KENDRION INDUSTRIAL BRAKES

Vario Line
Spring-applied single-disc brake
Operating Instructions 76 431..H00
Types: 76 43110H00 76 43111H00 76 43113H00
76 43114H00 76 43116H00 76 43119H00
76 43124H00 76 43129H00
Contents
1. General ................................................................................................................................................... 3
1.1 Introduction ............................................................................................................................................ 3
1.2 Standards and directives ....................................................................................................................... 3
1.3 Declaration of Incorporation
(in accordance with Annex II, part 1, Section B of Machinery Directive 2006/42/EC)........................... 3
1.4 EU Declaration of Conformity ................................................................................................................ 4
1.5 Manufacturer's liability ........................................................................................................................... 4
2. Product description............................................................................................................................... 5
2.1 Operating principle ................................................................................................................................. 5
2.2 Brake design .......................................................................................................................................... 5
3. Installation .............................................................................................................................................. 7
3.1 Mechanical installation ........................................................................................................................... 7
3.2 Installation of accessories...................................................................................................................... 8
3.3 Electrical connection and operation ....................................................................................................... 9
3.3.1 DC power supply ............................................................................................................................. 10
3.3.2 AC power supply .............................................................................................................................. 10
3.4 Electromagnetic compatibility .............................................................................................................. 13
3.5 Set-up & start-up .................................................................................................................................. 15
3.6 M2 rated torque adjustments ................................................................................................................ 16
4. Maintenance ......................................................................................................................................... 17
4.1 Checks and service ............................................................................................................................. 17
4.2 Spare parts and accessories ............................................................................................................... 18
5. Condition at delivery, transportation and storage ........................................................................... 18
6. Emissions ............................................................................................................................................. 19
6.1 Noise .................................................................................................................................................... 19
6.2 Heat ..................................................................................................................................................... 19
7. Troubleshooting .................................................................................................................................. 20
8. Safety .................................................................................................................................................... 21
8.1 Intended use ........................................................................................................................................ 21
8.2 General safety information................................................................................................................... 21
8.2.1 Set-up .............................................................................................................................................. 22
8.2.2 Set-up & start-up .............................................................................................................................. 22
8.2.3 Installation ........................................................................................................................................ 22
8.2.4 Operation ......................................................................................................................................... 22
8.2.5 Maintenance, repair and replacement ............................................................................................. 23
8.3 Warning symbols ................................................................................................................................. 23
9. Definitions ............................................................................................................................................ 24
10. Technical specifications ..................................................................................................................... 26
11. Product number / type number / version number ............................................................................ 28
12. Authorized repair shops for service & maintenance ....................................................................... 29
13. Revision history................................................................................................................................... 29

Document information:
Issued by: Kendrion (Villingen) GmbH Last updated: 13/03/2020
Replacement for document: - Replaces the issue dated: 25/03/2020
Document type: translation of original German operating Document status: released
instructions BA 76 431..H00
Document title: BA 76 431.. H00 Englisch

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 2 von 30

1. General

1.1 Introduction

These operating instructions describe the operating principle and features of the spring-applied brake types
76 431..H00. 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.

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
(Villingen) and ask for clarification before starting to use the brake. Spring-applied brakes 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.

1.2 Standards and directives

The state-of-the-art 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 brakes are also subject to the Low Voltage
Directive 2014/35/EU. The user is required to employ suitable switching devices and controls to ensure use of
the brakes in accordance with EMC Directive 2014/30/EU.

The products listed in Section 1.3 are entitled to bear the CSA certification mark to indicate that they are
approved to CSA standards (Canadian Standards Association).

1.3 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 and 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.

Manufacturer: Kendrion (Villingen) GmbH Person authorized Dominik Hettich

Wilhelm-Binder-Str. 4-6 to compile the Kendrion (Villingen) GmbH
78048 Villingen-Schwenningen documentation: Wilhelm-Binder-Str. 4-6
Germany 78048 Villingen-Schwenningen
Germany

Applied harmonized standards and other technical standards and regulations:

EN 60529 Enclosure protection ratings
DIN VDE 0580 Electromagnetic devices and components

Product: Electromagnetically released spring-applied single-disc brake

Types: 76 43110H00 76 43111H00 76 43113H00 76 43114H00

76 43116H00 76 43119H00 76 43124H00 76 43129H00

Kendrion (Villingen) GmbH Villingen Authorized signatory: .......................................................

13/03/2020 Dominik Hettich
(Head of Development)

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 3 von 30

1.4 EU Declaration of Conformity

We hereby declare that the products below, specifically the product versions brought into circulation, have
been designed and built in accordance with the requirements of Directives 2014/35/EU (Low Voltage Directive)
and 2011/65/EU (RoHS Directive). The products are classified as category 11 equipment subject to Directive
2011/65/EU (RoHS Directive). This declaration will cease to be valid if modifications are made to the product
without prior permission from the manufacturer.

Manufacturer: Kendrion (Villingen) GmbH Person authorized: Dominik Hettich

Wilhelm-Binder-Str. 4-6 Kendrion (Villingen) GmbH
78048 Villingen-Schwenningen Wilhelm-Binder-Str. 4-6
Germany 78048 Villingen-Schwenningen
Germany

Applied harmonized standards and other technical standards and regulations:

EN 60529 Enclosure protection ratings
DIN VDE 0580 Electromagnetic devices and components

Product: Electromagnetically released spring-applied single-disc brake

Types: 76 43110H00 76 43111H00 76 43113H00 76 43114H00

76 43116H00 76 43119H00 76 43124H00 76 43129H00

Kendrion (Villingen) GmbH Villingen Authorized signatory: .......................................................

13/03/2020 Dominik Hettich
(Head of Development)

1.5 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.

