Brake. Operating manual. for brakes. Status : June, 2015 ZFB ZFG ZFL

Operating manual for brakes Status : June, 2015 ZFB ZFG ZFL Copyright ABM Greiffenberger Antriebstechnik GmbH, Friedenfelser Straße 24, 95615 Marktredwitz, 2013

Contents 1. General safety information... 3 1.1. General... 3 1.2. Explanation of symbols... 3 1.3. Personnel... 3 1.4. Mechanical hazard... 4 1.5. Thermal hazard... 4 2. General... 5 2.1. General information... 5 2.2. Used terms... 5 2.3. Modification of the product... 6 2.4. Liability and warranty claims... 6 2.5. Addresses... 7 3. Specification... 8 3.1. Brake structure (schematic diagram)... 8 3.2. Name plate... 11 3.3. Type designation code... 11 3.4. Standards and guidelines... 12 3.5. Use for its intended purpose... 12 3.6. Optional modules... 13 4. Preparation of the drives for operation... 14 5. Operation... 16 5.1. Safety instructions... 16 5.2. Error diagnosis and fault removal... 17 6. Maintenance... 18 6.1. Safety instructions... 18 6.2. Disassembling... 19 6.3. Disassembling the brake unit... 21 6.4. Assembling the Brake Unit... 21 6.5. Assembly of the manual release for ZFG/ZFL-brakes... 21 6.6. Brake mounting... 23 6.7. Brake Re-adjustment (ZFB)... 24 6.8. Replacing the rotor (ZFL/ZFG)... 25 6.9. Spare parts... 26 7. Decommissioning and disposal... 27 7.1. Decommissioning... 27 7.2. Recycling and disposal... 27 8. Illustrations... 28 9. Tables... 28 10. Index... 29 Annex... 30 A Functional dimensions... 30 B Tightening torques... 31 C Safety parameters for brakes... 31

1. General safety information 1.1. General Any work for the transport, storage, installation, commissioning and maintenance may be carried out with the personal protective equipment required for the work. 1.2. Explanation of symbols Signal words: Signal word field with signal word DANGER WARNING CAUTION Meaning Indicates a hazard with a high degree of risk which leads to death or severe injuries if it is not prevented. Indicates a hazard with a medium degree of risk, which can lead to death or severe injuries if it is not prevented. Indicates a hazard with a low degree of risk which can cause minor or moderate injuries if it is not prevented. Table 1 : Signal words and their meaning The safety instructions in this operating manual are structured as follows: Signal word with illustration HAZARD Actions to prevent the hazard 1.3. Personnel Any work for the transport, storage, installation, commissioning and maintenance must only be carried out by qualified specialist personnel. The binding specifications for the qualification of electrically qualified persons and electrically skilled personnel apply as defined in DIN VDE 0105-100. 3

1.4. Mechanical hazard Transport, assembly, commissioning and decommissioning, as well as maintenance and inspection work must only be carried out using the personal protective equipment required for the respective work, and only by trained specialist personnel while the machine is idle, deenergised and cooled off. 1.5. Thermal hazard The applied brake converts mechanical work and kinetic energy into heat. This causes differential heating, depending on the operating conditions and waste heat discharge. WARNING HOT MACHINE PARTS Hot machine parts can cause burns in case of skin contact Do not touch hot surfaces! Wear the personal protective equipment for maintenance or troubleshooting work! Observe the cool-down times! 4

2. General 2.1. General information These operating instructions are valid in addition to the operating instructions for electric motor / gear motor. Please consider the references of that manual. Before working with the drive, carefully read the operating manual. This way, you ensure a riskfree and smooth function of the drive. The instructions of this operating manual must be observed. Special designs can deviate in technical details! This operating manual and all associated special documentations must be kept in close proximity to the drive. The reproduction, distribution and utilization of this document as well as the communication of its contents to others without express authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design. 2.2. Used terms Term Brake Working brake Holding brake Area of Application Environment of Application Drive Table 2 : Used terms ZFB-Brake ZFG-Brake ZFL-Brake Hereinafter used for Brake which implements friction work in regular operation, i.e. performs a braking function Brake which does not perform friction work in regular operation but merely holds the load in position. In case of an emergency, however, it may also perform a braking function. The area of application of the brake is limited to drives, which are integrated into plants and machines and is defined by the boundary conditions, performance data and dimensions indicated in the technical data sheet and on the name plate of the brake. The environment of application of the spring-applied brake must be designed such that after its proper assembly the brake may fulfil its function in perfect operation and will not pose any risk for persons and material assets. Changes in the environment of application (e.g. at the machine or plant which the brake is connected with) must only be carried out, if they have no influence on the first mentioned condition. Electric motor or gear motor 5

