HEB250 Brake User Manual
Contents
1. i 100 3 937 minimum 10 5 0 413 at TO z i i 209 8 228 MAXIMUM 3 Wy 7 SHAFT LENGTH 300 11 811 256 10 079 49 5 1 949 ERI ual Ji i 43 5 1 713 H af S 4 H 88 3 465 106 4 173 215 8 465 UNITS mm INCHES 255 9 173 Figure 2 HEB250 Dimensions www maxcessintl com MAGPOWR HEB250 High Efficiency Brake MI 850A346 1 Page 6 Safety Information To ensure safe and problem free installation of the pneumatic brake device the brake must be properly transported and stored professionally installed and placed in operation Proper operation and maintenance will ensure a long service life of the device Only persons who are acquainted with the installation commissioning operation and maintenance of the system and who possess the necessary qualifications for their activities may work on the pneumatic brake Note The safety information may not be comprehensive e The content of these instructions must be read and followed e All national state and local requirements for installation accident prevention and environmental protection must be followed The safety instructions and symbols described in this section are used to avoid possible dangers for users and to prevent material damage SIGNAL WORD Source of danger and its results Avoiding dangers gt The signal word WARNING refers to the danger of moderate to severe bodily injuries or death The signal word CAUTION2. see electrical installation section for details Position the fan shroud over the center of the HEB250 and connect the proximity sensor connector to the mating connector coming from one of the caliper mounting bracket halves Mount the fan shroud to the HEB250 by installing 4 ea M6 bolts and tightening to a torque of 8 Nm 6 lb ft www maxcessintl com MAGPOWR HEB250 High Efficiency Brake MI 850A346 1 Page 11 How to mount the brake using adapter plate HEB250BKPLT Mount adapter plate to existing safety chucks chucks bearing block or machine frame surface using existing bolt hole patterns in adapter plate or attached to customer supplied bracketry or custom weldments Proceed to step B in the previous section How to mount brake using adapter plate to Tidland safety chuck The HEB250BKPLT adapter plate is designed to fit the lagerdeckel bearing end plate for Tidland safety chuck sizes 22 30 30 40 and 40 50 Stock chucks use M6 bolts to secure the lagerdeckel to the chuck housing These holes must be re drilled and tapped to M8 or the M8 version of the aforementioned chucks must be ordered Remove the existing 4 ea M6 or M8 countersunk bolts from the lagerdeckel and replace with 4 ea M8 socket cap head screws These screws are used to attach the adapter plate and the bearing end plate to the safety chuck Tighten to a torque of 40 Nm 29 5 lb ft Proceed to step B in the previous section www maxcessintl com MAGPOWR HEB
3. x9 m __ a o a mm ao mmo 3 o a mm ao mmo a 49 414x9 ee ee ee H PADO o 33 5 mm exo m _ a o 52 mm texto mm s 5 mm exo mm _ Oo 36 4mm 16x0 mm O 37 m 16x10 m Oo 383 m 16x10 m O 39 mm 16x10 m p40 BL m 16x10 m O A re m 18x m ae L a mlendo d 1 4 wone wone 10 ee 5 16 18 UNC 19 170 www maxcessintl com MAGPOWR HEB250 High Efficiency Brake MI 850A346 1 Page 3 Table 1 Part number codes for bore diameter and rotor set screw tightening torques Highlighted Bores are Standard Bore Keyway Keyway Set Screw oe ue ee ee ee 3 8 16 UNC 34 300 ph BAG 1 S12 L e L o 3 o 20000 f inen rete neh 1 2 13 UNC 70 625 ee 2316 21875 moh 12x12 inch 68 25 16 2 3125 inch 5 8 x 5 8 Serial Number Key Serial number consists of a date code followed by a sequence number Date is formatted as 2 digits for month then 2 digits for day then 2 digits for year followed by a 3 digit number sequence starting at 001 each day Example serial number 021312002 This brake was produced on Feb 13 2012 and it was the second brake made that day Available Models All combinations of options are available except a proximity sensor without a fan A fan shroud is used to mount the fan and the connections for the proximity sensor Models without a fan or proximity sensor do not have a fan shroud For models with a proximity sensor on
