Dynamatic DCD-132 User manual

IM-160000-2019
DCD-132 THROUGH 160
EDDY CURRENT DRIVES
INSTRUCTION MANUAL
(Revised 2021)
DRIVE SOURCE INTERNATIONAL, INC.
7900 Durand Avenue, bldg. 3
Sturtevant, WI USA 53177
Toll Free: [phone]
Phone: [phone] - Fax: [phone]
Email: [e-mail]

DANGER HIGH VOLTAGE:
Motor control equipment and electronic controllers are connected to hazardous line voltage. When servicing drives and
electronic controllers, there may be exposed components with their cases and protrusions at or above line potential. Extreme
care should be taken to protect against shock. Stand on an insulating pad and make it a habit to use only one hand when
checking components. Always work with another person in case an emergency occurs. Disconnect power whenever
possible to check controllers or to perform maintenance. Be sure equipment is properly grounded. Wear safety glasses
whenever working on an electronic controller or electrical rotating equipment.
CAUTION:
Rotating shafts and above ground electrical components can be hazardous. Therefore, it is strongly recommended that all
electrical work conform to National Electrical Codes and local regulations. Installation alignment and maintenance should
be performed only by qualified personnel.
Factory recommended test procedures, included in the instruction manual, should be followed. Always disconnect electrical
power before working on the unit.
REFER TO OSHA RULES AND REGULAT IONS, PARAGRAPH 1910.219 FOR GUARDS ON MECHANICAL POWER
TRANSMISSION APPARAT US.
Note: Since Improvements are continually being made to available equipment, the enclosed data is subject to change
without notice. All drawings, unless verified, are for reference only. For additional information, contact DSI/Dynamatic® at
1-800/548-2169 or 262/554-7977.
IMPORTANT NOTICE:
The printed contents in this manual are to be used for reference only. Due to periodic engineering design changes and the
addition of modifications, this material is provided as a guide only.
Please refer to the engineering drawings, which are available for your specific unit.
For additional information regarding contents of this manual, please send your request to DSI/Dynamatic®, Fax: 262-554-
7041, or call: 262/554-7977, or Toll free at 1-800/548-2169.
This notice is provided to clarify the intent of the instruction book contents and to inform our customers how to obtain
appropriate technical assistance from the proper source.
2

3
Please Observe the Following Safety Guidelines:
Allow Installation and Service by Qualified Personnel Only
Electrical rotating equipment and associated controls can be
dangerous. Therefore, it is essential that only trained personnel
be allowed to work with this equipment, under competent
supervision. The danger is increased when the equipment is not
handled, installed, maintained or used properly. This equipment
must be installed, adjusted and serviced only by qualified
personnel familiar with the construction and operation of the
equipment and the hazards involved. Failure to observe this
precaution could result in equipment damage, personal injury
and/or death.
Read Instructions and Warnings:
These instructions should be read and clearly understood before
working on the equipment. Become especially familiar with all
safety instructions and procedures. Read and heed all danger,
warning and caution notices contained in this manual and
attached to the equipment and be sure to instruct others in their
meaning and importance.
Danger, High Voltage
Disconnect Power before Servicing Equipment
Various component parts and terminals of the drive equipment
are at or above line voltage when AC power is connected to the
input terminals. All ungrounded conductors of the AC power line
must be disconnected before it is safe to touch any internal parts
of this equipment. Some control equipment may contain
capacitors that retain a hazardous electrical charge for a period
after power is removed. After power is removed, wait at least two
minutes to allow capacitors to discharge before touching any
internal parts of the equipment. Failure to observe these
precautions could result in fatal injury.
Precautions When Working on Live Circuits:
Stand on an insulating mat. Make a habit of using only one hand.
Make sure that there is another person nearby in case
emergency assistance is required.
Application of Equipment and Safety Devices:
The adjustable speed drive and all components of the drive
system, such as operator control devices, electrical power
distribution equipment, the motor and mechanical power
transmission equipment, must be properly selected and applied
to assure a safe and reliable installation. Each individual
installation has unique requirements for safety equipment such
as emergency stop pushbuttons, pre-start alarms, motor and
power disconnect devices and guards on mechanical power
transmission apparatus. The party responsible for the overall
design and operation of the facility must make sure that qualified
personnel are employed to select and apply all components of
the drive system including appropriate safety devices.
Hazard of personal injury/death or equipment damage exists if
the drive and/or the driven machine are operated above their
rated speed due to maladjustment or electronic failure. Be sure
to consider this factor in selecting gear ratios and safety devices.
Always Wear Safety Glasses:
Safety glasses should be worn by all personnel involved in
installing or maintaining the equipment. This applies equally to
all electrical and mechanical workers. Other safety clothing
should be selected as appropriate to the task and work
environment.
© Copyright Drive Source International, Inc., 2002
Handle with Care
Handle the equipment carefully to avoid personal injury or
damage to the unit.
Provide Appropriate Guards Around Moving Parts:
Before operating the equipment, make sure that appropriate
guards and other safety devices are in place. Refer to OSHA
rules and regulations, paragraph 1910.219 for guards on
mechanical power transmission apparatus.
Observe Requirements of the National Electric Code
All wiring must be in accordance with the National Electrical
Code (NEC) and/or other codes as required by the authority
having jurisdiction. The electrical connections completed by the
installer must conform to the instructions and diagrams supplied.
National Electric Code Article 430-102 requires a disconnecting
means for each motor and controller located in sight from the
motor, controller and driven machinery locations or capable of
being locked in the open position if not located in sight. This
disconnecting means is not included with the drive equipment
unless specifically ordered.
Not for Use in Hazardous Locations:
Unless specifically labeled as approved for such use, this
equipment is not suitable for use in an explosive atmosphere or
in a “Hazardous (Classified) Location” as defined in article 500
of the National Electrical Code.
Provide Adequate Ground Connections:
For personnel safety and reliable equipment operation, firmly
earth ground each piece of equipment as directed in this manual
and shown on the connection diagrams provided. The ground
conductor should be the same size as the incoming power wires
or sized according to NEC table 250-95. A copper or aluminum
conductor must be used. Grounded conduit connections are not
adequate for use as equipment ground connections.
Instruction Material and Drawings:
In addition to this manual, data sheets, drawings, supplementary
instruction sheets and errata sheets may be included in the
package of instruction material that is furnished for each drive.
Be sure to save each of these items for future reference. The
drawings and data included in this manual are generally
representative of the product line, but do not accurately include
every detail pertaining to specific equipment provided for an
individual customer order. Drawings and data sheets that are
identified by PRO/Serial number as pertaining to a specific piece
of equipment take precedence over this manual. Note: The
information furnished may not cover changes made to the
equipment after shipment. All data is subject to change
without notice.
Technical Assistance:
It is best to request assistance through DSI/Dynamatic® Service
Repair Department, 1-800/548-2169.

