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P/N 8-078-905-60

Spring-Set Disc Brakes effective 06/14/11


For replacement parts refer to sheets:

Installation & Service Instructions Series


1-056-000
Sheet Part No.
8-078-906-00
1-056-100 8-078-906-01
for 1-056-X00* Series (all revisions) 1-056-200
1-056-300
8-078-906-02
8-078-906-03
Manual Adjust Brakes 1-056-400
1-056-500
8-078-906-04
8-078-906-05
*This sheet includes Series 1-056,000; 1-056,100; 1-056,200; 1-056-600 8-078-906-06
1-056,300; 1-056,400; 1-056,500; 1-056,600 and 1-056,900.
1-056-900 8-078-906-09
For other series consult factory.
Also available at www.stearns.rexnord.com
1-056-100
1-056-600 ing, avoid causing the dust to become air-
borne. Collect the dust in a container, such
1-056-000 as a bag, which can be sealed off.
1-056-400
1-056-500 10. Caution! While the brake is equipped with
a manual release to allow manual shaft
1-056-200 rotation, the motor should not be run with
1-056-900 the manual release engaged, to avoid over-
heating the friction disc(s).
General Description
These series of brakes are spring-set, elec-
trically released. They contain one or more
1-056-300 Tools required for installation and servicing: rotating friction discs (4) driven by a hub (16)
0-300 lb-in torque wrench mounted on the motor or other shaft.
3/8 hex wrench 5/16 nut driver Note: Fan-guard mounted brakes requiring
5/16 hex wrench 1/4 screwdriver IP54 & IP55 protection may require additional
3/16 hex wrench 8 adjustable wrench sealing measures beyond seals provided with
this brake. Pressurized sprays aimed at the
fan and brake hub surfaces can result in fluid
Typical Nameplate the use of suitably designed and installed
migration along the motor shaft and keyway,
HazLoc equipment. When questions arise
and into the brake. The use of an appropri-
consult local Authority Having Jurisdiction
ate sealant such as RTV or a forsheda seal is
(AHJ).
advised.
3. To prevent an electrical hazard, disconnect
power source before working on the brake. Operating Principle
If power disconnect point is out of sight, These series contain one or more friction discs
lock disconnect in the off position and tag (4) assembled alternately between the endplate
to prevent accidental application of power. (2) friction surface, stationary disc(s) (3) and
4. Make certain power source conforms to pressure plate (also called stationary disc) (3).
the requirements specified on the brake The stationary disc(s) are restrained from rotat-
nameplate. ing by being keyed into the endplate. With the
brake released, all disc pack components are
5. Be careful when touching the exterior of an free to slide axially and the friction disc(s) to
operating brake. Allow sufficient time for rotate.
brake to cool before disassembly. Surfaces
may be hot enough to be painful or cause Brake release occurs when the solenoid coil
Important
injury. is electrically energized, causing the solenoid
Please read these instructions carefully before plunger to travel a specified distance and
installing, operating, or servicing your Stearns 6. Do not operate brake with housing through a lever system, overcoming the pres-
Brake. Failure to comply with these instructions removed. All moving parts should be sure spring force. This action releases the
could cause injury to personnel and/or damage guarded. clamping force on the disc pack, thereby allow-
to property if the brake is installed or operated 7. Installation and servicing should be per- ing the friction disc(s) and brake hub to rotate.
incorrectly. For definition of limited warranty/lia- formed only by qualified personnel familiar Brake sets and torque is produced when electric
bility, contact Rexnord Industries, LLC, Stearns with the construction and operation of the current to the solenoid coil is interrupted, there-
Division,5150 S. International Dr., Cudahy, WI brake. by collapsing the solenoid magnetic field. The
53110, (414) 272-1100. 8. For proper performance and operation, only solenoid plunger returns to its original de-ener-
genuine Stearns parts should be used for gized position allowing the lever arm to move
Caution
repairs and replacements. forward by virtue of the compressed torque
1. Installation and servicing must be made
9. After usage, the brake interior will contain springs. This action compresses the disc pack
in compliance with all local safety codes
burnt and degraded friction material dust. components which applies a retarding torque to
including Occupational Safety and Health
This dust must be removed before servic- the brake hub and ultimately restores the brake
Act (OSHA). All wiring and electrical con-
ing or adjusting the brake. to a spring-set static condition.
nections must comply with the National
Electric Code (NEC) and local electric DO NOT BLOW OFF DUST using an air
codes in effect. hose. It is important to avoid
2. Use of this brake in atmospheres contain- dispersing dust into the air or inhaling it, as
ing explosive gases and dusts must be this may be dangerous to your health.
in accordance with NEC article 501. This a) Wear a filtered mask or a respirator
brake is not suitable for use in certain while removing dust from the inside of a
atmospheres containing explosive gases brake.
and dusts. HazLoc inspection authorities b) Use a vacuum cleaner or a soft brush to
are responsible for verifying and authorizing remove dust from the brake. When brush-
BRAKE MOUNTING (Manual Adjust) 1-056-X00

