Dings 70 Series User manual

70 Series
Double “C” Face
Brake Instructions
IMPORTANT
Read carefully before attempting to assemble, install,
operate or maintain the product described. Protect yourself
and others by observing all safety information. Failure to
comply with instructions could result in personal injury
and/or property damage! Retain instructions for future
reference. When unpacking the brake, inspect it carefully
for damage that may have occurred during transit.
Bulletin No. BK4620 (2/18)
4740 WEST ELECTRIC AVENUElMILWAUKEE, WI 53219lP ONE 414/672-7830 lFAX 414/672-5354 lwww. dingsbrakes.com
ARNING
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 mainte-
nance may cause brake failure which could result in damage to prop-
erty 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.
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 all 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. This brake is offered in 2
housing styles: Standard (NEMA 2) and Enclosed (NEMA 4).
Figure 1. iring Diagram
INSTALLATION
Refer to Figures 1 & 2
Insert key into motor shaft keyway. Key length to be as
shown below for models designated.
Used on all models except
71010, 71015, 72025, and
72035 with 1-1/8” dia. shaft.
For models 71010, 71015,
72025 and 72035 with
1-1/8” dia. shaft.
Slide brake onto motor shaft, aligning key in motor shaft
with keywayin brake shaft. Secure brake to motor “C” face
with four 1/2” socket head capscrews. Connect coil leads
per appropriate diagram.
Key must be full length
of keyway and flush with
end of shaft
Key to extend to
end of keyway
X
Model X ± 1/32
71010
71015 1-15/16
72025
72035 2-7/16

MANUAL RELEASE
(See Figure 4)
To operate release, rotate two nuts (16) clockwise until stop
screw (14) hits pin. Brake will remain in released position until rods
are manually returned to original position, or until electrical power
is restored, automatically resetting the brake.
TORQUE ADJUSTMENT
(See Figures 2 & 4–Table 1)
Brake is factory set for rated torque per spring length “ ”. To increase
stopping time and lower torque, turn two locknuts (9) counterclockwise,
increasing dimension “ ”. Both springs must be set to the same length.
Do not decrease spring length “ ” as this may cause coil to burn out.
MAINTENANCE AND SERVICE
EAR ADJUSTMENT
(See Figures 2 & 4– Table 1)
Magnet gap “D” increases as friction discs wear. When gap approaches
“D” max., adjust gap to “D” min. dimension by turning nuts (23 and 24).
Magnet gap can vary from nominal + .005” between corners. After
setting gap, readjust torque spring length “ ”.
CAUTION: MAGNET GAP MUST NOT EXCEED
“D” MAXIMUM.
FRICTION DISC REPLACEMENT
(See Figure 4 & Table 1)
When the rotating friction disc (4) wears down to a thickness of 7/32”,
replace disc. Remove brake from its associated equipment (reducer-
motor-etc.). Remove retaining ring (28) and press shaft (1) out of bear-
ing in brake case (25). A wheel puller, utilizing openings in side of
case, can be used. Continue disassembling in this order: two nuts (26),
brake case (25), roll pins (17), manual release knobs (16), manual
release screws (14), manual release washers (12), manual release
shims(13), two nuts (24), magnet mounting plate assembly (18), two
nuts (23), two nuts (9), torque spring washers (8), torque springs (7),
pressure plate assembly (6) and discs (4) (5).
Lay bracket (2) on a flat table. Place shaft (1) in center of bracket, with
a spacer under hub. Spacer thickness to be 13/16”. Replace worn
friction discs (4) and reassemble disc pack. Continue reassembling in
reverse order, setting torque spring dimension “ ,” and magnet gap “D”
min. (Table 1.). When assembling manual relase, turn release rod (10)
counter-clockwise until screw (14) strikes pin. Wind torsion spring (11)
about 1/4 turn and hook spring over pin.
