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KTR-STOP

M-xxx B-xx-xx

Operating/Assembly instructions

KTR-N
Sheet:
Edition:

445102 EN
2 of 22
3

Please observe protection

note ISO 16016.

Drawn:

2020-03-25 Shg/Wie

Replacing:

KTR-N dated 2019-08-26

Verified:

2020-03-25 Shg

Replaced by:

The KTR brake system was designed to operate as a service brake/emergency stop brake on rotating
brake disks. For any other applications please consult with KTR.

Safety and advice symbols

2.3

General hazard warnings

2.4

Intended use

Storage, transport and packaging

3.1

Storage

3.2

Transport and packaging

Assembly

4.1

Components of the brake

4.2

Preparation of assembly

4.3

Brake pads

4.4

Assembly of the brake

4.5

Pressure port of a brake

4.6

Pressure port of several brakes

4.7

Start-up of the brake

4.8

Setting/Re-setting of the brake

4.9

Recommendation of liquids to be used

4.10

Disassembly of the brake

4.11

Spares inventory, customer service addresses

Replacement of brake pads

5.2

Maintenance of the brake / replacement of single parts

5.3

Maintenance and service

Accessories - Sensor

6.1

Technical Data „State/wear sensor“

6.2

Assembly / start-up

Table of contents

Содержание KTR-STOP M B Series

Страница 1: ...6016 Drawn 2020 03 25 Shg Wie Replacing KTR N dated 2019 08 26 Verified 2020 03 25 Shg Replaced by KTR STOP M xxx B xx xx M xxx B xx xx is a spring actuated brake in a fixed calliper design serving to ge nerate a brake force onto a brake disk in order to decelerate a plant s movement or stop it respectively or keep it at standstill ...

Страница 2: ...torage transport and packaging 6 3 1 Storage 6 3 2 Transport and packaging 6 4 Assembly 6 4 1 Components of the brake 6 4 2 Preparation of assembly 7 4 3 Brake pads 8 4 4 Assembly of the brake 8 4 5 Pressure port of a brake 10 4 6 Pressure port of several brakes 11 4 7 Start up of the brake 12 4 8 Setting Re setting of the brake 13 4 9 Recommendation of liquids to be used 15 4 10 Disassembly of th...

Страница 3: ...xx xx Weight kg Approx 185 215 1 Width of brake pad mm 200 Surface of each brake pad organic mm2 57 900 powder metal mm2 53 500 Max wear of each brake pad mm 10 Rated coefficient of friction 2 μ 0 4 Total brake piston surface complete brake cm2 137 4 Volume for each brake caliper with 1 mm stroke cm3 13 74 Max operating pressure bar 200 Pressure port G 1 4 Oil bleed G 1 8 Min diameter of brake dis...

Страница 4: ...00 KTR STOP M 130 B xx xx 130 5 0 140 31200 67600 93600 KTR STOP M 140 B xx xx 140 4 5 150 33600 72800 100800 KTR STOP M 150 B xx xx 150 7 5 165 36000 78000 108000 KTR STOP M 160 B xx xx 160 7 0 180 38400 83200 115200 KTR STOP M 170 B xx xx 170 6 5 190 40800 88400 122400 KTR STOP M 180 B xx xx 180 6 0 190 43200 93600 129600 2 The friction coefficient each depends on the application or material of ...

Страница 5: ...rve the following safety indica tions All operations on and with the brake have to be performed taking into account safety first Make sure to switch off the power pack before you perform your work on the brake Secure the power pack against accidental switch on e g by providing warning signs at the place of switch on or removing the fuse for current supply Do not reach into the operating area of th...

Страница 6: ...age rooms are not suitable Please make sure that condensation is not generated The best relative air humidity is less than 65 In order to avoid any injuries and any kind of damage please always make use of proper transport and lifting equipment The brake is packed differently each depending on number and kind of transport Unless otherwise contractually agreed packaging will follow the in house pac...

Страница 7: ...n plug nylon 1 17 1 Distance plate 1 18 2 Countersunk screw 1 19 1 Connection adapter 1 20 1 Screw plug VSTI acc to DIN 908 Component assembly 2 Pad retraction sets Compo nent Quantity Description Illustration 5 Pad retraction set 2 1 1 Cap screw DIN EN ISO 4762 10 9 2 2 1 Pressure spring 2 3 1 Sealing plug To ensure the full braking power the preparation for assembly needs to be carefully per for...

Страница 8: ...placed and disposed of We would recommend to store the brake pads in their package as long as possible to pro tect them from any kind of dirt Brake pads which have worn off to the wear limit have to be replaced immediately Make sure to replace by original parts only If one half of the brake has to be mounted under pressure without transport lock for reasons of space please consult with KTR STOP In...