Place hub on motor shaft. Position hub on shaft as shown. Tighten set screws to motor shaft.
156-165 lb-in
.188
(4.77mm)

Remove brake housing. Slide endplate over hub noting position


of stabilizer clips, if used.
Housings vary by series number. (Refer to Friction Disc
See page 1. Replacement, view 3 and 3A.)
Tighten mounting screws.

counter- 180-240 lb-in


clockwise
*Brakes under 20 lb-ft torque
rating, with IP-23 enclosure rating only
require two 3/8-16 mounting bolts.
- Do not use lock-washers with mounting bolts.
- For vertical assembly of 20 & 25 lb-ft brakes,
refer to page 3

AC coils are 50/60 Hz, single Replace brake housing and tighten to torque specified below:
phase rated. Power supply to
coil must not have current or Brake series Torque
frequency limiting output that is 1-056-000 1-056-300
8-10 lb-in
less then the coil requirement. 1-056-400 1-056-500
1-056-100 1-056-200
12-14 lb-in
- Connect leadwires to power 1-056-600 1-056-900
source. Verify voltage rating*
per nametag on coil.
- Keep wiring away from pinch
points and moving components. clockwise

* For DC voltages see


sheet 8-078-950-00.

FRICTION DISC REPLACEMENT SERIES 1-056-X00


Install new friction disc(s) and
Remove support plate screws and
stationary disc(s) as shown.
lift support from brake
Note: Stabilizer clips should never be located over the set
screws of the hub.

Single disc brakes always use two stabilizer clips, locate at 90


counter- from each other.
clockwise
Double disc brakes typically will not require stabilizer clips, how-
ever there are some special modifications that will use them.

Rev A & B may have these clips may have these clips located
1 per disc, and should never be positioned in line with each
other.

Rev C will have only one clip, used on the inner-most disc. No
Remove and discard old friction disc. clip will be used on the outer-most disc.

Three disc brakes will never use stabilizer clips on friction discs.

Reposition support plate on endplate and


tighten mounting screws to 55-58 lb-in.
clockwise

Note: Friction discs can wear to 1/2 their original thicknes, or .093

2
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)
Torque
Disc Torque Min/Max
1 1.5, 3 & 6 .38 - .69
2 10 & 15 .45 - .69
3 20 & 25 .50 - .69 clockwise

56,X00 Series Air Gap (REV C)


Disc Torque Min/Max
3, 6, 3/16 hex wrench 3/16 hex wrench
2 .45 - .69
10 & 15 counter-clockwise
3 20 & 25 .50 - .69
Maximum gap should not exceed .69

COIL REPLACEMENT SERIES 1-056-X00


Remove housing and disconnect power and wiring to coil.
Insert screwdriver between support Lift plunger/solenoid Remove plunger guide.
plate and lever arm and pry forward. lever assembly
out of coil.

Discard coil. A) Insert new coil. (Lead wires A) Re-insert plunger into coil; drop
in same position as old coil.) pivot pin into cradle of support plate.
B) Insert plunger guide. B) Remove screwdriver.

A B
B

Reconnect coil and replace housing per installation instructions, page 2.

VERTICAL SPRING ASSEMBLY 1-056-X00


Vertical Brake Assembly Installation Procedure for 20 and Mount support plate and torque screws
25 lb-ft brakes if mounted vertical evenly to 55-58 lb-in.
Single disc brakes are universal mount and
do not require separator springs. Double to motor shaft (These brakes are
disc brakes are universal mount but require factory assembled for horizontal operation.)
separator springs which are preassembled Remove support plate by loosening the
to the stationary disc. These discs are three mounting screws.
inserted spring first into the brake. Remove stationary discs and friction discs.
Refer to figure 5A below. Using the spring kit provided with this
brake, insert three springs of identical color
into each stationary disc hole. Springs are Figure 5B
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
Figure 5A until the large coil diameter bottoms out
against the disc.
Reassemble the disc pack with the
stationary discs in the proper arrangement Figure 5C
shown in Figure 5C.

