Global Series Brakes User Manual
Contents
1. 222 W Memorial Road Oklahoma City OK 73114 2317 MAGPOWR international Phone 1 800 624 7697 Fax 405 755 8425 Company www magpowr com E mail magpowr magpowr com INSTRUCTION MANUAL GLOBAL SERIES BRAKE MODELS GBA GBAM GBB GBBM GBC GBCM GBD GBDM GBE GBEM CAUTION This product contains rotating parts which could cause injury at time of installation Appropriate protective guards should be installed by the user according to his use of this product All of the information herein is the exclusive proprietary property of Maxcess International and is disclosed with the understanding that it will be retained in confidence and will neither be duplicated nor copied in whole or in part nor be used for any purpose other than for which disclosed Copyright 2008 all rights reserved Periodically there will be updates to this manual The latest version is available at www magpowr com or by calling 1 800 MAGPOWR 624 7697 THEORY OF OPERATION The brake construction consists of two stators a rotor a coil assembly magnetic powder and two bearings The bearings support and align the rotor with the stators and allow the rotor to rotate within the brake assembly The magnetic powder occupies the space between the stators and the rotor and represents a key element in the operation of the brake The stators are connected to the machine frame through a torque arm and remain stationary The rotor is connected to a rotating2. C GBCM 1 18 0 32 GCC GCCM 1 18 0 32 GBD GBDM 1 54 0 39 GCD GCDM 1 54 0 39 GBE GBEM 1 58 0 46 GCE GCEM 1 58 0 46 ENVIRONMENTAL SPECIFICATIONS Temperature Range Operating 0 C to 40 C Storage 30 to 80 C Relative Humidity 5 to 85 Pollution Degree 2 IEC664 1 Altitude to 2000 meters MAINTENANCE Due to its small number of moving components and its basic design maintenance of the brake is generally necessary only after extended service When a problem appears in the system ensure that all couplings belts etc and the control device are functioning properly Use the Troubleshooting guide below to determine the cause of the problem For general maintenance the brakes can be rebuilt with a repair kit A repair kit includes a new powder charge and the appropriate bearings seals and snap rings generally needed to rebuild the unit NOTE When ordering parts not contained in the kit provide the model number serial number and parts list item number and description from Figure 1 TROUBLESHOOTING PROBLEM POSSIBLE CAUSE ACTION Load is not controlled by brake Power supply voltage output low Replace or repair control Magnetic powder has deteriorated Overhaul the brake Coil is open Replace coil Load operates in an intermittent Coil is intermittently open Replace coil manner with proper voltage Brake is noisy and has vibration Bearings are worn Overhaul brake using repair kit DISASSEMBLY
3. Refer to Figure 1 1 Remove the set screws and collar from the rotor shaft Remove the external snap rings from both sides of the rotor shaft 2 3 Remove the three four screws which hold the left and right stators together 4 Separate the stator frames by tapping on the end of the rotor with a soft mallet all models except GBE and GBEM Tap on the right stator side first The rotor will remain attached to the left stator For the GBE and GBEM insert 4 bolts 5 16 18 or M8x1 25 in the tapped holes in the left stator frame and screw them in evenly to separate the stator halves The bolts should be 5 inches 127mm or longer in length NOTE Removal of the junction box and cover are not required CAUTION Do not attempt to pry the left and right stators apart with a screwdriver or wedge 5 Remove the coil and the coil gaskets from the stators 6 Remove the rotor from the left stator by tapping on the rotor shaft with a soft mallet from the left stator side 7 Remove the powder seals from the stators by prying around the inner lip with a screwdriver 8 Remove the internal snap rings from both stators 9 Press the bearing out of each stator 10 Remove the powder fill screw and washer for GBA GBAM GBB amp GBBM only from the right stator For all other models remove the blind rivet NOTE Discard all bearings powder seals gaskets snap rings and magnetic powder These parts must be replaced and are included i
4. dels GBA GBAM GBB AND GBBM Install the coil gasket into the slot in the left stator Insure that the coil gasket is evenly seated all the way around the stator slot NOTE For Models GBC GBCM GBD and GBDM GBE and GBEM Install the coil gasket into the slot in the coil bobbin Insure that the coil gasket is evenly seated all the way around the bobbin slot Use a few drops of instant adhesive to keep gasket from moving during assembly Place the coil into the left stator with the leads exiting through the slot into the junction box Install the right side coil gasket NOTE For Models GBA GBAM GBB AND GBBM Install the coil gasket into the slot in the right stator Insure that the gasket is evenly seated all the way around the stator slot NOTE For Models GBC GBCM GBD AND GBDM GBE and GBEM Install the coil gasket into the slot in the coil bobbin Insure that the coil gasket is seated evenly all the way around the bobbin slot Use a few drops of instant adhesive to keep gasket from moving during assembly 12 13 14 15 16 17 18 19 20 Support the left stator assembly on a bench with the cross drilled holes facing up Wrap a 6 x 6 152 mm x 152 mm piece of stiff paper thin plastic or shim stock around the rotor shaft forming a sleeve This will allow the powder seal to slide over the end of the rotor shaft and the external snap ring groove Slide the right stator and powder seal over the thin sleeve until
