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KEB COMBISTOP 38, Instruction Manual

The KEB Combistop 38 Instruction Manual is an essential resource for users of this high-quality product. This comprehensive manual is available for free download from our website, ensuring that customers have easy access to all the necessary information to utilize their KEB Combistop 38 effectively.

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Installation 

©

 2021 KEB America, Inc. 

 

21 

 

 

 

 

4  Installation 

NOTICE 

 

Stay Safe! Stay Informed! 

  Read and follow all safety instructions prior to installing the Load 

Brake. 

 

 

The following sections detail the steps for unpacking and installing the size 09 

COMBISTOP type 38 Load Brake (shown below). Read this chapter thoroughly before 

beginning the installation process. 
 

 

Figure 2 Load Brake with optional Hand Release Lever and Microswitch 

4.1  Required Tools 

You will need the following tools before you begin the Load Brake installation. 

•

  Customer supplied hex head key (Design A) 

•

  6mm or 8mm hex head key (Design B) 

•

  KEB Alignment Tool (Design B, Optional): Part number 0938007-007U 

•

  17mm wrench 

•

  Feeler gauge 

Brake with hand release: 

•

  13mm wrench 

Brake with Microswitch: 

•

  Small flathead screwdriver 

•

  4mm hex head key 

•

  8mm wrench 

•

  Digital multimeter 

 

Summary of Contents for COMBISTOP 38

Page 1: ...COMBISTOP type 38 Instruction Manual Load Brake Size 9 Original Manual Load Brake Size 9 Document 20139598 000 01 Material No 0938TUM K001 ...

Page 2: ...2 2021 KEB America Inc ...

Page 3: ...g signs DANGER Dangerous situation which will cause death or serious injury if this safety warning is ignored WARNING Hazardous situation which may cause death or serious injury if this safety warning is ignored CAUTION Hazardous situation which may cause minor or moderate injury if this safety warning is ignored NOTICE Situation which may cause property damage if this safety warning is ignored RE...

Page 4: ...he target application is beyond our control and therefore exclusively the responsibility of the machine manufacturer system integrator or customer The information contained in this document as well as any user specific advice in spoken or written form or generated through testing is provided to best of our knowledge and is considered for informational purposes only KEB America Inc bears no respons...

Page 5: ...d Brake 11 2 Safety Instructions 12 2 1 Target Audience 12 2 2 Specified Application 13 2 3 General Safety Guidelines 13 2 4 Electrical Safety Guidelines 13 2 5 Installation and Operation Safety Guidelines 14 2 6 Maintenance Safety Guidelines 14 2 7 Personal Protective Equipment 15 3 Product Description 16 3 1 Scope of this Manual 16 3 2 Description 17 3 2 1 Brake Components 17 3 2 2 Brake Assembl...

Page 6: ...he Hub 26 4 3 2 4 Mount the Magnet 27 4 4 Checking the Air Gap 28 4 5 Testing the Brake Function 29 5 Optional Components and Accessories 30 5 1 Hand Release Lever 30 5 1 1 Installation 31 5 2 Microswitch 33 5 2 1 Installation 33 6 Operation 37 6 1 Normal Operation 37 6 2 Manual Operation 37 7 Rectifiers 38 7 1 Example Wiring Diagrams 38 7 1 1 AC Side Switching 38 7 1 2 DC Side Switching 40 7 1 3 ...

Page 7: ...ure 17 Plunger Attachment 34 Figure 18 Plunger Position 34 Figure 19 Microswitch Wire Attachment 35 Figure 20 Microswitch Attachment 35 Figure 21 Plunger Adjustment 36 Figure 22 Rectifier Wiring AC Side Switching Relay Switching Phase to Neutral 38 Figure 23 Rectifier Wiring AC Side Switching Independent Contactor Switching Phase to Phase 39 Figure 24 Rectifier Wiring AC Side Switching Motor Conta...

Page 8: ...021 KEB America Inc List of Tables Table 1 Part Numbers 19 Table 2 Coil Specifications 20 Table 3 Resistance Ranges 20 Table 4 Optional Accessories 30 Table 5 Hand Release Components 30 Table 6 Microswitch Components 33 ...

Page 9: ...on of the electrical distribution system that extends beyond the final branch circuit protection device A branch circuit is used to run motors or other appliances and is what is commonly found inside a building CE European safety standards for products in the European Economic Area Manufacturers self test products against these standards to maintain CE certification The CE mark indicates a product...

Page 10: ...al Electric Code Safety standard for electrical installations used in the United States Product KEB Product See Device Recommended tightening torque The torque required to fully screw a socket head screw into a mounting surface The recommended tightening torque depends on the type of screw used as well as the material thread depth and locking components if any used in the mounting surface Refer to...