4
Table of Contents
Section 1 7
General Information 7
Introduction 7
Technical Assistance 7
Safety 7
Hazard Label Examples 7
Training 7
Receiving and Damage Claims 7
Warranty 8
Handling 8
Storage 9
List of Patents 9
Section 2 10
Equipment Description 10
Introduction 10
Ratings and Model Numbers 10
Construction 11
Catalog Data 13
Models DCD-132 through DCD-160 Drive Ratings 14
Outline Drawings – DCD-132 & DCD-160 15
Alternate Flange Outline Dimensions 16
Section 3 17
Installation 17
Location and Environment 17
Site Preparation 17
Unit Preparation 17
Sizing Sheaves and Sprockets (Overhung Load) 18
Installing Sheaves, Sprocket or Couplings 18
Initial Mounting 19
Alignment 19
Direct Coupled Shafts 19
Parallel Connected Shafts 20
Belt Tension 20
Final Mounting 21
Lubrication 21
Shaft and Belt Guards 21
Electrical Wiring 21
Transformer Winding (Applies to Models DCD-132 through DCD-225 ONLY) 21
AC Motor Leads 22
Clutch and Brake Coil Leads 22
Tachometer Generator Leads 22
Section 4 23
Operation 23
Normal Operation 23
Operating Limitations 24
Section 5 24
Start-Up 24
Preliminary Checks 24
Initial Start-up 24
Signs of Trouble 24
Section 6 26
Maintenance 26
Preventive Maintenance 26
Check List 26
Inspection 26
Cleaning 26
Lubrication 27

5
Insulation Testing 28
Troubleshooting 28
Dis-Assembly Instructions 30
Assembly Instructions 31
Drive Feet Mounting Procedure 33
Section 7 34
Service & Renewal Parts 34
Field Service 34
Repair Service 34
Return Instructions 34
Repair Instructions 34
Renewal Parts 34

6
Figures & Tables
Hazard Label Examples
Figure 1-1
8
Typical Dynamatic DCD Adjustable Speed Drive
Figure 2-1
10
Typical Dynamatic® Model DCD
Figure 2-2
11
Typical Torque/Slip Curves
Figure 2-3
12
Model Number Decoding
Figure 2-4
13
60 Hz. Drives
Table 2-1
14
Standard Service Conditions
Table 3-1
18
Load Factors
Table 3-2
19
Tension Factors
Table 3-3
19
Locating Position Factors
Figure 3-1
19
Offset Alignment Check
Figure 3-2
20
Angular Alignment Check
Figure 3-3
20
Parallel Shaft Alignment
Figure 3-4
21
Perpendicular Shaft Alignment
Figure 3-5
21
Precision Tension Check
Figure 3-6
22
Belt Modulus Factors (Mf)
Table 3-4
22
Typical Wiring Connections
Figure 3-7
23
Tach Generator Leads
Table 3-5
23
Maintenance Check List
Table 6-1
27
Typical Assembly Drawing of DCD Drive
Figure 6-1
28
Recommended Greases
Table 6-2
28
Recommended Amount of Grease (Oz.)
Table 6-3
29
Troubleshooting Guide
Table 6-4
29
Typical Assembly Drawing of DCD Drive
Figure 6-2
32
Parts List
Table 6-5
33
DCD Assembly Print
Figure 6-3
34

