SM429gb - rev 06/11

S Electrically Released Brakes

E
R ERS VAR11-01 FT = 4100 N
V
I
C
E

M
A
N
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L

EC type certificate ABV 775/1

TUV
According to drawing 1 12 106946 SUD

Industrie Service

WARNER ELECTRIC EUROPE

Rue Champfleur, B.P. 20095, F- 49182 St Barthélemy d’Anjou Cedex
Tél. +33 (0)2 41 21 24 24, Fax + 33 (0)2 41 21 24 00
www.warnerelectric-eu.com
 Declaration of conformity:
During the design of this product, the EU directives applicables were taken into account.
An attestation of conformity is available on request.
For Incorporating the product, the manufacturer of a machine or system need to take into account the EU
directives applicables.

Summary of the directives and standards used:

Directives:
2006/95/EC Low voltage equipment directive 95/16/EC Lifts directive
2004/108/EC Electromagnetic compatibility directive
Standards:
DIN VDE 0580 Electromagnetic devices and components, General requirements
EN 81-1 Safety rules for the construction and installation of lifts - Part 1: Electric lifts
NFC 79300 Industrial electrical apparatus. Electromagnetic apparatus for mechanical applications. Requirements.

CONTENTS
1 Technical specifications 2 4 Maintenance 4
2 Precautions and restrictions on use 3 4.1 Adjusting the airgap 4-5
2.1 Restrictions on use 3 4.2 Adjusting the microswitch 5
2.2 Precautions and safety measures 3 4.3 Brake exchange 5
3 Installation 3 5 Electrical connection 6
3.1 Transport - storage 3 5.1 Important recommendations 6
3.2 Handling 3 5.2 Grounding 6
3.3 Montage 3-4 5.3 Connector / free wires 6
3.3.1 Hand lever configuration 4 6 Spare parts 7
3.3.2 Installation 4 7 Tools 7
8 Troubleshooting 7

1 Technical specifications
Airgap
Hand release

Grounding
screw M5

Friction Counter-
pads nuts Screws
for airgap
adjustment

Detection screw,
stroke measure
Customer’s
Fig. 1 Fig. 2 friction disc
Holes for mounting pins
Table 1
Warner Electrie Reference ERS VAR11-01 FT = 4100 N
Nominal static torque Nm (See curve on customer’s drawing)
Maximum linear speed m/s 10 (outside diameter of the disc)
Nominal airgap mm 0,35
Maximum airgap after wear mm 0,6
Overexcitation voltage (+5% /-10%)(1sec) VDC 103,5 207
Holding voltage (+5% /-10%) VDC 52 103,5
Power (holding) (20°C) W 44,4 51
Power (overexcitation) (20°C) W 176 204
Cyclic duration factor (%) ED 60
Weight kg 14,3
Maximum force on the hand lever N 1000
WARNER ELECTRIC EUROPE - Rue Champfleur, B.P. 20095, F - 49182 St Barthélemy d’Anjou Cedex SM429gb - rev 06/11 2/7
 Symbol designating Symbol designating an Symbol designating an elec-
an action that might action that might be dan- trical action that might be
damage the brake gerous to human safety dangerous to human safety

2 Precautions and restrictions on use 2.2 Precautions and safety measures

2.1 Restrictions on use ● During maintenance, make sure that the mechanism
to be braked by the brake, is stopped and that
● For the brake to comply with directive 95/16/ EC, there is no risk of it accidentally starting up. All
the integrator must observe the general intervention have to be made by qualified personnel,
conditions for installation, as stated in the EC owning this manual.
type-examination certificate ref. ABV775/1 of
03/05/2010 from TÜV SÜD Industrie Service. ● Any modification made to the brake without the
● These brakes are designed to work in dry condi- express authorisation of a representative of
tions. Any contact with oil, grease, water or Warner Electric, in the same way than any use
abrasive dust causes a decrease in torque. out of the contractual specifications accepted
Warning : It is the responsibility of the by "Warner Electric", will result in the warranty
customer to install the necessary protection to being invalidated and Warner Electric will no
prevent pollution of the friction surfaces and to longer be liable in any way with regard to
ensure that these same friction surfaces are conformity.
thoroughly degreased and clean before mounting
the brake.
● Torque subject to decrease in case of water 3 Installation
contamination.
Warning : brake must be replaced after water 3.1 Transport / storage
contamination.
● This product is not suitable for use according to These devices are delivered in a package guaran-
ATEX/94/9/EC. teeing the preservation of the product providing it
● These units are designed for use in an ambiant is by surface transportation.
temperature between 0° C and +40° C maximum. In case of a specific request (air or sea transport, long-term
Warning : at low temperature, any freezing of storage, etc) contact our factory.
the friction face, due to condensation, generates
a loss of torque. It is the responsability of the
customer to take measures to avoid this problem. 3.2 Handling