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 4 von 30

2. Product description

2.1 Operating principle

The spring-applied single-disc brakes described in these operating instructions are intended for direct
attachment to electric motors. The brakes are designed to operate dry. The force generated by an
electromagnetic field is utilized to overcome the braking effect produced by the spring force. The spring-applied
single-disc brake engages in unpowered condition and releases when DC voltage is applied. The brake is
connected with the motor shaft via a centrally arranged hub. The friction disc of the brake is connected with
the hub in such a way that it is axially movable and tangentially fixed. The hub and motor shaft are firmly
connected with each other. This ensures that the motor shaft is blocked / slowed down when the brake is
engaged.

2.2 Brake design

The solenoid housing (1.1) of the spring-applied single-disc brake accommodates the firmly fitted field
coil (1.2) with connecting cable (1.3) – which exits on the brake circumference – and the compression
springs (4). The compression springs (4) press the friction disc (7) over the armature (2) against the friction
plate or flange1) (12) and thus against the mounting surface (9) (e.g. motor end shield). The frictional
connection obtained in this manner between the friction surfaces of the friction disc (7) and armature (2) or
friction plate (12) / flange (12) produces the braking effect of the spring-applied brake. The rated air gap 'sN' is
factory-adjusted by means of the spacer sleeves (5). The spacer sleeves (5) are tightly pressed into the
solenoid housing (1.1). They ensure that the armature (2) is kept in a fixed tangential position. The
friction disc (7) is connected with the hub (13) via a spline connection or square socket 2). This connection
ensures that the friction disc (7) is tangentially fixed, but movable in axial direction. The hub (13) is firmly fixed
to the shaft (e.g. motor shaft) (17). The brake is firmly mounted to the mounting surface (9) (e.g. motor end
shield) with the mounting screws (14) (see Fig. 6/1). When DC voltage is applied to the brake field coil (1.2),
the force of the electromagnetic field thus generated counteracts the spring force of the compression springs
(4). The armature (2) is moved axially towards the solenoid housing (1.1) and the braking action is neutralized.
The shaft to be braked (17) (e.g. motor shaft) is not exposed to any axial loads exerted by the spring-applied
single-disc brake. When using spring-applied single-disc brakes with hand release (10), openings must be
provided in the part enclosing the brake (e.g. fan cover) so that the hand release can be installed. The hand
release (10) allows the brake to be released manually (e.g. in case of power failure). When a collar (11) is
fitted to the brake, the hand release (10) can only be operated by pushing the lever away from the mounting
surface (9).

List of reference numerals in Fig. 6/1:

1.1 Solenoid housing 10.2 Tie bolt
1.2 Field coil 10.3 Socket head cap screw
1.3 Connecting cable 10.4 Return spring
2 Armature 10.5 Disc
3 Adjusting ring 10.6 Yoke
4 Compression spring 11 Collar
5 Spacer sleeve 12 Friction plate / Flange 1)
6 Pole enlargement 13 Hub
7 Friction disc 14 Mounting screws
8 Rating plate 15 Screw plug
9 Mounting surface (e.g. motor end shield) 16 Sealing ring
10 Hand release 17 Shaft (e.g. motor shaft)
10.1 Lever 18 Feather key
19 Circlip

Table 5/1: List of reference numerals for spring-applied single-disc brake

1) Sizes 19 to 29.
2) Sizes 13, 16, 19, 24.

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 5 von 30

 Fig. 6/1: Spring-applied single-disc brake 76 431..H00
Rated air gap
N

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 6 von 30

3. Installation

3.1 Mechanical installation

Slip the hub (13) on a shaft (17) provided with a feather key (18) to
DIN 6885, sheet 1, and secure it axially (with a shaft collar, circlip (19) or the
like. Make sure that the hub (13) is set back by L1 (see Fig. 7/1 and Table 7/1)
relative to the friction surface of the friction disc (7). If a friction plate (12) or
flange 3) (12) (accessories) is used, mount the friction plate (12) or flange 3) (12)
to the mounting surface (9) (e.g. motor end shield). Push the friction disc (7) onto
the hub (13). Check that you feel only little resistance when sliding the friction
disc (7) along the hub (13). Then fix the field coil of the spring-applied single-
disc brake to the mounting surface (9) (e.g. motor end shield) by means of the
mounting screws (14). If sealing rings (16) (accessories) are used, they must be
slipped on the mounting screws (14).

Warning!
Fig. 7/1: Hub (13) position
The brake user has to ensure that the tolerance, strength and quality of the shaft (17) (e.g. motor shaft) and
the type of feather key (18) employed are suitable to achieve reliable transmission of the generated brake
torques from the hub (13) to the shaft (17) (e.g. motor shaft).

Attention!

The MA tightening torque (see Table 7/1) specified for the mounting screws (14) must be strictly observed.
Tighten the mounting screws (14) evenly in several steps. The axial position of the hub (13) (see Fig. 7/1 and
Table 7/1) must be maintained to ensure reliable torque transmission by the hub (13).

Size
10 11 13 14 16 19 24 29
L [mm] 20 20 25 30 30 35 40 50
L1 [mm] 2.5 3.5 3 3 3 4 5 4.5
MA [Nm] 6 10 10 25 25 25 40 40

Table 7/1: Hub (13) dimensions; tightening torques for mounting screws (14)

Check that the mounting surface (e.g. motor end shield) (9) meets the following requirements before installing
the brake:

• Axial runout relative to the shaft <0.1mm (measuring radius = pitch circle)
• Surface roughness max. Rz16
• Surface hardness min. 100HB
• Material: steel, cast iron – with excellent thermal conductivity. If other materials are used (e.g. aluminium),
the friction plate (12) or flange (12) must be installed.
• Absence of oil and grease

Centre the brake on the mounting surface (e.g. motor end shield) (9) by means of the mounting screws (14)
to ensure correct operation. Correct tightening of the mounting screws (14) is essential to ensure sufficient
centring of the spring-applied single-disc brake. The rated air gap 'sN' (see Table 26/1) is factory-adjusted and
need not be changed.

3) Sizes 19 to 29.

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 7 von 30

 Note!

If the friction disc (7) and/or hub (13) are equipped with rubber buffers for noise reduction, the buffers must be
slightly greased before installation to reduce fitting forces during brake mounting. Check that the
friction disc (7) can be easily moved along the hub (13) by hand.

