Changing and Adjusting Diana Machine’s Brake.

Brake-Monitoring Using 2 NC Contacts in Series

R & D Department

Changing and Adjusting

Diana Machine’s Brake.
Brake-Monitoring Using 2
NC Contacts in Series

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 Changing and Adjusting Diana Machine’s Brake.
Brake-Monitoring Using 2 NC Contacts in Series
R & D Department

Index
Index............................................................................................................................2
Material Needed. .........................................................................................................3
Diagram. ......................................................................................................................4
Procedure ....................................................................................................................5
1 Removing the Brake............................................................................................5
2 Fitting the Brake .................................................................................................7
3 Adjusting the Air Gap .........................................................................................9
4 Adjusting Braking Torque.................................................................................12
5 Adjusting the Brake Monitoring Switch............................................................14
6 Assembling the Brake .......................................................................................15

SECURITY
When adjusting the brakes, working on top of the
car, all security devices necessary for this purpose
are to be used.

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 Changing and Adjusting Diana Machine’s Brake.
Brake-Monitoring Using 2 NC Contacts in Series
R & D Department

Material Needed.
1.1 Allen Keys 4, 5, 6, 14.

1.2 Vernier Caliper.

1.3 Shim from 0.07 to 0.1 mm.

1.4 Diana Machine brake coil. Two different models are used
depending on the machine. DB335-M for 450 Kg and DB335-L
for 630 Kg.

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 CONTROL MACHINE Diagram.
PANEL
Brake
Monitoring
Switch

Fecha de Revisión:05/01/2007
NC1

NO1

NC2

NO2

Rescue
System

Revisión: 1
Brake
R & D Department

Voltage between 6 and 7 > 190 Vdc

Resistance between 6 and 7 115 Ω

aprox.
Brake-Monitoring Using 2 NC Contacts in Series
Changing and Adjusting Diana Machine’s Brake.

Resistance of each coil: 250 Ω aprox

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 Changing and Adjusting Diana Machine’s Brake.
Brake-Monitoring Using 2 NC Contacts in Series
R & D Department

Procedure
1 Removing the Brake.
1.1 Using the 5 mm Allen screwdriver, remove the motor’s pulley
protection. Attention, be aware of the small nuts between the
pulley’s protector and the machine’s sling.

1.2 Disconnect all electrical connections corresponding to the

brake being replaced. These are found at the side of the
motor. Disconnect the coil and the brake-monitoring switch.

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 Changing and Adjusting Diana Machine’s Brake.
Brake-Monitoring Using 2 NC Contacts in Series
R & D Department

1.3 Unscrew the 14 mm screws to release the brake. They must be

unscrewed alternatively.

1.4 Remove the brake. Attention, make sure coil and brake shoe
are grabbed together to avoid them from falling apart. This
should happen, go to chapter 6 to assemble it again.
Attention, the brake weights 20 Kg!

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 Changing and Adjusting Diana Machine’s Brake.
Brake-Monitoring Using 2 NC Contacts in Series
R & D Department

2 Fitting the Brake

2.1 Place the brake in its position. Attention, maintain grabbed
brake and coil together so they do not dismount. This should
happen, go to chapter 6 to assemble it again.

2.2 Screw the 14 mm Allen screws. Screw them by hand, do not

tight too much.

2.3 In order to fit the brake properly, the coil needs to be

energized. Supply the coil with 220 Vdc. Move the brake until
the brake shoe perfectly adapts to the to the machine’s drum.
Attention, only energize the brake being placed!

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 Changing and Adjusting Diana Machine’s Brake.
Brake-Monitoring Using 2 NC Contacts in Series
R & D Department

2.4 Screw the 6mm Allen screws to their maximum. The air gap
(distance between brake shoe holder and coil guard) should
be 0 mm.

2.5 Screw to their maximum the 14 mm Allen screws. They should

be screwed alternatively.

2.6 Disconnect power supply from the brake coil. Confirm that
the air gap is 0 mm.

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 Changing and Adjusting Diana Machine’s Brake.
Brake-Monitoring Using 2 NC Contacts in Series
R & D Department

3 Adjusting the Air Gap

The air gap is the distance between the drum and the brake shoe
when the brake coil is energized. This distance should be adjusted
within 0.07 to 0.12 mm. If the air gap is lower it could result in
waving during the ride because of the friction between drum and
brake shoe. While, with a higher air gap, the brake may become
louder when falling.
3.1 Increasing the air gap
3.1.1 Unscrew 1 turn the 14 mm Allen screws.

3.1.2 Screw the 6 mm Allen screws. Never screw more than 15

degrees. It is important to be aware of that a 15º turn could
increase the air gap in 0.07 mm. It is recommended to
make very small adjustments.

<15º

3.1.3 Screw back the 14 mm Allen screws. Do this operation in

the same way at both sides of the brake, first in one side
then in the other.

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 Changing and Adjusting Diana Machine’s Brake.
Brake-Monitoring Using 2 NC Contacts in Series
R & D Department

3.1.4 Supply 220 Vdc to the brake coil and using the shims
measure the air gap. It is very important to do this measure
at both sides of the brake and throughout the entire
braking surface.

3.1.5 In case the 0.07 shim does not fit between brake shoe and
drum repeat step 3.1.
3.1.6 In case that the 0.12 mm shim fits between brake and
drum, reducing the air gap is necessary, go to step 3.2
3.1.7 The air gap is adjusted when the shim of 0.07 mm fits
between brake shoe and drum and the 0.12 mm does not.
Go to step 4 to adjust the braking torque.
3.2 Decreasing the air gap
3.2.1 Unscrew 1 turn the 14 mm Allen screws.

