EMB-STOP - ICP Wind

www.ktr.com

EMB-STOP

Electromechanical Brake Systems

2

Three letters settingthe world in motion

When competence meets creativity

KTR stands for quality and innovative strength, speed and reliability, flexibility and proximity to customers. As a leading manufacturer of high-quality drive, hydraulic, brake and cooling components we supply our products to satisfied customers all over the world. With more than 50 years of experience in power transmission we are trendsetters in the development of innovative solutions.

Our claim is to not only be a subcontractor, but a solution provider. The knowledge gained from innumerable applica-tions in the field allows us to find optimum, low-cost solu-tions for customized applications. Every year we produce more than 10,000 new developments ordered by custo-mers with a trend increasing continuously.

In addition to the high competence and creativity of our en-gineers, our efficiency is mainly based on the permanently monitored production on KTR’s in-house production lines. This will allow us to assure the high accuracy and quality, ensure a fast and low-cost production, continue to improve our performance and products to be one step ahead to-wards our competitors in the end.

Our personal advice has a part in this advance, too: Our technical sales engineers and our well-trained sales staff are always at your disposal: throughout the world and for every product, including the coupling and cooling systems as well as hydraulic or electromechanical brakes.

On www.ktr.com you will find all details about KTR, the KTR products, their respective 3D-CAD models and assembly instructions.

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Two systems from one single source

Taking over EM Brake Systems in 2013, KTR have con-tinued to extend their competence in the range of brake systems. With the hydraulic KTR-STOP® and the electromechanical EMB-STOP, KTR is the only manufac-turer offering two different brake systems in their portfolio which allows to provide their customers with components or systems tailor-made for their individual demands.

Active and passive brakes

Already in 2011 the engineers of EM Brake Systems de-veloped their own ideas for high-quality electromechani-cal brakes which are specifically suitable for those plants which were designed without any hydraulics. Shortly after-wards the active electromechanical brake having a braking force of 100 kN had its debut in a wind power station. In the subsequent years it was followed by other active and passive brakes having various braking forces and electro-mechanical locking pins.

KTR Competence Center for Brake Systems

In Schloss Holte-Stukenbrock where the headquarters of KTR Brake Systems GmbH are located, KTR’s Compe-tence Center for Brake Systems has settled. In addition to the development and designing of components, exten-sive material and performance testing of the KTR-STOP and EMB-STOP series takes place here, for example in a special cryogenic climatic chamber allowing for tests with ambient temperatures of down to -70 °C.

KTR and EM Brake Systems:Portfolio with a perspective

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Brakes with a system:The new EMB-STOP brake systems

In 2011 the hydraulic brake KTR-STOP was launched onto the market successfully all over the world: One of the most powerful and most resistant brake sys-tems which are currently available in the market. In 2014 KTR offers you an alternative without fluid: the electromechanical brake EMB-STOP.

The electromechanical brakes of the EMB-STOP series generate their clamping power via an electric motor and a motion gearbox located directly on the brake caliper. Since they require 30 to 50 per cent less components than hydraulic brakes, our electromechanical brakes are even more compact, easier to assemble and can be used on numerous applications. Dispensing with the use of hy-draulic drives, the personnel-intensive and cost-intensive replacement and disposal of oil can be done without. EMB-STOP is absolutely maintenance-free, only the brake pads have to be replaced from time to time.

Compact and maintenance-free

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Germany is a world champion, both as a user of wind ener-gy and an exporter of know-how and technology. KTR has a considerable share in this globally accepted expertise: This is not surprising with more than 20 years of expe-rience with wind energy plants around the world.

Perfect for wind and weather

The designing of wind power plants is said to be particu-larly sophisticated from the point of view technology, since the plants never rest: Both material and components are continuously subjected to alternating loads such as per-manent changes of weather and temperature. These ad-verse environmental conditions set high demands on the systems and components.

The electromechanical brakes of the EMB-STOP series were specifically designed for the use in wind power plants: They operate extremely reliably, are free from failu-res or maintenance and are therefore mainly used as rotor brakes. This is not only the case with gearless wind power stations: It goes without saying that EMB-STOP can be perfectly combined with a KTR coupling without much ef-fort.