2.3. Modification of the product The permissible state of application of the brake includes the operationally perfect state of all components (in case of worn parts: exchange in time) and the observance of the operating and assembly requirements specified in these instructions as well as the omission of any retrofits, changes or modification of the brake, unless authorised by ABM. The latter also includes the use of only original spare and exchange parts. 2.4. Liability and warranty claims Drive and brake must only be operated in compliance with the specifications in the operating manual. In case of property and personal damage caused by improper handling or noncompliance with the safety instructions, any liability and warranty claim expires. 6

2.5. Addresses Germany ABM Greiffenberger Antriebstechnik GmbH Postfach 140 Friedenfelser Str. 24 D - 95614 Marktredwitz D - 95615 Marktredwitz Phone: +49 9231 67-0 Fax: +49 9231 67-5295 e-mail: sales@abm-drives.com USA ABM DRIVES INC. 2000 Ford Circle, Suite E Milford, Ohio 45150 Phone: +1 513 5761300 Fax: +1 513 5764999 e-mail: abmus@abm-drives.com Austria ABM Antriebstechnik GmbH Ortstrasse 18/1/5-7 A - 2331 Vösendorf Phone: +43 1 69911620 Fax: +43 1 699116223 e-mail: abm-austria@abm-antriebe.de France ABM Systèmes d'entraiment S.A.R.L. 40, rue Jean Monet Melpark Bat. 5 F - 68200 Mulhouse Phone: +33 3 89334401 Fax: +33 3 89334405 e-mail: infofr@abm-drives.com P.R. China ABM Drives (Suzhou) Co., Ltd. Kuachun Industrial Area Unit 9G, Chun Hui Lu, Weiting Town VR China - 215122 Suzhou Phone: +86 512-8717 1081 Fax: +86 512-8717 1084 e-mail: infocn@abm-drives.com Turkey ABM Greiffenberger Hareket Sistemleri Ticaret Limited Şirketi Barbaros Mah. Bezirgan Sok. No:3 Deluxia Suites A Blok Daire:17 Batı Ataşehir-İstanbul, TR 34746 Phone: +90 216 2903525 Fax: +90 216 2903526 e-mail: abmtr@abm-drives.com 7

3. Specification 3.1. Brake structure (schematic diagram) Deviations are possible depending on the design. Basic version ZFB: 1 2 3 4 5 6 7 8 [1] Rotor with brake liners [5] Magnet body [2] Armature plate [6] Hub [3] Brake coil [7] Hollow-core bolts [4] Pressure spring [8] Screw Illustration 1 : Design of the brake type ZFB 8

Basic version ZFG / ZFL: 1 2 3 4 5 6 7 8 9 10 11 12 [1] Rotor with brake liners [7] O-ring [2] Plug [8] Hub [3] Hollow-core bolts [9] Armature plate [4] Brake coil [10] Pressure spring [5] Screw [11] Tab connector (only ZFL) [6] Flange, friction plate [12] Magnet body Illustration 2 : Design of the brake type ZFG / ZFL 9

Description of function: The electromagnetically released spring-applied brakes ZFB, ZFG and ZFL are failsafe brakes with two friction surfaces. The braking torque is generated by means of spring force. The pressure springs apply pressure to the axially movable armature plate, trapping the rotor which is keyed to the machine shaft against the motor flange. The braking torque is generated. A magnetic force is produced through applying a direct voltage to the magnet body via the field winding, Said magnetic force draws the armature disk to the magnet body. The brake rotor ist released. If brakes are designed with manual release, the brake rotor can be released mechanically, e.g. if there is a power failure. By pulling the manual release handle the armature disk is mechanically pulled against the magnet body. The brake rotor ist released. The spring-pressure brakes are supplied pre-assembled. The standard type is delivered with a fixed braking torque. For the ZFB-brake the option with central adjusting ring is possible. The nominal braking torque has been adjusted as soon as the ring firmly contacts the magnet housing. Screwing out will result in a step-by-step reduction of the braking torque Manual release Adjusting ring (only ZFB) Illustration 3 : ZFB-brake with manual release and adjusting ring 10