7
Section 1
General Information
Introduction
This manual provides general information and operating
instructions for Dynamatic air cooled, adjustable speed
drives, consisting of a magnetic clutch and a flange
mounted, AC motor. This manual generally covers all
model numbers beginning with the letters DCD, followed
by a hyphen and a number between 132 and 225, and
ending with a hyphen followed by a number between 4041
and 4181. Section 2 of this manual provides detailed
information regarding the various models covered.
All drives covered by this manual require a separately
mounted Dynamatic® electronic controller to provide the
necessary DC coil excitation and closed loop speed or
torque control (see the controller manual for details).
The information, drawings and data included in this
manual are generally applicable to the products covered
but may not include every detail pertaining to specific
equipment provided for an individual customer order.
Certified drawings and other information provided for
specific items of equipment shall take precedence over
this manual when the two differ in content.
The instructions given are arranged in the order they
would normally be used. They begin with general
information and proceed from receiving, handling and
storage, through installation, operation, start-up and
maintenance to modifications.
Technical Assistance
While every effort has been made to provide a complete
and accurate instruction manual, there is no substitute for
trained, qualified personnel to handle unusual situations.
It is best to request assistance through the
DSI/Dynamatic® Service Repair Department, 1-800/548-
2169.
Safety
Electrical rotating equipment and associated controls can
be dangerous. Therefore, it is essential that only trained
personnel be allowed to work with this equipment, under
competent supervision. The danger is increased when the
equipment is not handled, installed, maintained or used
properly.
Read appropriate sections of this manual before
beginning work. Become especially familiar with all safety
instructions and procedures. Heed any hazard labels on
the equipment and be sure to instruct others in their
meaning and importance. The various types of labels
used to alert personnel of hazards and their degree of
hazard potential are as follows:
DANGER: Used to call attention to an immediate hazard,
where failure to follow instructions could be fatal.
WARNING: Identifies hazards having possibilities for
injury to personnel.
CAUTION: Used to warn of potential hazards and unsafe
practices.
INSTRUCTION NOTE: Used where there is a need for
special instruction relating to safety, proper operation or
maintenance.
Hazard Label Examples
See Figure 1-1 for examples of the hazard labels that may
appear on this equipment. Study them carefully; they are
put on the unit for safety. Acquaint maintenance and
operating personnel with their appearance and content.
Training
Training programs are an essential part of safe and
correct operation. Training provides the knowledge
necessary to obtain top performance from your
equipment. DSI/Dynamatic® recognizes this fact and
conducts training schools to educate your plant personnel
in safe maintenance and operating procedures. Special
training schools structured around your specific
equipment can be arranged.
Receiving and Damage Claims
This equipment is assembled and tested prior to shipment
to make sure it functions property. After testing, the unit is
carefully packed for shipment, using approved packaging
methods. The carrier, in accepting the shipment, agrees
that the packing is proper and assumes the responsibility
for safe delivery.
Although every precaution is taken to assure that your
equipment arrives in good condition, a careful inspection
should be made on delivery. Check all items against the
packing list to be sure the shipment is complete; then
carefully inspect for damage. Any evidence of rough
handling may be an indication of hidden damage.
NOTE: Shipping damages are not covered by the
warranty; the carrier assumes responsibility for safe
delivery. If you note damage or missing items,
immediately file a claim with the carrier. At the same
time, notify the DSI/Dynamatic® customer service
department. To expedite this service, refer to your
equipment by purchase order, model, PRO and serial
number.

8
Hazard Label Examples Figure 1-1
The following check list is included to assist with the
receiving inspection:
1. Inspect the packaging, covering and skid for signs of
mistreatment.
2. Inspect the housing to make sure there is no damage.
3. Manually rotate both shafts to be sure they are free
from binding and noise. The AC motor rotor and clutch
drum should rotate independently of the output shaft.
Independent rotation can be checked by rotating the
clutch drum with a small rod inserted through the grille
while holding the output shaft. Do not use the rod
against any electrical winding.
4. Check for moisture and foreign material in the unit,
especially on electrical windings, around the shaft
and bearing caps and in accessories.
Warranty
Your new Dynamatic® adjustable speed drive is covered
by a 1-year warranty against any manufacturing defect in
either material or workmanship. This warranty starts on
the day of shipment from our factory. The complete
warranty is contained in the Standard Terms and
Conditions of Sale printed in the DSI/Dynamatic®
Adjustable Speed Drives Catalog. If a warranty failure
occurs, contact your local DSI/Dynamatic® sales office or
the factory’s Service Department directly, for
instructions on how to obtain the required repair. All repair
arrangements must be approved by DSI/Dynamatic® in
advance of returning any products to the factory. Note that
freight charges, both ways, are your responsibility. For
additional information, refer to Section 7, "Service and
Renewal Parts".
Handling
Only skilled personnel, following standard safety
practices, should handle this equipment. Avoid jarring or
pounding on shaft. Do not attempt lifting by the output
shaft. Handling is best accomplished with a forklift or
crane. When using a forklift, be sure the unit is well
supported, with the forks adequately spread and centered
under the skid.
The units can also be lifted by a crane. To avoid damage,
attach the crane cables to all eyebolts provided on the
unit. When two or more cables are used, maintain a near-
vertical pull on the eyebolts. If near- vertical pull is not
possible, use a spreader bar to take side pull off of the
eyebolts. Approximate weight tables are included in
Section 2 of this manual.
Units mounted on a common base with other equipment
may be lifted with a suitable sling under the base or by
attaching cables to eye bolts designed and installed into