With EMB-STOP the critical process of engaging the pin is performed via inching operation: The braking force can be finely dosed (inching) to reach the right position quickly and accurately for engaging the pin safely and smoothly.

Leading throughout the world

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EMB-STOP brake systems:Both versatile and variable

KTR supplies the electromechanical brake systems in different designs with a braking power from 50 to 375 kN. The compact design allows for versatile appli-cations not only in wind power technology.

The specific nature of KTR’s electromechanical brakes is the structure of the braking force. It can be dosed smooth-ly and continuously increasing via a sensor until the ma-ximum braking force is reached. Regardless of any basic conditions it is obvious: You can rely on EMB-STOP brake systems for 100 % even with extreme ambient conditions such as intense heat or cold, since temperature-sensitive materials are not used.

Controlled structure of braking force

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Electromechanical brake systems are interesting for nu-merous applications: From wind power technology as well as crane construction and mining, materials-handling technology through to marine and offshore technology, EMB-STOP brakes of KTR are first choice as an efficient and fail-safe system solution.

Looking at the example of marine and offshore technology: On the high seas EMB-STOP brake systems brake anchor windlasses, winches or deck cranes reliably and safely, with severe cold, strong seas or other adverse ambient conditions. We have considered these special demands with the designing and choice of material which we have continuously inspected, elaborated and perfected.

You will have realized: The electromechanical brakes by KTR can be used for multiple purposes. If this is not the case right away, our engineers will find a solution anyway. They combine our approved designing standards with your individual requests for application, in this way creating bra-ke systems which meet with utmost demands both from the point of view design and quality. Challenge us!

One system, innumerable applications There is no such thing as impossible

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Simple. Vigorous. Unique:Your benefits with EMB-STOP

The new EMB-STOP brake systems mainly convince by their high reliability and efficiency. They are a flexi-ble and clean solution for an extremely long operating period with low operating expenses and utmost safety of the plant.

There is one design criterion in KTR: We make all com-ponents as compact as possible to leave you the maxi-mum space. The same applies for the electromechanical EMB-STOP brake systems. The space-saving design allows for high braking force with low weight and compact dimensions while reducing the expenses for transport, sto-rage and installation further.

Eight types, one objective

EMB-STOP brake systems are available as an active floa-ting caliper brake (floater) in two designs (with lever or gearbox, respectively) and three or two sizes, as a passive floating caliper brake with gearbox and Rotor Lock in two sizes. Further types are currently being developed which are only aiming at one objective just like the existing types: Setting new standards on quality and reliability just as you are used to from KTR for some decades.

Optimum design, efficient solution

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The electromechanical EMB-STOP brake systems by KTR convince in many respects and pay off extraordinarily in the long run:

Compact design with 30 to 50 per cent less compo-nents compared to a hydraulic brake

Easy installation with final assembly

Saving of costs and space by doing without the hyd-raulic power pack

Maintenance costs for replacement and disposal of oil can be omitted completely

Maintenance-free, fail-safe system, therefore longer availability of the plant

Higher safety of the plant by reducing the fire hazard

Benefits that pay off

EMB-STOP M-A-F Lever

EMB-STOP L-A-F Lever

EMB-STOP S-A-F

EMB-STOP L-A-F

EMB-STOP S-xx-F

EMB-STOP S-A-F Lever

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0 50 100

150

200

250

300

350

Active floating caliper brakes

Passive floating caliper brakes

EMB-STOPElectromechanical brakes

Summary of clamping forces

You will find continuously updated data in our online catalogue at www.ktr.com

Types of brakeClamping forces (kN)

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Table of contents


EMB-STOP Active floating caliper brakesEMB-STOP S-A-F Lever 12EMB-STOP M-A-F Lever 14EMB-STOP L-A-F Lever 16EMB-STOP S-A-F 18EMB-STOP L-A-F 20

EMB-STOP Passive floating caliper brakesEMB-STOP S-xx-F 22

EMB-STOP Rotor LocksEMB-STOP RL S 24EMB-STOP RL M 25

KTRYour system supplier 26

EMB-STOP S A F A 30

EMB brake Size of brake Active Floater Variation Width of brake disk

12

EMB-STOP S-A-F LeverTotal weight 90 kgWidth of brake pad 25 - 35 mmMax. wear of brake pad each side 4 mmNominal coefficient of friction of brake pad2) µ = 0,4Min. clamping force 30 kNMax. clamping force 50 kNOperating temperature range -30 bis +50 °CMotor power 300 WMotor voltage 230 VACVoltage of electric signals 230 VAC / 24 VDC


1) Tolerances depending on air gap 2) The coefficient of friction each depends on the application or material of the brake pad, respectively. Please consult with KTR.

