DYNAMICS GROUP Dings 80 Series User manual

80 Series
4 Post
Brake Instructions
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. BK4604 (12/01)
4740 WEST ELECTRIC AVENUE lMILWAUKEE, WI 53219 lPHONE 414/672-7830 lFAX 414/672-5354 lwww. dingsco.com
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 enclo-
sure 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 prealignment of rotating discs for
ease of installation.
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
check periodically and adjusted when necessary,
INSTALLATION
(See Figures 3, 5 & 6,Tables 1, 2 &3)
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 lb. ft.
torque.
2. Remove cover screws (24) and cover (23), plus gasket (28) on
enclosed and severe duty models.
3. Place brake on motor, guiding discs on hub.
4. Bolt brake to motor “C” face with four 1/2 inch socket head cap
screws. See Figures 5 and 6 for screw length thru bracket.
5. Connect coil leads per appropriate wiring diagram in Figure 2 and
replace cover.
Standard Housing Enclosed Housing
Figure 1.
Figure 2.Wiring Diagram
1

MANUAL RELEASE
(See Figure 3)
To operate release, rotate two rods(10) clockwise until stop screw
(14) hits pin. (Enclosed Models only; Release cap (29) must be
removed by unscrewing, before rods can be rotated.) Brake will
remain in released position until rods are manually returned to origi-
nal position, or until electrical power is restored which automatically
returns the release rods to the set position.
TORQUE ADJUSTMENT
(See Figures 3, 5 & 6)
Brake is factory set for rated torque per spring length “H”.To
increase stopping time and lower torque, turn four locknuts (9)
counterclockwise, increasing dimension“H”. All four springs must be
set to the same length. Do not decrease spring length “H” as this
may cause coil to burn out.
WEAR ADJUSTMENT
(See Figures 3, 5 & 6,Tables 2 or 3)
Magnet gap “D” increases as friction discs wear.When gap approach-
es “D” max., adjust gap to “D” min. dimension by turning nuts (21
and 22). Magnet gap can vary from nominal +.005” between cor-
ners. After setting gap, readjust torque spring length “H”.
CAUTION: MAGNET GAP MUST NOT EXCEED
“D” MAXIMUM.
FRICTION DISC REPLACEMENT
(See Figures 3, 5 & 6,Tables 2 or 3)
*When the rotating friction disc (4) wears down to a thickness of
7/32”, replace disc.
1. Remove cover screws (24) and cover (23), plus gasket (28) and
gasket (32) on severe duty and enclosed models.
2. Unhook loop of torsion springs (11) from pins at rear of magnet
plate (16). Remove release stop screws (14), washers (12) and
shims (13).
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 RELEASE ASSEMBLY
(See Figure 3)
When assembling a standard manual release mechanism (Figure 3),
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 stop screws (14). Wind each torsion spring
(11) approximately 1/4 turn and hook spring loop over pin.
MAGNET COIL REPLACEMENT
(See Figures 3 & 4)
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 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 2). The brake will not operate properly unless coils are all in
the correct position.
Figure 4. Fastening of Replacement Magnet Coils
Figure 3. ExplodedView of Brake
2

ITEM
NO. PCS. REQ’D DESCRIPTION
2-80000-29
SERIES
PART NO.
4-80000-29
SERIES
PART NO.
6-80000-32
SERIES
PART NO.
11Hub
21Bracket W/Studs –1Disc H080105-001
21Bracket W/Studs –2 Disc H080105-002
21Bracket W/Studs –3 Disc H080105-003
21Bracket W/Studs –4 Disc H080105-004
21Bracket W/Studs –5 Disc H080105-005
2a 1Bracket W/High Tensile Studs –1 Disc H080105-006
2a 1Bracket W/High Tensile Studs –2 Disc H080105-007
2a 1Bracket W/High Tensile Studs –3 Disc H080105-008
2a 1Bracket W/High Tensile Studs –4 Disc H080105-009
2a 1Bracket W/High Tensile Studs –5 Disc H080105-010
34Stud –1 Disc G070213-001
34Stud –2 Disc G070213-002
34Stud –3 Disc G070213-003
34Stud –4 Disc G070213-004
34Stud –5 Disc G070213-005
3a 4Stud –1 Disc High Tensile G070219-001
3a 4Stud –2 Disc High Tensile G070219-002
3a 4Stud –3 Disc High Tensile G070219-003
3a 4Stud –4 Disc High Tensile G070219-004
3a 4Stud –5 Disc High Tensile G070219-005
4(1) Rotating Friction Disc H080002-002
4a (1) Heavy Duty Rotating Friction Disc (Alt.) H080026-003
5(2) Stationary Disc K080179-001
61Pressure Plate K080072-001
74Torque Spring (25, 50, 75 Lb. Ft.) G070011-001
74Torque Spring (35, 70,105,125,175 Lb. Ft.) G070019-001
84Torque Spring Washer W004004-001
94Torque Adjusting Nut W003001-022
10 2Manual Release Rod G070001-002
11 2Manual Release Spring G060010-001
12 2Manual Release Washer W004004-003
13 As Req’d Manual Release Shim W004004-004
14 2Manual Release Stop Screw G060029-001
15 2Manual Release Lockwasher W004007-007
16 1Magnet Assembly, Single Phase –Complete with Coils K080126 (3)
16 1Magnet Assembly, Three Phase –Complete with Coils K080127 (3)
17 1Magnet Plate w/o Coils, Single Phase K080152-001
17a 1Magnet Plate w/o Coils, Three Phase K080101-001
18 4Magnet Coil –Single Phase K080083 (3)
18a 6Magnet Coil –Three Phase H080062 (3)
19 2Insulating Washer –Single Phase G080148-001
19a 2Insulating Washer –Three Phase G080016-001
20 2Shading Coil, Single Phase Only G080022-001
21 4Gap Adjusting Nut W003003-023
22 4Gap Adjusting Nut W003001-020
23 1Cover, Standard L080067-001 L080056-002
23 1Cover, w/ Thru Shaft L080067 (4) L080056-003
24 6Cover Screw W001013-028A
25 1Conduit Hole Plug W008003-001 W010002-004
26 1Name Plate H050020-001
27 1Hub Seal --- W011001-008 ---
28 1Cover Gasket --- K080143-001
29 2Release Cap --- G060170-002
30 1Thru-Shaft Sleeve --- H080036 (5)
31 1Thru-Shaft Seal --- W011001-007
32 6Lockwasher, 1/4 W004007-009 W004006-006 W004007-009
33 1Drain Hole Plug --- W010002-001
34 2Release Cap Gasket --- G070381-001
35 2Drive Screw W001012-048
(1) Number of rotating discs is shown as second digit of Model No. (3) Basic part number shown –specify model number, voltage,
Example: 2-82050-28 phase and frequency.
(2) Number of stationary discs is one less than the number of rotating discs. (4) Basic part number shown –specify shaft diameter.
(5) Basic part number shown –specify shaft diameter and keyway.
Table 1. Parts List
3

