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Maintenance and Troubleshooting

2021 KEB America, Inc.

8.3 Troubleshooting

The following are some common issues that may occur with the COMBISTOP type 38

brake, as well as steps to resolving these issues.

Before performing any troubleshooting, follow all relevant safety guidelines.

→

See section Maintenance Safety Guidelines for details.



Contact your local KEB agency for any problems not covered by

this manual, or if the troubleshooting steps listed do not fully

resolve the problem.

Problem

Potential Causes

Solution

Brake Does

Not Release

Incorrect voltage

Only operate the brake with the correct

voltage (see brake label for details)

Rectifier failure

Replace the rectifier.

Air gap too large /

maximum air gap reached

Adjust air gap or replace the friction lining.

→

See section.

Foreign particles between

armature and lining

Remove foreign particles. Use industrial

brake cleaner to clean the brake.

Magnet coil or connecting

cable defective

Replace the brake.

Excessive heating from

high duty cycle

Install a high-speed circuit breaker (for

example, KEB Powerbox)

Brake Does

Not Engage

Damaged hub and lining

interface

Replace the friction lining and hub.

Friction surfaces

contaminated

Clean the friction surfaces. Replace if

necessary.

Hub rubbing on armature

Relocate the hub position to adjusting

dimension m.

→

See section Installing the Brake.

Hand release m

dimension too small

Readjust to proper adjusting dimension m.

See section Installing the Hand Release

Lever.

Brake

Engagement

Delay, Long

Reaction Time

Brake is switched on the

AC side of the rectifier.

Switch the brake on the DC side of the

rectifier.

Microswitch

Does Not

Switch

The setting point of the

microswitch has been

changed.

Check the microswich and adjust as

necessary, or replace the microswitch.
→

See section Adjusting the

Microswitch Settings.

Содержание COMBISTOP

Страница 1: ...COMBISTOP INSTRUCTION MANUAL Type 38 SPRING SET BRAKE Original manual COMBISTOP type 38 Document 20243560 000 01 ...

Страница 2: ...2 2021 KEB America Inc ...

Страница 3: ... 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 RES...

Страница 4: ... in the 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 re...

Страница 5: ...ions 13 2 1 Target Audience 13 2 2 Specified Application 13 2 3 General Safety Guidelines 14 2 4 Electrical Safety Guidelines 14 2 5 Installation and Operation Safety Guidelines 14 2 6 Maintenance Safety Guidelines 15 2 7 Personal Protective Equipment 16 2 8 Permissible Friction Work 17 3 Product Description 18 3 1 Scope of this Manual 18 3 2 Description 18 3 3 Torque and Operating Power 19 3 4 Pa...

Страница 6: ...itching 29 5 4 1 2 DC Side Switching 30 5 4 1 3 DC Side Switching with External MOV 31 5 4 2 Switching Cycles and Times 32 5 5 Uninstallation of the Brake 34 5 5 1 Brake Disposal 34 6 Optional Components 35 6 1 Hand Release Lever 35 6 1 1 Installing the Hand Release Lever 36 6 2 Microswitch 38 6 2 1 Microswitch Replacement 39 6 2 2 Adjusting the Microswitch Settings 40 7 Operation 41 7 1 Before Yo...

Страница 7: ...rica Inc 7 8 1 3 Replacing the Friction Lining 46 8 2 Torque Adjustment 47 8 3 Troubleshooting 48 9 Appendix 49 9 1 Appendix 1 Technical Specifications 49 9 2 Appendix 2 Certification 50 9 3 Appendix 3 Revision History 51 ...

Страница 8: ...e 8 Rectifier Wiring Independent Supply 29 Figure 9 Rectifier Wiring Motor Supply 29 Figure 10 Rectifier Wiring Phase to Phase 29 Figure 11 Rectifier Wiring DC Switching 30 Figure 12 Rectifier Wiring External MOV 31 Figure 13 Hand Release Lever Parts 35 Figure 14 Microswitch Parts 38 Figure 15 Hand Release Lever Operation 42 Figure 16 Checking the Air Gap 43 Figure 17 Wear Dimensions 44 Figure 18 ...

Страница 9: ... 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 meets EEA safety standards CEC Canadian Electric Cod...

Страница 10: ... Load The components of a mechanical system driven by a motor The load refers to the entire system powered by the motor See Driven Shaft Surface for the individual component connected directly to the drive shaft Machine Manufacturer The manufacturer of the application in which the COMBISTOP brake is installed Not KEB America Inc Magnet The component of the brake which contains the magnetic compone...

Страница 11: ...always the same as the Application in which the device is being used System Integrator The technician installing the COMBISTOP brake into the application UL Independent Standardization Company that tests and certifies products according to defined and industry leading safety standards The UL mark indicates a product meets UL safety standards ...

