P/N 8-078-905-60
effective 03/16/06
®
Spring-Set Disc Brakes
For replacement parts refer to sheets:
Series
Sheet Part No.
8-078-906-00
8-078-906-01
8-078-906-02
8-078-906-03
8-078-906-04
8-078-906-05
8-078-906-06
8-078-906-09
Installation and Service Instructions
for 1-056-X00* Series (all revisions)
Manual Adjust Brakes
1-056-000
1-056-100
1-056-200
1-056-300
1-056-400
1-056-500
1-056-600
1-056-900
This sheet includes Series 1-056,000; 1-056,100; 1-056,200;
1-056,300; 1-056,400; 1-056,500; 1-056,600 and 1-056,900.
For other series consult factory.
*
Also available at www.rexnord.com
1-056-100
1-056-600
a) Wear a filtered mask or a respirator
while removing dust from the inside
of a brake.
b) Use a vacuum cleaner or a soft
brush to remove dust from the
brake. When brushing, avoid caus-
ing the dust to become airborne.
Collect the dust in a container, such
as a bag, which can be sealed off.
1-056-000
1-056-400
1-056-500
1-056-200
1-056-900
10. Caution! While the brake is
equipped with a manual release to
allow manual shaft rotation, the
motor should not be run with the
manual release engaged, to avoid
overheating the friction disc(s).
1-056-300
Tools required for installation and servicing:
3/8” hex wrench
5/16” hex wrench
3/16” hex wrench
5/16” nut driver
1/4” screwdriver
8” adjustable wrench
General Description
3. To prevent an electrical hazard,
disconnect power source before
working on the brake. If power
disconnect point is out of sight, lock
disconnect in the off position and tag
to prevent accidental application of
power.
Typical Nameplate
These series of brakes are spring-set,
electrically released. They contain one or
more rotating friction discs (4) driven by a
hub (16) mounted on the motor or other
shaft.
Operating Principle
These series contain one or more friction
discs (4) assembled alternately between
the endplate (2) friction surface, stationary
disc(s) (3) and pressure plate (also called
stationary disc) (3). The stationary disc(s)
are restrained from rotating by being keyed
into the endplate. With the brake released,
all disc pack components are free to slide
axially and the friction disc(s) to rotate.
Brake release occurs when the solenoid
coil is electrically energized, causing the
solenoid plunger to travel a specified
distance and through a lever system,
overcoming the pressure spring force.
This action releases the clamping force
on the disc pack, thereby allowing the
friction disc(s) and brake hub to rotate.
Brake sets and torque is produced when
electric current to the solenoid coil is
interrupted, thereby collapsing the
solenoid magnetic field. The solenoid
plunger returns to its original
de-energized position allowing the lever
arm to move forward by virtue of the
compressed torque springs. This action
compresses the disc pack components
which applies a retarding torque to the
brake hub and ultimately restores the
brake to a spring-set static condition.
4. Make certain power source conforms
to the requirements specified on the
brake nameplate.
5. Be careful when touching the exterior
of an operating brake. Allow sufficient
time for brake to cool before
disassembly. Surfaces may be hot
enough to be painful or cause injury.
6. Do not operate brake with housing
removed. All moving parts should be
guarded.
7. Installation and servicing should be
performed only by qualified personnel
familiar with the construction and oper-
ation of the brake.
8. For proper performance and
operation, only genuine Stearns parts
should be used for repairs and
replacements.
9. After usage, the brake interior will con-
tain burnt and degraded friction mate-
rial dust. This dust must be removed
before servicing or adjusting the
brake.
Important
Please read these instructions carefully
before installing, operating, or servicing
your Stearns Brake. Failure to comply
with these instructions could cause injury
to personnel and/or damage to property if
the brake is installed or operated incor-
rectly. For definition of limited warranty/lia-
bility, contact Rexnord Industries, LLC,
Stearns Division,5150 S. International Dr.,
Cudahy, WI 53110, (414) 272-1100.
Caution
1. Installation and servicing must be
made in compliance with all local
safety codes including Occupational
Safety and Health Act (OSHA). All
wiring and electrical connections must
comply with the National Electric Code
(NEC) and local electric codes in
effect.