1)

Technical features Easy replacement of brake pads Mechanical manual operation possible Suitable for harsh ambient conditions Variable setting of clamping force by the manufacturer Common mechanical interfaces available Large pad surface for low surface pressure and low wear

Options Various types of AC and DC drives Individual mechanical interfaces on request Automatic mechanical air gap centering Automatic mechanical wear adjustment on request For low temperature applications down to -40 °C Fail-safe principle with capacitor backup system for emergency

power supply



Ordering example:

Fb = Fc • 2 • µ

Mb = z • Fb • Dav 2

Fb = Braking force [kN]Fc = Clamping force [kN]Mb = Braking torque [kNm]

z = Number of brakesDav = Effective diameter of brake [m]

Calculation of braking force

A

A

A

B

A

B

13

DC max. = DA – 130 DC max. = DA – 105DC max. = DA – 110



Connection dimensions of brake

Optional


Calculation of brake diskØDA = 500 ... 1000 mm ØDA = 1000 ... 1800 mm ØDA = 1800 ... 3000 mm

Various colours available Sensor indicating wear of pad and status Temperature sensor Alternative brake pad materials

EMB-STOP M A F A 40


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EMB-STOP M-A-F LeverTotal weight 115 kgWidth of brake pad 25 - 35 mmMax. wear of brake pad each side 4 mmNominal coefficient of friction of brake pad2) µ = 0,4Min. clamping force 80 kNMax. clamping force 125 kNOperating temperature range -30 bis +50 °CMotor power 300 WMotor voltage 24 VDCVoltage of electric signals 230 VAC / 24 VDC



Fb = Fc • 2 • µ





1)

1)


EMB-STOP M-A-F LeverTechnical features Easy replacement of brake pads Mechanical manual operation Suitable for harsh ambient conditions Variable setting of clamping force by the manufacturer Common mechanical interfaces available Large pad surface for low surface pressure and low wear


power supply

Ordering example:

A

A

A

B

A

B

15

Dav = DA – 130



EMB-STOP M-A-F Lever


Optional


Calculation of brake diskØDA ≥ 800 mm

EMB-STOP L A F A 30


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EMB-STOP L-A-F LeverTotal weight 280 kgWidth of brake pad 25 - 40 mmMax. wear of brake pad each side 5 mmNominal coefficient of friction of brake pad2) µ = 0,4Min. clamping force 125 kNMax. clamping force 375 kNOperating temperature range -30 bis +50 °CMotor power 1100 WMotor voltage 400 VACVoltage of electric signals 230 VAC / 24 VDC



Fb = Fc • 2 • µ





1)


EMB-STOP L-A-F LeverTechnical features Easy replacement of brake pads Mechanical manual operation Suitable for harsh ambient conditions Variable setting of clamping force by the manufacturer Common mechanical interfaces available Large pad surface for low surface pressure and low wear


power supply

Ordering example:

A

AAB

B

A

17

Dav = DA – 130 Dav = DA – 120


EMB-STOP L-A-F Lever


Optional


Calculation of brake diskØDA ≤ 1800 mm ØDA > 1800 mm


EMB-STOP S A F A 30


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EMB-STOP S-A-FTotal weight 90 kgWidth of brake pad 25 - 35 mmMax. wear of brake pad each side 4 mmNominal coefficient of friction of brake pad2) µ = 0,4Min. clamping force 30 kNMax. clamping force 50 kNOperating temperature range -30 bis +50 °CMotor power 250 WMotor voltage 400 VACVoltage of electric signals 230 VAC / 24 VDC



Fb = Fc • 2 • µ





1)


EMB-STOP S-A-FTechnical features Easy replacement of brake pads Mechanical manual operation Suitable for harsh ambient conditions Variable setting of clamping force by the manufacturer Common mechanical interfaces available Large pad surface for low surface pressure and low wear


power supply

Ordering example:

A

A

B

B

A

A

4

B

19

Dav = DA – 130 Dav = DA – 105Dav = DA – 110


EMB-STOP S-A-F


Optional


Calculation of brake diskØDA = 500 ... 1000 mm ØDA = 1000 ... 1800 mm ØDA = 1800 mm


EMB-STOP L A F A 30


20

EMB-STOP L-A-FTotal weight 235 kgWidth of brake pad 25 - 40 mmMax. wear of brake pad each side 8 mmNominal coefficient of friction of brake pad2) µ = 0,4Min. clamping force 125 kNMax. clamping force 375 kNOperating temperature range -30 bis +50 °CMotor power 1100 WMotor voltage 400 VACVoltage of electric signals 230 VAC / 24 VDC


2) The coefficient of friction each depends on the application or material of the brake pad, respectively. Please consult with KTR.

Fb = Fc • 2 • µ






EMB-STOP L-A-FTechnical features Easy replacement of brake pads Mechanical manual operation Suitable for harsh ambient conditions Variable setting of clamping force by the manufacturer Common mechanical interfaces available Large pad surface for low surface pressure and low wear


power supply

Ordering example:

A

AAB

B

A

21

Dav = DA – 130 Dav = DA – 120


EMB-STOP L-A-F


Optional


Calculation of brake diskØDA ≤ 1800 mm ØDA > 1800 mm


EMB-STOP S 40 F A 30


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EMB-STOP S-xx-FTotal weight 93 kgWidth of brake pad 25 - 35 mmMax. wear of brake pad each side 4 mmNominal coefficient of friction of brake pad2) µ = 0,4Min. clamping force 30 kNMax. clamping force 50 kNOperating temperature range -30 bis +50 °CMotor power 250 WMotor voltage 400 VACVoltage of electric signals 230 VAC / 24 VDC



Fb = Fc • 2 • µ





1)


EMB-STOP S-xx-FTechnical features Easy replacement of brake pads Mechanical manual operation Suitable for harsh ambient conditions Variable setting of clamping force by the manufacturer Common mechanical interfaces available Large pad surface for low surface pressure and low wear Fail-safe principle spring-activated

Options Various types of AC and DC drives Individual mechanical interfaces on request Automatic mechanical air gap centering Automatic mechanical wear adjustment on request For low temperature applications down to -40 °C

Ordering example:

A

A

B

B

A

A

4

B

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Dav = DA – 130 Dav = DA – 105Dav = DA – 110


EMB-STOP S-xx-F


Optional


Calculation of brake diskØDA = 500 ... 1000 mm ØDA = 1000 ... 1800 mm ØDA = 1800 ... 3000 mm


FL = Lateral force [kN]

ML = Locking torque [kNm]

z = Number of Rotor Locks

Deff. = Pitch circle diameter of locking disk [m]

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EMB-STOP RL SMax. stroke (h) 75 mm Motor power 1100 kWMax. lateral force1) 2000 kN Motor voltage 230 / 400 VACAxial force fore stroke F+ 160 kN Voltage of electric signals 230 VAC / 24 VDCAxial force back stroke F– 160 kN Speed with 50 Hz 160 mm/min.Total weight approx.2) 150 kg Size of industrial connector Han10B / HAN18EE (male)

EMB-STOP RL S S A1) 697

EMB-Rotor Lock Size of Rotor Lock Variation Mounting length (L)

EMB-STOP RLRotor Lock

EMB-STOP RL S

Connection dimensions

Technical features Rotor Lock for wind power stations Easy assembly Mechanical manual operation possible Suitable for harsh ambient conditions Electric interface via industrial connector Mechanical terminal position detection Signal generation via safety limit switch

Options Larger stroke on request Individual mechanical interfaces on request Force sensitive engagement of pin Fully mechanical design on request Various types of AC drives For low temperature applications down to -40 °C


Ordering example:

1) Please note that the lateral force refers to the Rotor Lock only.2) Weight with L = 355.

