56 143 5TC Coupler Brake Installation Service Instructions
56 143 5TC Coupler Brake Installation Service Instructions
56 143 5TC Coupler Brake Installation Service Instructions
effective 03/25/2005
ELECTRIC MOTORS
GEARMOTORS AND DRIVES
For replacement parts refer to sheet
Installation and Service Instructions part number 8-078-906-07.
Instructions and parts list also avail-
for 56/143-5TC Double C-Face Coupler able at www.rexnord.com/stearns.
Drain Plug
(See Page 4
(WASHGUARD brakes only)
Important position and tag to prevent accidental dust into the air or inhaling it, as this may
Please read these instructions carefully application of power. be dangerous to your health.
before installing, operating, or servicing 4. Make certain power source conforms to a) Wear a filtered mask or a respirator
your brake. Failure to comply with these the requirements specified on the brake while removing dust from the inside of a
instructions could cause injury to personnel nameplate. brake.
and/or damage to property if the brake is 5. Be careful when touching the exterior of b) Use a vacuum cleaner or a soft brush
installed or operated incorrectly. For defini- an operating brake. Allow sufficient time to remove dust from the brake. When
tion of limited warranty/liability, contact for brake to cool before disassembly. brushing, avoid causing the dust to
Leeson Electric Corporation, P.O. Box 241, Surfaces may be hot enough to be become airborne. Collect the dust in a
2100 Washington Street, Grafton, WI painful or cause injury. container, such as a bag, which can be
53024-0241, (262) 377-8810. sealed off.
6. Do not operate brake with housing
Caution removed. All moving parts should be 10. Caution! While the brake is equipped
1. Installation and servicing must be made guarded. with a manual release to allow manual
in compliance with all local safety codes shaft rotation, the motor should not be
7. Installation and servicing should be per-
including Occupational Safety and run with the manual release engaged, to
formed only by qualified personnel
Health Act (OSHA). All wiring and elec- avoid overheating the friction disc(s).
familiar with the construction and opera-
trical connections must comply with the tion of the brake. Warning! Do not apply overhung or side
National Electric Code (NEC) and local load to brake output shaft
8. For proper performance and operation,
electric codes in effect. only genuine Stearns parts should be General Description
2. Do not operate the brake in used for repairs and replacements. The 56,700 Series coupler is a spring-set,
atmospheres containing explosive electrically released brake, containing either
9. After usage, the brake interior will con-
gases or dusts. one or more rotating friction discs (4) driven
tain burnt and degraded friction material
3. To prevent an electrical hazard, discon- by a hub (16) mounted on the motor shaft.
dust. This dust must be removed before
nect power source before working on The double C-face allows the brake to directly
servicing or adjusting the brake.
the brake. If power disconnect point is couple a C-face motor to a C-face gear
DO NOT BLOW OFF DUST using an air reducer.
out of sight, lock disconnect in the off hose. It is important to avoid dispersing
LEESON ELECTRIC P.O. BOX 241 2100 Washington Street Grafton, WI 53024-0241 U.S.A
A Subsidiary of Regal-Beloit Corporation
BRAKE MOUNTING (Manual Adjust)
.188”
(4.77mm)
clockwise
Install new friction disc(s) and
Remove support plate screws and Remove and discard old friction disc.
stationary disc(s) as shown.
lift support from brake
For brakes
with vertical
counter- springs see
clockwise Vertical
Spring
Assembly
Section.
3A * Stabilizer clips
are for use on
Reposition support plate on endplate and
tighten mounting screws to 55 lb-in.
single disc units
only. Position
clips opposite
set screw holes.
clockwise
Note: Friction discs can wear to 1/2 their original thickness, or .093”
2
AIR GAP ADJUSTMENT
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.
Air Gap Settings*
To decrease air gap, turn both adjusting
screws (10) clockwise.
Torque
Torque (lb-ft) 56,X00 Series
3&6 .38” ± .03”
10 & 15 .45” ± .03” clockwise
*For reference only
Insert screwdriver
between support
plate and lever
Lift plunger/solenoid
lever assembly
out of coil.
