Kendrion 77 500 B Series Manuale utente

MODULE LINE

Operating Instructions 77 500..B..

Spring-applied single-disc brake module

Types: 77 50013B16 77 50019B15

77 50024B15 77 50029B15

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 2

Contents

1.General information .............................................................................................................................. 3

1.1Introduction............................................................................................................................................ 3

1.2Standards and directives....................................................................................................................... 3

1.3Manufacturer’s liability........................................................................................................................... 3

1.4Declaration of Incorporation (in accordance with Annex II, part 1, Section B of Machinery Directive

2006/42/EC)........................................................................................................................................... 4

2.Safety...................................................................................................................................................... 5

2.1Safety and warning symbols / Safety information ................................................................................. 5

2.2Intended use.......................................................................................................................................... 5

2.3General safety information..................................................................................................................... 6

2.3.1Installation.......................................................................................................................................... 6

2.3.2Start-up.............................................................................................................................................. 6

2.3.3Operation........................................................................................................................................... 6

2.3.4Maintenance and repair..................................................................................................................... 7

3.Emissions............................................................................................................................................... 7

3.1Noise...................................................................................................................................................... 7

3.2Heat ....................................................................................................................................................... 7

3.3Electromagnetic compatibility................................................................................................................ 7

4.Product description ............................................................................................................................ 10

4.1Operating principle............................................................................................................................... 10

4.2Design.................................................................................................................................................. 10

5.Installation............................................................................................................................................ 12

5.1Mechanical installation......................................................................................................................... 12

5.1.1Brake shaft (13) installation............................................................................................................. 12

5.1.2Mounting the brake module to the motor......................................................................................... 13

5.2Installation of accessories (not applicable to the brake shaft (13)) ..................................................... 14

5.3Electrical connection and operation..................................................................................................... 15

5.3.1DC power supply ............................................................................................................................. 17

5.3.2AC power supply.............................................................................................................................. 17

5.3.3Electrical connection of brake modules with microswitch (27)........................................................ 18

5.4Set-up and start-up.............................................................................................................................. 18

5.4.1Manual brake release...................................................................................................................... 19

5.5M4transmissible torque adjustments................................................................................................... 20

6.Maintenance......................................................................................................................................... 21

6.1Checks and service ............................................................................................................................. 21

6.2Brake module removal from motor and replacement of component parts.......................................... 22

6.3Microswitch (27) adjustment (only applicable to brake modules with microswitch (27))..................... 23

6.4Brake shaft (13) removal ..................................................................................................................... 24

7.Motor design........................................................................................................................................ 25

8.Driven components, balancing.......................................................................................................... 26

9.Condition at delivery........................................................................................................................... 26

10.Troubleshooting.................................................................................................................................. 27

11.Definitions............................................................................................................................................ 28

12.Technical specifications..................................................................................................................... 28

13.Revision history .................................................................................................................................. 29

Document information:

Issued by: Kendrion (Villingen) GmbH Division: Industrial Drive Systems

Replacement for document: - Replaces the issue dated: 2 July 2012

Type of document: Translation of German operating Document status: Released

instructions BA 77 500..B..

Designation of document: BA 77 500..B.. Englisch

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 3

1. General information

1.1 Introduction

These Operating Instructions describe the operating principle and features of Kendrion Binder spring-applied

single-disc brake modules type 77 500..B...

The safety information provided in this manual must be strictly observed during the set-up of the machine

(e.g. motor) and during the start-up, operation and maintenance of the spring-applied brake module.

Should any queries arise with respect to torques, torque variations, installation position, wear, wear reserve,

switching work, break-in conditions, release range, ambient conditions and the like, please contact Kendrion

Binder and ask for clarification before starting to use the brake.

Kendrion Binder spring-applied single-disc brake modules type 77 500..B.. are not ready-to-use devices, but

are intended to be incorporated into or assembled with other equipment. Consequently, these brakes will be

referred to as components in the following sections. The output side of the spring-applied single-disc brake

modules has the same fitting dimensions as the motor end shield. As a result, the brakes are designed as

fail-safe holding brakes with emergency stop function for attachment to electric motors.

1.2 Standards and directives

The state-of-the-art spring-applied brakes have been designed, built and tested in accordance with the

requirements of DIN VDE 0580 concerning electromagnetic devices and components. Being classified as

"electromagnetic components", spring-applied single-disc brake modules are not subject to the Low Voltage

Directive and must not bear a CE mark of conformity. The user is required to employ suitable switching

devices and controls to ensure use of the brakes in accordance with EMC Directive 2004/108/EC.