Страница 12: ...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 1910 13...

Страница 13: ...he 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 electrical products Must be familiar with the installation and operation of the product as specified in this manual See the Ins...

Страница 14: ...upply and secure it against switching on prior to any work on the device Wait until the system has come to a complete stop prior to any work on the device Never bridge branch circuit protection devices Observe all relevant safety standards during the electrical installation See the Standards for COMBISTOP type 38 Brakes section for details specific to the product Use only wire gauges and fuses rat...

Страница 15: ...sk of electrical shock Turn off the power supply and secure it against switching on prior to any maintenance on the brake WARNING Moving parts can crush and cut Contact with rotation or moving parts may cause serious injury Wait until the drive has come to a complete stop before performing any maintenance Secure the drive against accidental movement prior to performing any maintenance CAUTION Hot ...

Страница 16: ...t When installing or performing maintenance on the brake use the following personal protective equipment Long sleeved protective clothing Safety gloves Safety shoes Safety goggles The personal protective equipment must be provided by the operating company and must comply with any applicable safety regulations See Standards for COMBISTOP type 38 Brakes for details ...

Страница 17: ...ecrease in braking torque NOTICE The WRmax table below is only valid for standard brakes with a secondary friction surface of cast steel Rust free secondary friction surfaces or speeds higher than specified will reduce the permissible friction work If rated torque is reduced by optional adjustment screws the permissible work will increase Permissible Friction Work Values Size Range Speed 00 07 300...

Страница 18: ...vice Device part numbers follow the format XX YY ZZZ where o XX Size o YY Type o ZZZ Design 3 2 Description The COMBISTOP type 38 brake is an electromagnetically activated dual surface spring applied brake for dry operation The brake is engaged when powered OFF and disengaged when powered ON The braking force is generated when the brake is powered OFF by pressure springs which press the armature a...

Страница 19: ...d application Braking torque and operating power by brake size is shown below Brake Size Rated Braking Torque1 Nm Wattage W Type N Type H Type N Type H 00 0 5 2 11 15 02 5 7 5 25 25 03 10 15 30 30 04 20 30 30 30 05 36 50 48 48 06 70 90 62 75 07 100 150 65 90 08 150 225 75 90 09 250 375 80 115 10 500 750 130 180 11 1000 1500 180 280 1 After running in process ...

Страница 20: ...ion 1 Magnet System 1 1 Magnet 1 2 Adjusting Spacer 1 3 Armature 2a Fingered Hub for size A brakes 2b Splined Hub for size B brakes 3a Molded Friction Lining for size A brakes 3b Splined Friction Lining with Aluminum Carrier for size B brakes 4 Friction Disk Optional 5 Flange Optional 6 Hand Release Lever Optional 7 Dust Protection Ring Optional ...

Страница 21: ...red to monitor armature movement the PLC or VFD control can be programmed to prevent the motor from starting until the brake is released to avoid wear and tear on the motor When configured to monitor wear the microswitch can be adjusted to signal after Xn of wear to the friction lining For microswitch installation instructions see section Microswitch 3 5 2 Hand Release Lever The hand release lever...

Страница 22: ...nsport large size COMBISTOP devices See Appendix 1 Technical Specifications for size and weight details 4 3 Packaging COMBISTOP brakes and clutches are shipped using biodegradable cardboard packaging Packaging should be recycled or disposed of according to local regulations 4 4 Temporary Storage If the COMBISTOP brake is not installed immediately upon delivery it must be stored in a dry environmen...

Страница 23: ...ails Ensure the brake is not damaged or corroded and that no foreign material obstructs the air gap of the device If corrosion is present thoroughly clean off any corrosion with appropriate cleaning materials Ensure the friction surfaces are free of grease or oil Clean all friction surfaces thoroughly before installing the brake Use only sealed bearings when installing the brake o Never use aggres...

Страница 24: ...alling the COMBISTOP brake For visual examples of installing the brake and adjusting the air gap you can view a tutorial video at the following link Installation Video on Youtube COMBISTOP Installation Video The following images show a cross view of a fully assembled brake both with flange and with friction disk Figure 3 Brake with Flange Figure 4 Brake with Friction Disk 1 If using a friction dis...

Страница 25: ...a space of 0 5mm to 1mm between hub and friction surface to prevent friction and wear and tear on the hub See Figure 7 Air Gap for details Figure 5 Mounting the Hub Figure 6 Gap between Hub and Friction Surface 5 Carefully slide the friction lining 3 onto the hub splines or fingers 2 The friction lining must be free to move axially on the hub 6 Slide the magnet system 1 onto the shaft until the ho...