9
the base for lifting the complete assembly. Refer to the
certified drawings. Do not use the eyebolts on the unit if
the unit is attached to another piece of machinery or
gearbox, unless the drawings show they were designed
for lifting the assembly.
Storage
When the unit is not put to immediate use, store it in a
clean, dry and protected area. Do not store unit where it
would be subjected to corrosive atmospheres or high
levels of moisture, shock or vibration. Excessive moisture
content of the air is detrimental. Maintain the temperature
between 32º and 104ºF (0º and 40ºC).
If the storage period exceeds three months, or when the
unit must be stored in an unprotected area, special
storage procedures are required. Coat all external
unprotected machined surfaces with a rust preventive
solution. Cover the unit to protect it from dirt, moisture and
debris, but leave air openings at the bottom to permit air
circulation. Do not try to seal the unit in plastic wrapping
with a moisture absorbent, as the integrity of the seal
cannot be assured.
Use screens around openings to prevent rodents from
nesting inside. When the ambient temperature is not
controlled, install and energize space heaters to keep the
unit's temperature above freezing and always above the
dew point.
Long-time storage requires special attention to bearings
and lubricants. To minimize brinelling and rusting, rotate
shafts once every three months to redistribute the
lubricant and re-coat bearing surfaces. Mark the shaft to
stop in a different position each time. The bearing
chambers of grease lubricated machines are packed
with grease at assembly and should not require additional
grease unless unusually severe environmental conditions
exist. Refer to Section 6 for grease specifications and
procedure to follow if periodic greasing is necessary.
Consult the Service Department at the factory whenever
a question exists regarding long- time storage.
Placing unit into service after storage requires careful
inspection. Look for signs of damage and moisture.
Correct any deficiency observed. Check the insulation
resistance of the motor stator, clutch coil and brake coil (if
used), as described in Section 6. When storage exceeds
one year, add grease, as described in Section 6, before
starting. If storage was three years or longer, the bearings
should probably be replaced, or at least inspected.
List of Patents
Dynamatic® Ajusto-Spede® drives are manufactured
under one or more of the following patents:
U.S. Patents:
3,624,433
3,624,436
3,641,375
3,742,270
3,845,337
3,863,083
3,996,485
4,138,618
4,446,392
4,469,968
4,362,958
4,476,410
4,520,284
4,757,225
4,780,637
4,853,573
Canadian Patents:
931,514/73 962,3l2/75 983,081/76 1,009,054/77
1,022,984/77 1,170,301/84 1,201,801/86
Other U.S. and Canadian Patents Pending.
CAUTION: Lifting lugs are designed to handle the
weight of the unit and any accessory mounted on the
unit. Do not use these lugs to lift a unit attached to
other equipment.
CAUTION: Do not apply power to the motor, clutch or
other electrical devices if moisture is detected. Dry
them thoroughly. Consult the factory or one of the
authorized service shops for assistance to dry out a
unit.

10
Section 2
Equipment Description
Introduction
The DCD Line adjustable speed drive is an integral
combination of an air-cooled magnetic clutch and an AC
motor. Models covered in this manual use a C-Face or D-
Flange, AC induction motor attached to the input end of
the clutch housing. The input member of the clutch is a
steel drum that is driven at a constant speed by the AC
motor. The output member of the clutch is a rotor and
shaft assembly that is driven by a magnetic field that
transmits torque from the drum to the rotor. The magnetic
field is created by a clutch excitation coil that is energized
by an electronic speed or torque controller that provides
the necessary DC coil excitation. The various size units
available are similar in design, construction, performance
and appearance.
Ratings and Model Numbers
A magnetic clutch is simply a torque transmitter.
Appropriate clutch frame sizes have been selected for
various standard motors by matching the torque ratings of
the motors to the clutch ratings, taking into consideration
starting torque, overload torque, speed range and thermal
limits. The resulting motor and clutch combinations
comprise the adjustable speed drive product line.
Standard horsepower and speed range selections,
specifications, application engineering data and outline
drawings can be found elsewhere in this section of this
manual. Tables list the horsepower ratings, speed ranges
and model numbers for various drives covered by this
manual. The model numbers consist of a two-letter prefix
followed by a hyphen and a six-digit number, then another
hyphen and a four-digit number. The following paragraphs
describe the major design types.
Model DCD drives are general-purpose models furnished
with NEMA standard motors. The last four digits of the
model number designate the speed range and other
design characteristics as listed in the rating tables,
marked on the nameplate or described in other
documentation provided for specific equipment furnished
for an individual customer order.
Typical Dynamatic DCD Adjustable Speed Drive Figure 2-1

11
Typical Dynamatic® Model DCD Figure 2-2
Adjustable Speed Drive - Cutaway View
Description of Operation
The eddy-current principle is utilized to transmit power
from the AC induction motor to the load. The clutch input
and output members have no physical contact between
each other, except for the center support bearing. The
clutch couples the motor to the load through a magnetic
field. The motor runs at full speed; it is not stopped or
started each time the load is stopped and started. This
prolongs motor and starter life and it permits the motor to
be started under no-load conditions. The only parts
subject to wear during normal operation are the bearings.
The two major parts of the eddy-current clutch are the
drum assembly and the output rotor and shaft assembly
(see Figure 2-2). The AC motor rotates the drum at a
constant speed, while the rotor and shaft assembly
remains stationary until voltage is applied to the field coil.
With no load attached to the output shaft, bearing friction
and grease in the center support bearing, and windage
between the drum and rotor assembly may produce some
minimal torque and could cause the output shaft to rotate.
The driven load is usually sufficient to hold the output
shaft stationary.
Energizing the field coil produces magnetic flux. This flux
crosses the air gap from the rotor assembly poles to the
drum assembly, passes along the drum assembly axially
and returns across the air gap back to the rotor assembly
poles. This magnetic flux path is disrupted when the drum
is rotating relative to the rotor assembly.
As a result, eddy-currents are generated in the inner
surface of the drum. These eddy-currents produce a
series of magnetic poles on the drum surface that interact
with the electromagnetic poles of the rotor assembly to
produce torque. It is this torque that causes the rotor
assembly and output shaft to rotate with the motor.
To generate eddy-currents and produce torque, there
must be a relative speed difference between the clutch
drum and rotor assembly. This speed difference is called
“slip”. With zero slip, there are no eddy-currents
generated and no torque produced. As slip increases,
torque increases. Similarly, torque is increased by
increasing field coil current. This torque versus slip, with
various current relationships, is shown in Figure 2-3.
Because some slip must occur to produce the required
torque, no torque is produced at zero rpm. For this reason,
maximum output speed is always less than motor speed.
Since the eddy-current clutch is a torque transmitter, it has
no inherent speed sense. Without external control, output
speed depends on load. This feature is frequently used to
advantage in helper drives, tensioning drives and winder
applications where torque is the prime requirement. When
speed control is needed, a tachometer generator provides
velocity feedback to an electronic controller. The controller
varies field coil current to match torque output with load
demand to hold desired preset speed.
A tachometer generator is included in each clutch for
velocity feedback. The rotor, a permanent magnet with
alternating poles around its outer diameter, is locked to
the output shaft near the output end of the clutch. The
rotor is positioned inside a laminated field winding. An AC
voltage proportional to speed is generated in the field
winding.
Construction
The input drum of the magnetic clutch is mounted directly
on the motor shaft and it is supported by the motor
bearings. The output rotor and shaft assembly is
supported by a bearing on the end of the motor, or input
shaft, and a bearing in the output end bracket. They are
referred to as the center support bearing and output
bearing, respectively.
In the cutaway view in Figure 2-2, note that the clutch
excitation coil is mounted on a stationary ring that extends
into a hollow space in the output member. This allows the
coil leads to be wired directly to the conduit box without
requiring slip rings and brushes.
Cooling
Eddy-currents in the inner surface of the drum produce
heat. This heat is proportional to slip and is sometimes
referred to as "slip heat." The greater the load and the
slower the speed, the greater the heat generated.
Conversely, very little heat is produced at full speed.
Air is used to cool the clutch. The input drum acts as a
fan, drawing air in through the output end bracket and
across both sides of the drum. Air is discharged through
openings on both sides of the housing. Since the drum is
driven by the motor at a constant speed, maximum
cooling is achieved.

