Stearns DVD Recorder 1 056 X00 User Manual

P/N 8-078-905-60  
effective 03/16/06  
®
Spring-Set Disc Brakes  
For replacement parts refer to sheets:  
Series  
Sheet Part No.  
8-078-906-00  
8-078-906-01  
8-078-906-02  
8-078-906-03  
8-078-906-04  
8-078-906-05  
8-078-906-06  
8-078-906-09  
Installation and Service Instructions  
for 1-056-X00* Series (all revisions)  
Manual Adjust Brakes  
1-056-000  
1-056-100  
1-056-200  
1-056-300  
1-056-400  
1-056-500  
1-056-600  
1-056-900  
This sheet includes Series 1-056,000; 1-056,100; 1-056,200;  
1-056,300; 1-056,400; 1-056,500; 1-056,600 and 1-056,900.  
For other series consult factory.  
*
Also available at www.rexnord.com  
1-056-100  
1-056-600  
a) Wear a filtered mask or a respirator  
while removing dust from the inside  
of a brake.  
b) Use a vacuum cleaner or a soft  
brush to remove dust from the  
brake. When brushing, avoid caus-  
ing the dust to become airborne.  
Collect the dust in a container, such  
as a bag, which can be sealed off.  
1-056-000  
1-056-400  
1-056-500  
1-056-200  
1-056-900  
10. Caution! While the brake is  
equipped with a manual release to  
allow manual shaft rotation, the  
motor should not be run with the  
manual release engaged, to avoid  
overheating the friction disc(s).  
1-056-300  
Tools required for installation and servicing:  
3/8” hex wrench  
5/16” hex wrench  
3/16” hex wrench  
5/16” nut driver  
1/4” screwdriver  
8” adjustable wrench  
General Description  
3. To prevent an electrical hazard,  
disconnect power source before  
working on the brake. If power  
disconnect point is out of sight, lock  
disconnect in the off position and tag  
to prevent accidental application of  
power.  
Typical Nameplate  
These series of brakes are spring-set,  
electrically released. They contain one or  
more rotating friction discs (4) driven by a  
hub (16) mounted on the motor or other  
shaft.  
Operating Principle  
These series contain one or more friction  
discs (4) assembled alternately between  
the endplate (2) friction surface, stationary  
disc(s) (3) and pressure plate (also called  
stationary disc) (3). The stationary disc(s)  
are restrained from rotating by being keyed  
into the endplate. With the brake released,  
all disc pack components are free to slide  
axially and the friction disc(s) to rotate.  
Brake release occurs when the solenoid  
coil is electrically energized, causing the  
solenoid plunger to travel a specified  
distance and through a lever system,  
overcoming the pressure spring force.  
This action releases the clamping force  
on the disc pack, thereby allowing the  
friction disc(s) and brake hub to rotate.  
Brake sets and torque is produced when  
electric current to the solenoid coil is  
interrupted, thereby collapsing the  
solenoid magnetic field. The solenoid  
plunger returns to its original  
de-energized position allowing the lever  
arm to move forward by virtue of the  
compressed torque springs. This action  
compresses the disc pack components  
which applies a retarding torque to the  
brake hub and ultimately restores the  
brake to a spring-set static condition.  
4. Make certain power source conforms  
to the requirements specified on the  
brake nameplate.  
5. Be careful when touching the exterior  
of an operating brake. Allow sufficient  
time for brake to cool before  
disassembly. Surfaces may be hot  
enough to be painful or cause injury.  
6. Do not operate brake with housing  
removed. All moving parts should be  
guarded.  
7. Installation and servicing should be  
performed only by qualified personnel  
familiar with the construction and oper-  
ation of the brake.  
8. For proper performance and  
operation, only genuine Stearns parts  
should be used for repairs and  
replacements.  
9. After usage, the brake interior will con-  
tain burnt and degraded friction mate-  
rial dust. This dust must be removed  
before servicing or adjusting the  
brake.  
Important  
Please read these instructions carefully  
before installing, operating, or servicing  
your Stearns Brake. Failure to comply  
with these instructions could cause injury  
to personnel and/or damage to property if  
the brake is installed or operated incor-  
rectly. For definition of limited warranty/lia-  
bility, contact Rexnord Industries, LLC,  
Stearns Division,5150 S. International Dr.,  
Cudahy, WI 53110, (414) 272-1100.  