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 Changing and Adjusting Diana Machine’s Brake.
Brake-Monitoring Using 2 NC Contacts in Series
R & D Department

3.2.2 Unscrew the 6 mm Allen screws. Never turn more than 15

degrees. It is important to be aware of that a 15º turn could
decrease the air gap in 0.07 mm. It is recommended to
make very small adjustments..

<15º

3.2.3 Screw back the 14 mm Allen screws. Do this operation in

the same way at both sides of the brake, first in one side
then in the other.
3.2.4 Supply 220 Vdc to the brake coil and use the shims to
measure the air gap. It is very important to do this measure
at both sides of the brake and throughout the entire
braking surface.

3.2.5 In case the 0.07 shim does not fit between brake shoe and
drum repeat step 3.1.
3.2.6 In case that the 0.12 mm shim fits between brake and
drum, reducing the air gap is necessary, go to step 3.2
3.2.7 The air gap is adjusted when the shim of 0.07 mm fits
between brake shoe and drum and the 0.12 mm does not.
Go to step 4 to adjust the braking torque.

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 Changing and Adjusting Diana Machine’s Brake.
Brake-Monitoring Using 2 NC Contacts in Series
R & D Department

4 Adjusting Braking Torque

The 5 mm Allen screws on top of the brake are for adjusting the
braking torque. For the brake DB335-M there are 10 screws while for
the DB335-L there are 12. Look Figure 1 and Figure 2. It is very
important that all screws are adjusted at the same level in order to
apply a uniform torque throughout the entire braking surface.

Figure 1 Brake DB335-L Figure 2 Brake DB335-M

4.1 The braking torque is measured by the depth of the 5 mm

Allen screws placed at the top of the brake. Use the Vernier
Caliper for this purpose.

4.2 The depth of every screw must be the same. A depth of 2.5
mm applies the rated torque for the two kinds of brakes used.
The deeper the screws are the higher the braking torque will
be.

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 Changing and Adjusting Diana Machine’s Brake.
Brake-Monitoring Using 2 NC Contacts in Series
R & D Department

4.3 The 2.5 mm depth is a typical value. Usually once the screws
have been adjusted to this depth, a fine adjustment could be
necessary.
4.4 It is important to check that the lift complies with the
standard EN81-1:1998 12.4.2.1:
This brake on its own shall be capable of stopping the machine
when the car is traveling downward at rated speed and with the rated
load plus 25 %. In these conditions the retardation of the car shall not
exceed that resulting from operation of the safety gear or stopping on
the buffer.
All the mechanical components of the brake which take part in the
application of the braking action on the drum or disk shall be installed
in two sets. If one of the components is not working a sufficient
braking effort to slow down the car, traveling downwards at rated
speed and with rated load shall continue to be exercised.
4.5 Each screw adjustment shall not be greater than 10º. A turn of
10 degrees results in a considerable torque increase.

<10º

4.6 Important. It is necessary to follow the tests described by the

standard EN81-1 every time the braking torque is modified.
4.7 A fine adjustment of the braking torque is very important. A
low torque could result in the lift not braking. While an
excessive torque results not only in increasing the power
consumption, thus reducing the coil’s lifetime; but also, the
coil may not have enough power to overcome the braking
torque; hence the brake will not let the drum move freely,
resulting in vibrations or waving during the ride.

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 Changing and Adjusting Diana Machine’s Brake.
Brake-Monitoring Using 2 NC Contacts in Series
R & D Department

5 Adjusting the Brake Monitoring Switch

The Altamira controller uses two normally closed contacts in series to
monitor the brake. These contacts are opened when the brake coil is
energized. When the brake shoe lifts, it hits the switch, which opens
the contact. The central, screw 4 mm Allen, is to adjust the height of
this switch, so it is active when the brake coil is energized and closed
when the brake is closed.

Adjusting the Brake

Monitoring Switch

5.1 Test that when the coil is energized the contact opens and
when the coil is de-energized the contact closes.
5.2 If the contact is closed either when the coil is energized or
not; the switch must be lowered. Screw the 4 mm Allen screw.
Attention! Make very small adjustments, if the switch is set
too low the brake can damage the switch when lifted. This
should happen go, to the assembling the brake chapter.
Adjustments shall not exceed 10 degrees.
5.3 If the contact is always open the switch must be set higher.
Unscrew the 4 mm Allen screw. Make small adjustments,
never more than 10 degrees and test the switch again.

<10º

Important. An incorrect set of the switch may result in the control

panel not being able to monitor the opening and closing of the brake.

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 Changing and Adjusting Diana Machine’s Brake.
Brake-Monitoring Using 2 NC Contacts in Series
R & D Department

6 Assembling the Brake

The machine’s brake includes the brake shoe along with its support
and the brake coil guard. The brake coil guard holds the coil, the brake
confirmation switch and the torque adjusting screws. Depending on
the brake model the number of screws varies from 10 to 12, for the
brakes DB335-M and DB335-L respectively. To each screw corresponds
one spring coupled to the coil guard by a circular plate. Attention, it is
important to keep coil and brake together as the springs and their
supports can fall down. In case that separating coil and brake shoe is
necessary, it must always be done with the brake shoe facing upwards
to avoid the springs from falling.

Guide for Brake

shoe holder

Brake Braking
Monitoring Springs
Switch

6.1 The next pictures show how to place the springs with their
support into the brake coil guard:

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 Changing and Adjusting Diana Machine’s Brake.
Brake-Monitoring Using 2 NC Contacts in Series
R & D Department

6.2 Adjusting the brake-monitoring switch.

6.2.1 The metallic part of the switch shall never excel the surface
of the brake coil holder. If this happens the brake shoe will
damage the switch when lifted by the coil.

6.2.2 Once the brake is assembled the height of the switch can
be adjusted with the 4 mm screw placed at the center of
the top part of the brake, as told in chapter 5.

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