NOTE: When assembling manual release mechanism, add only
enough shim washers (13) to obtain proper release action.
With too many shim washers, brake will not automatically reset when
electrical power is applied. With too few shim washers, motor shaft will
not turn freely with brake in manually released position.
IMPORTANT: Make sure release is working properly
before proceeding.
Place case (25) over shaft (1). Release brake by turning two nuts (16)
clockwise. Press bearing (in case) onto shaft by applying pressure to
bearing inner race. Complete assembly in this order: snap ring (28)
and two nuts (26).
NOTE::Units with 1-3/8” dia. output shafts–remove brake case by
first removing outside retaining rin (41) and two nuts (26).
Then press shaft (1) out of bearing. Next remove remaining retaining
ring (41) and pull shaft out of brake.
MODEL
NUMBER
NEMA 2
MODEL
NUMBER
NEMA 4
# of
friction
discs
Torque
Lb-Ft
Weight
lbs.
Thermal
Capacity
PS/Min
Inertia
WK2
LB-FT2
DIMENSIONS
AC C
D A (Motor Shaft Length)
Max. Min. 1-1/8” Dia. 1-3/8” Dia.
Max. Min. Max. Min.
71010-38 71010-46 1 10 45 11 .069 1.19 6.84 .070 .030 1.31
2.81 2.50
*1.81 *1.69
71015-38 71015-46 1 15 45 11 .069 .070 .030 1.31
72025-38 72025-46 2 25 49 12 .110 1.63 7.47 .070 .035 1.31 *2.44 *2.31
73025-38 73025-46 3 25 53 13 .150 2.25 8.09 .070 .040 1.25 3.13 2.94
72035-38 72035-46 2 35 49 12 .110 1.63 7.47 .070 .035 1.21 *2.44 *2.31
73035-38 73035-46 3 35 53 13 .150 2.25 8.09 .070 .040 1.27 3.13 2.94
73050-38 73050-46 3 50 53 13 .150 2.25 8.09 .070 .040 1.25 3.13 2.94
74075-38 74075-46 4 75 57 14 .190 2.88 8.72 .070 .040 1.21 3.25 3.00
Figure 2. Outline Drawing
Table1. List of Models and Dimensions *Std. NEMA Motor Shafts will have to be shortened.
2

MAGNET COIL REPLACEMENT
(See Figures 1, 3 & 4)
Remove magnet assembly as outlined under FRICTION DISC
REPLACEMENT.
Coils (21) 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 (20) below the coils. Order insulating wash-
ers when ordering coils. An insulating 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 1). The brake will not operate properly unless coils
are all in the correct position.
Reassemble all parts in reverse order.
TROUBLE SHOOTING
A. IF BRAKE DOES NOT RELEASE:
1. Check brake visually for broken or damaged parts.
2. Check for broken leadwire 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 ADJUST
MENT.)
6. Check for failure or 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 C ATTERS OR UMS:
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 (22) 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 quantity of shim washers (13) under release stop
screws. (See Manual Release Assembly under
“FRICTION DISC REPACEMENT”.)
Figure 3. Fastening of Replacement Magnet Coils
SPECIFICATIONS
MOTOR FRAMES - 182TC, 184TC, 213TC, 215TC, 254TC, 256TC.
ENCLOSURES - NEMA 2 or NEMA 4
(material: aluminum and cast iron)
DUTY - Rated for continuous duty.
VOLTAGES - All standard NEMA voltages and frequencies available.
Other voltages and frequencies are optional.
MOUNTING - Direct to NEMA “C” face, with one additional “C” face for
mounting of equipemnt to brake. Some standard motor shafts may
need modification, see Table 1.
orizontal or vertical mounting with modifications.
ORDERING INFORMATION
The following data should be furnished with your order for:
REPLACEMENT PARTS
Brake Model Number
Part Number from Tables
Part Description from Tables
ub Bore & Keyway. Shaft Extension Diameter & Keyway.