Страница 26: ...he fastening screws after securely attaching the magnet system The following table shows screw number and sizes for each size of COMBISTOP brake Size 02 03 04 05 06 07 08 09 10 11 of Screws 3 3 3 3 3 3 3 3 6 6 Screw Size M4x40 M5x45 M6x55 M6x60 M8x70 M8x80 M8x90 M10x 110 M10x 120 M12x 150 Min Class 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 Use a feeler gauge F to check the air gap X between the ma...

Страница 27: ... 4 0 5 0 6 9 Connect the COMBISTOP brake lead lines to an appropriate DC voltage to test brake function The brake will release when voltage is applied and engage when the voltage supply is powered off 10 The COMBISTOP brake is now ready for use Refer to the following chapter for instructions on installing optional components ...

Страница 28: ...ell as in Appendix B Technical Specifications Refer to the sections below for installing an AC to DC rectifier For brakes with rectifiers the brake can be switched on or off on the AC or DC side of the rectifier AC side switching offers reduced wear on the relay switching contacts but slower brake engagement time DC side switching requires a contactor to support the high voltages which are present...

Страница 29: ... amp class CC fuse is recommended for Fbrk in the diagrams below The contact rating of the relay or contactor should be minimum 5 amps with the minimum voltage based on the applied AC voltage 125VAC for 120V supply and 250VAC for 208 and 230V supplies Figure 8 Rectifier Wiring Independent Supply Figure 9 Rectifier Wiring Motor Supply Figure 10 Rectifier Wiring Phase to Phase Rectifier Models 04910...

Страница 30: ... contactor Kbrk_ac should be minimum 5 amps with the minimum voltage based on the applied AC voltage 125VAC for 120V supply 250VAC for 208V or 230V supplies and 600VAC for 400 or 480V supplies The DC side contactor Kbrk_dc must be a three way phase power contactor rated for 600VAC and minimum of 9 amps inductive AC3 All three contacts are wired in series as indicated in figure 11 Figure 11 Rectifi...

Страница 31: ...ls can result in an overload of the rectifier In this case an external MOV should be used connected in parallel to the brake as shown below The voltage rating of the MOV is dependent on the supply voltage of the rectifier Figure 12 Rectifier Wiring External MOV The following MOVs are recommended for use with the listed supply voltage Supply Voltage KEB Material Number Varistor Voltage 120V 208V 23...

Страница 32: ...20 25 50 05 25 50 120 110 180 220 240 25 55 06 5 10 240 200 260 330 25 90 07 5 10 240 220 400 650 50 40 150 120 08 5 10 300 320 700 900 60 50 180 09 2 5 350 900 1200 60 220 10 1 3 350 400 1400 1800 2000 60 100 250 300 11 1 2 750 3100 3500 150 1000 1 rated torque after running in process SC1 applicable for rectifiers 0210010 CE07 0291020 CE07 0291010 CEMV Numbers in red are for COMBISTOP designatio...

Страница 33: ...Installation 2021 KEB America Inc 33 Current Time Voltage Time Torque Time Diagrams AC Side Switching DC Side Switching t1 Engagement Time t11 Engagement Delay Time t2 Release Time ...

Страница 34: ...pose of brake components in accordance with applicable environmental regulations The following key numbers can be used when disposing of electromagnetic brake components These key numbers are subject to change depending on the disassembly process Component Category Key Number Magnet with coil cables and all other steel parts Steel scrap EAK 12 01 02 Aluminum components Nonferrous metals including ...

Страница 35: ...wing image shows the parts for the hand release lever i The parts and design of the hand release lever depends on the design of the brake N or H and the size of the brake Refer to the following table to see which parts are included for each size design of COMBISTOP Figure 13 Hand Release Lever Parts ...

Страница 36: ...dle 2 onto the hand release yoke 1 2 Attach the springs washers locking plates and nuts to the provided holes in the magnet as shown in the image on the previous page o For small sized brakes 02 07 size attach components 3 5 or 6 and 4 as shown in the upper line of the image o For large sized brakes 08 10 attach components 8 6 and 4 as show in the lower line of the image 3 Slide the hand release y...

Страница 37: ...ing torque Do not operate the brake with wear beyond Xn as listed above i The adjustment dimension m on the previous table applies to the listed rated torque nominal air gap and rated voltage for the brake If you are operating the brake with different values than those listed in this manual contact KEB America Inc for adjusted m dimensions 5 Verify the air gap X is set to the adjusted dimension as...

Страница 38: ...croswitch The drive control should not allow the motor to start until the brake is disengaged and the shaft can rotate freely CAUTION Brake Malfunction Changing microswitch settings may cause brake or motor malfunctions WARNING Moving Parts may Crush or Cut Carefully secure the shaft and disconnect the load before replacing the Microswitch to prevent any movement from the shaft while performing wo...