3.2. Name plate Name plate (example) Illustration 4 : Name plate 3.3. Type designation code This documentation applies to brakes with the following type designation (example): ZFB100H Brake type designation code Brake type ZFB / ZFG ZFL Frame size (Max. torque) 1 = 10 Nm 2 = 20 Nm 4 = 40 Nm 5 = 45 Nm 6 = 60 Nm 7 = 70 Nm 10 = 100 Nm 11 = 110 Nm 15 = 150 Nm 18 = 180 Nm 25 = 250 Nm 08 = 8 Nm 15 = 15 Nm 30 = 30 Nm 1. Add-on 2. Add-on 0 = standard version 1 = adjustable braking torque 1) 2 = corrosion protection 3 = adjustable braking torque + corrosion protection 1) 4 = special version 5 = standard version with different hub-ø 7 = corrosion protection with different hub-ø H = manual release with stroke limiter S = dust ring K = flange corrosion protected So = special version - H = manual release 1) Only available for ZFB 10 to 40 Table 3 : Brake type designation code 11

3.4. Standards and guidelines The brakes comply with the following standards : Standard IEC / EN 60034-5 IEC / EN 60204-1 Table 4 : Standards Title Rotating electrical machines - Part 5: Degrees of protection provided by integral design of rotating electrical machines (IP code) - Classification Safety of machinery - Electrical equipment of machines - Part 1: General requirements If the products fall within their scope, the following guidelines and and regulations apply: Number Brief description 2006/95/EG Low voltage directive 2011/65/EU ROHS directive Regulation EG 1907/2006 REACH Table 5 : Guidelines and regulations The brake motor is no independently functional machine and together with the brake motor it is intended for the integration into another machine. The commissioning is prohibited until it has been determined that the machine complies with the regulations of the EC directives 3.5. Use for its intended purpose The ZFB/ZFG/ZFL-brakes are designed for secure braking and positioning of drives. The protection class is IP54 as standard. The brake is an integral part of the ABM brake motor. The environmental requirements comply with the motor and are available in the separate operating instructions for electric motor / gear motor. The disc brakes are electromagnetically operated. They are working according to the static current principle i.e. brake torque is present in the non-powered state. In case of power loss or disconnection, the drive is automatically slowed and the motor shaft kept motionless until powered up again. The technical data on the type plate must be observed. The documentation must be complied with. For applications in which the failure of a drive or brake could cause a danger to persons, corresponding safety precautions must be provided. 12

3.6. Optional modules Optional modules for ZFB-brakes: manual release adjusting ring dust ring flange corrosion protected Optional modules for ZFG sand ZFL-brakes: manual release protection class IP65 13

4. Preparation of the drives for operation Please consider the references of the operating instructions for electric motor / gear motor. Electrical installation: DANGER ELECTRIC SHOCK Electrical parts are energized with hazardous voltage. When touching these parts you will get an electric shock. Death or severe injuries are the result. Any work for electrical installations must only be carried out by qualified specialists! Connecting work must only be carried out in deenergized condition! General instructions: The coil of the magnetic body is operated by direct current voltage. The DC current is taken from a rectifier set type E4, B40 or PMG500-S. For the rectifier E4 a 1-pulse connection is used (single circuit). For the rectifier Typ B40 a 2-pulse connection is used (bridge circuit). The PMG500-S is a high-speed excitation rectifier for switching from 2-pulse configuration (bridge circuit) to 1-pulse configuration (single circuit). The supply voltage is 230 V / 50-60 Hz by default. The maximum voltage is 400 V. Lower voltages are possible on request. By selection of electrical connection the brake time can be adapted to the special application situation. 14

When connecting the rectifier proceed as follows: 1. Connect the rectifier to the mains or to the terminal board of the motor. The connecting terminals are uniformly labelled with 1 and 2. The connecting voltage is indicated on the name plate. 2. When switching on the DC side, connect the NO contact to terminals 5 and 6. 3. Additional temperature sensors located in the motor wiring can be connected to terminals 7 and 8 of the rectifier B40. Illustration 5 : Connecting plans for rectifiers E4, B40 and PMG500-S 15