1.3 Manufacturer’s liability

The manufacturer will not assume any responsibility for damage caused by failure to use the products in

accordance with their intended use or by failure to observe safety information and other instructions provided

in this manual. The information in this manual was correct and up-to-date before going to print. The

information contained herein shall not entitle users to raise claims with respect to components purchased at

an earlier date.

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 4

1.4 Declaration of Incorporation

(in accordance with Annex II, part 1, Section B of Machinery Directive 2006/42/EC)

We hereby declare that the products below comply with the essential health and safety requirements

specified in Annex I of Machinery Directive 2006/42/EC:

Annex I General Principles, Annex I Sections 1.1.2, 1.1.3, 1.1.5, 1.3.2, 1.5.1

The partly completed machinery must not be put into service until the final machinery into which it is to be

incorporated has been declared in conformity with the provisions of Machinery Directive 2006/42/EC. The

relevant technical documentation required for the partly completed machinery has been compiled in

accordance with Annex VII, part B of Machinery Directive 2006/42/EC. The manufacturer undertakes to

submit an electronic copy of the relevant technical documentation compiled for the partly completed

machinery if reasonably requested by national authorities.

Standards and directives:

EN 60529 Enclosure protection ratings

DIN VDE 0580 Electromagnetic devices and components

Products: Electromagnetically released spring-applied single-disc brake module

77 50013B16

77 50019B15

77 50024B15

77 50029B15

Manufacturer: Kendrion (Villingen) GmbH

Industrial Drive Systems

Wilhelm-Binder-Straße 4-6

78048 Villingen-Schwenningen

Germany

Person authorized Dr Uwe Gnauert

to compile the Kendrion (Villingen) GmbH

documentation: Industrial Drive Systems

Wilhelm-Binder-Straße 4-6

78048 Villingen-Schwenningen

Germany

Kendrion (Villingen) GmbH

Industrial Drive Systems Villingen Authorized signatory: ....................................................

12 Dec. 2013 (Dr Uwe Gnauert)

(Head of Development at IDS)

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 5

2. Safety

2.1 Safety and warning symbols / Safety information

Personal injury or equipment damage

Symbol / Signal word Warns against ... Potential risks and hazards

Danger imminent personal injury fatal accidents or serious injury

Warning potential risk of serious

personal injury fatal accidents or serious injury

Caution potential risk of personal injury minor injury

Attention potential risk of equipment

damage damage to components or other

equipment

Information

Symbol / Signal word Provides information on …

Note the safe use and operation of the product

The brakes described in these Operating Instructions have been designed and built on the basis of an

analysis of hazards and in accordance with the requirements of the applicable harmonized standards and

technical specifications. They correspond to the state of the art and provide maximum safety. However,

safety hazards can only be avoided if the user of the equipment takes adequate precautions and makes sure

that safety instructions are strictly adhered to. It is the duty of the user of the machine to plan these

measures and to check their implementation.

The user is required to ensure that:

the brakes are only used in accordance with their intended use (see "Product description" section).

the brakes are in perfect working order and checked at regular intervals.

a complete copy of these Operating Instructions is kept available at the place of use of the brakes at

all times.

all applicable local and machinery-specific regulations and requirements are followed.

start-up, maintenance and repair work is only done by authorized and suitably qualified personnel.

such personnel are kept informed on all relevant occupational safety and environmental protection

issues and familiar with these Operating Instructions and with the safety information contained

herein.

brake functionality is not interfered with by an external magnetic field.

2.2 Intended use

The brake modules described in these Operating Instructions are intended to be assembled with electric

machines, in particular electric motors, for use on industrial equipment. Operation in potentially explosive or

firedamp atmospheres is not allowed. The brake modules must be used in accordance with the operating

requirements detailed in this manual. The rated power limits specified herein must not be exceeded. Use of

the brake modules as service brakes or safety brakes is not permitted.

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 6

2.3 General safety information

Brakes fitted to motors feature hazardous live components and rotating parts and may exhibit hot surfaces.

Any work associated with the transport, connection, start-up and periodical maintenance of the brakes must

be carried out by authorized and qualified specialist personnel (in accordance with VDE 0105; IEC 364).

Failure to observe safety, operating and maintenance instructions may cause serious personal injury and

severe damage to the equipment. Whenever special measures are required in accordance with the

instructions contained herein, such measures should be agreed with the brake manufacturer before the

machinery into which the brake is to be incorporated is set up.

