Dings Dynamics Group 40 Series small frame User Manual

40 Series Brake

Instructions

Bulletin No. BK4042 (2/12)

Standard Housing Inertia

Wt. Lbs. Rotating

Model Torque Parts

Lb. Ft. Net Pkg’d WK

2

in

Lb. Ft.

2

2-42001-012 3/4 or 3/8 1 1/2 2 1/2 .001

Table 1. List of Models

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 enclosure 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.

Figure 2. Dimensions of Brake

4740 W. Electric Avenue  Milwaukee, WI 53219  414/672-7830  FAX [phone]  www. dingsbrakes.com

IMPORTANT
Read this bulletin carefully before installing or operating
this brake. Failure to comply with these instructions
cancels all warranties.

Figure 1. 40 Series Brake

G040099-001

DESCRIPTION

This brake is spring set, electromagnetically released. It uses
rotating and stationary disc contact to supply positive braking
action. When energized, the release mechanism compresses a
spring removing force on a pressure plate, and permits free rotation
of a motor shaft.
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 checked periodically and adjusted when necessary.
NOTE: This brake is not intended for accurate positioning applications.
It is designed for applications that require rapid stopping and holding
power such as conveyors, door openers, etc.

INSTALLATION (See Figures 2, 3, 4 & 5)

Before installing, refer to section on Torque Selection.

1. Position hub (8) on motor shaft 1/32” from mounting surface of
motor fan guard and securely tighten both set screws. Bore in hub
(See Figure 2) is designed to give minimum clearance between hub
and motor shaft. If hub is tight on shaft, use emery cloth on motor
shaft, so that hub slides on freely. Loctite or similar adhesive may be
used on motor shaft extension.

2. Remove cover screws (17), lockwashers (18) and cover (16).

3. Place brake on motor, guiding rotating discs (9) on hub. Mount
brake so that grommet (7) is on the wire connection box side of
motor. Depress operator assembly lever (19) and align discs if
needed. Attach brake securely to motor mounting surface using
machine screws (5), lock washer (4) and spacers (2). Use of
needlenose pliers to guide and hold spacer may be helpful. Brake
bracket (3) is to be concentric with motor shaft within .010 T.I.R. and
square within .010.

4. Brake is connected in parallel with motor line leads, therefore
brake is energized when power is applied to motor (115V, 60Hz).

5. Energize brake and motor briefly to insure proper action.

6. Bring solenoid lead wires thru grommet (7) to make the electrical
connection. Replace cover and cover screws.

TORQUE SELECTION

The brake is designed so that the torque can be changed from 3/4
lb. ft. to 3/8 lb. ft.
The brake as furnished has two rotating discs (9), and will have a
nominal static torque rating of 3/4 lb. ft. To reduce torque to 3/8 lb. ft.
a rotating disc must be removed and the solenoid air gap has to be
readjusted. Proceed as follows:
Depress solenoid plunger and remove the rotating disc (9) which
is closest to the solenoid. Release plunger. Set air gap “A” at 3/8
inches by turning set screw (23) clockwise. Depress solenoid
plunger several times and recheck air gap “A”.

MAINTENANCE AND SERVICE

FRICTION DISC REPLACEMENT (See Figures 3 & 5)

CAUTION: High start-stop rates may damage motor and/or brake.
Consult motor manufacturer whenever high cycling rates are
involved.
When total wear on rotating discs (9) reaches .04”, replace discs
as follows:

1. Disconnect solenoid (25) from circuit and remove cover (16).

2. Remove locknuts (15), washers (14), operator assembly (13),
pressure plate (12), stationary disc (11), friction disc (9), stationary
disc (10), and friction disc (9).

3. Replace worn discs and assemble in reverse order. Discs must
slide freely on hub (8).
NOTE: Stationary disc (10) is .060 in. thick, and must be in the
location shown in Fig. 5. Stationary disc (11) is .030 in. thick, and
must be located as shown.

4. Before installing operator assembly (13) turn adjusting screw (23)
counterclockwise 4 or 5 turns to allow operator to be bolted down
without interference.

5. Readjust air gap “A” (See Wear Adjustment).

SOLENOID REPLACEMENT (See Figure 3)

CAUTION: Load to be removed or blocked. Brake will be inoperative
during this procedure.

1. Disconnect solenoid (25) from circuit, and remove cover (16).

2. Remove solenoid assembly (25) and torque spring (21) by
removing fillister head screws (28) and split lock washers (27).

3. Insert new solenoid assembly by sliding plunger (20) into slot of

operator assembly lever (19), keeping torque spring around plunger.

4. Fasten solenoid assembly to mounting bracket (26) with fillister

head screws (28) and split lock washers (27).

5. Adjust air gap “A” (See Wear Adjustment).

WEAR ADJUSTMENT (See Figure 3).

As friction discs wear, magnet air gap “A” increases, thereby
increasing stopping time of brake. Before air gap “A” reaches 716”
maximum (measured on center line of plunger) adjustment for wear
is required. Any delay in adjusting air gap will result in a loss of
torque and/or coil burn out.
To adjust brake, proceed as follows:

1. Remove cover (16).

2. Insert allen wrench into adjusting screw (23) and turn clockwise

until solenoid air gap is approximately 3/8”. Gap is measured
between operator assembly lever (19) and solenoid (25) “C” frame,
at center line of plunger (20).
NOTE: The 3/8” dimension for the air gap is a nominal position. On
low horsepower units, the gap may have to be slightly larger.
Observe motor starting characteristics after adjusting gap. Motor
should start quickly. If not, increase air gap by turning adjusting set
screw (23) 1/8 turn counterclockwise.

Figure 3. Brake Gap Adjustment