Dings 70 Series User manual

BULLETINNO.BK4603
DATE8/94
4740WESTELECTRICAVENUEŸMILWAUKEE,WI53219Ÿ(414)6727830 ŸFAX(414)6725354
1 
DIRACTBRAKES
70&80SERIES
INSTRUCTIONS
IMPORTANT
Readthisbulletincarefullybeforeinstallingoroperating
this brake. Failure to comply with these instructions
cancelsallwarrantiessincethesafetyoftheunitmaybe
endangered by improper installation or operating
procedures.
DESCRIPTION
Thisbrake is direct acting, electromagneticallyreleased
and spring set.  It uses rotating and stationary disc
contact to supply positive braking action.  It retains
quickreleaseandsettingcapabilitiesataltimes
Simplicity of design has reduced maintenance to an
absolute minimum.  As with any electromechanical
equipment,however,periodicinspectionandadjustment
willassure optimumperformance.  Asthe friction disc
wears, the magnet gap will increase.  The magnet gap
should be checked periodically and adjusted when
necessary.
INSTALLATION
RefertoFigures3&5,Tables1,2&4
Figure1illustratesDiractbrakeswithastandardmanual
release.Thisreleaseconsistsoftworodsvisiblethruthe
cover.  An optional release, the Mark II, has a single
leverasshowninFigure4.
1. Remove hub (1) from brakeand position on motor
shaft with key according to dimension “N”.
Stampedpartnumberonhubshouldfaceawayfrom
motor.  Tighten hub set screws with 12 ft. lbs.
torque.  On Mark II release models, motor shaft
shouldnotextendbeyondhub.
2. Removecoverscrews(24)andcover(23),plus“O”
ring (28) and gasket (32) on enclosed housing
models. OnMarkII models, moverelease lever to
horizontalposition.Removecover.
3. Place brake on motor, guiding discs on hub.  On
MarkIImodels,thereleaselevershouldhangdown.
Thereleasemechanism isresetbygravity.
4. Boltbrake to motor “C” face withfoursockethead
cap screws.  See Tables 1 and 2, and Figure 3 for
screwsize.
5. Connectcoilleadsperappropriatewiringdiagramin
Figure2andreplacecover.
WARNING
Brake performance and features must be carefully
matchedtotherequirementsoftheapplication.
Considerationmustbegiventotorquerequirements,
especially where an overhauling condition exists, as
well as thermal capacity, ambient temperature,
atmosphericexplosionhazards,typeofenclosureand
anyotherunusualconditions.
Improperselectionandinstallationofabrakeand/or
lack of maintenance may cause brake failure which
could result in damage to property and/or injury to
personnel.
If injury to personnel could be caused by brake
failure,additional means must beprovidedtoinsure
safetyofpersonnel.
Donotoperatemanualreleaseorenergizebrakecoil
beforeinstallation,inorderto preserveprealignment
ofrotatingdiscsforeaseofinstallation.

BULLETINNO.BK4603
DATE8/94
4740WESTELECTRICAVENUEŸMILWAUKEE,WI53219Ÿ(414)6727830 ŸFAX(414)6725354
2 
MANUALRELEASEOPERATION
RefertoFigures4&5
To operate standard release (Figure 5), rotate two rods
(10)clockwiseuntilstopscrew(14)hitspin.Tooperate
Mark II release (Figure 4), push lever (12) to upward
position.Brakewillremaininrelease position untilrods
or lever are manually returned to original position, or
until electrical power is restored which automatically
resetsthebrake.
TORQUEADJUSTMENT
RefertoFigures3&5,Tables1or2
Brake is factory set for rated torque per spring length
“H”.  To increase stopping time and lower torque, turn
two locknuts (9) counterclockwise, increasing
dimension “H”.  Both spring lengths should be equal.
Donotdecreasespringlength “H”asthismaycausecoil
toburnout.

BULLETINNO.BK4603
DATE8/94
4740WESTELECTRICAVENUEŸMILWAUKEE,WI53219Ÿ(414)6727830 ŸFAX(414)6725354
3 
MAINTENANCEANDSERVICE
WEARADJUSTMENT
Referto Figures3&5,Tables1or2
Magnet gap “D” increases as the rotating friction discs
wear. Whengapapproaches“D”max.,adjustgaptothe
“original setting” listed under “D” by turning nuts (21)
and (22).  The “original setting” is also the minimum
allowed.
Too small a gap will not provide the proper running
clearance, and will cause excessive wear and
overheatingoftherotatingfrictiondisc.Themagnetgap
canvaryfrom“originalsetting”±.005betweencorners.
After setting gap, readjust torque spring length per
dimension “H”.
CAUTION:MAGNETGAPMUSTNOTEXCEED
“D”MAXIMUM.
FRICTIONDISCREPLACEMENT
RefertoFigures3,4&5.Tables1or2
Whenrotating frictiondisc(4)wearsdowntoa
thicknessof7/32”,replacedisc.
1. Removecoverscrews(24)andcover(23),plus“O”
ring(28)andgasket(32)onenclosedmodels.
2. Standardreleasemodel:Unhookloopoftorsion
springs(11)frompinsatrearofmagnetplate(16).
Removereleasestopscrews(14)washers(12)and
shims(13).SeeFigure5.MarkIIreleasemodel:
Removecotterpin(13)andreleaselever(12).See
Figure4.
3. Removeadjustinglocknuts(22)magnetassembly
(16),adjustingnuts(21),torque nuts(9),washers
(8),torquespring(7)andpressureplate(6).
4. Removefrictiondisc(4)andstationarydisc(5).
Replacewornfrictiondiscs.
5. Reassembleallpartsinreverseorder.Setspring
length “H”andmagnetgap“D”.Assemblemanual
release.Seefollowingparagraph.
MANUALRLEASEASSEMBLY
RefertoFigures3,4&5
Whenassemblingastandardmanualreleasemechanism
(Figure5),add onlyenoughshim washers(13)toobtain
properreleaseaction.Toomanyshim washerswill
preventautomaticresetwhenelectricalpowerisapplied.
Toofewwasherswillpreventthemotorshaftfrom
turningfreely.Replacesopscrews(14).Windeach
torsionspring(11)approximately ¼ turnandhook
springloopoverpin.
WhenassemblingaMarkIImanualreleasemechanism
(Figure4),attachlever(12)toreleaserod(1)withpin
(11)andcotterpins(13).Withlever(12)inraised
position,rotateleveruntilpressureplate(6)makes
contactwithmagnetassembly(16)closinggap“D”.
Lowertheleverandturn counterclockwise ¼ turn.The
levershouldnowhangdown,andifnot,removelever
andrelocateitascloseaspossibletodownpositionas
holesinrod(10)allow. The levermusthangdown
because resetisbygravity(verticalmountedbrakeshave
returnsprings).
Tocheckreleaseaction,raiselever.Motorshaftshould
turnfreely.Applypower.Levershouldreturntodown
position automatically. Ifshaftdoesnotturnfreely,turn
leverclockwise ¼ turn.Relocatelevertodownposition.
Ifleverdoesnotreturnautomatically,turnlever
counterclockwise ¼ turn.Relocatelevertodown
position.