Страница 39: ...ews 2 4 Connect the microswitch as a normally open contact using the following connection diagram Microswitch Connections 1 Ground black 2 Normally closed contact brown 3 Normally open contact red 5 After installation verify the switching point for the microswitch by repeatedly powering the brake ON and OFF Verify the two switching states If necessary adjust the microswitch o Brake Energized ON si...

Страница 40: ...Loosen the hex head lock nut 5 2 Turn the hex head screw 4 towards the microswitch 1 until it contacts the microswitch tappet 3 Connect the measuring instrument to terminal 1 and 4 of the microswitch 4 Turn the hex head screw 4 towards the microswitch 1 until the normally open contact is closed ON signal 5 Turn the hex head screw 4 the opposite direction until the normally open contact opens OFF s...

Страница 41: ...p is properly adjusted and that the brake releases when switched ON Perform the Running In Process See section Running In Process CAUTION Loss of Braking Torque If the brake is damaged or contaminated or if the switching function can no longer be guaranteed do not put the brake into operation 7 1 1 Running In Process CAUTION Limited Braking Torque The nominal braking torque is not reached until a ...

Страница 42: ...ore using the hand release lever mechanically secure the load against unintended movements Extra care should be given for vertical applications i e lifts cranes winches To disengage the brake using the hand release lever steadily pull the lever directly away from the mounting surface until the brake is released as shown below Figure 15 Hand Release Lever Operation ...

Страница 43: ... intervals If the air gap is measured larger than the maximum air gap Xn the air gap should be re adjusted to the nominal air gap X or as close as possible If the air gap cannot be adjusted to within Xn by the re adjustment procedure the friction lining should be replaced and the air gap adjusted again The following sections describe checking and adjusting the air gap and replacing the friction li...

Страница 44: ...air gap at which the brake will function properly The minimum permissible thickness of the friction lining before replacement is denoted Gmin The hub counter bore is denoted R and shown above Size X mm V mm Xn mm Gmin mm R mm Design N H N H N H N H N H 02 0 2 2 0 0 4 0 4 5 5 0 5 03 0 2 1 5 0 5 04 6 5 1 5 04 0 2 2 5 06 0 5 8 0 1 5 05 0 2 2 0 0 8 0 7 10 0 2 0 06 0 3 2 0 0 9 0 7 10 0 2 0 07 0 3 4 0 1...

Страница 45: ... 6 With feeler gauge inserted turn the adjusting spacer to move toward the mounting surface and out of the magnet assembly until snug against the mounting surface 7 Repeat steps 3 6 at three locations around the perimeter of the magnet assembly to ensure uniform air gap width o The air gap must be uniform around the entire brake circumference o If one spacer is tight or lose it means you do not ha...

Страница 46: ...renced refer to Figure 2 Brake Parts List 1 Remove the socket head screws connecting the magnet to the mounting surface 2 Remove the magnet system 1 from the hub 2 Figure 19 Removing the Magnet System 3 Remove the friction lining 3 from the hub 2 4 Clean the new friction lining armature and secondary friction lining thoroughly with an alcohol based solvent and clean paper towel 5 Slide the new fri...

Страница 47: ... as well as the maximum permissible adjustment distances COMBISTOP sizes 02 06 use an adjustable E Ring to reduce braking torque The entire E Ring can be rotated to adjust the torque COMBISTOP sizes 07 11 use set screws to reduce braking torque All set screws should be turned the same number of rotations to ensure even braking torque Figure 20 Size 02 06 with E Ring Figure 21 Size 07 11 with Set S...

Страница 48: ...n armature and lining Remove foreign particles Use industrial brake cleaner to clean the brake Magnet coil or connecting cable defective Replace the brake Excessive heating from high duty cycle Install a high speed circuit breaker for example KEB Powerbox Brake Does Not Engage Damaged hub and lining interface Replace the friction lining and hub Friction surfaces contaminated Clean the friction sur...

Страница 49: ...e temperature for optimal braking function Use of the brake beyond this temperature range is not supported by KEB America Inc Max temperature 40 C 120 C May suffer loss of braking torque when operated within this range Exceeding these values will damage the device IP Rating IP20 Finger safe not waterproof IP44 with optional dust protection ring Protected from solid objects bigger than 1mm and wate...

Страница 50: ...Appendix 50 2021 KEB America Inc 9 2 Appendix 2 Certification ...

Страница 51: ...Appendix 2021 KEB America Inc 51 9 3 Appendix 3 Revision History Chapter Change Date Manual Initial Publication 12 2020 5 4 Added Comprehensive Rectifier Details 05 2021 ...

Страница 52: ...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 Shanghai P R China Tel 86 21 37746688 Fax 86 21 37746600 E Mail info keb cn Inter...

Страница 53: ...Automation with Drive www kebamerica com KEB America Inc 5100 Valley Industrial Blvd S Shakopee MN 55379 Tel 1 952 224 1400 E Mail info kebamerica com ...

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