DO NOT BLOW OFF DUST using an
air hose. It is important to avoid
dispersing dust into the air or inhaling
it, as this may be dangerous to your
health.
2. Do not operate the brake in
atmospheres containing explosive
gases or dusts.
AIR GAP ADJUSTMENT 1-056-X00
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. Use
To decrease air gap, turn both adjusting
3/16 hex wrench, or flat screwdriver on older models.
ꢀ
screws (10) clockwise.
ꢁ
56,X00 Series Air Gap* (REV A & B)
Disc Torque Min/Max
Torque
1
2
3
1.5, 3 & 6 .38” .69”
10 & 15 .45” .69”
20 & 25 .50” .69”
clockwise
*
.30”
56,X00 Series Air Gap* (REV C)
Disc
Torque
3, 6,
Min/Max
3/16 hex wrench
2
3
.45” .69”
3/16 hex wrench
counter-clockwise
10 & 15
20 & 25 .50” .69”
Maximum gap should never exceed .69”
* .30”
COIL REPLACEMENT SERIES 1-056-X00
Remove housing and disconnect power and wiring to coil.
Insert screwdriver between support
plate and lever arm and pry forward.
Lift plunger/solenoid
lever assembly
out of coil.
Remove plunger guide.
ꢀ
ꢆ
ꢃ
ꢁ
A) Re-insert plunger into coil; drop
pivot pin into cradle of support plate.
B) Remove screwdriver.
Discard coil.
A) Insert new coil. (Lead wires
in same position as old coil.)
B) Insert plunger guide.
ꢅ
ꢄ
A
B
B
A
Reconnect coil and replace housing per installation instructions, page 2.
VERTICAL SPRING ASSEMBLY 1-056-X00
Mount support plate and torque screws
evenly to 55 lb-in.
Vertical Brake Assembly
Installation Procedure for 20 and
25 lb-ft brakes if mounted vertical
to motor shaft (These brakes are
Single disc brakes (1.5, 3 & 6 lb-ft) are
universal mount and do not require
separator springs. Double disc brakes
(10-15 lb-ft.) are universal mount but require
separator springs which are preassembled
to the stationary disc. These discs are
inserted spring first into the brake.
Refer to figure 5A below.
factory assembled for horizontal operation.)
Remove support plate by loosening the
three mounting screws.
Remove stationary discs and friction discs.
Using the spring kit provided with this
brake, insert three springs of identical color
into each stationary disc hole. Springs are
inserted from the side opposite the indent
mark (see Figure 5B). Stationary disc
should be placed on a clean flat surface
with a clearance hole to allow the tip of the
spring to extend through the bottom side of
the stationary plate. Using the 1/8” pin
provided and a hammer, drive the spring
until the large coil diameter bottoms out
against the disc.
Figure 5B
Figure 5A
Reassemble the disc pack with the
stationary discs in the proper arrangement
shown in Figure 5C.
Figure 5C
3
TORQUE ADJUSTMENT
TABLE A
Torque Adjustment
Nominal Original Maximum % Torque
11
Brake is factory set for nominal rated static
torque which is maximum torque. Torque
may be decreased up to 50% for increased
stopping times up to 2 second stop time.
11
Static
Torque
(lb-ft)
1-1/2
3
Spring
Counter-
Reduction
per
Height clockwise
(inches)
1.56”
1.50”
1.50”
1.56”
1.56”
1.56”
1.50”
Turns
-
Turn
-
The torque on the 1-1/2 lb-ft brake may not
be reduced.
6
10
10
10
15
20
25
5-1/2
9%
Turn both spring adjustment screws (11),
Figure 6, equal amounts counterclockwise
to decrease torque. See Table A for torque
reduction permissible amounts.