Note!

Magnetic interference fields may affect reliable brake operation. Consequently, the brake should always be
installed outside the reach of magnetic interference fields. The assembled brake components, especially the
friction surfaces, must be free of grease and oil during operation. Make sure that lubricants and the like cannot
seep from the motor bearing into the brake. (Sealed bearings can be used to prevent lubricant leaks.) Minor
bearing play will not compromise safe and reliable brake operation. During installation of the power cable (1.3),
make sure to avoid cable damage by kinking the insulation.

3.2 Installation of accessories

Hand release (10):

Insert the 2 tie bolts (10.2) into the bores provided in the yoke (10.6). Push the yoke (10.6) with the inserted
tie bolts (10.2) into the cavity provided in the spring-applied single-disc brake. (Only brakes with hand release
option will have this cavity.) Push the 2 discs (10.5) and the 2 return springs (10.4) on a
socket head cap screw (10.3). Apply Loctite 241 to the 2 socket head cap screws (10.3). Insert the screws
with the discs (10.5) and return springs (10.4) through the bores provided in the solenoid housing (1.1) and
fasten them with the 2 tie bolts (10.2). Use a feeler gauge to adjust the distance s1 (see Table 8/1 and Fig. 6/1)
when the brake is released (attracted armature (2)). Check that s1 is not exceeded and that it is evenly adjusted
on both socket head cap screws (10.3). Screw the hand release lever (10.1) into the yoke (10.6) and secure it
by applying Loctite 241. The required actuation forces F and the maximum permitted actuation forces Fmax are
specified in Table 8/1. The specified actuation forces F apply at the maximum rated torque (standard).

Size
10 11 13 14 16 19 24 29
approx. approx. approx. approx. approx. approx. approx. approx.
Required actuation force F [N]
25 30 60 110 130 200 270 200
s1+0.1 [mm] 1.0 1.0 1.25 1.5 1.5 1.7 2.0 2.5
Max. permitted actuation force Fmax [N] 45 52 105 170 230 320 470 420

Table 8/1: Actuation force F, max. permitted actuation force Fmax and distance s1 of hand release (10)

Note!

Machinery-specific regulations and requirements (e.g. for hoists, cranes and elevators) must be observed
when using brakes with hand release (10).

Warning!

Check that the hand release (10) is in a central position (see Fig. 6/1) when not in use. This is crucial to ensure
reliable brake engagement. Otherwise, the full braking effect of the spring-applied single-disc brake may not
be reached. In this case, the machine (e.g. motor) must be stopped immediately and must not be restarted
until correct operation of the hand release (10) and automatic return of the hand release lever in its central
position (see Fig. 6/1) has been ensured.

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 8 von 30

 Caution!

The brake torque can be neutralized manually by means of the hand release (10). Consequently, the brake
must be installed in such a way that any unintentional actuation of the hand release (10) is excluded. The
maximum axial pre-travel s1 (free travel) of the hand release (10) also limits the axial stroke of the
armature (2). If the air gap 's' is equivalent to or greater than the pre-travel s1 the armature (2) is in contact
with the discs (10.5) of the hand release (10). This may affect the reliability of the brake system. The maximum
air gap smax (see Table 26/1) must not be exceeded throughout the entire brake service life. (Please refer to
Section 4 Maintenance for details.) When installing the hand release (10), check that the distance s1
(see Table 8/1) between the armature (2) and disc (10.5) is correctly adjusted after the brake has been
released. Apply Loctite 241 to the socket head cap screws (10.3) to secure them in the tie bolts (10.2).

Collar (11):
Pull the collar (11) over the solenoid housing (1.1). Check that the sealing lip of the collar (11) is located
precisely between the friction plate (12) and the mounting surface (e.g. motor end shield) (9) on the mounting
surface side or precisely in the flange (12) groove (sizes 19 to 29) (see Fig. 6/1). Ensure that on the brake side
the collar (11) sealing lip touches the circumference of the solenoid housing (1.1) or is located in the groove
(sizes 19 to 29). When a collar (11) is fitted to the brake, the hand release (10) can only be operated by pushing
the lever away from the mounting surface (e.g. motor end shield) (9).

Screw plug (15):

The screw plug (15), if used, must be inserted into the shaft opening on the rear of the brake (see Fig. 6/1).

3.3 Electrical connection and operation

The spring-applied single-disc brake must be connected to a DC power source using the power cable (1.3)
provided. Connection to an AC power source is via a bridge rectifier or half-wave rectifier or by using a
combination of the two rectifier types. Various Kendrion rectifier types (see Table 9/1 – list not exhaustive) can
be provided for this purpose. Depending on the brake size and torque, voltage ripple due to intermittent power
supply may cause brake humming or incorrect brake operation. Perfect brake operation must be ensured by
the user or system manufacturer by providing suitable electrical controls.

Max. output current

Rated input voltage range Output voltage R-load L-load
Rectifier series Rectifier type
U1/VAC (40-60Hz) U2/VDC I/ADC I/ADC

32 07.22B.0 half-wave 0-500 (±10%) U1 • 0.445 1.6 2.0

32 07.23B.0 bridge 0-400 (±10%) U1 • 0.890 1.6 2.0

The relevant rectifier specification sheets must be observed!

Table 9/1: Recommended rectifiers for single-phase AC voltage supply

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 9 von 30

3.3.1 DC power supply

The figure to the right shows the voltage curve after the field
coil (1.2) has been de-energized. M

M1
0,9 x M 2
Attention!
t

The peak voltage UVmax during disconnection without protective t 11

t1
circuit may reach several thousand volts in the millisecond
U
region. This may cause irreversible damage to the field coil (1.2),
switching contacts and electronic components. Sparking will occur
on the switch during disconnection. Consequently, a protective
circuit must be provided to reduce the current during UB
disconnection and to limit the voltage. The maximum permitted
overvoltage during disconnection is 1500V. If Kendrion rectifiers t

are used (see Table 9/1), the protective circuit required for the
built-in electronic components and field coil (1.2) is included in the U Vmax
rectifier. This does not apply to the external contacts required for
DC side switching as there would be no galvanic isolation of the
external contact.
UB operating voltage (coil voltage)
UVmax disconnection voltage
Attention!