Page 11: ...ling safety standards for electric installations in Canada NFPA 70 National Electric Code NEC o Region US o Electric safety code detailing safety standards for electric installations in the United States NFPA 79 Electrical Standard for Industrial Machinery o Region US o Industrial safety code detailing safety standards for industrial machinery to protect against fire and electrical hazards OSHA 19...

Page 12: ...structions please contact KEB prior to operating the device 2 1 Target Audience This manual is intended exclusively for the use of qualified electrical mechanical technicians Qualified technicians for the purpose of this document must meet the following Must have fully read and understood the safety instructions contained in this manual Must be familiar with the installation and assembly of electr...

Page 13: ...before returning the brake to operation Never use the brake in potentially explosive environments The brake may not be modified or altered in any way not intended by KEB America Inc 2 4 Electrical Safety Guidelines DANGER Rick of electrical shock Turn off the power supply and secure it against switching on prior to any work on the device Never bridge branch circuit protection devices Carefully obs...

Page 14: ...low the listed temperature limits for the device Ensure there is protection against accidental contact with rotating or moving parts Ensure there is sufficient protection from environmental factors such as moisture or aggressive gases that may compromise the integrity of the friction surface or armature 2 6 Maintenance Safety Guidelines DANGER Risk of electrical shock Turn off the power supply and...

Page 15: ...oreign particles entering the air gap during maintenance Ensure there is sufficient protection against moisture or aggressive gasses that may compromise the integrity of the friction surface or armature 2 7 Personal Protective Equipment When installing or performing maintenance on the brake or clutch use the following personal protective equipment Long sleeved protective clothing Safety gloves Saf...

Page 16: ...ally mounted brakes can be mounted directly to the bulkhead of the machine and are the simplest to install Externally mounted brakes are referred to as Design Style A See section Design A Installation for details Internally mounted brakes are mounted to the output of a gearbox internal to the machine Internally mounted brakes are referred to as Design Style B See section Design B Installation for ...

Page 17: ...ket assembly 1 2 Magnet assembly 1 3 Hub 1 4 M10 spring washers 12 4 per stud 5 M10 washers 3 1 per stud 6 M10 nylon lock nuts 3 1 per stud 7 Hand release lever optional 1 8 Microswitch optional 1 9 Spherical Washer included with Hand Release 2 10 Spherical Bolts included with Hand Release 2 11 Dust protection ring 1 Figure 1 Brake Components ...

Page 18: ... XX TY P A B C D E F Part Number Component Descriptions Number Name Options Description XX Brake Size 09 The only size described in this manual Fixed TY Type Code 38 Spring Set Brake Fixed P Disc Code M Multi Disk Brake Fixed A Flange Type 0 Generic Flange 1 KEB F4 K4 2 SEW 57 67 B 3 Torque Arm B Torque Rating 1 250 Nm 2 500 Nm 3 750 Nm 4 1000 Nm 5 1250 Nm 6 1500 Nm C Coil Voltage 0 24 VDC 1 105 V...

Page 19: ...35 mm 2 40 mm 3 45 mm 4 50 mm 5 55 mm 6 60 mm 7 65 mm Hub Bore Inches A 1 5 B 1 625 C 1 75 D 2 00 E 2 375 F 2 50 E Options 0 Bolt release no microswitch 1 Hand release no microswitch 2 Bolt release with microswitch 3 Hand release with microswitch F Special Designation 0 Standard X Special number C D and E are randomized Table 1 Part Numbers ...

Page 20: ...e Voltage Variable Power 135W Current 135W Coil Voltage Mounting Can be mounted vertically or horizontally Max Operating Speed 600 RPM Table 2 Coil Specifications Resistance Range Coil Voltage Resistance Ω 24 VDC 3 9 4 5 105 VDC 76 87 170 VDC 199 229 205 VDC 275 317 270 VDC 502 578 Table 3 Resistance Ranges ...

Page 21: ...ghly before beginning the installation process Figure 2 Load Brake with optional Hand Release Lever and Microswitch 4 1 Required Tools You will need the following tools before you begin the Load Brake installation Customer supplied hex head key Design A 6mm or 8mm hex head key Design B KEB Alignment Tool Design B Optional Part number 0938007 007U 17mm wrench Feeler gauge Brake with hand release 13...

Page 22: ... 5 Place the brake on a support such that the weight of the brake does not rest on the protruding internal mounting bolts Design B 4 3 Installing the Brake 4 3 1 Design A Installation 4 3 1 1 Install the Hub on the Shaft 1 Mount the hub 2 on the shaft 3 positioning the hub 1mm from the mounting surface 3 Ensure the hub is oriented with set screws facing out Figure 3 Hub Installation 2 Lock the hub...