Should any queries arise with respect to torques, torque variations, installation positions, wear, wear reserve,

switching work, break-in conditions, release range, ambient conditions and the like, please contact Kendrion

Binder and ask for clarification before using the brake.

Retrofitting or modification work to be carried out on the brake is subject to the approval from Kendrion

Binder.

Accident prevention regulations applying to the specific field of application of the brake must be strictly

observed.

The brakes described in this manual are not designed for use as "safety brakes". This means that torque

reductions caused by factors beyond the user's control cannot be excluded.

2.3.1 Installation

When connecting the brakes described in these Operating Instructions check that the voltage and voltage

type comply with the specifications on the rating plate. Sufficient heat dissipation must be ensured when the

brake is fitted to or incorporated into other equipment.

Adequate precautions must be taken to avoid overvoltage during disconnection or voltage peaks. The

magnetic field of the products may cause interference outside the brake or even feedback to the brake in

case of adverse installation conditions. Should you have queries concerning mounting and fitting conditions,

please contact the brake manufacturer and ask for clarification.

Adequate safety measures (DIN VDE 0848, part 4; DIN 31000/VDE 1000; DIN VDE 0100, part 0420) must

be taken by the brake user to avoid hazards to persons or damage to equipment caused by:

direct or indirect effects of electromagnetic fields,

heated components,

moving parts.

2.3.2 Start-up

The brakes must not be started up when:

power supply cables/wires or connections are damaged.

the solenoid housing or coil sheath is damaged.

other defects are suspected.

2.3.3 Operation

Make sure that live components such as plug contacts or the field coil are not exposed to water.

The brake cable connections must not be crushed, squeezed or exposed to mechanical loads.

Check that the friction surfaces of the friction elements are not contaminated with grease, oil or other fluids to

avoid substantial torque reduction. Bear in mind that the original torque cannot be restored even if the friction

surfaces are cleaned after contact with fluids.

The gradual brake wear towards the end of the brake service life may cause an approximately 10% torque

reduction. This must be taken into consideration in the set-up of the machine or overall system.

Due to the diverse ambient conditions in which the brakes may be used, always check that the brake module

is in perfect working order before start-up.

Torque reductions cannot be excluded if the brake module is used for applications where only minimum

friction work is required. In such cases, the user should ensure that the brake occasionally performs

sufficient friction work.

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 7

Note!

The maximum air gap smax (see Table 28/1: air gap snom and smax) must not be exceeded throughout the

entire brake module service life. (Please refer to Section 6 “Maintenance” for details.)

2.3.4 Maintenance and repair

Repair work must only be carried out by qualified specialist personnel (definition to IEC 364). Failure to

perform repairs according to requirements may cause serious personal injury or equipment damage.

Make sure that no voltage is applied to the brakes when carrying out maintenance work.

3. Emissions

3.1 Noise

The spring-applied single-disc brake module produces switching noise during engagement and release. The

noise level is determined by the installation conditions, circuitry and air gap. Depending on the mounting

position, operating conditions and state of the friction surfaces, audible vibrations (squealing) may be

produced during braking.

3.2 Heat

Braking operations and gradual heating of the field coil cause the solenoid housing temperature to increase

substantially. Under adverse conditions, the surface temperature may rise to well over 100°C.

Caution!

Risk of burns in case of contact with hot surfaces! Suitable covers and hand guards must be installed to

provide protection against accidental contact.

3.3 Electromagnetic compatibility

As required by the German Electromagnetic Compatibility Act (EMVG), electromagnetic compatibility must

be guaranteed to ensure immunity to external electromagnetic fields and conducted interference.

Furthermore, the emission of electromagnetic fields and line-conducted interference during brake operation

must be minimized. Since the brake features depend on the circuitry and operation, a declaration of

conformity with the applicable EMC standard can only be furnished for the wiring type, but not for a specific

brake.

The spring-applied single-disc brake modules type 77 500..B.. are designed for industrial applications to

which the following EMC standards apply: Generic Immunity Standard EN 61000-6-2 and Generic Emission

Standard EN 61000-6-3 / EN 61000-6-4.

Other applications may be subject to different generic standards which must be considered by the

manufacturer of the overall system. The requirements in terms of electromagnetic compatibility of devices

and components are determined by basic standards derived from the generic standards. Brake wiring

recommendations will be provided in the following sections to ensure compliance with the individual basic

standards that are relevant for industrial use of the brake and some other applications.

For additional information on electromagnetic compatibility, especially with respect to the recommended

electronic rectifiers specified in Section 5.3, please refer to the applicable data sheets.