4. HEB250 High Efficiency Brake MI 850A346 1 Page 16 Troubleshooting PROBLEM POSSIBLE CAUSE ACTION No torque or low torque Air line leaking Replace air line Air fitting leaking Replace air fitting Caliper seal leaking Order caliper repair kit RKHEBCAL One or more pads worn Order pad replacement kits HEBPKL HEBPKM or HEBPKH Check power supply Check wiring for opens Fan not running No power to fan Fan bearing failed Replace fan part number 20C23 1 Check power supply Check wiring for opens Proximity Sensor not pulsing No power to sensor NPN output needs a pull up load to 24 volts Table 1 Troubleshooting Verify connections Product Specifications f WARNING Do not use the devices outside of their rated specifications Temperature Range Operating 0 C to 50 C 32F to 122 F Storage 30 C to 80 C 22 F to 176 F Relative Humidity 5 to 85 Altitude O to 2000 meters 0 to 6562 feet Maximum RPM 1800 RPM Maximum Pressure 621 kPa 90 PSI Actuation Pressure 21 kPa 3 PSI Fan Voltage 24 VDC Current 1 5 ADC Proximity Sensor Supply Voltage 24 VDC Signal Output NPN Normally Open Max Signal Current 200 mADC Max Frequency 2 kHz Brake Pads Material Does not contain asbestos www maxcessintl com MAGPOWR HEB250 High Efficiency Brake MI 850A346 1 Page 17 Pressure vs Torque Torque at 60 psi 414 kPa Ib in Nm Torque at 90 psi 621 kPa Ib in Nm Numb
5. WARNING Danger of injury from crushing aut za a c n Eees fans JN MBX1 25 BOLTS l H Y BX Sei 1 2 inch CONDUIT FITTING CUSTOMER PROVIDED 121 24 4 773 12 0 472 280 11 024 g a 5 o Brake assembly may be either directly mounted to the machine frame or mounted to an adapter plate HEB250BKPLT with the correct bolt pattern pre established To mount directly to the machine frame drill and tap 8 ea M8x1 25 holes as shown in figure above Brake assembly was designed for the conduit fitting to be facing downwards in the installed position but can be installed with the conduit fitting facing upwards if desired Doing this will not change the bolt pattern Note The brake radiates heat so a generous space around the brake unit will ensure a lower average operating temperature and maximum brake pad life www maxcessintl com MAGPOWR HEB250 High Efficiency Brake MI 850A346 1 Page 9 MACHINE FRAME MOUNTING PLATE Mount the rotor on the shaft without tightening the set screws 100 3 937 MINIMUM TO 209 8 228 MAXIMUM SHAFT LENGTH 4 MOUNTING BOLTS Mount one of the caliper mounting halves halves are symmetrical so it does not matter which half to the machine frame using 4 ea M8x1 25 bolts Tighten bolts to a torque of 40 Nm 29 5 lb ft Center the rotor between the two brake pads Use feeler gauges or equivale
6. extending so far that the backing plate rubs the rotor New brake pads measure 15mm 0 591 in in thickness Since brake pads will stop extending with 6mm 0 236 in of overall thickness left half of this is a metal backing plate it is recommended to replace brake pads prior to wearing the brake pads down to the 6mm 0 236 in thickness Note brake pads do not contain asbestos WARNING danger to eyes Wear eye protection when working with compressed air How to replace the brake pads For brakes WITHOUT a fan shroud remove the fan finger guard For brakes WITH a fan shroud remove the fan shroud 4 MOUNTING BOLTS Remove 4 bolts to dismount each caliper mounting half Brake pads are clipped onto the piston and are easily removed Dismount brake pads by prying the brake pad away from the piston until it has become unclipped To replace with a new brake pad simply line up the tabs of the brake pad with the tabs of the caliper and press until the pad has clipped in place Remount caliper mounting halves using 4 each previously removed bolts www maxcessintl com MAGPOWR HEB250 High Efficiency Brake MI 850A346 1 Page 14 Replacement Part Kits Pad replacement kits Each kit contains 2 ea pads to fill 1 ea caliper Model Number HEBPKL HEB pad kit for low friction pads 0 21 HEBPKM HEB pad kit for medium friction pads 0 41 HEBPKH HEB pad kit for high friction pa