BULLETINNO.BK4603
DATE8/94
4740WESTELECTRICAVENUEŸMILWAUKEE,WI53219Ÿ(414)6727830 ŸFAX(414)6725354
4 

BULLETINNO.BK4603
DATE8/94
4740WESTELECTRICAVENUEŸMILWAUKEE,WI53219Ÿ(414)6727830 ŸFAX(414)6725354
5 

BULLETINNO.BK4603
DATE8/94
4740WESTELECTRICAVENUEŸMILWAUKEE,WI53219Ÿ(414)6727830 ŸFAX(414)6725354
6 
MAGNETCOILREPLACEMENT
Refertofigures5&6.
RemovemagnetassemblyasoutlinedunderFRICTIONDISC
REPLACEMENT.
Coils(18)areheldinplacewithepoxycement. Force coil offmagnet
mountingplateandremoveexcessepoxyfromallsurfaces.
Replacementcoilsshouldbeheldinplacewithnewepoxycement. The
epoxycementshouldbeheatresistantandshockresistant.Placean
insulatingwasher(19or19a)belowthecoils.Orderinsulatingwashers
whenorderingcoils.Aninsulation washercanbecuttosuitwhen
replacingonlyonecoilon amultiplecoilassembly.
Wheninstallingcoils,itisveryimportanttofollowEXACTLYthe
sequenceofblackandlightcoloredleadsasshowninwiringdiagram
(Figure2).Thebrakewillnotoperateproperlyunlesscoilsareallinthe
correctposition.

BULLETINNO.BK4603
DATE8/94
4740WESTELECTRICAVENUEŸMILWAUKEE,WI53219Ÿ(414)6727830 ŸFAX(414)6725354
7 
TROUBLESHOOTING
A. IFBRAKEDOESNOTRELEASE:
1. Checkbrakevisuallyforbrokenordamaged
parts.
2. Checkforbroken leadwireorbadelectrical
connection.
3. Checkforcorrectvoltage.Linevoltagemust
correspondtothevoltageforwhichthebrake
coilsareconnected.Ifthelinevoltageismore
than10%belowthevoltageforwhichthebrake
coilsareconnected,themagnetwillnotpullin,
causingthecoilstoburnoutwithinminutes.If
thelinevoltageismorethan10%above the
voltageforwhichthebrakecoilsareconnected,
thecoilswilloverheatandburnout.
4. Checkforburnedoutcoils(coilsmaybecharred
orburned).
5. Checkforexcessivemagnetgap.(SeeWEAR
ADJUSTMENT.)
6. Checkforfailureofpowersupplytobrake.
B. IFBRAKEDOESNOTSTOP:
1. Checkbrakevisuallyforbrokenordamaged
parts.
2. Makecertainhubhasnotshiftedpositiononthe
motorshaftandthatallrotatingdiscsarefully
engagedonthehub.
3. Check thatthemanual release isinthenormal
position.
4. Check discwear.(SeeWEAR
ADJUSTMENT).
C. IFBRAKECHATTERSORHUMS:
1. Seethatmagnetfacesareclean.Toremovedirt,
insertacleansheetofpaperbetweenmagnet
facesandenergizebrake.Movepaperaround
betweenfacestodislodgedirt,thenremove
paper.
2. Checkforlowvoltage.Magnetwillnotpullin,
andcoilswillburnoutiflinevoltageisbeyond
10%below thevoltagethebrakecoilsare
connectedfor.
3. Seethatmagnetfacesareparallelwithin
tolerance.Readjustmagnetgapto “D”min.
(SeeWEARADJUSTMENT).
4. Checkifshadingcoil(2)iscracked,brokenor
outofposition (singlephaseonly).
D. IFMANUALRELEASEDOESNOTWORK:
1. Checkforbroken ordamagedparts.
2. Check returnspring(11).Brakewillnotreset
automaticallyifthisspringisbroken.
3. Checkmagnetgapwithbrakeinreleased
position.(SeeMANUALRELEASE
ASSEMBLY).
4. Checkquantityofshimwashers(13)under
releasestopscrews.(SeeMANUALRELEASE
ASSEMBLY.)