1) A = automatic

min

Deff 2ML = z FL

Technical features Rotor Lock for wind power stations Easy assembly Mechanical manual operation possible Suitable for harsh ambient conditions Electric interface via industrial connector Mechanical terminal position detection Signal generation via safety limit switch

Options Larger stroke on request Individual mechanical interfaces on request Force sensitive engagement of pin Fully mechanical design on request Various types of AC drives For low temperature applications down to -40 °C

Deff 2ML = z FL

25

EMB-STOP RL MMax. stroke (h) 75 mm Motor power 1100 kWMax. lateral force1) 4000 kN Motor voltage 400 VACAxial force fore stroke F+ 160 kN Voltage of electric signals 230 VAC / 24 VDCAxial force back stroke F– 160 kN Speed with 50 Hz 160 mm/min.Total weight approx.2) 190 kg Size of industrial connector Han10B / HAN18EE (male)

EMB-STOP RL M M A1) 355

EMB-Rotor Lock Size of Rotor Lock Variation Mounting length (L)

FL = Lateral force [kN]

ML = Locking torque [kNm]

z = Number of Rotor Locks

Deff. = Pitch circle diameter of locking disk [m]

Connection dimensions

EMB-STOP RLRotor Lock

EMB-STOP RL M


Ordering example:

1) A = automatic

1) Please note that the lateral force refers to the Rotor Lock only.2) Weight with L = 355.

min

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KTR-STOP®

Coupling with brake disk

EMB-STOP

Stand

Hydraulics

Everything from one single source.KTR – Your system supplier

EMB-STOP

EMB-STOP is the new electromechanical brake system of KTR. It is absolutely maintenance-free and fail-safe, even with extreme temperatures.

KTR-STOP®

KTR is the hydraulic brake system of KTR. It is perfect for applications with high forces and adverse environmental conditions.

Hydraulics

The brake calipers of KTR-STOP are activated via the hy-draulic power pack. For that purpose we provide for power packs with solid components for a reliable use under har-dest conditions.

Coupling with brake disk

KTR manufacture drive components for numerous indus-trial applications. Our couplings are often supplied along with an integrated brake disk.

Stand

The steel plate serves for supporting the EMB-STOP and KTR-STOP brake systems and is adapted to the individual application by KTR.

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Belgium/LuxembourgKTR Benelux B. V. (Office Belgium)Blancefloerlaan 167/22BE-2050 AntwerpenPhone:Fax:E-mail:

+32 3 2110567+32 3 [email protected]

BrazilKTR do Brasil Ltda.Rua Jandaia do Sul 471 - Bairro Emiliano Perneta Pinhais - PR - Cep: 83324-440BrasilPhone:Fax:E-mail:

+55 41 36 69 57 13+55 41 36 69 57 [email protected]

ChinaKTR Power Transmission Technology(Shanghai) Co. Ltd. Building 1005, ZOBON Business Park999 Wangqiao RoadPudongShanghai 201201ChinaPhone:Fax:E-mail:

+86 21 58 38 18 00+86 21 58 38 19 [email protected]

Czech RepublicKTR CR, spol. s. r. o.Olomoucká 226CZ-569 43 JevíckoPhone:Fax:E-mail:

+420 461 325 162+420 461 325 [email protected]

FinlandKTR Finland OYTiistinniityntie 4FI-02230 EspooPL 23SF-02231 EspooPhone:Fax:E-mail:

+358 2 07 41 46 10+358 2 07 41 46 [email protected]

FranceKTR France S.A.R.L.46–48 Chemin de la BruyèreF-69570 DardillyPhone:Fax:E-mail:

+33 478 64 54 66+33 478 64 54 [email protected]

Great BritainKTR Couplings Ltd. Robert HouseUnit 7, Acorn Business ParkWoodseats CloseSheffieldEngland, S8 0TBPhone:Fax:E-mail:

+44 11 42 58 77 57+44 11 42 58 77 [email protected]

IndiaKTR Couplings (India) Pvt. Ltd.,T-36 / 37 / 38, MIDC BhosariPune 411026IndiaPhone:Fax:E-mail:

+91 20 27 12 73 22+91 20 27 12 73 [email protected]

ItalyKTR Kupplungstechnik GmbHSede senza rappresentanza stabile sul Territorio NazionaleVia Fermi, 25IT-40033 Casalecchio di Reno (BO)Phone:Fax:E-mail:

+39 051 613 32 32+39 02 700 37 [email protected]

JapanKTR Japan Co., Ltd.3-1-23 DaikaidoriHyogo-ku, Kobe-shi652-0803 JapanPhone:Fax:E-mail:

+81 7 85 74 03 13+81 7 85 74 03 [email protected]

KTR Japan – Tokyo Office1-11-6, Higashi-Ueno, Taito-Ku,Tokyo 110-0015 Japan(Takeno-building, 5F)JapanPhone:Fax:

+81 3 58 18 32 07+81 3 58 18 32 08

KoreaKTR Korea Ltd.# 101, 978-10, Topyung-DongGuri-City, Gyeonggi-Do471-060 KoreaPhone:Fax:E-mail:

+82 3 15 69 45 10+82 3 15 69 45 [email protected]

NetherlandsKTR Benelux B. V.Postbus 87NL-7550 AB Hengelo (O)Adam Smithstraat 37NL-7559 SW Hengelo (O)Phone:Fax:E-mail:

+31 74 2553680+31 74 [email protected]

NorwayKTR Kupplungstechnik Norge ASFjellbovegen 13NO-2016 FrognerPhone:Fax:E-mail:

+47 64 83 54 90+47 64 83 54 [email protected]

PolandKTR Polska SP. Z. O. O.ul. Czerwone Maki 65PL-30-392 KrakówPhone:Fax:E-mail:

+48 12 267 28 83+48 12 267 07 [email protected]

RussiaKTR Privodnaya technika, LLC6 Verhnii Pereulok 12Litera A, Office 229194292 St. PetersburgRussiaPhone:Fax:E-mail:Internet:

+7 812 383 51 20+7 812 383 51 [email protected]

SpainKTR Kupplungstechnik GmbHc) Estartetxe, n° 5 – Oficina 218ES-48940 Leioa (Vizcaya)Phone:Fax:E-mail:

+34 9 44 80 39 09+34 9 44 31 68 [email protected]

SwedenKTR Sverige ABBox 742SE-191 27 SollentunaPhone:Fax:E-mail:

+46 86 25 02 90+46 86 25 02 [email protected]

SwitzerlandKTR Kupplungstechnik AGBahnstr. 60CH-8105 RegensdorfPhone:Fax:E-mail:

+41 4 33 11 15 55+41 4 33 11 15 [email protected]

TaiwanKTR Taiwan Ltd.1 F, No.: 17, Industry 38 RoadTaichung Industry ZoneTaichungTaiwan, R. O. C.Phone:Fax:E-mail:

+886 4 23 59 32 78+886 4 23 59 75 [email protected]

TurkeyKTR TurkeyGüç Aktarma Sistemleri San. ve Tic. Ltd. Sti.Kayışdagı Cad. No: 117/2 TR-34758 Atasehir -İstanbulPhone:Fax:E-mail:

+90 216 574 37 80+90 216 574 34 [email protected]

USAKTR Corporation122 Anchor RoadMichigan City, Indiana 46360USAPhone:Fax:E-mail:

+1 2 19 8 72 91 00+1 2 19 8 72 91 [email protected]

KTR worldwide:

Thomas WienkotteDipl.-Ing. (FH) Head of Sales BrakesPeter-Schumacher-Straße 102D-50171 KerpenPhone: +49 2237 971796Fax: +49 2237 971795Mobile: +49 172 5859448E-mail: [email protected]

Headquarters:KTR Kupplungstechnik GmbHPostfach 1763D-48407 RheinePhone: +49 5971 798-0Fax: +49 5971 798-698 und 798-450E-mail: [email protected]: www.ktr.com

KTR Brake Systems GmbHCompetence Center for Brake SystemsZur Brinke 14D-33758 Schloss Holte-StukenbrockPhone: +49 5207 99161-0Fax: +49 5207 99161-11

KTR Kupplungstechnik GmbHPostfach 17 63D-48407 RheineTelefon: +49 5971 798-0Telefax: +49 5971 798-698 u. 798-450E-Mail: [email protected]: www.ktr.com

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EMB-STOP - ICP Wind

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Transcript of EMB-STOP - ICP Wind