Remove plunger guide.
TORQUE ADJUSTMENT
Torque Adjustment Table A
3
TROUBLESHOOTING
COIL FAILURE EXCESSIVE WEAR / OVERHEATING
AIR GAP CAUSE AIR GAP CORRECTION
SUPPLY VOLTAGE CAUSE SUPPLY VOLTAGE CORRECTION
Low solenoid air gap Reset air gap (refer to Air Gap
Line voltage >110% of coil rating Reduce voltage or replace with Adjustment)
proper rated coil Disc pack dragging Inspect endplate, hub and discs for dirt,
burrs, wiring and other sources of interfer-
Excessive voltage drop during inrush time Increase current rating of power supply. ence preventing disc “float”
CYCLE RATE CAUSE CYCLE RATE CORRECTION
WIRING CAUSE WIRING CORRECTION
Brake “jogging” exceeding coil cycle rate Reduce cycle rate or consider
Reroute wiring away from plunger and alternate control method
Leadwires interfering with plunger pull-in
other moving components.
Thermal capacity is being exceeded Reduce cycle rate, use alternate control
Excessive voltage drop during inrush time Increase leadwires size from power supply method or increase brake size
ALIGNMENT CAUSE ALIGNMENT CORRECTION
Coil leadwire shorted to ground Replace coil or leadwire and protect with
wire sleeving Broke endplate not concentric to motor Motor register must be within .004” on
C-Face concentricity;
SOLENOID ASSEMBLY Motor shaft runout is excessive Must be within .002”; runout; consult
SOLENOID ASSEMBLY CAUSE
CORRECTION motor manufacturer
Plunger not seating flush against Loosen solenoid mounting screws and Brake is being operated on a incline Vertical separator springs must be used to
solenoid frame reposition frame to allow full face contact greater than 15° above or below prevent discs from becoming cocked
horizontal
Plunger cocked in coil preventing pull-in Realign solenoid frame
WORN PARTS CAUSE WORN PARTS CORRECTION
Excessive solenoid/plunger wear at Friction disc excessively worn (disc can Replace friction discs.
Replace solenoid assembly
mating surface wear to 1/2 original thickness or .093”)
Broken shading coils Replace solenoid assembly Endplate, stationary disc or pressure Replace warped or worn component
plate warped
WORN PARTS CAUSE WORN PARTS CORRECTION
Linkages and/or pivot pins worn Replace all worn components
Excessive wear of solenoid link arm Replace link arm and link bolt; also Motor shaft endfloat excessive Endfloat must not exceed .020”;
and/or shoulder bolt inspect plunger thru-hole for elongation consult motor manufacturer
Plunger guides worn down and interfering Replace guides HUB CAUSE HUB CORRECTION
with plunger movement
Burr on hub interfering with disc “float” File off burr
APPLICATION CAUSE APPLICATION CORRECTION
Set screw backed out and interfering with Retighten set screw; use Loctite® 242 to
Machinery cycle rate is exceeding brake Reduce brake cycle rate or use disc help secure
rating alternate control method
MISCELLANEOUS MISCELLANEOUS
High ambient temperature (>110%) and Use Class H rated coil and /or find
thermal load exceeding coil insulation alternate method of cooling brake Solenoid plunger not pulling completely Check line voltage (±10% of
rating nameplate rating) or replace worn
solenoid assembly
Brake coil wired with windings of an Wire coil to dedicated power source with
Inverter motor or other voltage/current instantaneous coil rated voltage Wiring is restricting disc pack movement Reroute wiring
limiting device Excessive stop time Increase brake size/torque or use alter-
(2 seconds or greater) nate control method
MISCELLANEOUS CAUSE MISCELLANEOUS CORRECTION
High Ambient temperature Reduce cycle rate or use alternate
Wrong or over tightened torque Replace with proper spring or refer to (in excess of 110°F) method of cooling
Installation section for proper spring height
Moisture in brake Remove drain plug (WASHGUARD
Excessive air gap Reset, refer to Installation Section 4 brakes only). After fluid has drained
replace plug
Torque