3
TORQUE ADJUSTMENT
TABLE A
Torque Adjustment
Nominal Original Maximum % Torque
Brake is factory set for nominal rated static 11 11 Static Spring Counter- Reduction
torque which is maximum torque. Torque Torque Height clockwise per
may be decreased up to 50% for increased (lb-ft) (inches) Turns Turn
stopping times up to 2 second stop time. 1-1/2 1.69 - -
The torque on the 1-1/2 lb-ft brake may not 3 1.47
be reduced. 10 6 1.47
10
Turn both spring adjustment screws (11), 10 1.53 7 7%
Figure 6, equal amounts counterclockwise 15 1.53
to decrease torque. See Table A for torque Figure 6 20 1.53
reduction permissible amounts. 25 1.47

TROUBLESHOOTING
COIL FAILURE EXCESSIVE WEAR / OVERHEATING
SUPPLY VOLTAGE CAUSE SUPPLY VOLTAGE CORRECTION AIR GAP CAUSE AIR GAP CORRECTION
Low solenoid air gap Reset air gap (refer to Air Gap
Line voltage >110% of coil rating Reduce voltage or replace with
Adjustment)
proper rated coil
Disc pack dragging Inspect endplate, hub and discs for
AC input on a DC coil Replace rectifier or replace with dirt, burrs, wiring and other sources
proper rated coil. of interference preventing disc float
Excessive voltage drop during Increase current rating of power CYCLE RATE CAUSE CYCLE RATE CORRECTION
inrush time supply. Brake jogging exceeding coil Reduce cycle rate or consider
WIRING CAUSE WIRING CORRECTION cycle rate alternate control method
Leadwires interfering with plunger Reroute wiring away from plunger Reduce cycle rate, use alternate
Thermal capacity is being
pull-in and other moving components. control method or increase brake
exceeded
size
Excessive voltage drop during Increase leadwires size from power
inrush time supply ALIGNMENT CAUSE ALIGNMENT CORRECTION
Coil leadwire shorted to ground Replace coil or leadwire and protect Broke endplate not concentric to Motor register must be within
with wire sleeving motor C-Face .004 on concentricity.

SOLENOID ASSEMBLY
SOLENOID ASSEMBLY CAUSE Motor shaft runout is excessive Must be within .002; runout;
CORRECTION
consult motor manufacturer
Plunger not seating flush against Loosen solenoid mounting screws
solenoid frame and reposition frame to allow full Brake is being operated on a Vertical separator springs must be
face contact incline greater than 15 above or used to prevent discs from
below horizontal becoming cocked
Plunger cocked in coil preventing Realign solenoid frame
pull-in WORN PARTS CAUSE WORN PARTS CORRECTION
Excessive solenoid/plunger wear Replace solenoid assembly Friction disc excessively worn Replace friction discs.
at mating surface (disc can wear to 1/2 original
thickness or .093)
Broken shading coils Replace solenoid assembly
Endplate, stationary disc or Replace warped or worn component
WORN PARTS CAUSE WORN PARTS CORRECTION pressure plate warped
Excessive wear of solenoid link Replace link arm and link bolt; also Linkages and/or pivot pins worn Replace all worn components
arm and/or shoulder bolt inspect plunger thru-hole for
Motor shaft endfloat excessive Endfloat must not exceed .020;
elongation
consult motor manufacturer
Plunger guides worn down and Replace guides
HUB CAUSE HUB CORRECTION
interfering with plunger
movement Burr on hub interfering with disc File off burr
float
APPLICATION CAUSE APPLICATION CORRECTION
Machinery cycle rate is exceeding Reduce brake cycle rate or use Set screw backed out and Retighten set screw; use Loctite
brake rating alternate control method interfering with disc 242 to help secure
High ambient temperature Use Class H rated coil and /or find MISCELLANEOUS MISCELLANEOUS
(>110%) and thermal load alternate method of cooling brake Solenoid plunger not pulling Check line voltage (10% of
exceeding coil insulation rating completely nameplate rating) or replace worn
Brake coil wired with windings of Wire coil to dedicated power source solenoid assembly
an Inverter motor or other with instantaneous coil rated voltage Wiring is restricting disc pack Reroute wiring
voltage/current limiting device movement
MISCELLANEOUS CAUSE MISCELLANEOUS CORRECTION Excessive stop time Increase brake size/torque or use
(2 seconds or greater) alternate control method
Replace with proper spring or refer
Wrong or over tightened torque
to Installation section for proper Reduce cycle rate or use alternate
High Ambient temperature
spring height method of cooling
(in excess of 110F)
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.stearns.rexnord.com