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 8

Immunity according to EN 61000-4:

EN 61000-4-2 Electrostatic discharge:

The spring-applied single-disc brake modules comply at least with severity level 3 without requiring

additional measures. The recommended rectifiers specified in Section 5.3 conform to severity level 3 without

additional measures.

EN 61000-4-3 Electromagnetic fields:

The spring-applied single-disc brake modules comply at least with severity level 3 without requiring

additional measures. The recommended rectifiers conform to severity level 3 without additional measures.

EN 61000-4-4 Fast transients (burst):

The spring-applied single-disc brake modules comply at least with severity level 3 without requiring

additional measures. The recommended rectifiers conform to severity level 3.

EN 61000-4-5 Surge:

The spring-applied single-disc brake modules comply at least with severity level 3 without requiring

additional measures. The recommended rectifiers conform to severity level 3.

EN 61000-4-9 Pulse magnetic fields, EN 61000-4-10 Damped oscillatory magnetic fields:

Since the operating magnetic fields of the electromagnetic brakes are stronger many times over than

interference fields, the brake function will remain unaffected. The spring-applied single-disc brake modules

comply at least with severity level 4. The recommended rectifiers conform at least to severity level 3.

EN 61000-4-11 Voltage dips, short interruptions, and short supply voltage variations:

a) Voltage interruptions:

Spring-applied single-disc brake modules that comply with the requirements of DIN VDE 0580 are de-

energized after the specified switching times at the latest. The switching time depends on the control

and mains conditions (e.g. generator effect of running down motors). Voltage interruptions of shorter

duration than the response delay specified by DIN VDE 0580 will not cause any malfunctions. The user

must ensure that any consequential damage is avoided (e.g. motor start-up before the brake has been

released caused by phase failure in the case of two-phase energized motors or by the slipping of an

electromagnetically engaged system due to torque drop). The functional reliability of the

electromagnetic brake and its electronic accessories remains unaffected provided that the

aforementioned consequential damage is avoided.

b) Voltage dips and short supply voltage variations:

Electromagnetically released systems:

Voltage dips and supply voltage variations to below 60% of the rated voltage and lasting longer than the

response delay specified by DIN VDE 0580 may cause the brake to be de-energized temporarily.

Consequential damage as described under a) above must be avoided by the user by taking adequate

precautions.

Electromagnetically engaged systems:

Voltage dips and supply voltage variations to below the minimum tolerance threshold will cause torque

reductions. The user is required to take adequate precautions to avoid consequential damage.

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 9

Radio interference suppression in accordance with EN 55011:

The brake modules and the recommended electronic rectifiers are classified as Group 1 equipment in

accordance with EN 55011. As far as the emissions from this equipment are concerned, one distinguishes

between field guided radiated interference and line-conducted interference.

a) Radiated interference:

When operated with DC voltage or rectified 50/60 Hz AC

voltage, all brakes comply with the limit values

applicable to Class B equipment.

b) Conducted interference:

When connected to a DC power source, the

electromagnetic brakes meet the limit values applicable

to Class A equipment. If the brakes are connected to a

50/60 Hz AC power source and equipped with electronic

rectifiers or other electronic controls, interference

suppression measures as shown in Fig. 9/1 must be

taken to ensure compliance with the limit values

applicable to Class A equipment.

Interference suppression capacitors should be used which must be dimensioned to suit the connection

data of the electromagnetic components and the specific mains conditions. The recommended rectifiers

specified in Section 5.3 are CE mark certified in accordance with the EMC Directive. They have built-in

interference suppression components and comply at least with the requirements of EN 55011 for Class

A equipment, unless otherwise specified in the specification sheets. When brakes are used with the

specified rectifiers or with other types of rectifiers, the recommended values listed in Table 9/1 should

be observed.

Interference suppression components should be installed as close as possible to the consumer.

Interference caused during switching operations of the electromagnetic component is generally

attributable to the inductive load.

Where necessary, assemblies designed to limit the disconnection voltage (e.g. anti-parallel diode) or

voltage limiting components (e.g. varistors, suppressor diodes, resistance diodes and the like) can be

installed. However, such components will inevitably change the switching times of the brake and

increase the generated noise level. The rectifiers specified in Section 5.3 are equipped with free-wheel

diodes and/or varistors to limit the disconnection voltage.

In case of DC side switching, a varistor rated for the type-specific maximum operating voltage and

connected in parallel with the field coil (1.2) limits the peak voltage to the values specified in Table 9/2.

Note!