5. Operation 5.1. Safety instructions DANGER MOVING PARTS Rotating parts can cause injuries Never reach into moving parts and keep foreign materials away from these parts! Safety devices must be provided by the manufacturer of the complete machine and must not be removed or put out of operation! Observe the safety distance! During operation, surfaces must not be touched. The surfaces at the drives can become very hot. If required, provide a touch guard! WARNING HOT MACHINE PARTS Hot machine parts can cause burns in case of skin contact Do not touch hot surfaces! Observe the cool-down times! Carry out regular checks during the operation, depending on the operating conditions. In doing so, pay special attention to: Unusual or excessive noise or temperature generation, Loose fixing elements, The condition of the electric mains, Stronger vibrations, Changes in the rotational speed, Problems with the heat removal due to depositions on the drive system. In case of faults, contact the maintenance personnel immediately. 16

5.2. Error diagnosis and fault removal DANGER ELECTRIC SHOCK Electric parts Electrical parts are energized with hazardous voltage. When touching these parts you will get an electric shock. Death or severe injuries are the result. Any repair work must only be carried out by qualified specialists! Connecting work must only be carried out in deenergized condition! Fault Possible causes Remedy Brake does not release Brake releases with delay Brake does not apply Brake applies with delay Air gap too large Brake is not supplied with voltage Voltage at the coil too low Armature plate obstructed Defective Rectifier Air gap too large Voltage at the coil too low Voltage at the coil too large Armature plate obstructed Voltage at the coil too large Check and readjust air gap Check electrical connection Check the supply voltage of the coil Remove obstruction Check rectifier Check and readjust air gap Check the supply voltage of the coil Check the supply voltage of the coil Remove obstruction Check the supply voltage of the coil Table 6 : Error diagnosis 17

6. Maintenance 6.1. Safety instructions DANGER ELECTRIC SHOCK Electrical parts are energized with hazardous voltage. When touching these parts you will get an electric shock. Death or severe injuries are the result. Any maintenance work must only be carried out by qualified specialists! Maintenance work must only be carried out if the system is de-energised and secured against restart! WARNING HOT MACHINE PARTS Hot machine parts can cause burns in case of skin contact Do not touch hot surfaces! Observe the cool-down times! 18

6.2. Disassembling Illustration 6 : Sketch for disassembling / assembling [1] Brake end shield [13] Distance bushing [2] Magnet body [14] Washer [3] Armature plate [15] Plug [4] Rotor with brake liners [16] Sealing ring [5] Pressure spring [17] Friction plate [6] Hollow-core bolts [18] Fixing screw / Friction plate [7] Fixing screw / brake [19] Dust protection ring [8] Hub [20] Fan cover [9] Adjusting ring [21] Key [10] Manual release (lever and bracket) [22] Securing ring [11] Key [23] Fan [12] Securing ring 19

When disassembling the brake, proceed in the following manner (depending on the model, certain working steps can be dropped): 1. Disconnect the power supply and secure it against restart. 2. Remove the manual release lever (10). 3. Loosen the fastening screws and remove fan cover (20). 4. Remove the dust protection ring (19) from the magnet body (2) groove and pull over the brake end shield. 5. Remove friction dust with pressurized air. 6. Remove the securing ring (22). 7. Pull off the fan (23). 8. Remove the key (21). 9. Disconnect electric plug from magnet body (2). 10. Remove the fixing screws (7). Copper discs under the screw heads have to be renewed, in case of assembly. 11. Remove the magnet body (2) complete with - armature plate (3), - sealing ring (16), - hollow-core bolts (6), - pressure springs (5), - adjusting ring (9) and - manual release bracket (10) 12. Remove the brake rotor (4) from the hub (8). Caution: watch out for the spline. 13. Check the minimum thickness of the brake rotor - compare to table 9 or 10 / annex A. If the actual thickness is less than the listed minimum brake rotor it must be replaced. 14. Remove the fixing screws (18). 15. Remove the friction plate (17). 16. Remove the securing ring (12). 17. Remove distance washers (14) and pull off the hub (8) from motor shaft with appropriate bearing puller (sequence according brake versions). 18. Remove the key (11). 20