7. refers to the danger of slight to moderate bodily injuries or material damage WARNING CAUTION General danger or important note Reference to general hazards that may result in bodily injuries or damage to device or material WARNING CAUTION danger due to crushing Reference to danger of injury caused by crushing WARNING CAUTION danger due to cutting Reference to danger of injury caused by cutting WARNING CAUTION danger due to voltage electric shock Reference to danger of injury caused by electric shock due to voltage WARNING CAUTION danger due to hot surfaces Reference to risk of injury caused by burning WARNING CAUTION danger due to flying objects Reference to risk of injury caused by burning De PPK Basic Safety Information Proper Use The HEB brake is intended to produce braking torque proportional to input pneumatic pressure to create web tension in an unwind roll of material Intended for indoor operation only Improper Use Operation outside the technical specifications Operation in an Ex area or intrinsically safe area Any other use than the proper use shall be deemed inappropriate www maxcessintl com MAGPOWR HEB250 High Efficiency Brake MI 850A346 1 Page 7 Installation and commissioning Any brake which is damaged must not be installed or put into operation Only perform installation maintenance or repair tasks on the brake when the machine has been stopped and is secure
8. 250 High Efficiency Brake MI 850A346 1 Page 12 Electrical Installation WARNING Death or injury can result from electric shocks AN Installation of the fan shroud must be performed when there is no electrical power in the system Never place electrical cables under mechanical strain Always route wiring in either flexible or rigid conduit All wiring must comply with the essential requirements of the appropriate standard s and is the responsibility of the installer Wiring to the fan shroud must be insulated copper wire with a temperature rating of at least 105 C 221 F Wire size should be 0 52 or 0 82 mm 20 or 18 AWG Tightening torque for the terminals is 0 4 Nm 3 5 Ib in 1 Install a 12mm 500 in conduit fitting in the fan shroud 2 Connect the building or machine earth ground to the terminal with the green yellow wire 3 Connect a 24 VDC power supply by connecting the positive voltage to the terminal with the red wire and connect the negative voltage to the terminal with the black wire 4 Connect the wires for the proximity sensor to the terminal strip if used The terminal strip connector with the white wire is the positive signal from the proximity sensor and the connector with the black wire is the negative for the proximity sensor 5 Install a pull up resistor from the proximity sensor signal wire to the 24 volt supply The resistor should be no more than 10K ohms and no less than 120 ohms If the RPM monitor or PL
9. C which the proximity sensor signal is connected to already contains an internal pull up the external pull up is not necessary See proximity sensor specifications 6 Position the fan shroud over the center of the HEB250 and connect the proximity sensor connector to the mating connector coming from one of the caliper mounting bracket halves 7 Mount the fan shroud to the HEB250 by installing 4 ea M6 bolts and tightening to a torque of 8 Nm 6 lb ft 9 hoe PROXIMITY SENSOR i D100 o ah CONNECTOR i I SOooaeeo amp NPN NORMALLY OPEN 1 2 INCH 12 MM CONDUIT FITTING CUSTOMER PROVIDED 24 VDC WHITE NO SIGNAL COM PROXIMITY SENSOR DIAGRAM TERMINAL STRIP Figure 3 Electrical Wiring www maxcessintl com MAGPOWR HEB250 High Efficiency Brake MI 850A346 1 Page 13 Maintenance Maintenance and repair tasks on the brake must be performed only when the machine has been stopped WARNING Danger of injury from crushing and has been secured from being turned on again e Daily Keep the brake assembly free of dust and debris buildup during shift operation e As Needed Keep the rotor free of excessive dust and debris buildup Use a residue free brake cleaner such as turpentine acetone or BioBrake to wipe down the rotor e Fan Replacement Replace fan every three years or 30 000 hours of brake operation e Brake Pads Calipers assemblies are designed to prevent brake pads from