Sensitive electronic components (e.g. logical components) may also be damaged by the lower voltage.

3.3.2 AC power supply

Direct brake connection to an AC power source is only possible if a rectifier is used. The coupling times vary
depending on the switching type (DC side switching or AC side switching).

Half-wave rectification:

In case of half-wave rectification, the U2 coil voltage is lower by factor 0.445 than the rectifier input voltage.
Half-wave rectifiers produce voltage with high residual ripple which, depending on the brake size, may slightly
reduce the switching times when compared to bridge rectifiers. Due to the shorter switching times and the
lower coil voltage, half-wave rectifiers are generally preferred to bridge rectifiers. However, brake humming
may occur when small size brakes are used.

Bridge rectification:

Bridge rectifiers provide voltage with minimum residual ripple. This means that brake humming can be avoided
even if small size brakes are used. In case of bridge rectification, the U2 coil voltage is lower by factor 0.89
than the rectifier input voltage.

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 10 von 30

 M M
3~ 3~
2
2

- ~ ~ +
U
- ~ ~ +

1 U

1
L1 L2 L3 L1 L2 L3

AC side switching AC side switching

(Connected in parallel with the machine (e.g. motor))

M
3~
Half-wave or bridge
2 1 rectifier

2 Field coil (1.2)

- ~ ~ + Half-wave or bridge
3 rectifier with DC side
U

disconnection
3
L1 L2 L3

DC side switching

AC side switching:

The easiest wiring method is to connect the rectifier in parallel with the brake in the terminal box of the machine
(e.g. motor). It must be considered, however, that the motor may act as a generator after AC voltage has been
removed and thus extend the coupling time significantly (by factor 5 or over). The disconnection times remain
unchanged.
DC side switching:

In case of DC side brake switching, an auxiliary contact is provided on the motor contactor, for example. This
auxiliary contact is designed to interrupt the power supply on the DC side. The significant reduction in the
electric time constant results in fast brake engagement and shorter coupling times.

Attention!

In case of DC side switching, the brake must be provided with a protective circuit to avoid overvoltage.
Additional protective elements (e.g. varistors, spark arresters, etc.) must be installed to avoid damage such as
burns or fusing of contacts.

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 11 von 30

 Warning!

Work on the brake must only be carried out by suitably qualified personnel. Make sure that no voltage is applied
during brake connection. The specifications on the rating plate and the information provided in the circuit
diagram in the terminal box or in the operating instructions must be strictly observed.

Warning!

The brake is a DC operated system. Permanent voltage variations on the power source of the electromagnetic
brake must be limited to +/-10% of the rated voltage.

The following checks must be carried out when connecting the brake:

• Check that the connecting cables are suitable for the intended use and for the voltage and amperage of
the brake.
• Check that the connecting cables are secured with screws, clamps or other suitable fixtures to avoid
interruptions in the power supply.
• Check that the connecting cables are long enough for the intended use and that suitable torsion, strain
and shear relief features as well as bending protections are provided.
• Check that the PE conductor (only for protection class I) is connected to the earthing point.
• Check that no foreign matter, dirt or humidity is trapped inside the terminal box.
• Check that unused cable entries and the terminal box are suitably sealed to ensure compliance with the
protection class requirements to EN 60529.

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 12 von 30

3.4 Electromagnetic compatibility

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

essential 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 brakes 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 brake use and other applications. Please refer to the specification sheets for additional information
on electromagnetic compatibility, especially with respect to the recommended electronic rectifiers specified in
Section 3.3.

Immunity according to EN 61000-4:

EN 61000-4-2 Electrostatic discharge:

The spring-applied single-disc brakes comply at least with severity level 3 without requiring additional
measures. The recommended rectifiers specified in Section 3.3 conform to severity level 3 without additional
measures.

EN 61000-4-3 Electromagnetic fields:

The brakes 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 brakes 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 brakes 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 brakes 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:
Brakes 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 if 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.

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 13 von 30

Radio interference suppression in accordance with EN 55011:
The brakes 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 50/60Hz 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
50/60Hz AC power source and equipped with electronic R L
rectifiers or other electronic controls, interference
suppression measures as shown in Fig. 14/1 must be
taken to ensure compliance with the limit values
applicable to Class A equipment. Interference U
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
C
Section 3.3 are CE mark certified in accordance with the
EMC Directive. They have built-in interference
suppression components and comply at least with the Fig. 14/1
requirements of EN 55011 for Class A equipment, unless
otherwise specified in the specification sheet. When brakes are used with the specified rectifiers or with
other types of rectifiers, the recommended values listed in Table 15/1 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 3.3 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 15/2.

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.

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 14 von 30

 Rated input voltage range DC at L-load Capacitor
Rectifier series
U1/VAC (40-60Hz) (ADC) nF (VAC)
no additional
Bridge rectifier
up to 400 (±10%) up to 2.0 interference suppression
32 07.23B.0
measures required
no additional
Half-wave rectifier
up to 500 (±10%) up to 2.0 interference suppression
32 07.22B.0
measures required
Table 15/1

Max. rectifier operating voltage Recommended disconnection voltage for DC side switching
(VAC) (V)
250 700
440 1200
550 1500

Table 15/2

3.5 Set-up & start-up

Warning!

The functional check of the brake must not be performed unless the machine (e.g. motor) has been switched
off and secured against accidental or unintentional start-up.

The following checks must be carried out:

Check compliance with the specifications provided on the rating plate with respect to the mounting position
and protection class. After connection of the brake, a functional test must be performed to check that the friction
disc (7) runs smoothly. For this purpose, turn the shaft (17) (e.g. motor shaft) while the brake is energized and
the machine (e.g. motor) is unpowered. After completion of mounting, all necessary covers and guards must
be installed.