6.3. Disassembling the brake unit When disassembling the brake unit, proceed in the following manner (depending to the brake version some steps might not be required): 1. Remove the hollow-core bolts (6) from the magnet body (2). 2. Remove the cylinder screws from the manual release (10) and remove manual release bracket. 3. Remove the armature plate (3) and the sealing ring (16). 4. Remove adjusting ring (9). 5. Remove pressure springs (5) and plugs (15). 6.4. Assembling the Brake Unit Gehen Sie bei der Montage von ZFB-Bremsen folgendermaßen vor (je nach Ausführung können einige Arbeitsschritte entfallen): 1. Screw adjustment ring (if applicable) (9) into the magnet body and tighten (2). 2. Place plug (15) and pressure springs (5) in the magnet body (2). 3. Place armature plate (3) on the magnet body (2) 4. Screw the hollow-core bolts (6) into the magnetic body and tighten (2). 5. Adjust distance y between armature plate and screw head to limit stroke of the armature plate (table 9 or 10, annex A). 6.5. Assembly of the manual release for ZFG/ZFL-brakes Illustration 7 : Manual release structure ZFL / ZFG 21

Retrofitting the existing brake with manual release must be carried out as follows: 1. For the assembly of the manual release, the brake must be dismounted and de-energised! 2. Remove protective plug out of the bore for the assembly of the manual release 3. Push screw (31) equipped with disk (32), spring (34), disk (33) and O-ring (35) into the bore of the armature disk and of the magnetic housing. 4. Place manual release bracket (30) onto the magnet body (2). 5. Mount disk (32) with nut (36). Bolt Disc Disc Spring O-ring Nut Frame DIN 6912 DA x Lo Di x s DIN 985 Size (Pos. 31) (Pos. 32) (Pos. 33) (Pos. 34) (Pos. 35) (Pos. 36) ZFL 08 M3 x 35 Ø3,2xØ9x0,8 Ø3,2xØ8x0,5 Ø5 x 8,5 2,6 x 1,2 M3 ZFL 15 M4 x 40 Ø4,3xØ10x1 Ø4xØ8x1 Ø5,8 x 8,3 3 x 2 M4 ZFL 30 M4 x 45 Ø4,3xØ10x1 Ø4xØ8x1 Ø6,3 x 9,3 3 x 2 M4 Table 7 : Dimensions for manual release parts 6. Tighten both cylinder bolts (31) until the armature disk (3) sits closely and uniformly at the magnet body (2). 7. Loosen both cylinder bolts by X rotations (please refer to table 8). In doing so, the reference dimension "Y" of the manual release will be set. The reference dimension "Y" must be uniformly set and must not be readjusted any more later on. Frame Size Reference dimension Y +0,1 [mm] Thread designation Turn back bolts by X rotations ZFL 08 1 M3 2 ZFL 15 / 30 1 M4 1,5 Table 8 : Adjusting manual release 8. Secure the setting/adjustment by applying locking varnish on the nuts (36). 9. After assembly of the fan cover, firmly screw down the manual release lever into the manual release bracket (30) and tighten it. 22

6.6. Brake mounting When mounting the brake unit, proceed in the following manner (depending to the brake version some steps might not be required): 1. Insert key (11). 2. Press hub (8) on motor shaft with appropriate tool and add on distance washer (14) (sequence according brake versions). 3. Mount securing ring (12). 4. Attach friction plate (17). 5. Tighten the friction plate with cylinder screws (18) at the brake end shield (1). 6. Slide the rotor (4) - compare the minimum thickness of the brake rotor to table 9 or 10 / annex A onto the hub (8). 7. Mount complete brake to motor end shield (1) with 3 hexagon bolts (7). Tightening torque see annex B. Copper discs under the screw heads have to be renewed. Observe the following informations: For ZFL und ZFG-brakes the nominal air gap is triggered by the brake body. By removing the plug the air gap can be checked. After that the plug has to be mounted again. Illustration 8 : Checking the air gap at ZFL / ZFG-brakes For ZFB-brakes proceed as follows: Screw hexagon bolts (7) into motor end shield until air gap " s A " (annex A) can be measured with feeler gauges between armature plate and magnet body. Unscrew hollow-core bolts (6) from magnet body (1) until they sit firmly on motor end shield resp. friction plate (60). Equally tighten hexagonal bolts (7). Check size and uniformity of air gap " s A " with feeler gauge. 8. Insert O-ring (16) into the groove between armature plate (3) and magnet body (2). 9. Connect power supply with flat AMP plug. 10. Mount the key (21). 11. Mount the fan (23). 12. Mount the securing ring (22). 13. Mount the fan cover (20) onto the motor end shield. 14. Mount manual release lever (10). 15. Connect power supply. 16. Test function. 23