Caution  
1. Installation and servicing must be  
made in compliance with all local  
safety codes including Occupational  
Safety and Health Act (OSHA). All  
wiring and electrical connections must  
comply with the National Electric Code  
(NEC) and local electric codes in  
effect.  
DO NOT BLOW OFF DUST using an  
air hose. It is important to avoid  
dispersing dust into the air or inhaling  
it, as this may be dangerous to your  
health.  
2. Do not operate the brake in  
atmospheres containing explosive  
gases or dusts.  
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AIR GAP ADJUSTMENT 1-056-X00  
As friction disc wear the air gap will increase. When plunger gets to the reset position, the air gap must be adjusted.  
To increase air gap, turn both adjusting screws (10) counterclockwise. Use  
To decrease air gap, turn both adjusting  
3/16 hex wrench, or flat screwdriver on older models.  
screws (10) clockwise.  
56,X00 Series Air Gap* (REV A & B)  
Disc Torque Min/Max  
Torque  
1
2
3
1.5, 3 & 6 .38” .69”  
10 & 15 .45” .69”  
20 & 25 .50” .69”  
clockwise  
*
.30”  
56,X00 Series Air Gap* (REV C)  
Disc  
Torque  
3, 6,  
Min/Max  
3/16 hex wrench  
2
3
.45” .69”  
3/16 hex wrench  
counter-clockwise  
10 & 15  
20 & 25 .50” .69”  
Maximum gap should never exceed .69”  
* .30”  
COIL REPLACEMENT SERIES 1-056-X00  
Remove housing and disconnect power and wiring to coil.  
Insert screwdriver between support  
plate and lever arm and pry forward.  
Lift plunger/solenoid  
lever assembly  
out of coil.  
Remove plunger guide.  
A) Re-insert plunger into coil; drop  
pivot pin into cradle of support plate.  
B) Remove screwdriver.  
Discard coil.  
A) Insert new coil. (Lead wires  
in same position as old coil.)  
B) Insert plunger guide.  
A
B
B
A
Reconnect coil and replace housing per installation instructions, page 2.  
VERTICAL SPRING ASSEMBLY 1-056-X00  
Mount support plate and torque screws  
evenly to 55 lb-in.  
Vertical Brake Assembly  
Installation Procedure for 20 and  
25 lb-ft brakes if mounted vertical  
to motor shaft (These brakes are  
Single disc brakes (1.5, 3 & 6 lb-ft) are  
universal mount and do not require  
separator springs. Double disc brakes  
(10-15 lb-ft.) are universal mount but require  
separator springs which are preassembled  
to the stationary disc. These discs are  
inserted spring first into the brake.  
Refer to figure 5A below.  
factory assembled for horizontal operation.)  
Remove support plate by loosening the  
three mounting screws.  
Remove stationary discs and friction discs.  
Using the spring kit provided with this  
brake, insert three springs of identical color  
into each stationary disc hole. Springs are  
inserted from the side opposite the indent  
mark (see Figure 5B). Stationary disc  
should be placed on a clean flat surface  
with a clearance hole to allow the tip of the  
spring to extend through the bottom side of  
the stationary plate. Using the 1/8” pin  
provided and a hammer, drive the spring  
until the large coil diameter bottoms out  
against the disc.  
Figure 5B  
Figure 5A  
Reassemble the disc pack with the  
stationary discs in the proper arrangement  
shown in Figure 5C.  
Figure 5C  
3
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TORQUE ADJUSTMENT  
TABLE A  
Torque Adjustment  
Nominal Original Maximum % Torque  
11  
Brake is factory set for nominal rated static  
torque which is maximum torque. Torque  
may be decreased up to 50% for increased  
stopping times up to 2 second stop time.  
11  
Static  
Torque  
(lb-ft)  
1-1/2  
3
Spring  
Counter-  
Reduction  
per  
Height clockwise  
(inches)  
1.56”  
1.50”  
1.50”  
1.56”  
1.56”  
1.56”  
1.50”  
Turns  
-
Turn  
-
The torque on the 1-1/2 lb-ft brake may not  
be reduced.  
6
10  
10  
10  
15  
20  
25  
5-1/2  
9%  
Turn both spring adjustment screws (11),  
Figure 6, equal amounts counterclockwise  
to decrease torque. See Table A for torque  
reduction permissible amounts.  