12
Typical Torque/Slip Curves Figure 2-3
Each clutch frame size has a thermal dissipation
capability based on the motor speed or the air volume
available. Smaller size clutches can generally dissipate
full load slip losses. However, as frame size increases,
the maximum airflow cannot completely cool the unit over
the full speed range. Because of this, a thermal limit is
established for each clutch frame size with different motor
speeds. The nameplate of each unit is stamped to show
the minimum operating speed at full load. The minimum
speed can be reduced when the load is also reduced.
Tables found elsewhere in this section list the horsepower
capacities and speed ranges of standard drives. For other
ratings, consult the factory. The formula shown below is
used to calculate the minimum continuous operating
speed for a given load torque and horsepower dissipation
capacity.
RPM min. = RPM mtr. - (HPd x 5250)
T
Where:
RPM min. = Minimum operating speed
RPM mtr. = Full load speed of the AC motor
HPd = HP dissipation of the specific unit
T = Maximum load torque at which RPM
min. is required, in lbs. ft.

13
Catalog Data
The information contained on the following pages has
been excerpted from the DSI/Dynamatic® Product
Catalog and reprinted here for reference. Ratings,
weights and dimensions listed are approximate and
should not be used for construction purposes.
Drawings giving exact dimensions are available upon
request. All listed product specifications and ratings are
subject to change without notice.
Table 2-1 shows equivalent model numbers for the two
model types covered by this manual. The two model types
differ in speed range and torque capability as indicated by
the rating tables listed on the following pages.
Both model types are equivalent in the following
respects:
1. Weights and dimensions when motors and output
bearings are equivalent.
2. Clutch coil data - current and resistance for 45V coil.
3. Overhung load capacity when furnished with
equivalent bearings.
4. Inertia of clutch output member.
Contact the factory for weights, dimensions, overhung
load ratings and other engineering data for model/motor
frame combinations and other configurations not listed.
Model Number Decoding Figure 2-4

14
Models DCD-132 through DCD-225 Drive Ratings
the Basic Model DCD drive includes a TEFC AC
induction motor flange mounted to an eddy-current
clutch. Table 2-1 lists units requiring a 230/460 VAC,
3 phase, 60 Hz, 1.15 SF input. NEMA design B,
Class F insulation is used in all motors.
60 Hz. Drives Table 2-1
HP
Speed
Range
RPM
TEFC
Model
Number
TEFC
Motor
Frame
Size
3
1630-0
DCD-132030-4141
145TC
5
1500-0
DCD-132050-4141
145TC
5
3300-0
DCD-132050-4121
182TC
7.5
3300-50
DCD-132075-4121
184TC
7.5
1660-350
1680-50
DCD-132075-4141
DCD-160075-4141
213TC
213TC
10
3250-0
1580-0
DCD-132100-4121
DCD-160100-4141
215TC
215TC
15
3300-0
1550-340
DCD-160150-4121
DCD-160150-4141
254TC
254TC
20
3250-0
1615-145
DCD-160200-4121
DCD-160200-4141
256TC
256TC
25
3250-640 DCD-160250-4121 284TSC
All drives have 100% rated motor torque continuously
available over the speed range shown in the tables
below.