6.7. Brake Re-adjustment (ZFB) The air gap " s A " is measured in braking position between armature plate (3) and magnet body (2) and compared to correct size in annex A depending on brake type. The air gap increases with wear of brake disc. If wear of brake lining has progressed to maximum air gap " s A max " it will be necessary to re-adjust brake to assure safe brake release. Same condition is present when actual armature plate stroke exceeds the limits. These conditions result in reduced brake torque or longer stopping distance Re-adjustment is done as follows: 1. Disconnect power supply to brake. 2. Remove manual release lever (10). 3. Remove fan cover bolts with cover (20). 4. Remove the dust protection ring (19) from the magnet body (2) groove and pull over the brake end shield. 5. Remove friction dust with pressurized air. 6. Check the minimum thickness of the brake rotor - compare to table 9 or 10 / annex A. If the actual thickness is less than the listed minimum brake rotor it must be replaced. 7. Loosen hexagonal bolts (7) half a turn. 8. Screw hollow-core bolts (6) approximately 1 mm into magnet body (2). 9. Screw hexagon bolts (7) into motor end shield until air gap " s A " (according annex A) can be measured with feeler gauges between armature plate and magnet body. 10. Unscrew hollow-core bolts (6) from the magnet body (2) until they sit firmly on motor end shield resp. additional wear plate (17). 11. Equally tighten hexagonal bolts (7). 12. Check size and uniformity of air gap "s A " with feeler gauge. For proper brake operation the air gap must be uniform around the magnet body. Check on several locations 13. If necessary correct air gap as described in 7. to 12.. 14. Tighten hexagonal bolts (7) with the torque wrench (tightening torques according annex B) 15. Insert O-ring (16) into the groove between armature plate (3) and magnet body (2). 16. Connect power supply with flat AMP plug. 17. Mount the fan cover (20) onto the motor end shield. 18. Mount manual release lever (10). 19. Connect power supply. 20. Test function. Maximum allowable wear on OD of hollow-core bolts 0.25mm per side. Maximum allowable oversize for hollow-core bolt holes in armature plate 0.5mm. If any maximum allowable values are exceeded parts must be replaced! 24

6.8. Replacing the rotor (ZFL/ZFG) Due to the structural design of the stator, the air gap cannot be installed downstream. When the wear limit is reached the rotor has to be replaced. By removing the plug (11) the air gap can be checked. After this the plug has to be mounted again. For replacing the rotor, proceed in the following manner (depending on the model, certain working steps can be dropped): 1. Disconnect the power supply and secure it against restart. 2. Remove manual release lever. 3. Loosen the fastening screws and remove fan cover. 4. Remove the securing ring of the fan. 5. Pull off the fan. 6. Remove the key 7. Detach the electrical connection. 8. Remove the fixing screws (7). Copper discs under the screw heads have to be renewed, in case of assembly. 9. Remove the magnet body (2) complete with - armature plate (3), - pressure springs (5), 10. Remove the brake rotor (4) from the hub (8). Caution: watch out for the spline. 11. Check the minimum thickness of the brake rotor - compare to table 9 or 10 / annex A. If the actual thickness is less than the listed minimum brake rotor it must be replaced Continue with chapter 6.6 step 6 25

6.9. Spare parts We expressly point out that spare and equipment parts, which were not delivered by ABM, were also not tested and approved by ABM. The installation and / or use of such products could therefore have a negative impact on the constructive properties of your drive. The liability of the manufacturer is excluded for damages arising from the use of non-original spare parts and non-original equipment. Request a separate spare parts drawing and list for your drive. 26

7. Decommissioning and disposal 7.1. Decommissioning Please consider the references of the operating instructions for electric motor / gear motor. 7.2. Recycling and disposal Divide the components into the following category for recycling: Iron scrap Non-ferrous metal Plastics Insulation material, cables Brake lining Dispose of the components in compliance with the national and local regulations. 27

8. Illustrations Illustration 1 : Design of the brake type ZFB... 8 Illustration 2 : Design of the brake type ZFG / ZFL... 9 Illustration 3 : ZFB-brake with manual release and adjusting ring... 10 Illustration 4 : Name plate... 11 Illustration 5 : Connecting plans for rectifiers E4, B40 and PMG500-S... 15 Illustration 6 : Sketch for disassembling / assembling... 19 Illustration 7 : Manual release structure ZFL / ZFG... 21 Illustration 8 : Checking the air gap at ZFL / ZFG-brakes... 23 9. Tables Table 1 : Signal words and their meaning... 3 Table 2 : Used terms... 5 Table 3 : Brake type designation code... 11 Table 4 : Standards... 12 Table 5 : Guidelines and regulations... 12 Table 6 : Error diagnosis... 17 Table 7 : Dimensions for manual release parts... 22 Table 8 : Adjusting manual release... 22 Table 9 : Functional dimensions ZFB / ZFG... 30 Table 10 : Functional dimensions ZFL... 30 Table 11 : Screw tightening torques in Nm... 31 Table 12 : Safety parameters for brakes... 31 28