If the brake is used in connection with other electronic accessories, the user is responsible to ensure

compliance with EMC requirements. Compliance with applicable standards concerning the design and

operation of components, sub-assemblies or equipment employed shall not relieve the user and

manufacturer of the overall system from their obligation to furnish proof of conformity of the overall system

with such standards.

Rectifier type Rated input voltage range

U1/VAC (40-60 Hz) DC at L-load

(ADC) Capacitor

(nF/VAC)

Half-wave rectifier

32 07332B40 up to 500 (10%) up to 2.0 no additional

interference suppression

measures required

Table 9/1

Max. rectifier operating voltage

(VAC) Recommended disconnection voltage for DC side switching

(V)

250 700

Table 9/2

Fig. 9/1

Kendrion (Villingen) GmbH Operating Instructions 77 500..B.. Last updated: 12 Dec. 2013 Page 10

4. Product description

4.1 Operating principle

The brake module is an electromagnetic component with built-in electromagnetically released spring-applied

single-disc brake designed to operate dry. The braking effect is produced by the spring force and neutralized

electromagnetically. The brake module with ball bearing supported brake shaft should preferably be mounted

to the A-face end shield of electric motors. The brake can also be equipped with an optional hand release so

that it can be released manually.

4.2 Design

The solenoid housing (1.1) with the encapsulated field coil (1.2) accommodates the armature (2), friction disc

(4) and flange (3). The flange is fixed by means of the cheese head screws (10). The compression springs

(7) located in the solenoid housing (1.1) are supported on the adjusting ring (9) and solenoid housing (1.1)

by the studs (8) (size 13 brakes: compression springs (7) only). These compression springs generate an

axial force that is transmitted to the friction disc (4) through the armature (2). As a result, the friction disc (4)

is clamped between the firmly fixed flange (3) and the armature (2) and the braking effect (torque) is

produced. Straight pins (5) are provided which act as tangential torque supports for the armature (2) relative

to the solenoid housing (1.1).

When DC voltage is applied to the field coil (1.2), the electromagnetic force thus generated causes the

armature (2) to be attracted, overcoming the force of the compression springs (7). The friction disc (4) is thus

released and the braking effect is neutralized.

As the brake module is a closed system, no forces are transmitted outwards away from the brake.

Transmission of the braking force from the axially moveable friction disc (4) to the brake shaft (13) is

achieved through the form-fit connection of the square socket in the friction disc with the brake shaft (13),

with the brake shaft being rigidly connected with the motor shaft. This applies to size 13, 19 and 24 brakes.

When a size 29 brake is used, the friction disc is connected with the brake shaft by means of the teeth

provided on the disc and shaft. The ball bearing (15) located between the solenoid housing (1.1) and brake

shaft (13) ensures that the brake can be centred relative to the brake shaft (13) and motor shaft when it is

mounted to the motor flange. The bearing also absorbs transverse forces that act radially on the brake shaft

(13). The ball bearing is factory-sealed.

An additional sealing ring (6) is provided which protects the friction disc (4) against dirt, grease or oil ingress

in case the factory-installed ball bearing sealing rings are damaged and ensures that abrasive grit and dust

produced by the friction disc cannot escape.

On the drive side, the flange (3) and brake shaft (13) are sealed by the sealing ring (11). The optional hand

release (24) allows the spring-applied single-disc brake module to be released manually (e.g. in case of

power failure). The brake must be connected directly to the terminals in the connector box (19).

The transmissible torque of the brake module can be changed with the adjusting ring (9). Rubber bolts (18)

and an O-ring (26) are provided to reduce the noise and vibration produced by the friction disc (4).

Key to Fig. 11/1:

1.1 Solenoid housing 15 Ball bearing

1.2 Field coil 16 Circlip

2 Armature 17 Screw plug

3 Flange 18 Rubber bolt

4 Friction disc 19 Connector box

5 Straight pin 20 Feather key

6 Sealing ring

7 Compression spring 22 Sealing washer

8 Stud (not used in size 13 brakes) 23 Cover (2 x arranged at 180°)

9 Adjusting ring (not used in size 13 brakes) 24 Hand release (accessories)

10 Cheese head screw 25 Set screw

11 Sealing ring 26 O-ring

12 Disc E Adjusting ring clearance

13 Brake shaft A Contact surface motor side

14 Spring washer B Contact surface brake shaft (13)

1) bonded with Loctite 243; installed in brake shaft (13)

2) accessories for size 19 and 24 brakes; included as standard parts of friction disc (4) in size 13 brakes

3) only used in brakes without hand release (24)

4) only in size 29 brakes

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