Страница 9: ...ction plate respectively stand Illustration 6 You should preferably insert the connec tion screw marked with 1 in illustration 6 Insert the second half of the brake in the correct position towards the connection plate or stand respectively Push the connection screw screwed in before through the second half of the brake and align it symmetrically Fasten the connection screw at the tightening torque...

Страница 10: ...loaded with the full braking power on one side in case that one half of the brake fails It is not recommended to use steel plugs for venting Connect the drain line to the brake see illustration 7 and 8 For that purpose remove the sealing plugs befo rehand If no drain line is connected a vacuum may be generated inside the brake which will dama ge the gaskets Never give any pressure on the drain lin...

Страница 11: ...the gaskets may be damaged and the operation of the brake is no longer ensured Illustration 9 Pressure port of several brakes in parallel Illustration 10 Pressure port of several brakes in a series The pressure port on top serves for venting the brake For a wash up system please make use of one of the pressure ports on top Always connect the brake consisting of two halves to a pressure line see il...

Страница 12: ... is sufficient liquid in the hydraulic system during and after the venting process recommendation of liquid see chapter 4 9 Switch on the hydraulic system for a short while to make sure that the brake is rinsed with hydraulic oil Repeat this process until a stream of clean oil dissipates from the miniature measuring hose Remove the miniature measuring hose If the miniature measuring coupling is re...

Страница 13: ...chieve the nominal coefficient of friction Please observe the instructions for grinding in according to KTR N The brake needs to be set with the initial assembly or after having replaced the brake pads or single parts respectively Only in this way it is ensured that the brake has the clamping force specified In case of wear of the brake pads the brake needs to be regularly reset Before you reset t...

Страница 14: ...ge Set the gap to 1 mm on both sides by screwing the setting nut either upwards or downwards Applying for resetting of the brake only wear of brake pad With a wear of the brake pad 1 mm wear for each brake pad of 2 mm the setting nut needs to be screwed in by one revolu tion Insert the O ring component 1 9 on both sides between the housing and the setting nut Illustration 12 Setting of adjusting n...

Страница 15: ...exceed 500 mm2 s and the viscosity during operation should not fall below 12 mm2 s Filtration When filling and re filling the hydraulic system and replacing the hydraulic liquid the oil needs to be filtered For that purpose use an offline filter or a respective fill unit In addition we would recommend to use an inline filter The service life of the brake system is extended depending on the degree ...

Страница 16: ... point component 1 13 from the venting hole see illustrations 9 and 10 Drain the hydraulic oil completely from the brake Dispose of the hydraulic oil as per chapter 4 12 Disconnect the drain and pressure oil line from the brake Screw the screw plugs component 1 13 into all pressure ports or venting holes see illustrations 7 to 10 Remove the 6 off connection screws serving for fixing the brake to t...

Страница 17: ...achine Secure the components before disassembly Never keep your fingers between brake disk and brake when locking the brake in order to prevent serious injuries of your hands Before every maintenance operation please make sure that the brake is fully secured against activating Remove the screw plug component 1 20 or the sensor component 4 on both sidesfrom the setting nut component 1 7 Put the ope...

Страница 18: ...e g conglutinating with Loctite average strength Repeat chapter 4 8 Setting re setting of the brake Please make sure that the brake disk can rotate freely while not touching the brake pads or the housing Please note chapter 4 4 Assembly of the brake Before you reactivate the brake observe chapter 4 7 Start up of the brake To ensure the full braking power both disassembly and assembly have to be pe...

Страница 19: ...necessary use some hydraulic oil Remove the gaskets component 1 4 and 1 5 and the scraper component 1 3 When removing the gaskets and scrapers make sure that the keyways in the housing are not damaged The components have to be cleaned from dirt grease and corrosion protection The components can easily be cleaned by means of solvents Afterwards dry the components Please observe the manufacturer s i...

Страница 20: ... properly with Molykote MoS2 Please make sure that the set of disk springs is mounted in the same arrangement as it was supplied If a new set of disk springs is used the condition of supply needs to be observed in detail Screw the setting nut component 1 7 into the housing and set it to the right dimension see illustration 12 Put the opening pressure see table 2 onto the hydraulic system Hand tigh...

Страница 21: ...rake locked 2 Switch position 0 unlocked 1 locked Switch S2 only shows the wear status reliably when the brake is activated locked If the brake is not activated unlocked a statement about the condition of wear cannot be given The wear of the brake pad is only measured if the brake is activated If the brake is not acti vated there is no signal Resetting necessary is displayed as soon as the brake p...

Страница 22: ...1 2 20 Nm Max tightening torque M12 hand tight Length of cable 5 m 10 m or 15 m Material of cable PUR Dimension of cable 5 0 34 mm2 Illustration 19 Pin assignment of plug in connection Remove the screw plug component 1 20 from the setting nut component 1 7 Hand tighten the sensor component 4 into the settting nut first see illustration 20 Tighten the sensor at the tightening torque TA 20 Nm Provid...

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