Figure 6  
TROUBLESHOOTING  
COIL FAILURE  
SUPPLY VOLTAGE CAUSE  
EXCESSIVE WEAR / OVERHEATING  
AIR GAP CAUSE  
Low solenoid air gap  
AIR GAP CORRECTION  
Reset air gap (refer to Air Gap  
Adjustment)  
Inspect endplate, hub and discs for  
dirt, burrs, wiring and other sources  
of interference preventing disc “float”  
SUPPLY VOLTAGE CORRECTION  
Line voltage >110% of coil rating Reduce voltage or replace with  
proper rated coil  
Disc pack dragging  
AC input on a DC coil  
Replace rectifier or replace with  
proper rated coil.  
Excessive voltage drop during  
inrush time  
Increase current rating of power  
supply.  
CYCLE RATE CAUSE  
Brake “jogging” exceeding coil  
cycle rate  
CYCLE RATE CORRECTION  
Reduce cycle rate or consider  
alternate control method  
WIRING CAUSE  
WIRING CORRECTION  
Reduce cycle rate, use alternate  
control method or increase brake  
size  
Leadwires interfering with plunger Reroute wiring away from plunger  
Thermal capacity is being  
exceeded  
pull-in  
and other moving components.  
Excessive voltage drop during  
inrush time  
Increase leadwires size from power  
supply  
ALIGNMENT CAUSE  
ALIGNMENT CORRECTION  
Broke endplate not concentric to  
motor C-Face  
Motor register must be within  
.004” on concentricity.  
Coil leadwire shorted to ground  
Replace coil or leadwire and protect  
with wire sleeving  
SOLENOID ASSEMBLY  
CORRECTION  
SOLENOID ASSEMBLY CAUSE  
Motor shaft runout is excessive  
Must be within .002”; runout;  
consult motor manufacturer  
Plunger not seating flush against Loosen solenoid mounting screws  
Brake is being operated on a  
incline greater than 15° above or  
below horizontal  
Vertical separator springs must be  
used to prevent discs from  
becoming cocked  
solenoid frame  
and reposition frame to allow full  
face contact  
Plunger cocked in coil preventing Realign solenoid frame  
pull-in  
WORN PARTS CAUSE  
WORN PARTS CORRECTION  
Friction disc excessively worn  
(disc can wear to 1/2 original  
thickness or .093”)  
Endplate, stationary disc or  
pressure plate warped  
Replace friction discs.  
Excessive solenoid/plunger wear Replace solenoid assembly  
at mating surface  
Broken shading coils  
WORN PARTS CAUSE  
Replace solenoid assembly  
Replace warped or worn component  
Replace all worn components  
WORN PARTS CORRECTION  
Excessive wear of solenoid link  
arm and/or shoulder bolt  
Replace link arm and link bolt; also  
inspect plunger thru-hole for  
elongation  
Linkages and/or pivot pins worn  
Motor shaft endfloat excessive  
Endfloat must not exceed .020”;  
consult motor manufacturer  
HUB CORRECTION  
File off burr  
Plunger guides worn down and  
interfering with plunger  
movement  
Replace guides  
HUB CAUSE  
Burr on hub interfering with disc  
“float”  
APPLICATION CAUSE  
APPLICATION CORRECTION  
Set screw backed out and  
interfering with disc  
Retighten set screw; use Loctite®  
242 to help secure  
Machinery cycle rate is exceeding Reduce brake cycle rate or use  
brake rating  
alternate control method  
MISCELLANEOUS  
MISCELLANEOUS  
High ambient temperature  
(>110%) and thermal load  
exceeding coil insulation rating  
Brake coil wired with windings of Wire coil to dedicated power source  
an Inverter motor or other  
voltage/current limiting device  
Use Class H rated coil and /or find  
alternate method of cooling brake  
Solenoid plunger not pulling  
completely  
Check line voltage ( 10% of  
nameplate rating) or replace worn  
solenoid assembly  
with instantaneous coil rated voltage  
Wiring is restricting disc pack  
movement  
Reroute wiring  
MISCELLANEOUS CAUSE  
MISCELLANEOUS CORRECTION  
Increase brake size/torque or use  
alternate control method  
Excessive stop time  
(2 seconds or greater)  
Replace with proper spring or refer  
to Installation section for proper  
spring height  
Wrong or over tightened torque  
Reduce cycle rate or use alternate  
method of cooling  
High Ambient temperature  
(in excess of 110°F)  
Excessive air gap  
Reset, refer to Installation Section 4  
Rexnord Industries, LLC., Stearns Division, 5150 S. International Dr., Cudahy, WI 53110, (414) 272-1100 Fax: (414) 277-4364 www.rexnord.com  
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