For electrical parts specify voltage, phase, and frequency.
REPLACEMENT BRAKE
Model Number
Voltage, Phase & Frequency
ub Bore & Keyway Dimensions. Shaft Extension Diameter & Keyway.
Mounting - orizontal or Vertical. (If vertical, specify whether above or
below motor.
3

Table 2. Parts List
* Number of rotating discs is designated by model number; example:72025-38 has two rotating discs.
Also see table 1 for number of rotating discs.
** Number of stationary discs is one less than the number of rotating discs.
4740 WEST ELECTRIC AVENUE
MILWAUKEE, WI 53219
P ONE 414/672-7830 FAX [phone]
www. dingsbrakes.com
ITEM
NO.
PCS.
REQ’D DESCRIPTION PART NUMBER
NEMA 2 NEMA 4
1 1 ub & shaft assembly
(Specify both diameters & keyways) Consult Factory
2 1 Bracket (Specify brake model no.) L070203
3 2 Studs (Specify brake model no.) 070180
4 * Rotating friction disc 070103-008
5 ** Stationary disc K070485-001
6 1 Pressure plate assembly K070045-001
7 2 Torque spring See torque spring table
8 2 Torque spring washer W004004-001
9 2 Torque adjusting nut W003001-022
10 2 Manual release rod G070472-001
11 2 Manual release spring G060010-001
12 2 Manual release washer W004004-003C
13 As Req’d Manual release shims- .006” thick W004004-004C
14 2 Manaul release stop screw G060029-001
15 2 Manual release lockwasher W004007-007
16 2 Manual release knob G070471-001
17 2 Roll pin, 3/32 x 9/16 lg. W005003-039
18 1 Magnet mounting plate assembly
for 3-Phase magnets (Includes items 19-20) K070097
18 1 Magnet mounting plate assembly
for 1-Phase magnets (Includes items 19-22) K070335
19 1 Roll pin, 5/32 x 1/-18 lg. W005003-109
20 2 Coils-single phase (See ordering info.) 070013
20 6 Coils-three phase (See ordering info.) 020003
21 2 Insulating washers, 1-Phase coils G070029-001
22 2 Shading coil (single phse only) G070032-001
23 2 ex jam nut 1/2-20 W003003-023
24 2 ESNA locknut 1/2-20 W003001-020
25 1 Adapter housing (1-1/8 output shaft) L070202-002
25 1 Adapter housing (1-3/8 output shaft) L070212-002
26 1 ESNA locknut 1/2-20 W003001-020
27 1 Ball bearing-double seal (1-1/8 output shaft) W009001-002
28 1 Retaining ring (1-1/8 output shaft) W006004-001
29 1 Retaining ring (1-1/8 output shaft) W006002-002
30 1 Wrap cover K070278-001 K070279-001
31 1 Nameplate with two drive screws K060473-001
32 1 Cap plug W008003-001
33 1 Pipe plug - 1/8 NPT W010002-001
34 1 “O” ring W006001-010
35 2 Gasket for brake mounting K070250
36 2 Gasket W011004-001
37 2 RD. D. screw, #10-32 x 1” lg. W001051-126 W001051-126
38 2 ex nut #10-32 W003021-008 W003021-008
39 1 Ball bearing-double seal (1-3/8 output shaft) W009001-003
40 1 Retaining ring (1-3/8 output shaft) W006002-003
41 2 Retaining ring (1-3/8 output shaft) W006007-003
Model
Number
NEMA 2
Model
Number
NEMA 4
Torque
Spring P/N
71010-38 71010-46 G070011-001
71015-38 71015-46 G070012-001
72025-38 72025-46 G070019-001
73025-38 73025-46 G070525-001
72035-38 72035-46 G070012-001
73035-38 73035-56 G070011-001
73050-38 73050-46 G070012-001
74075-38 74075-46 G070012-001
Torque spring (Item 7) table