5. it bottoms on the left stator assembly Pull the sleeve off the end of the rotor shaft Install the three four stator screws split lockwashers and nuts loosely NOTE The long stator screw should be installed 180 from the junction box Press the other bearing onto the end of the rotor shaft until it seats against the internal snap ring of the right stator NOTE The seal side of the bearing must face the inside of the brake Tighten the stator screws evenly until the left and right stators are clamped together Apply 2 or 3 drops of wicking Loctite to the inner and outer race of both bearings Wait ten seconds and wipe off the excess Loctite Install the other external snap ring on the rotor shaft against the bearing This step is made easier by supporting the brake on the opposite end of the rotor shaft NOTE Insure that the right bearing is seated against the internal snap ring before attempting to install the external snap ring Manually rotate the rotor shaft to insure smooth operation of the rotating parts Place the brake on a clean piece of paper Support the brake at 45 so that the cross drilled holes are facing up Fill the brake with all of the magnetic powder supplied in the repair kit While filling slowly rotate the rotor to evenly distribute the magnetic powder NOTE Collect any spilled magnetic powder from the clean paper and pour it into the brake Install the powder fill screw and washer for GBA GBAM GBB a
6. l earth protective earth connections to ground are mandatory The protective earth ground connection is required for safety and regulatory compliance The functional earth ground connection is required for noise immunity reliability and Electromagnetic Compliance EMC with the European Union EU EMC directive for CE mark conformance RATED COIL CURRENTS NOTE The coil system has been changed from Class A to Class F Refer to the nameplate on your unit to determine which insulation class you have If you have Class F insulation the nameplate will denote Class F If you have Class A there will be no notation on the nameplate Maximum Current 0 C adc Supply Voltage vdc Maximum Current 0 C adc Supply Voltage vdc 0 24 0 90 0 24 0 90 Model Class A Class F Class A Class F Model Class Class F Class A Class F GBA GBAM 0 94 1 32 0 25 0 28 GCA GCAM 0 94 1 32 0 25 0 28 GBB GBBM 1 06 1 75 0 28 0 37 GCB GCBM 1 06 1 75 0 28 0 37 GBC GBCM 1 56 2 06 0 42 0 55 GCC GCCM 1 56 2 06 0 42 0 55 GBD GBDM 2 03 2 68 0 54 0 69 GCD GCDM 2 03 2 68 0 54 0 69 GBE GBEM 2 76 0 80 Rated Current adc Rated Current adc Supply Voltage vdc Supply Voltage vdc 0 24 0 90 0 24 0 90 Model Class F Class F Model Class F Class F GBA GBAM 0 76 0 16 GCA GCAM 0 76 0 16 GBB GBBM 1 00 0 21 GCB GCBM 1 00 0 21 GB
7. machine shaft which supports the weight of the brake The magnetic powder functions as the adjustable bond or link between the stators and the rotor It is the medium for the transmission of torque An electric current in the coil creates a magnetic field flux which passes through the stators magnetic powder and the rotor The flux aligns the powder particles forming a bond or link between the stators and the rotor The strength of the bonding action torque is proportional to the amount of current in the coil The torque is transmitted to the rotating shaft through the rotor MECHANICAL INSTALLATION The rotor shaft centerline must be mounted within 30 of the horizontal plane 2 Prior to installation manually check the rotation of the rotor to observe that it is smooth and free of binding or scraping 3 Mount the brake on the shaft and tighten the two set screws 4 Attach a torque arm between the extension bolt and the machine frame with a loose or floating mount to prevent binding forces on the brake bearings The torque arm will prevent the rotation of the brake stators Protective guards should be installed by the user according to his use of this product 850A169 1 03 09 Rev H ELECTRICAL INSTALLATION For both 24vdc and 90vdc devices 1 Connect vdc power source to the terminals marked 1 2 2 Connect protective grounding circuit to the terminal marked with the P E symbol D NOTE Both the functiona
8. mp GBBM only into the right stator All other models have a blind rivet 21 Install the collar and set screws onto the rotor shaft LEFT STATOR 5 RIGHT STATOR COIL AND GASKET CONFIGURATION ON GBC AND GBD 12 Gaskets 12 ZZZXINNNNAN Semen 100000010 10 MAGNETIC POWDER ROTOR ASSEMBLY 1 11 POWDER FILL SCREW ey EXTERNAL SNAP RINGS 9 COLLAR 7 POWDER SEALS BEARINGS 6 PARTS LIST ROTOR ASSEMBLY COIL COLLAR LEFT STATOR RIGHT STATOR BEARINGS POWDER SEALS INTERNAL SNAP RINGS EXTERNAL SNAP RINGS MAGNETIC POWDER POWDER FILL SCREW AND WASHER FOR GBA GBAM GBB amp GBBM ONLY COIL GASKETS POMONA ARONS N BRAKE CROSS SECTIONAL VIEW MAXCESS INTERNATIONAL COMPANIES GUIDING INSPECTION TENSION CONTROL SLITTING WINDING
9. n the repair kit RE ASSEMBLY 10 11 IMPORTANT Re assembly of the brake must be performed in a clean dry area The brake components must be cleaned with solvent and must be dry and totally free of grease and oil Grease or oil on brake parts will cause failure when the unit is rebuilt CAUTION Do not immerse the coil in solvent Install the internal snap rings in the stators Press the new powder seals into the left and right stators The powder seals will bottom on the internal snap rings NOTE The seal lip must face toward the inside of the brake Support the rotor on a bench with the cross drilled holes facing down Wrap a 6 x 6 152 mm x 152 mm piece of stiff paper thin plastic or shim stock around the rotor shaft forming a sleeve This will allow the powder seal to slide over the end of the rotor shaft and the external snap ring groove Slide the left stator and powder seal over the thin sleeve until it bottoms on the rotor Pull the sleeve off the end of the rotor shaft Press one bearing onto the end of the rotor shaft until it seats against the internal snap ring of the left stator NOTE The seal side of the bearing must face the inside of the brake Apply 2 or 3 drops of wicking Loctite to the inner and outer race of both bearings Wait ten seconds and wipe off the excess Loctite Install the external snap ring on the rotor shaft Turn this assembly over Install the left side coil gasket NOTE For Mo
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