Specifications on rating plate (order-specific, example brake type 76 43110H00-0001):

Note: The product number of the brake consists of the type number followed by the version number,
e.g. 76 43110H00-0001.

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 15 von 30

 Warning!

Before starting the motor test run without driven components, the feather key (if used) must be secured in such
a way that it cannot be hurled out. The shaft (e.g. motor shaft) (17) must not be exposed to load torques.
Before the machine is re-started, the brake must be de-energized.

Caution!

The brake surface temperature may rise to over 100°C. Heat-sensitive parts such as conventional cables or
electronic components must not be fixed to or be in contact with these surfaces. If necessary, suitable
protections and hand guards must be installed to avoid accidental contact with hot surfaces. If the shaft (17)
needs to be turned during set-up operations while the motor is switched off, the brake must be released
electromagnetically or, if necessary, by means of the hand release (10).

Attention!

High-voltage tests performed during brake installation within an overall system or during start-up must be
carried out in such a way that damage to the built-in electronic accessories is avoided. The limits for high-
voltage tests and follow-up tests specified by DIN VDE 0580 must be observed.

Attention!

Check that the brake has been connected in accordance with the specifications provided on the rating plate
before it is put into operation. Even short-term operation outside the specified supply voltage limits may cause
irreversible damage to the brake or electronic accessories. Such damage may not be apparent immediately.
DC side brake switching without protective circuit as described in Section 3.4 will cause damage to electronic
rectifiers, electronic accessories, switching contacts and to the field coil (1.2).

3.6 M2 rated torque adjustments

The brakes are factory-adjusted to the M2 rated torque (as specified in the purchase order). The factory-
adjusted M2 rated torque is specified on the rating plate (8) of the brake. The position of the adjusting ring (3)
is marked by an arrow or notch 4) / punch mark 4) on the ring (3) and by a punch mark on the solenoid
housing (1.1). The adjusting ring clearance b7 (see Fig. 6/1) can be changed by fastening or loosening the
adjusting ring (3) by means of a pin spanner or sickle spanner. The changes in the M2 rated torque resulting
from this adjustment are specified in Table 16/1. The max. adjusting ring clearance b7 (see Table 16/1) must
not be exceeded.

Size
10 11 13 14 16 19 24 29
∆M2/mm [Nm] 2 3 5 7 8 10.5 24 50
b7 [mm] 3.5-6.5 4.0-8.0 5.0-10.0 5.0-10.0 5.5-13 6.0-14.5 7.0-15.0 7.0-13.5

Table 16/1: Change in the M2 rated torque resulting from a 1 mm axial adjustment of the adjusting ring (3);
minimum and maximum adjusting ring clearances b7

Note!

The adjusting ring (3) of size 29 brakes is secured with a set screw (M5 thread) so that it cannot turn. Unscrew
the set screw if you need to turn the adjusting ring. Make sure to retighten the set screw after you have adjusted
the M2 rated torque. The tightening torque to be applied is MA = 3Nm. The adjusting ring (3) must be turned in
such a way that the set screw can be located between the studs (only if size 24 and 29 brakes are used).

4) Sizes 19 to 29.

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 16 von 30

 Note!

Any adjustments of the M2 rated torque must be performed with extreme caution by qualified and specifically
trained specialist or service personnel.

4. Maintenance

4.1 Checks and service

The spring-applied single-disc brake does not require any maintenance except that the air gap 's' must be
measured at regular intervals. Replace the friction disc (7) by a new one when the maximum air gap smax
(see Table 26/1) between the armature (2) and solenoid housing (1.1) has been reached. Unscrew the
mounting screws (14) and remove the field coil assembly of the spring-applied single-disc brake. Remove the
worn friction disc (7) from the hub (13) and replace it by a new one. The air gap 's' cannot be adjusted. Proceed
to install the coil system as described in Section 3.1.

Attention!

When the spring-applied single-disc brake is mounted to the machine, it is crucial that the mounting
screws (14) be tightened applying the MA tightening torque specified in Table 7/1.

Attention!

Depending on its operating condition, it may no longer be possible to release the spring-applied single-disc
brake when the maximum air gap smax (see Table 26/1) has been exceeded. In this case, the braking action
cannot be neutralized. This may cause thermal overloading of and irreversible damage to the brake if the motor
is started before the brake has been released. Thermal overloading of the motor may occur if it is not started
while the brake is still engaged.

Caution!

If a hand release (10) is fitted to the brake and the maximum air gap smax has been exceeded (see Table 26/1),
the tie bolts (10.2) of the hand release (10) will limit the axial movement of the armature (2). This will cause
the torque to fall to zero. Whenever carrying out service and maintenance work, always check the air gap 's'
and replace the friction disc (7) well before the maximum air gap smax (see Table 26/1) is reached.

Warning!

Whenever inspection and maintenance work is carried out, ensure that

• the motor is secured against accidental or unintentional start-up.

• no load torque acts on the shaft (e.g. motor shaft) (17).
• the lock provided to prevent accidental motor start-up is removed after completion of inspection and
maintenance work.
• all friction surfaces are free from grease and oil. An oily or greasy friction disc (7) cannot be cleaned.
• no swelling or glazing of the friction lining has occurred.

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 17 von 30

 Note!

Any tests conducted to confirm correct brake function and operational safety and reliability must be performed
with extreme caution and by qualified specialist personnel only.