15
Outline Drawings – DCD-132 & DCD-160
Model Poles
Max
Speed
(RPM)
Motor
Power
(HP)
Wt.
Lbs.
Overall & Mounting Dimensions
A B C H K AB AD BD BC HA HC L L
4
1630-0
3
232
4
1500-0
5
247
DCD-132
2
3300-0
5
249
8.50
3.15
4.84
5.20
.50
10.63
6.90
6.25
1.50
.56
13.00
14.7
14.7
2
3300-0
7.5
286
2
3250-0
10
300
4
1630-0
7.5
475
4
1580-0
10
498
DCD-160
4
2
1550-340
3300-0
15
15
590
582
10.0 3.935 3.86 6.299 .59 12.80 8.55 11.03 5.14 .55 15.00 17.2 21.26
2
3250-0
20
625
2
3250-640
25
760
Notes:
Terminal box mounting is optional on right or left side.
Totally enclosed covers are available for several models.
Alternate flanges are available for basic and freestanding models (see page
54).
Weight is approximate and includes motor.
Dimension includes flange (see page 54).
DIMENSIONS ARE IN INCHES
Model
Hp
Frame
AC
LE
AA
2E
2F
KK
3
182TC
8.8
13.65
.75
--
--
--
DCD-132
5
7.5
184TC
213TC
8.8
10.25
14.50
15.00
.75
1.00
--
--
--
--
--
--
10
215TC
10.25
16.25
1.00
--
--
--
7.5
213TC
10.25
15.00
1.00
8.50
5.50
.41
10
215TC
10.25
15.00
1.00
8.50
7.00
.41
DCD-160
15
254TC
12.70
19.25
1.25
10.00
8.25
.53
20
256TC
12.70
19.75
1.25
10.00
10.00
.53
25
284TC
14.50
23.00
1.25
11.00
9.50
.53
Output Shaft Data
Model
ES
NW
U
S
R
DCD-132
1.75
2.75
1.125
.25
.987
DCD-160
2.375
3.375
1.375
.3125
1.201

16
Alternate Flange Outline Dimensions
Model
C
LA
LF
M
N
P
T
NW
SS
DCD-132
4.84
.74
7.4
6.10
8.46
9.84
.16
2.75
.6
DCD-160
7.87
.63
8.74
10.43
9.06
14.0
.16
3.375
.6
DIMENSIONS ARE IN INCHES

17
Section 3
Installation
Proper operation and long life of the eddy-current unit
depend on its installation, location and environment.
These instructions are intended as a guide for safe and
proper installation, but do not cover all possible situations
that may arise. Refer any questions to DSI/Dynamatic 1-
800/548-2169.
Location and Environment
The clutch is an open, drip-proof, self-ventilated unit that
should be installed in an area suitable to its design. An
adequate supply of clean, dry cooling air is required.
Locate the unit away from any obstruction, usually at least
twelve inches from a wall, to permit free air movement and
accessibility for routine maintenance and inspection. Do
not obstruct ventilating openings or mount the unit within
the base of a machine without making provisions for
adequate inlet and outlet of cooling air.
These units are designed to operate under standard
service conditions unless purchased for certain specific
environmental conditions. Standard service conditions
are listed in Table 3-1. If purchased for special
environmental conditions, consult the contract papers for
the unit.
conditions by the local code inspection and enforcement
agencies.
Site Preparation
Before installation, make sure the jobsite is free of debris
and all heavy construction, especially overhead. Provide
protection for all personnel and equipment in the area, as
required by the conditions. Clean up construction dust,
dirt and scrap material so they are not pulled into the unit
by cooling fan suction.
When planning the installation, be sure to include access
for maintenance, the correct size, number and location of
conduits, and adequate electrical service for the
equipment. Remember, the location should provide
adequate space for the removal of the unit or a component
of it.
Mounting surfaces must be machined flat and level to
support all feet evenly and be rigid enough to prevent
flexing or resonance. As a rule, the base plate should be
at least as thick as the mounting feet or flange. Do not set
the unit directly on a wood or concrete floor. Consult the
factory for weight and center of gravity data.
Standard Service Conditions Table 3-1
The unit must be mounted with its shaft in a horizontal
position unless it is a vertical model that is specifically
designed for vertical mounting and operation. Other
models must be mounted horizontally unless certified
drawings or other documentation, furnished for equipment
supplied for a specific customer order, indicates that the
equipment is designed for vertical mounting and
operation.
Operation in ambient above 104ºF (40ºC) requires the HP
dissipation to be de-rated 10% for each 10ºF (5.5ºC)
interval to a maximum ambient of 148ºF (65ºC). For
operation above 3300 feet (1000 meters), it is necessary
to de-rate the HP dissipation 5% for each 1100-foot (330
meter) interval to an altitude of 10,000 feet (3000 meters).
Alternative altitude and ambient temperature ratings can
also be calculated by decreasing the maximum ambient
temperature rating by 4.6ºF per 1000 feet (8.33ºC per
1000 meters) above 3300 feet (1000 meters).
The unit should never be placed in any hazardous
location restricted by the National Electrical Code, Article
500, unless it is specifically designed for a specific
hazardous service and it is approved for such service
2. Use a light to check inside openings for foreign
material.
Unit Preparation
Move the unit to the jobsite using proper handling
procedures. Refer to Section 1, "Handling," for more
information. If the unit has been stored in a cool location,
allow it to reach room temperature before removing
packing material. Then remove all temporary screens,
cover plates, tie down bolts and banding. Before
proceeding, review the application requirements and
check the unit nameplate to be sure the correct unit is
being installed and electrical service is correct.
Examine the unit for damage or lost accessories. The
following check should be made before installation:
1. Turn shafts by hand and observe any binding, rubbing
or noise that may indicate damage to bearings or
other components.
3. Open junction box covers and check continuity and
leakage to ground.
Altitude
not exceeding 3300 ft.
(1000 meters)
Ambient Temperature
32ºF to 104ºF (0ºC to 40ºC)
Coil Voltage
not exceeding 10% over
nameplate rating
Environment
clear of dust, dirt, high
moisture and vapors
Line Voltage Variation
+/- 10% of nameplate rating
CAUTION: Beware of re-circulation of cooling air. Hot
air discharge must not be allowed to re-enter the unit
or any adjacent air-cooled unit.
CAUTION: Electric welding equipment must be solidly
earth grounded. Do not use clutch or motor as a
current path. Serious bearing and insulation damage
may result.