10. MAGPOWR TENSION CONTROLS AN MAXCESS MAGPOWR HEB250 High Efficiency Brake Installation Operation and Maintenance MI 850A346 1 HEB250 User Installation Manual 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 2012 all rights reserved Periodically there will be updates to this manual The latest version is available at www magpowr com or by calling 800 MAGPOWR 800 624 7697 or 405 755 1600 These brake devices must not be installed or used in a machine or system which does not comply with the machinery directive 2006 42 EC These brake devices were designed and manufactured to be installed as Partly Completed Machinery into a machine or partly completed machine The instructions must be read and used by all persons who have the responsibility of installing and maintaining these brake devices These instructions must be retained and incorporated in the technical documentation for the machine or partly completed machinery into which the brake device is installed CE Marking Only the 2006 42 EC Machinery directive applies to these devices and they are not marked with the CE sign Theory of Operation Supplied pneumatic pressure acts on a pneumatic seal piston assembly whic
11. Sensor 1 0 NoFan 0 No Proximity Sensor 00__ 10mm pilot hole P _ Proximity Sensor 4 Calipers 5 Calipers 6 6 Calipers 60 mm 1 000 in 53 1 375 in 1 3 8 in 32 50mm 6omm Specials 3 Other bore diameters etc 1 If a proximity sensor is selected then a fan must be selected and the maximum number of calipers is 5 2 Listed rotor bores are standard See Table 1 for complete list of rotor bore diameters 3 Blank if standard www maxcessintl com MAGPOWR HEB250 High Efficiency Brake MI 850A346 1 Page 2 Example model number HEB250 4 M F P 10 is an HEB250 with 4 ea calipers medium coefficient of friction brake pads with a fan witha proximity sensor and a rotor with a 28mm bore diameter Table 1 Part number codes for bore diameter and rotor set screw tightening torques Highlighted Bores are Standard Bore Keyway Set Screw nod ue 10 mm Pilot Hole A ____ Na ee ere ee oe 02 mm 6x6 mm M6x10 8 171 o3 a x e mm Zo i o a o 4 mm 8x7 m o 5 mm 8x7 m o s mm 8x7 m o 27 mm 8x7 mm 8x19 een 10 28 mm 8x7 mm po mm 8x7 m 12 30 _ mm 8x7 m ps Tt mm 10x8 m M10x15 35 1310 mi ie 20 3 mm 10x8 m a o 3 mmh 2x8 m __ 22 o m 2x8 m 23 a m 2x8 m __ a 42 m 2x8 m __ 5 B m 2x8 m __ s 44 m 2x8 m oa T a5 mm xo mm __ a 6 m
12. d from being turned on Only perform installation maintenance or repair tasks on the brake when there is no electrical power in the system The brake must be securely mounted before being placed in operation Only replacement parts obtained from Fife may be used No modifications may be made to the brake Do not place electrical cables under mechanical strain Do not bring this brake into contact with water or other fluids Grease or oil on the internal brake parts will cause a loss of torque Decommissioning The brake must be disposed of in accordance with all the applicable national state and local regulations Operation A CAUTION Burns can result from touching the brake surface during operation The brake device converts mechanical motion into heat and the surface of the brake will become hot during operation Appropriate guards must be installed by the user according to his use of the product Maintenance and repair 4A WARNING Danger of injury from crushing Maintenance and repair tasks on the brake must be performed only when the machine has been stopped and has been secured from being turned on again www maxcessintl com MAGPOWR HEB250 High Efficiency Brake MI 850A346 1 Page 8 Mechanical Installation Installation of the brake must be performed only when the machine has been stopped and has been secured from being turned on again How to mount the brake to the machine frame Units mm inches