4.2 Spare parts and accessories

Designation, order number

Friction plate/ Hand Mounting Screw Friction Sealing
Size flange 5) (12) release (10) screw (14)
Collar (11)
plug (15) disc (7) ring (16)
A A A A A S A
10 76 43110H00004 76 43110H00940 304065 76 43110H00005 412859 76 43110H00200 326005

11 76 43111H00004 76 43111H00940 304051 76 43111H00005 412842 76 43111H00200 326006

13 76 43113H00004 76 43113H00940 304052 76 43113H00005 412843 76 24113E00400 326006

14 76 43114H00004 76 43114H00940 304078 71 10116A3013 412843 76 43114H00400 326007

16 76 43116H00004 76 43116H00940 304079 76 43116H00005 412860 73 24116E00400 326007

19 76 43119H00024 76 43119H00940 304080 76 43119H00005 412841 76 14119E00400 326007

24 76 43124H00024 76 43124H00940 304117 76 43124H00005 412885 76 14124E00400 326008

29 76 43129H00024 76 43129H00940 304118 76 43129H00005 - 76 14129E00400 326008

Table 18/1: Spare parts (S) and accessories (A)

5. Condition at delivery, transportation and storage

The electromagnetic single-disc brake is delivered ready for mounting. A brief break-in process is completed
at the manufacturer's premises before shipment. The rated air gap sN is factory-adjusted. The hub (7) and
mounting screws (9) are delivered together with the brake. Upon receipt of the shipment, the brake must be
checked for transit damage before storage. If the brake is not installed immediately upon delivery, it must be
stored in a dry, dust-free and vibration-proof place.

Note!

The coil system and the armature are factory-adjusted to ensure reliable brake release (opening).
Consequently, individual components cannot be replaced. If the brake is not installed immediately upon
delivery, it must be stored in a dry, dust-free and vibration-proof place.

Note!

The environmental conditions specified in Table 19/1 and in EN IEC 60721-3-2 / EN IEC 60721-3-1 must be
considered during transport and storage of the brake, especially when long-term storage is envisaged.

5) Sizes 19 to 29.

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 18 von 30

 Environmental conditions
Conditions for storage Conditions for transport
to EN IEC 60721-3-1 to EN IEC 60721-3-2
Mechanical environmental conditions 1M11 2M4
Climatic environmental conditions 1K21 and 1Z2 2K12
Biological environmental conditions 1B1 2B1
Mechanically active substances 1S11 2S5
Chemically active substances 1C1 2C1

Table 19/1: Environmental conditions for storage and transport as specified in EN IEC 60721-3-1 and
EN IEC 60721-3-2

6. Emissions

6.1 Noise

The spring-applied single-disc brake produces switching noise during engagement and release. The noise
level is determined by the installation conditions, circuitry (e.g. with overexcitation) and air gap. Depending on
the mounting position, operating conditions and state of the friction surfaces, audible vibrations (squealing)
may be produced during braking.

6.2 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 60°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.

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 19 von 30

7. Troubleshooting

Fault Cause Corrective actions

Check the air gap. Install a new friction disc (7), if
• Air gap too large
necessary.
Check the electrical connection and correct faults, if
• No voltage applied to brake
found.
• Voltage applied to field coil (1.2) too Check the supply voltage of the field coil (1.2) and
Brake release low correct faults, if found.
failure • Armature (2) blocked mechanically Eliminate mechanical blocks.
• Damaged rectifier Check the rectifier and replace it, if necessary.
Check the resistance of the field coil (1.2). Install a
• Damaged field coil (1.2)
new brake, if necessary.
• Irreversible thermal damage of Install a new friction disc (7) or a new brake, if
friction disc (7) linings necessary.
Check the air gap. Install a new friction disc (7), if
• Air gap too large
Delayed brake necessary.
release • Voltage applied to field coil (1.2) too Check the supply voltage of the field coil (1.2) and
low correct faults, if found.
• Voltage applied to field coil (1.2) in
Check whether residual voltage is applied to the field
Brake engagement unpowered condition too high
coil (1.2) and correct faults, if found.
failure (residual voltage)
• Armature (2) blocked mechanically Eliminate mechanical blocks.
Delayed brake • Voltage applied to field coil (1.2) too Check the supply voltage of the field coil (1.2) and
engagement high correct faults, if found.
Check the air gap. Install a new friction disc (7), if
• Air gap too large
necessary.
Check the friction surfaces. Install a new friction disc
Brake torque too • Oily or greasy friction surfaces
(7), if necessary.
low
Check the distance s1 and adjust it, if necessary.
• Axial movement of armature (2)
Check the air gap and install a new friction disc (7), if
blocked by hand release (10)
necessary.

Table 20/1: Possible faults, causes and corrective actions (list not exhaustive)

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 20 von 30

8. Safety

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 machine owner to plan these measures and to check
their implementation.

The machine owner is required to ensure that:

• the brakes are only used in accordance with their intended use (see Section 2 Product description).
• the brakes are in perfect working order and checked at regular intervals.
• a complete and fully legible copy of these operating instructions is kept available at the place of use of the
brakes at all times.
• 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 here in.
• the brakes are not exposed to other strong magnetic fields.

8.1 Intended use

The brakes described in these operating instructions are intended to be assembled with machines, in particular
electric motors, for use on industrial plant. Operation in potentially explosive or firedamp atmospheres is not
allowed. The brakes must be used in accordance with the operating requirements detailed in this manual. The
rated power limits specified herein must not be exceeded.

8.2 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 suitably qualified specialist personnel in accordance with EN 50110-1,
EN 50110-2, IEC 60364-1. 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 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 (Villingen). 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.

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 21 von 30

8.2.1 Set-up

Requirements in terms of the permitted number of switching operations per hour and the maximum switching
work per switching operation specified in the technical specifications must be strictly observed during the set-
up of machines and plant (inching mode). Failure to observe these instructions may irreversibly diminish the
braking effect and cause malfunctions. Normal operating conditions are those specified by DIN VDE 0580.
The protection rating conforms to EN 60529. In case of deviations, special measures must be taken after prior
consultation with the manufacturer. If vertical brake operation is envisaged, any special requirements must be
agreed with the manufacturer. Bear in mind that the friction disc may freeze if ambient temperatures fall below
-5°C or if the brake remains unpowered for prolonged periods of time. In this case, special precautions must
be taken after consultation with the manufacturer.

8.2.2 Set-up & start-up

The brakes must not be put into operation when:

• power supply cables/wires or connections are damaged.

• the solenoid housing or coil sheath is damaged.
• other defects are suspected.