DIMENSIONS
DMODEL
NO. TORQUE LB. FT. WEIGHT LBS.
THERMAL
CAPACITY
HPS/MIN
INERTIA
WK
2
LB. FT.
2
CMAX MIN HN +1/32 AC X
2-81025-28 25 65 15 .095 6.31 .065 .035 1.31 1.75 1.50 1.00
2-81035-28 35 65 15 .095 6.31 .065 .035 1.31 1.75 1.50 1.00
2-82050-28 50 71 17 .169 6.94 .065 .035 1.31 2.25 2.12 1.50
2-82070-28 70 71 17 .169 6.94 .065 .035 1.31 2.25 2.12 1.50
2-83075-28 75 77 19 .244 7.56 .070 .040 1.31 2.75 2.75 2.00
2-83105-28 105 77 19 .244 7.56 .070 .040 1.31 2.75 2.75 2.00
2-84125-28 125 83 21 .318 8.19 .080 .050 1.43 3.25 3.38 2.50
2-85175-28 175 89 21 .395 8.81 .080 .050 1.31 3.87 4.00 3.12
Table 2. Standard Housing
Figure 5. Standard Housing
4

MODEL NO. DIMENSIONS
DX
ENCLOSED SEVERE
DUTY TORQUE
LB. FT. WEIGHT LBS.
THERMAL
CAPACITY
HPS/MIN
INERTIA
WK2
LB. FT.2CMAX MIN HN
+1/32 ENCL S.D. AC
4-81025-29 6-81025-32 25 81 15 .095 6.37 .065 .035 1.31 1.75 1.31 1.00 1.50
4-81035-29 6-81035-32 35 81 15 .095 6.37 .065 .035 1.31 1.75 1.31 1.00 1.50
4-82050-29 6-82050-32 50 87 17 .169 7.00 .065 .035 1.31 2.25 1.81 1.50 2.12
4-82070-29 6-82070-32 70 87 17 .169 7.00 .065 .035 1.31 2.25 1.81 1.50 2.12
4-83075-29 6-83075-32 75 93 19 .244 7.62 .070 .040 1.31 2.75 2.31 2.00 2.75
4-83105-29 6-83105-32 105 93 19 .244 7.62 .070 .040 1.31 2.75 2.31 2.00 2.75
4-84125-29 6-84125-32 125 99 21 .318 8.25 .080 .050 1.43 3.25 2.81 2.50 3.38
4-85175-29 6-85175-32 175 105 21 .395 8.87 .080 .050 1.31 3.87 3.44 3.12 4.00
Table 3. Enclosed Housing
Figure 6. Enclosed Housing
5

4740 W. ELECTRIC AVE. ll MILWAUKEE, WI 53219 ll 414/672-7830 ll FAX [phone] ll www.dingsco.com
Printed in U.S.A. BK4604 (12/01)
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
ADJUSTMENT.)
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. (SeeWEAR 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 (20) is cracked, broken
or out of position (single phase only).
D. IF MANUAL RELEASE DOES NOTWORK:
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.)
SPECIFICATIONS
MOTOR FRAMES - 284TC, 286TC.
HOUSINGS - Standard is cast iron and aluminum. Enclosed is all
cast iron.
DUTY - Rated for continuous duty.
VOLTAGES - All standard NEMA voltages and frequencies avail-
able. Other voltages and frequencies are optional.
MOUNTING - Direct to NEMA “C” motor flanges. Adaptors for
larger or smaller frames, foot mounting and vertical mounting are
available.
SHAFTS - NEMA standard length motor shafts and thru shafts may
be used on all models except units with Mark II Release (Cover
modification required for thru shafts).
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
(On hub order furnish bore dia. & keyway dimensions. On
electrical parts specify voltage, phase & frequency.)
REPLACEMENT BRAKE
Model Number
Voltage, Phase & Frequency
Hub Bore &Keyway Dimensions
Mounting - Horizontal orVertical. (If vertical, specify whether above
or below motor. If brake includes foot mounting bracket or adaptor,
specify.)
6