The technical data specified by the customer is a component of the
intended use. Insofar as a specification sheet which has been approved by
both sides is present, it is also essential. The customer is responsible for
the correctness of its data.
Our product is intended to be integrated into a system or machine or to be
assembled with other components to form a system or machine. For this
reason, the product should only be brought into circulation once the system
or machine into which the product is to be integrated has completely
fulfilled the applicable EU machinery directive.
Intended use also includes complying with the directions given in this oper-
ating manual, and paying attention to any residual dangers. Remaining
hazards are described in the hazard warning sections of the following
chapters. During the various applications (operating stages) in which
damage to the machine or hazards to personnel can arise, the operator
must ensure that appropriate safety measures are applied. Observe the
applicable national regulations pertaining to accident prevention and envi-
ronmental protection.

Ortlinghaus-Werke GmbH Operating instructions TPI 215 EN
03.2012 7
2.3. Improper use
Any other use or use going beyond the use described in the chapter
“Intended purpose” and “Proper use” is considered to be improper use.
Ortlinghaus is not liable for damages arising from this.
In particular, but not exclusively, our product is considered to be subjected
to improper use if it:
➜is used as a bearing in the sense of supporting and guiding moving
machine parts with respect to the stationary part
➜is overloaded by an excessive speed, an excessive torque during
braking or by an excessive operating pressure (also briefly by pressure
peaks)
➜is overloaded by excessively long sliding actions on the friction surfaces
(e.g. by overloading)
➜is operated with insufficient cooling or with an operating pressure that is
too low
➜is loaded by an excessively high switching frequency e.g. in activation
mode
➜is brought into service with contaminated or oily friction linings
➜is operated with an excessive quantity of oil in the compressed air
NOTE!
➜If the safety instructions and residual hazards are not observed then this
is also considered improper use.
WARNING!
• Unauthorised conversions and modifications on the product are not
permitted for reasons of safety.
➜Modifications to or on our products are prohibited. Where this is not
observed, any claims made against Ortlinghaus-Werke GmbH will be
deemed void.

Ortlinghaus-Werke GmbH Operating instructions TPI 215 EN
8 03.2012
2.4. Functional description
ATTENTION!
• The normal operating pressure is 5.5 bar
• The maximum permissible pressure 6 bar
➜Never operate the brake at a higher pressure due to the risk of cylinder
breakage.
NOTE!
➜Always use dust-free, dry compressed air (a maintenance unit is
required).
➜Set the oiler of your maintenance unit so that it delivers from 1 to
3 drops of oil per m3air.
➜It is essential that the friction linings are kept free of oil.
2.4.1. Braking
Pressure springs 4press against piston 3in the cylinder. This causes
brake plate 2to be pressed against the stop plate, thus bringing about the
braking action. If the piston 3is acted on with the required operating pres-
sure via the air feeds 5, then the brake plate 2is released and the brake is
disengaged.
2.4.2. Engaging the clutch (optional version)
The brake of the model series 450 can optionally be used as a spring-
loaded clutch. By replacing the brake plate 2with a clutch plate enables a
spring-loaded clutching.
The piston (3) is pressurised with compressed air via the air feeds (5). This
disengages the clutch plate (instead of the brake plate 2) and the clutch is
released. Springs 4load the piston 3in the cylinder in the unpressurised
state and the clutch is engaged.
2
3
4
5
Fig. 1: Function

Ortlinghaus-Werke GmbH Operating instructions TPI 215 EN
03.2012 9
2.5. Variants
2.5.1. Different ways in which the plates are suspended
The brake plates can be suspended in one of three different ways:
Table 2: Means of securing
Twelve-point suspension of the plates series 0450 - . . 9 - . . -
Two-point suspension of the plates series 0450 - . . 7 - . . -
series 0450 - . . 8 - . . -
2.5.2. Different friction linings
The brakes can be equipped with two different friction linings:
➜with lining segments which are glued or riveted on
➜with friction blocks
2.5.3. Special versions
Starting from size 61, brakes can be supplied with a reduced cylinder
volume. They are optionally equipped with a wear indicator.
Brakes with twelve-point suspension can be equipped with six spring cups
per plate, each offset by 60°, in order to insure a smoother idle mode.
With twelve-point suspension of plates, two ball studs offset by 120° (the
balls must point outward) can be installed, which hold the suspension
without play in idle mode. It is possible to subsequently replace them
with two sleeves. If need be, plastic sleeves can also be used to produce
smooth running.

Ortlinghaus-Werke GmbH Operating instructions TPI 215 EN
10 03.2012
3. Transport, packaging
The delivery is to be checked for transport damage and any apparent
deficiencies upon receipt. In the event of damage, inform Ortlinghaus
accordingly. Only products that are in technically flawless condition are to
be installed or commissioned.
NOTE!
➜Read the OI before commencing further work.
3.1. Hazard notes on transport, packaging
3.2. Condition on delivery
The scope of the deliverables is defined on the shipping documents.
Check whether the delivery is complete and correct. The packaging is in
accordance with the order.
Hazard Cause Effects Remedial actions, safety
information
Loose parts can shift during
transportation Moving part comes into contact
with static part
Injury, crushing,
abrading,
catching,
rollover
Secure loose parts against moving and do
not reach into assemblies during transporta-
tion
Falling objects Note the position of the packaging (note
TOP direction!), wear safety footwear
Transportation, handling,
moving Falling objects Use of secure lifting gear with sufficient load capacity
Open the packaging, lift with
adequately rated lifting acces-
sories
Gravity (stored
energy) Note the position of the packaging (note TOP direction!), use appropriately dimen-
sioned lifting accessories, wear safety
footwear
Greased or oiled parts could
become dislodged during
transportation
Slippery surfaces Secure parts, set down on stable and non-
slip base, wear safety footwear and gloves
When removing from pack-
aging, transportation without
packaging
Sharp edges,
pointed parts Secure parts for transportation, check for damage and sharp edges before removing
parts, wear safety gloves/footwear
If stored on its circumferen-
tial edge No stability/struc- tural safety Secure parts against rolling or tipping during transportation
Straining,
posture Fatigue, musculo- skeletal strain Note weight information, use transportation devices, perform work in upright position
Mechanical hazards:
Ergonomic hazards:
The clutch/brake combinations are delivered in a fully assembled state
(exception: clutch plate)