8.2.3 Installation

The voltage level and voltage type specified on the rating plate must be strictly observed when connecting the
brakes described in these operating instructions. 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 31000; DIN VDE 0100-420) must be taken by the brake user to avoid hazards
to persons and animals or damage to equipment caused by:

• direct or indirect effects of electromagnetic fields,

• heated components,
• mobile parts.

8.2.4 Operation

Ensure 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. Make absolutely sure 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 and the resulting torque reduction of spring-applied
brakes 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 is in perfect working order
before start-up. Torque reductions cannot be excluded if the brake 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. Operation of the brake as pure holding brake without friction work is only allowed after prior
consultation with the manufacturer. If brakes equipped with hand release are used, the hand release lever
must only be moved up to the release position in order to avoid deformation or breaks.

Note!

The maximum air gap smax (see Table 26/1) must not be exceeded throughout the entire brake service life.
(Please refer to Section 4 Maintenance for details.)

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 22 von 30

 Notice!

During brake operation, ensure that the coil temperature does not rise above the permissible limit temperature
applicable to the insulating materials of the specified insulation class (see Table 26/1). Fast cooling of the field
coil with scavenging air is not allowed. Ensure that the permissible relative humidity range (see Table 27/1) is
not exceeded.

Note!

The torque of the spring-applied brake may be reduced if the brake has been stored for a prolonged period of
time. Torque reductions may also occur during the brake service life or if the brake is only used as holding
brake. In this case, the brake user should ensure that a break-in process as specified in Table 27/2 is
conducted at regular intervals.

8.2.5 Maintenance, repair and replacement

Brake service, maintenance, repair or replacement must only be carried out by qualified specialist personnel
in accordance with EN 50110-1, EN 50110-2, IEC 60364-1. 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.

8.3 Warning symbols

Personal injury or equipment damage

Symbol / Term Warns against... Potential risks and hazards

Danger imminent personal injury fatal accidents or serious injury

potential risk of serious

Warning fatal accidents or serious injury
personal injury

Caution potential risk of personal injury minor injury

potential risk of equipment damage to components or other

Attention!
damage equipment

Information
Symbol / Term Provides information on …

Note the safe use and operation of the product

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 23 von 30

9. Definitions

(based on: DIN VDE 0580:2011-11, not exhaustive)

Switching torque M1 torque acting on the shaft during brake or clutch slip.
Rated torque M2 switching torque specified by the manufacturer to identify the brake.
The rated torque M2 is the mean value of at least 3 measurements of
the maximum switching torque M1 after completion of the transient
response.
Transmissible torque M4 highest torque that can be applied to the engaged brake or clutch
without causing the brake/clutch to slip.
Residual torque M5 torque transmitted by the released brake or clutch
Load torque M6 torque acting on the drive of the engaged brake or clutch; determined
by the power requirement of the driven machine at a given speed.
Switching work W heat generated by friction inside the brake or clutch as a result of the
switching operation.
Maximum switching work Wmax maximum switching work to which the brake or clutch may be exposed.
Switching power P switching work converted into heat per unit of time.
Maximum switching power Pmax maximum permitted switching work converted into heat per unit of
time.
Coil ON time t5 time between power on and power off.
Coil OFF time t6 time between power off and power on.
Total cycle time t7 coil ON time plus coil OFF time.
Duty cycle percentage relationship of coil ON time to total cycle time.
Switching operation one complete switching on and off operation.
Switching frequency Z number of regular switching operations per hour.
Response delay during coupling t11 time between power off (releasing systems) or power on (engaging
systems) and beginning of torque increase.
Rise time t12 time it takes to reach 90% of the M2 rated torque from the beginning
of the torque increase.
Coupling time t1 response delay t11 plus rise time t12.
Response delay during disconnection t21 time between power on (releasing systems) or power off (engaging
systems) and beginning of torque decrease
Fall time t22 time it takes for the torque from the beginning of the torque decrease
to fall to 10% of the M2 rated torque.
Disconnection time t2 response delay t21 plus fall time t22.
Slip time t3 time from the beginning of the torque increase up to the end of the
braking process (brakes) or until the synchronization torque M3 has
been reached (clutches).
Making time t4 response delay t11 plus slip time t3 (braking or acceleration time).

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 24 von 30

Operating condition at operating temperature condition at which the steady-state temperature is reached. The
operating temperature corresponds to the overtemperature according
to DIN VDE 0580 plus the ambient temperature. Unless otherwise
specified, the ambient temperature is 35°C.
Overtemperature ∆ϑ31 difference between the temperature of the electromagnetic device or
a part thereof and the ambient temperature.
Limit temperatures of coil insulating materials in accordance with DIN VDE 0580. The individual insulating materials
are classified by insulation classes to DIN IEC 60085.
Rated voltage UN supply voltage specified by the manufacturer for voltage windings to
identify the device or component.
Rated current IB amperage determined by the manufacturer for the specified operating
conditions. Unless otherwise specified, the rated current refers to the
rated voltage, 20°C winding temperature and to the rated frequency
for a given operating mode of voltage windings.
Rated power PN power value to identify the device or component.
Rated power at 20° winding temperature PB determined from the rated current of voltage-controlled devices and
components and the R20 resistance at 20°C winding temperature.