13. ds 0 51 Replacement Calipers Each kit contains a front and back caliper half Note brake pad s are NOT included Model Number HEBCALREPL Caliper Rebuild kit Each kit contains seals bearing strips and o rings which will rebuild both the front and back caliper half Model Number RKHEBCAL Replacement Rotor kit Add the appropriate 2 digit bore core from table 1 to the end of the model number Model Number HEB250RTR xx Adapter Plate HEB250BKPLT Exploded views of the caliper assemblies Item Qty Description Part Number 6 1 Compression Spring 8 1 Internal Retaining Ring 28098 059 I oot a Brake Pad Assembly 145C24 X Pneumatic Fitting Tee 5C344 2 Piston Retaining Plate 712C128 1 Pneumatic Fitting 90 Deg 5C347 2 Figure 4 Front Caliper Assembly Exploded View www maxcessintl com MAGPOWR HEB250 High Efficiency Brake MI 850A346 1 Page 15 Item Qty Description Part Number 6 1 Compression Spring 5A349 1 8 1 Internal Retaining Ring 28098 059 _ 9 1 Brake Pad Assembly 145C24 X__ 1 7120127 1 Figure 5 Back Caliper Assembly Exploded View 1 Proximity Sensor Caliper __ 712C130 1 Proximity Sensor with Hex 32011 1 Nuts Plug 3 Male Crimp Terminal 12B215 1 RE ped eal 6 2 Locknut M4 27608 002 1 Item 8 C9 ty 7 r 2 2 2 1 7 3 Figure 6 Proximity Sensor Assembly Exploded View www maxcessintl com MAGPOWR
14. e of the calipers is used to mount the sensor so the maximum number of calipers with pads is 5 www maxcessintl com MAGPOWR HEB250 High Efficiency Brake MI 850A346 1 Page 4 Caliper Positioning Illustrations below represent the positioning of active calipers in all possible configurations All unused active caliper positions are filled with dummy calipers Views are top views looking at the front calipers 1 Caliper with or w o proximity sensor DUMMY DUMMY ACTIVE DUMMY CALIPER MOUNTING BRACKET PROXIMITY SENSOR 4 Calipers with or w o proximity sensor ACTIVE DUMMY ACTIVE ACTIVE DUMMY ACTIVE O PROXIMITY CALIPER SENSOR MOUNTING BRACKET 2 Calipers with or w o proximity sensor DUMMY DUMMY ACTIVE ACTIVE DUMMY OR PROXIMITY CALIPER SENSOR MOUNTING BRACKET 5 Calipers with or w o proximity sensor ACTIVE ACTIVE ACTIVE ACTIVE DUMMY ACTIVE OR PROXIMITY CALIPER SENSOR MOUNTING BRACKET Figure 1 Caliper Positioning 3 Calipers with or w o proximity sensor DUMMY ACTIVE ACTIVE DUMMY ACTIVE OR PROXIMITY CALIPER SENSOR MOUNTING BRACKET 6 Calipers no proximity sensor available in this configuration ACTIVE ACTIVE ACTIVE ACTIVE ACTIVE ACTIVE CALIPER MOUNTING BRACKET www maxcessintl com MAGPOWR HEB250 High Efficiency Brake MI 850A346 1 Page 5 Dimensions 267 4 10 528 oes E A 4 U 5 el ol TTA
15. er of Number of Coefficient of friction of pad Coefficient of friction of pad 0 12 0 41 0 51 0 12 0 41 0 51 321 36 1007 114 1174 133 338 38 1423 161 1753 198 Calipers 3 6 962 109 3021 341 3521 398 1014 115 4270 482 5259 594 4 8 1282 145 4027 455 4695 530 1352 153 5693 643 7012 792 6 12 1923 217 6041 683 2028 229 8540 965 10 518 1 188 Pressure vs Torque for 1 Caliper 2 Pads 2000 225 1800 t 200 1600 175 1400 A oo yO 150 bab 1200 gt a xen oS 125 E T lt S 1000 oo WN 4 100 am 800 Pa 75 600 50 400 200 Low coefficient___ 25 0 0 10 20 30 40 50 60 70 80 90 0 69 138 207 276 345 414 483 552 621 Pressure psi Thermal Heat Dissipation Capacity Thermal Heat Dissipation Capacity f do Medium COF Horsepower hp Kilowatts kW Medium COF with Fan Medium COF without Fan Low amp High COF with Fan owe Low amp High COF without Fan 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 RPM www maxcessintl com MAGPOWR HEB250 High Efficiency Brake MI 850A346 1 Page 18 Service requests and replacement parts To request service or to get replacement parts contact one of the following addresses When ordering replaceme