18
4. If unit has been stored outdoors and especially in
humid climates, check for condensation and water
damage to insulation and bearings.
5. Make sure accessory equipment is complete and
undamaged. Movable devices should be operated to
determine if they function freely and correctly.
Correct any deficiency and remove dirt, rust and
protective coatings. Use a safe solvent to clean shaft,
flange face and mounting feet. Remove burrs with a fine
file or scraper. Do not use emery cloth, sandpaper or any
other abrasive.
Sizing Sheaves and Sprockets (Overhung Load)
Before a sheave or sprocket is installed on the shaft,
make sure it does not exceed the minimum diameter
limitation. This is a limitation established by the
overhung load capacity of the unit. Too small a sheave
may result in early bearing failure or a broken shaft.
Calculate the minimum sheave diameter using the
following formula:
(126,000 x HP x Lf x Tf)
PD min. = (OHL x Pf x RPM)
Where:
PD min. = Minimum pitch diameter, in inches.
HP = Rated horsepower of clutch from clutch nameplate.
Lf = Load factor of clutch is a ratio of maximum
expected load to rated load, usually at least a
factor of 1.5. See Table 3-2.
OHL = Overhung load capacity of shaft in pounds. Obtain
from Section 2 of this manual. Contact your
local sales office for configurations that are
not listed.
Tf = Tension factor for type of bell drive used.
See Table 3-3.
Pf = Position factor, a factor, used to correct
overhung load capacity when the center of
belt pull is not on the center of the shaft
keyway extension. Location "L” is on the
center of keyway. See Table 3-4 and Figure
3-1.
The pitch diameter of the sheave or sprocket must be
equal to or larger than the minimum calculated. When a
smaller diameter must be used, mount the pulley on a
separate jackshaft, supported by separate bearings. Align
the jackshaft to the unit's shaft as described for directly
connected shafts.
The overhung load ratings listed in Section 2 are for units
with a standard-length output shaft and either standard
output ball bearing or optional/standard output spherical
roller bearing, as indicated in the tables. Units with an
external brake have a longer shaft. Separate overhung
load rating tables are provided for units with a brake.
For non-standard models, contact
DSI/Dynamatic® to obtain the overhung load rating. To
determine if your unit is standard, compare its dimensions
(shaft length) and the model number imprinted on its
nameplate with the model numbers and engineering data
tables in Section 2 of this manual.
Note that OHL is in pounds force at the center of the shaft
keyway. Positioning the pulley so the center of belt pull is
not at the center of the keyway changes the OHL capacity.
Table 3-4 lists the Position Factors used to correct the
OHL. Factors are provided for 1 inch closer to the bearing
(L-1); and 1 inch (L+1), 2 inches (L+2) and 3 inches (L+3)
further away from the bearing. If belt center is on the
keyway center, Position Factor L is 1.0.
Load Factors Table 3-2
Type of Load
Lf
Load never exceeds full load
1.00
Load sometimes equals 125% of full load
1.25
Normal loads
1.50
Occasional loads equal to 200% of full
load
2.50
Tension Factors Table 3-3
Tension Factors
Tf
Chain and sprocket
1.00
Pinion or gear
1.25
V-belt and sheave
1.50
Flat belt and pulley
2.50
Installing Sheaves, Sprocket or Couplings
Coupling halves, sheaves, sprockets or gears should be
installed on the shaft before mounting the unit. Before
installing these hubs on the shaft, inspect the shaft and its
key. Remove any burrs using a fine file. Do not use emery
cloth or other abrasives. Also, be sure the key fits snugly
to the sides of the keyways on both the shaft and device
hubs. Some clearance between the top of the key and the
hub keyway is acceptable and will make installation
easier.
Locating Position Factors Figure 3-1
On Standard Shafts
Generally, the device should be installed on the shafts by
following the device manufacturer's instructions. Devices
with split hubs or light interference fits that use