● It is mandatory to follow instructions and datas ● Avoid any impact to the brake so that its
given in documentation and marking of the units, performance is not impaired.
in order to ensure the performance of
the brake. ● Never lift the brake by its cables
● This brake may only be used in a “horizontal
axis”. The customer must be careful not to alter
the factory-set airgap and the working clearance 3.3 Installation mounting
of the brake and the hand lever.
● Protection class: ● In case of long storage, check the brakes, before
Mechanical : IP10 setting the drives, in order to avoid, in case of
Electrical : IP54 large temperature variation, any risk of sticking
● Insulation class: F 155 °C from the friction material, able to hindrance the
● This brake is designed for static applications. Any start of the drive.
dynamic braking is restricted to emergency
braking and test braking. This brake can in no ● Data for customer friction disc:
way replace the safety braking system used Material: steel (150 to 250 HV) or cast iron,
during lift descent. thickness of the friction disc: 15 mm +0/-0,1,
● Nominal torque is reached by burnishing of roughness of the friction faces: Ra ≤ 1,6.
brake in customer plant. Recommended: Protection: dry phosphatizing or Nitriding.
permanent sliding 11 RPM during 300 s.
● If maximum rotation speeds are exceeded, the Geometric tolerances:
guarantee is no longer valid.
● When switching on DC-side the coil must be 0,1 Friction face / Pulley axis
protected against voltage transients. 0,1

WARNER ELECTRIC EUROPE - Rue Champfleur, B.P. 20095, F - 49182 St Barthélemy d’Anjou Cedex SM429gb - rev 06/11 3/7
 Data for mounting pins: • Engage the brake, armature attracted under voltage
Material: steel (min. 900 N/mm2), diameter 25h8, or with hand release, on his disc.
roughness: Ra ≤ 0.8.
Protection: dry phosphatizing or Nitriding • Mount the mounting pins, then the connecting bar and
tighten with the indicated torque for the locknuts.
0,1 Support axis / Pulley axis

3.3.1 Hand lever configuration 4 Maintenance

According to the hand lever side of actuation, the custo- 4.1 Adjusting the airgap
mer must fit the pins, for limitation of the hand lever travel,
in the selected position. Dimension of the pin out of the Check the airgap at each maintenance inspection.
magnet: 6 max. (see Fig. 7).
Release right
Reminder: This brake is intended for a static appli-
cation as a safety brake. Any dynamic braking is
restricted to emergency and test braking. Normal use will
not lead to any noticeable wear on the lining.

The airgap adjustment must be reset before

the max. airgap is reached. This to eliminate
any functional problems because of the hand release
travel.

• Slide two feeler gauges 0,3 mm thick in the airgap,

Fig. 3a avoiding the dampers, between the armature and the
Release left magnet (Fig. 5).

• Energize magnet.
Screw
Friction Nut
pad

Armature
Disc
Fig. 3b
Airgap

3.3.2 Installation
Feeler
gauge
The brake is delivered pre-assembled with pre-set Feeler
microswitches and airgaps. gauge
Hand
release Connecting bar

Counter-
nut

Fig. 5

• Tighten the airgap adjusting screws H M12 (18 A/F),

until you reach contact, with a torque of 2 Nm.

Mounting
• Tighten the counter nut (18 A/F) with a torque of
pins 40 Nm ± 4 Nm in holding the screw to avoid it rotating.

Disc
Screws for airgap adjustment
Fig. 4

WARNER ELECTRIC EUROPE - Rue Champfleur, B.P. 20095, F - 49182 St Barthélemy d’Anjou Cedex SM429gb - rev 06/11 4/7
Checking airgap area, see Fig. 6. Microswitch connection :

Checking airgap According to versions, the brake is supplied either with a

area male connector, or with free wires of 1500 mm length (see
chapter 5.3).

• Normally closed
(Connector version)

• Normally closed or normally opened, with the choice.

(free wires version)
Red
"NC"
Black
Blue
"NO"

4.3 Brake exchange

All works on the electrical connections have to be

made with power off.

Fig. 6 During maintenance, make sure that the mechanism

to be braked by the brake, is stopped and that
there is no risk of it accidentally starting up. All intervention
4.2 Adjusting the microswitch have to be made by qualified personnel, owning this manual.