16. h in turn pushes the brake pad against the rotor to cause frictional torque on the rotor Torque supplied to the rotor is transmitted to a roll of material and acts to create tension in the web being unwound on the roll Introduction HEB pneumatic brake has a 250 mm 10 in diameter rotor Caliper configurations range from 1 to 6 calipers Brake pads come in 3 different coefficients of friction L low M medium and H high Rotor design dissipates heat equally in either direction of rotation i e clockwise or counterclockwise simplifying sizing and installation requirements The brake also features an anti squeal design using grooved pads holes in the rotor face and a damper situated between the piston and brake pad Brake pads feature a snap in design for easy pad replacement An optional cooling fan is available For measuring roll RPM a proximity sensor measuring 1 pulse per revolution is also available The brake uses a precision machined bore and keyway for mounting to the shaft of a machine Special bore diameters are available as an option Model Number Key The model number and serial numbers are shown on the top of brakes without fan shrouds and on the side of the shroud for brakes with a fan shroud The model number consists of the base model HEB250 followed by 6 digits specifying the options and an additional 2 digits for specials when applicable Format HEB250 A B C D EE FF B _ Friction Coefficient D Proximity
17. nt parts please indicate where possible part number drawing number and model description Fife Corporation Fife Tidland GmbH 222 West Memorial Rd Fifestrasse 1 Siemensstrasse 13 15 Oklahoma City OK 73114 USA 65779 Kelkheim 48683 Ahaus Phone 1 405 755 1600 Deutschland Deutschland Fax 1 405 755 8425 Telefon 49 6195 7002 0 Web www maxcessintl com Fax 49 6195 7002 933 Web www maxcess eu www maxcessintl com MAGPOWR HEB250 High Efficiency Brake MI 850A346 1 Page 19 All rights reserved No part of this publication may be reproduced transmitted transcribed or translated into any language in any form by any means without the written permission of Tidland NORTH AMERICA Toll Free 800 639 3433 Tel 1 405 755 1600 Fax 1 405 755 8425 sales maxcessintl com www maxcessintl com MAXCESS SOUTH AMERICA Tel 55 11 3959 0990 Fax 55 11 3856 0990 southamerica maxcessintl com www maxcessintl com br EUROPE Tel 49 6195 7002 0 Fax 49 6195 7002 933 sales maxcess eu Www maxcess eu INDIA Tel 91 22 27602633 Fax 91 22 27602634 india maxcessintl com www maxcess in CHINA KOREA TAIWAN Tel 86 756 881 98398 AND SE ASIA Fax 86 756 881 9393 Tel 65 9620 3883 sales maxcessintl com cn Fax 65 6235 4818 www maxcessintl com cn asia maxcessintl com JAPAN Tel 81 43 421 1622 Fax 81 43 421 2895 japan maxcessintl com WWwW maxcess jp 2012 Maxcess
18. nt to ensure equal distance between the brake pad and rotor on each side Manually rotate the rotor to verify the rotor does not touch any brake pads during a full rotation Secure the rotor by tightening the two set screws to the torque listed in the Table 1 Install rotor set screws using LOCTITE 266 high temperature high strength threadlocker or equivalent Mount the other caliper mounting half to the machine frame using 4 ea M8x1 25 bolts Tighten bolts to a torque of 40 Nm 29 5 lb ft Install the air lines using 6 mm 0 237 in outside diameter tubing Air supply should be clean and dry and the pressure must not exceed 621 kPa 90 PSI www maxcessintl com MAGPOWR HEB250 High Efficiency Brake MI 850A346 1 Page 10 SVS mN NNS Ani AD For brakes WITHOUT a fan shroud remove the existing 2 ea M4 1 ea M6 screws and nameplate on the caliper mounting halves Install the fan finger guard and the nameplate using the previously removed 2 ea M4 and 1 ea M6 screws as shown in the illustration above For brakes WITH a fan and or proximity sensor install a 12mm 1 2 inch conduit fitting in the fan shroud Route power wires through conduit connector and fan shroud to terminal block on the inside of the fan shroud see electrical installation section for details Connect the wires for the proximity sensor to the terminal strip if used
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