19
set screws should not present any problems. Devices with
hubs that rely on heavy interference fits, however, must
be installed with care. Do not pound such hubs in place.
Instead, heat the hub in an oil bath or oven to 275ºF
(135ºC) to expand the bore. Then, after coating the shaft
with a light film of oil, slip the hub on the shaft. Be very
careful to stop the hub at the correct position on the shaft,
as it will quickly shrink once the heat is transferred to the
shaft.
Initial Mounting
After preparing the site and unit, place the unit on a metal
mounting base or plate. Then proceed as follows:
1. One or more mounting feet on the unit may not
contact their mounting pads. With a feeler gauge, find
and measure gap between each foot and its pad.
2. Place slotted shim, equal in thickness to measured
gap, under each high mounting foot.
3. Install mounting bolts or nuts finger tight.
4. Proceed with alignment as described below under
"Alignment."
Any burrs or other irregularities that would prevent proper
seating must be removed. Once base is determined to be
level, set unit in place. Any high spots on the base should
be scraped or filed.
Alignment
Proper alignment of this unit is a condition of its warranty.
Misalignment between directly connected shafts will
cause increased bearing loads and vibration, even when
a flexible shaft coupling is used. After alignment, other
factors can cause the alignment to change. For this
reason, the original alignment should be as accurate as
possible.
Direct Coupled Shafts
All couplings, even flexible couplings, are designed to
permit only a limited amount of misalignment. Generally,
a coupling manufacturer specifies limits for both angular
and offset misalignment.
When using such limits in place of the values specified in
this alignment procedure, remember that the limits are
maximums and they cannot be used at the same time. If,
as an example, angular misalignment is at its limit, then
offset misalignment must be zero. Always use a dial
indicator to check alignment.
Offset Alignment Check Figure 3-2
Note - Dial indicators used for alignment must be non-
magnetic due to possible magnetism of the unit’s shaft. If
possible, rotate both shafts when required in procedure. If
one shaft cannot be turned, alignment can still be checked
by rotating the other shaft with indicator attached to it.
1. Clamp base of indicator to hub of unit’s shaft and
position its indicator button on machined outer
diameter of other hub, as shown in Figure 3-2.
2. Scribe a mark to indicate position of button.
3. Read indicator dial. Zero if convenient. Then rotate
both shafts equally, keeping button on scribe mark
and noting dial readings. Locate position of maximum
reading and record it. Then rotate shafts and take
readings at each one-quarter revolution. The
maximum difference, or run out, between any two
readings should not exceed 0.002 inch. If it does,
realign the units and repeat.
4. Once run out is acceptable, reposition indicator
button on machined face of driven shaft hub as shown
in Figure 3-3.
5. Scribe a mark to indicate position of button.
6. Read indicator dial. Zero if convenient. Then rotate
both shafts equally, keeping button on scribe mark
and noting dial readings. Locate position of maximum
reading and record it. Then rotate shafts and take
readings at each one-quarter revolution. Compare
four readings and calculate maximum difference
between any two readings. Divide resulting value by
twice the distance from shaft centerline to button
position. The result, angular misalignment, should not
exceed 0.002 inch per inch. If it does, realign units
and repeat.
Angular Alignment Check Figure 3-3
The alignment check is done similarly for either horizontal
or vertical shafts. Shimming to correct alignment is done
somewhat differently.
For horizontal or foot mounted units, the shims are placed
under the feet. Because of an uneven mounting surface,
it may be necessary to install more shims at one end than
at the other to reduce angular misalignment. The shims
should be the same size as the mounting foot and slotted
to permit inserting without removing the bolt. Try to obtain
shims of the thickness required or use as few thick shims
as possible. Do not use many thin

20
shims stacked to make up the thickness required. De- burr
shim edges.
Vertical flange mounted drives require shims inserted
between the flange faces. Use the following procedure
when placing shims to avoid twisting the flange. De-burr
shim edges and use as few thick shims as possible
instead of many thin shims. See Figure 3-4.
1. Determine thickness of shim needed to correct
angular alignment by calculation or trial and error.
This shim is placed on the flange face at the point
where the smallest misalignment reading was taken.
2. Shim should not be wider than the distance from the
outer flange edge to the bolt circle of the hold down
bolts and the length should be twice the width. Notch
for bolt.
3. Cut two additional shims the same size but one half
the thickness and place them 90º from the thick shim,
on either side. Notch to clear hold down bolts, if
necessary.
Parallel Connected Shafts
Parallel shafts must be aligned to prevent excessive
thrust loads on the unit's shaft and to minimize belt or
chain wear. To check parallel shaft alignment, simply
place a straightedge across the faces of the two sheaves
or sprockets as shown in Figure 3-5. When properly
aligned, the straightedge should contact the faces of both
devices squarely. The object is to have the belt leave or
enter the groove without rubbing or thrusting against the
side of the groove.
Quarter-twist belts are often used to transmit power
between a horizontal and vertical shaft. These shafts
must be perpendicular and aligned as shown in Figure 3-
6 to minimize bell wear and bearing loads. When looking
down, as shown in the top view, a line perpendicular to
the horizontal sheave at the center of its sheave must
pass through the center of the vertical shaft. When looking
at the end of the horizontal shaft, as shown in the front
view, a line perpendicular to the vertical shaft at the center
of its sheave must pass a distance "Y" below the center
of the horizontal shaft.
Belt Tension
Belt and chain drives are tensioned by sliding the unit
sideways after loosening the hold down bolts. It is very
important to establish the proper tension, which is one just
above the point of slippage. Belts that are too loose will
slip, preventing proper acceleration or full output speed
while creating belt overheating and pulley grove wear. On
the other hand, tightening the belt or chain more than is
necessary increases wear of the belt, bearings and shaft.
When available, follow the belt manufacturer's
instructions for optimum tensioning. When such
instructions are not available and the belt and sheave are
not sized marginally, a simple check may be made to
determine belt tension. To perform this check, place
thumb on belt at a point midway between the two
sheaves and press downward. The belt should deflect a
distance equal to one-half of its thickness for each 24
inches of distance between the sheaves.
Because the simple check described above is not very
precise, it is not recommended when the sheave is at or
near the minimum size permitted by the unit's overhung
load capacity. In such cases, even slight over-tightening
of the belts can cause serious damage. To avoid these
problems, check tension of marginally sized belts or
sheaves with a belt tension gauge following the directions
furnished with the gauge, or use the following procedure:
1. Calculate the value for a test weight or deflection
pressure using the following formula:
Weight (Lbs.) = (OHL x Pf x 0.03125) +Mf
No. of belts used
Where:
OHL = Overhung load capacity of shaft in pounds.
Obtain from engineering data tables in section
2 of this manual. Contact your local sales
office for configurations that are not listed.
Parallel Shaft Alignment Figure 3-4
Perpendicular Shaft Alignment Figure 3-5