Slide a wedge 0,10 mm thick close to the screw between • Disconnect the electrical connection, of the brake.
the face of the magnet and the moving armature. Switch
on the current and tighten the adjusting screw H M5 (8/flat) • Remove the brake.
in contact with the microswitch until you reach the com-
mutation point. Check that it functions correctly by a few • Clean the friction surfaces with a clean dry doth.
successive draws and releases (see Fig. 7).
Fit again a 0,10 mm thick gauge and check if the adjust- These brakes are designed to work in dry conditions.
ment is stable. Fit a 0,15 mm thick gauge and check that Any contact with oil, grease, water or abrasive dust
the microswitch is not actuated. causes a decrease in torque.

Detection Detection screw, • Mount the new brake, following the instructions in
screw Airgap stroke measure
chapter 3.3.
Microswitch
Warning: after replacement, it is necessary to
Pin: make a dynamic braking test, in order to validate the
6 max. installation.
see
Nut 3.3.1

Fig. 7

Operation microswitch

Current range 10 mA min. to 100 mA max. at 24 VDC

Maximum electrical lifetime of the microswitch ensure only

by switching under resistive load.

WARNER ELECTRIC EUROPE - Rue Champfleur, B.P. 20095, F - 49182 St Barthélemy d’Anjou Cedex SM429gb - rev 06/11 5/7
5 Electrical connection Microswitch

Brake ERS VAR11-01 operates on a direct current supply. Coil

Polarity does not affect the way the brake operates.

5.1 Important recommendations

All works on the electrical connections have to be

made with power off.

Make sure that the nominal supply voltage is always

maintained. A lack of power results in a reduction
to the maximum airgap.

Emergency braking : for emergency braking the

switching OFF must be connected on DC current
side, in order to obtain short engaging time of the brake.

Service braking : for service braking, the switching OFF

and the switching ON must be connected on AC current
side, in order to obtain silent switching.

The connecting wires must be thick enough to help prevent

sudden drops in voltage between the source and the brake. Fig. 8

Length of cable 0 to 10 m from 10 to 20 m

Cross section 1,5 mm2 2,5 mm2 • The brake version with free wires is supplied with conduit
box where it is possible to connect a protective sheath.
Tolerances on the supply voltage at the brake terminals
+5% / -10% (NF C 79-300).
When connecting the conduits on the conduit box
( Fig. 9), the customer must avoid any restraint,
5.2 Grounding able to prevent the self-floating of the brake.

To be compliant with VDE 580, the customer must ground Conduit box
the brake (see Fig. 1). Grounding screw and safety washer
supplied.

5.3 Connector / free wires

According to versions, the brake is supplied either with a

male connector (Fig.8), which is linked to the coil and the
microswitch, or with free wires of 1500 mm length (Fig. 9).

Male connection supplied with the brake

AMP male connector ref : 003507791
AMP contact ref. 926-894-1

Female connection (not supplied) :

AMP female connector ref : 003507801
AMP contact ref. 926-893-1 (indicative) Protective
sheath
Fig. 9 connection

WARNER ELECTRIC EUROPE - Rue Champfleur, B.P. 20095, F - 49182 St Barthélemy d’Anjou Cedex SM429gb - rev 06/11 6/7
6 Spare parts

Part
Friction pads Thank you to join to your request for spare part, the reference and the part number of the brake, (see
Microswitch example below).
Date of the
Nominal voltage Power manufacture Reference Tangential force

/----

Part number of the brake 95/16/EC certification by the

Batch of production Serial number TÜV SÜD Industrie Service

7 Tools

Tools Function
Feeler gauge Airgap & microswitch adjustment
Open jawed spanner 18 mm A/F Airgap adjustment
Torque wrench (measurement range > 50 Nm) with open ended spanner attachement 18 mm A/F Airgap adjustment
Open jawed spanner 8 mm A/F Microswitch adjustment
Multimeter Voltage checking

8 Troubleshooting and fault elimination

Troubleshooting
Fault Cause Remedy

Brake does not • Supply voltage too low • Check and adjust supply voltage
release • Power supply is interrupted • Reconnect power supply, check the adjustment of microswitch
• Airgap too large • Re-adjust the airgap (chapter 4.1)
• Worn friction pads • Replace pads
• Coil is damaged • Replace the brake
• Airgap too small • Re-adjust the airgap (chapter 4.1)
• Overexcitation time too short • Increase overexcitation time

Brake does not • Voltage present at switch off position • Check the microswitch’s adjustment and the customer’s
engage power supply
• Grease on friction faces • Clean the disc and replace the brake
• Hand release lever actuated • Release the lever
Nuisance braking • Holding voltage too low • Check and adjust the holding voltage
• State of microswitch incorrect • Re-adjust the microswitch

Subject to alteration without prior notice

WARNER ELECTRIC EUROPE - Rue Champfleur, B.P. 20095, F - 49182 St Barthélemy d’Anjou Cedex SM429gb - rev 06/11 7/7