10. Index Address... 7 Air gap... 30 Assembling... 21, 22, 23 Brake Re-adjustment... 24 Brake structure... 8, 9 Checks... 16 Decommisioning... 27 Description of function... 10 Disassembling... 19, 20, 21 Error... 17 A B C D E Name plate... 11 Operation... 16 Optional modules... 13 Preparation... 14 Qualification... 3 Rectifier... 14, 15 Recycling... 27 Reference dimension... 30 Replacing... 25 Rotor size... 30 N O P Q R Fastening... 16 Fault removal... 17 Guidelines... 12 Intended purpose... 12 Maintenance... 18 Modification... 6 F G I M Safety... 3 Safety parameter... 32 Signal words... 3 Spare parts... 26 Standards... 12 Switching cycles... 32 Terms... 5 Tightening torques... 32 Type designation code... 11 Warranty... 6, 26 S T W 29

Annex A Functional dimensions Type ZFB / ZFG Size 10 20 40 60 100 150 250 Air gap sa mm 0,2 0,3 0,3 0,4 0,4 0,4 0,5 Air gap max. sa max mm 0,7 0,8 0,9 1 1,1 1,1 1,2 Reference dimension y mm 1 1 1 1,2 1,2 1,5 1,5 Rotor size min. s min mm 5,5 7,5 9,5 11.5 12,5 14,5 16,5 Table 9 : Functional dimensions ZFB / ZFG Size Type Ref. dim Nominal torque Nominal air gap sa 30 without manual release Max. air gap sa max [mm] ZFL with manual release Min. rotor size [mm] without manual release with manual release y a +0,2mm [mm] [Nm] [mm] 08 1 7,5 0,2 0,4 0,4 4,8 4,8 4,2 0,7 0,7 4,5 4,5 3 0,9 0,8 4,3 4,4 2,2 1,0 0,8 4,2 4,4 1,4 1,1 0,8 4,1 4,4 1 1,6 0,8 3,6 4,4 15 1 15 0,2 0,4 5,8 10 0,6 0,6 5,6 7,5 0,7 0.7 5,5 5,5 6 0,8 0.8 5,4 5,4 4,2 0,8 0.8 5,4 5,4 3 1,0 0.8 5,2 5,4 2,2 1,2 0.8 5,0 5,4 1,4 1,2 0.8 5,0 5,4 1 1,2 0.8 5,0 5,4 0,7 1,2 0.8 5,0 5,4 30 1 30 0,3 0,5 0,5 5,8 5,8 25 0,7 0,7 5,6 5,6 20 0,8 0,8 5,5 5,5 17 0,8 0,8 5,5 5,5 13 0,9 0,9 5,4 5,4 8 1,2 1,0 5,1 5,3 Table 10 : Functional dimensions ZFL

B Tightening torques Thread Strength class of screw connection 8.8 10.9 12.9 M4 3,2 5 6 M5 6,4 9 11 M6 11 16 19 M8 27 39 46 M10 53 78 91 M12 92 135 155 Tolerance of all tightening torques = 15% Table 11 : Screw tightening torques in Nm C Safety parameters for brakes Definition of the characteristic safety value B10d: According to EN ISO 13849-1 the value B10d specifies the number of cycles at which 10% of components have failed dangerously. Failed dangerously means in this context, that the break is not applied when required und does not deliver the necessary braking torque Type Size Type Size B 10d [switching cycles] ZFB / ZFG 05 ZFL 08 10.000.000 ZFB / ZFG 10 / 1x ZFL 15 10.000.000 ZFB / ZFG 20 / 2x ZFL 30 10.000.000 ZFB / ZFG 40 / 4x 8.000.000 ZFB / ZFG 60 / 6x 6.000.000 ZFB / ZFG 100 / 10x 4.000.000 ZFB / ZFG 150 / 15x 4.000.000 ZFB / ZFG 250 / 25x 3.000.000 Table 12 : Safety parameters for brakes 31