Figure 6
TROUBLESHOOTING
COIL FAILURE
SUPPLY VOLTAGE CAUSE
EXCESSIVE WEAR / OVERHEATING
AIR GAP CAUSE
Low solenoid air gap
AIR GAP CORRECTION
Reset air gap (refer to Air Gap
Adjustment)
Inspect endplate, hub and discs for
dirt, burrs, wiring and other sources
of interference preventing disc “float”
SUPPLY VOLTAGE CORRECTION
Line voltage >110% of coil rating Reduce voltage or replace with
proper rated coil
Disc pack dragging
AC input on a DC coil
Replace rectifier or replace with
proper rated coil.
Excessive voltage drop during
inrush time
Increase current rating of power
supply.
CYCLE RATE CAUSE
Brake “jogging” exceeding coil
cycle rate
CYCLE RATE CORRECTION
Reduce cycle rate or consider
alternate control method
WIRING CAUSE
WIRING CORRECTION
Reduce cycle rate, use alternate
control method or increase brake
size
Leadwires interfering with plunger Reroute wiring away from plunger
Thermal capacity is being
exceeded
pull-in
and other moving components.
Excessive voltage drop during
inrush time
Increase leadwires size from power
supply
ALIGNMENT CAUSE
ALIGNMENT CORRECTION
Broke endplate not concentric to
motor C-Face
Motor register must be within
.004” on concentricity.
Coil leadwire shorted to ground
Replace coil or leadwire and protect
with wire sleeving
SOLENOID ASSEMBLY
CORRECTION
SOLENOID ASSEMBLY CAUSE
Motor shaft runout is excessive
Must be within .002”; runout;
consult motor manufacturer
Plunger not seating flush against Loosen solenoid mounting screws
Brake is being operated on a
incline greater than 15° above or
below horizontal
Vertical separator springs must be
used to prevent discs from
becoming cocked
solenoid frame
and reposition frame to allow full
face contact
Plunger cocked in coil preventing Realign solenoid frame
pull-in
WORN PARTS CAUSE
WORN PARTS CORRECTION
Friction disc excessively worn
(disc can wear to 1/2 original
thickness or .093”)
Endplate, stationary disc or
pressure plate warped
Replace friction discs.
Excessive solenoid/plunger wear Replace solenoid assembly
at mating surface
Broken shading coils
WORN PARTS CAUSE
Replace solenoid assembly
Replace warped or worn component
Replace all worn components
WORN PARTS CORRECTION
Excessive wear of solenoid link
arm and/or shoulder bolt
Replace link arm and link bolt; also
inspect plunger thru-hole for
elongation
Linkages and/or pivot pins worn
Motor shaft endfloat excessive
Endfloat must not exceed .020”;
consult motor manufacturer
HUB CORRECTION
File off burr
Plunger guides worn down and
interfering with plunger
movement
Replace guides
HUB CAUSE
Burr on hub interfering with disc
“float”
APPLICATION CAUSE
APPLICATION CORRECTION
Set screw backed out and
interfering with disc
Retighten set screw; use Loctite®
242 to help secure
Machinery cycle rate is exceeding Reduce brake cycle rate or use
brake rating
alternate control method
MISCELLANEOUS
MISCELLANEOUS
High ambient temperature
(>110%) and thermal load
exceeding coil insulation rating
Brake coil wired with windings of Wire coil to dedicated power source
an Inverter motor or other
voltage/current limiting device
Use Class H rated coil and /or find
alternate method of cooling brake
Solenoid plunger not pulling
completely
Check line voltage ( 10% of
nameplate rating) or replace worn
solenoid assembly
with instantaneous coil rated voltage
Wiring is restricting disc pack
movement
Reroute wiring
MISCELLANEOUS CAUSE
MISCELLANEOUS CORRECTION
Increase brake size/torque or use
alternate control method
Excessive stop time
(2 seconds or greater)
Replace with proper spring or refer
to Installation section for proper
spring height
Wrong or over tightened torque
Reduce cycle rate or use alternate
method of cooling
High Ambient temperature
(in excess of 110°F)
Excessive air gap
Reset, refer to Installation Section 4
Rexnord Industries, LLC., Stearns Division, 5150 S. International Dr., Cudahy, WI 53110, (414) 272-1100 Fax: (414) 277-4364 www.rexnord.com
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