Page 23: ... friction disk 3 Ensure the brake assembly 4 fits snugly against the mounting surface 1 Figure 4 Brake Assembly Installation CAUTION Do not force the brake assembly onto the hub Doing so may damage the brake 4 Apply LOCTITE to the threads of the six external socket head mounting bolts customer supplied Start the bolts using the appropriate hex head key 5 Tighten the bolts equally in two stages unt...

Page 24: ...n and remove the three M10 lock nuts 1 holding the magnet housing on the brake assembly using a 17mm wrench i Do not loosen or remove the two black manual release bolts if included as they hold the magnet together 2 Lift the magnet assembly 2 off the mounting studs 3 and set it aside Figure 5 Magnet Removal 3 Remove the hub 4 from the brake assembly 5 and set it aside Figure 6 Hub Removal ...

Page 25: ...ay be used to secure washers to the mounting studs if the brake must be moved before reassembly 4 3 2 2 Mount the Brake Assembly 1 Apply LOCTITE to the threads on the internal flat head mounting bolts 2 2 Mount the brake assembly 3 over the shaft 4 and align with the motor 1 Figure 7 Brake Assembly Installation 3 Fasten the brake assembly to the gear motor using the mounting bolts 2 4 Tighten the ...

Page 26: ...ection Required Tools for details on the alignment tool 2 Mount the hub 5 onto the shaft 4 ensuring the hub is oriented with set screws facing out Figure 8 Hub Installation 3 Align the hub 5 onto the teeth of the friction disks 7 using the alignment tool 6 to hold the friction disks steady if used Some rotation of the hub may be necessary to align all of the friction disks if the optional alignmen...

Page 27: ... Slide the magnet 9 onto the M10 mounting studs 8 Figure 10 Magnet Installation 3 Slide the washers 10 onto the M10 mounting studs 8 and fasten a nylon lock nut 11 to each stud 4 Tighten the lock nuts equally in stages to compress the pressure springs and reduce the air gap between the magnet and armature Proceed to Checking the Air Gap ...

Page 28: ... s circumference to ensure the air gap is equal throughout the entire brake circumference If the air gap is not within tolerance tighten or loosen the lock nuts or bolts to expand or contract the air gap as appropriate Ensure the air gap is equal throughout the entire brake circumference after adjusting the air gap After checking the air gap re install the dust protection ring 1 over the lead wire...

Page 29: ...th nominal voltage and verify the armature disengages 2 Check for free rotation of the shaft while the brake is powered on 3 Power off the brake and verify the armature engages 4 Check for free rotation of the shaft while the brake is powered off The shaft should not rotate with the brake engaged WARNING After performing an emergency stop inspect the brake components and test the brake performance...

Page 30: ...520 M01U Microswitch 0938270 M01U Table 4 Optional Accessories 5 1 Hand Release Lever Part Number 0938520 M01U Kit Components Component Number Included Handle 1 Yoke 1 Spherical Bolt 2 Spherical Washer 2 Table 5 Hand Release Components The optional Hand Release Lever provides a manual backup to the standard electronic brake release for releasing the brake in power failure situations To use the Han...

Page 31: ... two standard bolts 1 from the magnet assembly as shown above 2 Mount the hand release yoke 2 to the magnet using the spherical bolts and washers included with the kit as shown below Figure 14 Hand Release Yoke Attachment 3 Tighten the bolts to 60Nm with a 13mm wrench socket 4 Screw the hand release handle 3 to the yoke ensuring a tight fit ...

Page 32: ...ssories 32 2021 KEB America Inc Figure 15 Hand Release Lever Attachment 5 Test the Hand Release Lever before returning the brake to operation i A pull force of 70lbs is required to release the Load Brake via the hand release lever ...

Page 33: ...Microswitch Components Typically a Microswitch is used to detect when the powered on brake disengages This can be used to signal the system that the shaft is free to rotate or that the motor is free to engage 5 2 1 Installation 1 Install the anti rotation wire 1 onto the magnet fitting both ends of the wire into the guide holes 2 This wire keeps the plunger from rotating out of alignment Figure 16...

Page 34: ...ew 4 Figure 17 Plunger Attachment 3 Tighten the plunger with an 8mm wrench until there is at least a one inch gap from the plunger tip to the top of the magnet Figure 18 Plunger Position 4 Fasten the microswitch wire to the magnet housing via the pipe clip 5 Tighten the bolt with a 4mm hex head key ...

Page 35: ...wdriver Figure 20 Microswitch Attachment 6 Connect the microswitch leads to a digital multimeter microswitch black to red normally open and set the meter to diode test settings The multimeter should read OL indicating there the microswitch is open 7 Attach the brake power leads to the power supply and power the brake on 8 Using an 8mm wrench rotate the plunger upward until it contacts the microswi...