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 25 von 30

10. Technical specifications

Product built and tested to DIN VDE 0580

Size
10 11 13 14 16 19 24 29
Rated torque range
4-8 8-16 16-32 30-60 40-80 80-150 150-240 280-400
(standard) M2 [Nm]
Max. reachable rated
torque with fully
10 20 40 65 100 170 300 600
tightened adjusting
ring M2max [Nm]
Max. speed nmax [rpm] 3500 3500 3500 3500 3500 3000 3000 3000
Max. switching power
320 430 650 800 1000 1200 1400 1600
Pmax [kJ/h]
Rated power PN [W] 26 30 40 53 55 80 110 130
20 30 45 86 90 130 225 115
Coupling time t1 [ms] (M2=8Nm) (M2=16Nm) (M2=32Nm) (M2=60Nm) (M2=80Nm) (M2=150Nm) (M2=240Nm) (M2=400Nm)

Disconnection 95 80 90 84 190 270 235 560

time t2 [ms] (M2=8Nm) (M2=16Nm) (M2=32Nm) (M2=60Nm) (M2=80Nm) (M2=150Nm) (M2=240Nm) (M2=400Nm)

Moment of inertia J –
hub and 1.2 2 6 8 16 38 108 230
friction disc [kgcm2]
Weight m [kg] 1.3 2.8 3.7 5.7 8.4 13.1 22 36
Rated air gap
0.2 0.2 0.25 0.3 0.35 0.35 0.4 0.45
sN+0.15 [mm]
Max. air gap (at 70% of
rated current) 0.8 0.95 0.8 0.9 1.2 1.5 1.5 1.5
smax 6) [mm]
Duty cycle [%] 100 100 100 100 100 100 100 100
Standard rated
24, 102, 178, 205
voltage [VDC]
Insulation class F
Pollution degree 2
IP 55 (when installed under motor fan hood)
Protection
IP 65 (with accessories and when installed under motor fan hood)
Brake type dynamic brake

Table 26/1: Technical specifications

6) Max.
air gap smax related to maximum rated torque (standard). Max. air gap smax when M2max rated torque is
approx. 60% of values specified in the table (see "Technical specifications").

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 26 von 30

 Rated operating conditions
Rated voltage tolerance ±10%
Frequency range ±1% of rated frequency
Ambient temperature ϑ13 [°C] -5 to +35
Relative humidity 30% to 80% within ambient temperature range
Other climatic environmental conditions 3Z2 and 3Z4 to EN 60721-3-3
Mechanical environmental conditions 3M8 to EN 60721-3-3
Biological environmental conditions 3B1 to EN 60721-3-3
Mechanically active substances 3S2 to EN 60721-3-3
Chemically active substances 3C1 to EN 60721-3-3
Installation height up to 2000 m a.m.s.l.

Table 27/1: Required operating conditions for spring-applied single-disc brakes

Size
10 11 13 14 16 19 24 29
Speed n [rpm] 250 250 250 250 250 250 250 125
Coil ON time t5 [s] 2 2 6 6 6 6 6 6
Coil OFF time t6 [s] 1 1 1 1 1 1 1 1
Break-in period ttotal [min] approx. 1 approx. 1 approx. 1 approx. 1 approx. 1 approx. 1 approx. 1 approx. 1

Table 27/2:Break-in process parameters for the spring-applied single-disc brake after installation and during
brake service life

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 27 von 30

Explanations on the technical specifications:

W max (maximum switching work) is the switching work that

1000000
must not be exceeded during braking operations at max.
1500rpm. Braking operations at speeds greater than
1500rpm substantially reduce the maximum permitted J
switching work per switching operation. Such operation
must be agreed with the manufacturer. The maximum 100000 Size 29
Gr. 29
Size 24
Gr. 24
switching power Pmax is the switching work W that can be Size 19
Gr. 19
Size 16
converted by the brake per hour. In case of applications Gr. 16
Size 14
Gr. 14
where the number of switching operations per hour is Z>1, Size 13
Gr. 13
Size 11
Gr. 11
Fig. 28/1 applies (W max as a function of the number of 10000 Size 10
Gr. 10

switching operations per hour Z). The Pmax and W max

values are approximate values. They apply to applications Wmax.
where the brake is mounted between the B-face end
shield of the motor and the motor fan. The specified times
1000
apply to the following conditions: DC side brake switching,
operating temperature, rated voltage, and rated air gap.
All values are mean values that are subject to variation. In
case of AC side brake switching, the coupling time t1 is
substantially longer. The specified rated torques M2 100

characterize the torque level of the brakes. Depending on

the application the brake is used for, the switching torque
M1 and the transmissible torque M4 may differ from the
specified M2 values. The switching torque M1 depends on 10
the speed (rpm). If the friction surfaces are contaminated 1 10 100 1000 h
-1
10000
with oil or grease the transmissible torque M4 and the Z
switching torque M1 may drop. The technical
specifications apply after the break-in process has been Fig. 28/1: Max. switching work W max per
completed (see Table 27/2). Vertical brake operation is switching operation as a function of the
only allowed after prior consultation with the number of switching operations per hour Z
manufacturer. (values based on n=1500rpm)

Note: A current level corresponding to 70% of the rated current is reached when the brake is operated at rated
voltage and at a coil temperature of 130°C.

The required operating conditions specified in Table 27/1 and the information provided in the VARIO LINE
specification sheet and offer drawing for the specific brake types must be observed during operation of the
spring-applied single-disc brake.

Specifications subject to change without notice!

11. Product number / type number / version number

The product number to be quoted in purchase orders and required to identify the brake version consists of the
type number followed by the 4-digit version number. Individual brake types may be available in different
versions. So the version number identifies the relevant brake model.

Example:

Type number: 76 43110H00 Version number: 0001

Product number: 76 43110H00-0001

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 28 von 30

12. Specialist repair shops

Kendrion (Villingen) GmbH

Wilhelm-Binder-Str. 4-6
78048 Villingen-Schwenningen
Germany
Tel. +49 (0)7721 877-1417

13. Revision history

Date of issues Changes

26/03/2002 New issue.

25/02/2003 Operating instructions revised in content.

18/06/2004 Operating instructions revised in content.

12/12/2008 Operating instructions revised in content.

30/12/2009 Operating instructions revised in content.Updated layout (design) of operating instructions.

Added Declaration of Conformity in accordance with Low Voltage Directive 2006/95/EC and RoHS
20/03/2015
Directive 2011/65/EU. Changed company name. Text revisions.

Standards updated. Information about storage and transportation of the component in chapter 5
25/03/2019
added. Updated layout (design) of operating instructions

13/03/2020 Operating instructions revised in content. Updated layout (design) of operating instructions.

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 29 von 30

Betriebsanleitung 76 43119H03

Operating Instructions BA 76 431..H00 // Last updated: 13/03/2020 // Page 1 von 30