Page 36: ...rica Inc Figure 21 Plunger Adjustment 9 Rotate the plunger outward 1 6 turn further The microswitch is now set 10 Test the microswitch functionality by power cycling the brake several times to verify the microswitch triggers when the brake is powered on ...

Page 37: ...tically through a customer supplied control system There is no manual operation of the Load Brake unless the optional Hand Release Lever is installed 6 2 Manual Operation With the optional Hand Release Lever the brake may be disengaged manually by pulling the lever directly away from the mounting surface to which the brake is attached When the lever is released the brake engages once more preventi...

Page 38: ...and reduces contact erosion For simultaneous switching it is recommended to also use a MOV on the DC side AC side switching will yield slower switching times but requires no protective measures for the coil and switching contacts 7 1 Example Wiring Diagrams 7 1 1 AC Side Switching AC Side Relay Switching Phase to Neutral Switching AC Side Rectifier Full wave Model Number 0291020 CE07 Line Voltage ...

Page 39: ...actor rated 300VAC min 5A AC1 Figure 23 Rectifier Wiring AC Side Switching Independent Contactor Switching Phase to Phase AC Side Motor Contactor Switching Phase to Phase Figure 4 2 5 Switching AC Side Rectifier Half wave Model Number 0691020 CE07 Line Voltage 400VAC Input Voltage 400VAC Coil Voltage 170VDC Line Voltage 480VAC Input Voltage 480VAC Coil Voltage 205VDC Fbrk Class CC fuse max 5A Moto...

Page 40: ... Line Voltage 230VAC Input Voltage 230VAC Coil Voltage 105VDC Rectifier Full wave Model Number 0491020 CE07 Line Voltage 208VAC Input Voltage 208VAC Coil Voltage 170VDC Line Voltage 230VAC Input Voltage 230VAC Coil Voltage 205VDC Fbrk Class CC fuse max 5A Kbrk_dc min 300VDC 9A AC3 Optional redundant contactor for safety Kbrk_ac min 300VAC 5A AC1 Figure 25 Rectifier Wiring DC Side Switching Indepen...

Page 41: ... 400VAC Input Voltage 400VAC Coil Voltage 170VDC Line Voltage 480VAC Input Voltage 480VAC Coil Voltage 205VDC Fbrk Class CC fuse max 5A Kbrk_dc min 600VDC 9A AC3 MOV 625Vrms 1000Vpk 500J Installed at the brake Optional redundant contactor for safety Kbrk_ac min 600VAC 5A AC1 Figure 26 Rectifier Wiring DC Side Switching Independent Contactor Switching with External MOV Phase to Phase ...

Page 42: ...he engagement of the brake when the voltage is switched off AC Side Independent Contactor Switching Phase to Phase Figure 4 2 4 Switching AC Side Rectifier OEX Switch Model Number 9098200 CE09 Line Voltage 208VAC Input Voltage 208VAC Coil Voltage 170VDC Line Voltage 230VAC Input Voltage 230VAC Coil Voltage 205VDC Fbrk Class CC fuse max 5A Independent Contactor rated 300VAC min 5A AC1 Figure 27 OEX...

Page 43: ...l Number 9098200 CE09 Line Voltage 208VAC Input Voltage 208VAC Coil Voltage 170VDC Line Voltage 230VAC Input Voltage 230VAC Coil Voltage 205VDC Fbrk Class CC fuse max 5A Kbrk_dc min 300VDC 9A AC3 Optional redundant contactor for safety Kbrk_ac min 300VAC 5A AC1 Figure 28 OEX Wiring DC Side Switching Independent Contactor Switching Phase to Phase ...

Page 44: ...Appendix 44 2021 KEB America Inc 8 Appendix 8 1 Appendix 1 Certification ...

Page 45: ...Revision History 2021 KEB America Inc 45 9 Revision History Chapter Change Date Instruction Manual Initial Publication 07 2021 ...

Page 46: ...Revision History 46 2021 KEB America Inc ...

Page 47: ...Via Newton 2 20019 Settimo Milanese Milano Italia Tel 39 02 3353531 Fax 39 02 33500790 E Mail info keb it Internet www keb it Japan KEB Japan Ltd 15 16 2 Chome Takanawa Minato ku Tokyo 108 0074 Japan Tel 81 33 445 8515 Fax 81 33 445 8215 E Mail info keb jp Internet www keb jp P R China KEB Power Transmission Technology Shanghai Co Ltd No 435 QianPu Road Chedun Town Songjiang District 201611 Shangh...

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