Procedure to Install the New Autogap
components in ER-1225 and ER825
Brake with inverted Armature Hub
®
P-230-1
819-0376
Installation & Operating Instructions
2
Warner Electric • 800-825-9050 P-230-1
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Kit Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembling Armature/Hub Assembly . . . . . 3
Assembling the New Autogap . . . . . . . . . . . . . 4
Warranty . . . . . . . . . . . . . . . . . . . . . . Back Page
Failure to follow these
instructions may result in product damage, equipment damage, and serious or
fatal injury to personnel.
Introduction
This instruction sheet provides detailed instructions for the replacement of existing autogap
assemblies with new design autogap assemblies
on Warner Electric® ER brakes for MontgomeryKone®
Note: Please review the entire installation procedure prior to starting any work.
Please follow these instructions carefully to ensure proper operation.
Failure to comply with these instructions can
result in damage to property and injury or
even death to personnel.
Applying power to the brake
will release its hold on the escalator and may
allow it to move. To prevent escalator movement and the damage and/or injury that may
result, the escalator must be held in place by
another means.
Keep fingers clear of the air
gap area between the magnet (item 11) and
the armature (item 3) - as the armature will
be pulled sharply toward the magnet after the
gap between them is closed to approximately
1/8 inch. See Figure 1. Injury can result if fingers are pinched between the armature and
magnet.
3
2
11
1
Armature
See Detail A
Hub
Magnet
Taper Lock
Bushing
9
8
10
4
3
5
2
7
6
Follow
Up Cup
Blue
Spring
Retainer
Ring
Pin
Armature
Yellow Spring
Hub
Detent Ring
Detent Cup
Detail A
12 Set Screw
Airgap
Figure 1
3
Warner Electric • 800-825-9050 P-230-1
The kit part number for ER-825 is 5250-101-008
and for ER-1225 is 5252-101-005. The kit
includes the following parts.
Kit Parts List - See Figure 3
(Item Model 825 Model 1225
Name No.) (Qty) (Qty)
Pin & detent assembly 4 & 7 3 4
Detent Cup 6 3 4
Yellow Conical Spring 5 3 4
Red Straight Spring 8 3 4
Follow Up Cup 9 3 4
Retainer Ring 10 3 4
Instruction Manual 1 1
Claim Form 1 1
Tools required (not included)
• 1/4" Hex key wrench for taper lock bushing
set screws – ER-1225.
• 3/16" Hex key wrench for taper lock bushing
set screws – ER-825.
• 5/16" Hex key wrench for pins.
• 7/32" Hex key wrench for mounting screws.
• Tube Grade 242 Loctite.
• Snap ring pliers, external.
• Torque wrench minimum 200 lb.ft. reading
– ER-825.
• Torque wrench minimum 400 lb.ft. reading
– ER-1225.
• 3 steel shims, equal thickness, not less than
1/16", nor greater than 1/8".
• Small hammer (approximately 8 ounce).
• Drift
Disassembling the Armature/Hub
Assembly (See Figure 1)
Do not pry the armature away
from the magnet. If armature is distorted the
entire brake must be replaced.
Note: Steps (1) and (2) are to be performed at
the motor and (3), (4), (5), (6) and (7) are to be
performed on a bench away from the motor.
Note: Make sure power to the brake is turned
off. See Figure 1 for the following seven
steps.
Step 1: Loosen the taper-lock bushing (item1)
on the motor shaft.
To loosen, remove both set screws
(item 12) from the taper lock bushing
(item 1) using a hex key wrench. Insert
one set screw into the previously
vacant hole in the taper lock bushing
and tighten this screw until the bushing is loosened in the hub (item 2). If
the bushing does not loosen, tap on
the hub with a drift and small hammer.
Step 2: Apply power to the brake. The arma-
ture will then spring away from the
magnet. If it does not, check electrical
connections and release voltage per
Montgomery-Kone® instructions.
Remove taper lock bushing (item 1)
and armature assembly (items 2 & 3)
from the motor shaft. Set the bushing
aside. Do not discard the bushing.
Step 3: Remove the retainer rings (item 10)
from pins (item 4). Discard rings.
Step 4: Remove the blue conical springs (item
8). Discard them.
Step 5: Remove the follow-up cups (item 9).
Discard them.
Step 6: Remove the armature (item 3) and set
it aside.
Do not discard.
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Warner Electric • 800-825-9050 P-230-1
Step 7: Use hex key wrench to remove the
four drive pins (item 4). Discard four
pins together with four detent rings
(item 7), four detent cups (item 6), and
four yellow springs (item 5). Do not
discard hub.
Note: Do not remove the magnet from the
motor.
Assembling the New Autogap
Components with the existing Hub and
Armature
(See Figures 2, 3, 4, & 5).
Note: Steps 1 through 8 below are to be done
on a bench away from the motor.
During Steps 1 through 3,
ensure that the detent ring (item 7) does not
slide off the pin (item 4). Make sure the yellow spring (item 5) is not pinched between
the pin (item 4) and the hub (item 2).
Step 1: Each new detent ring (item 7) is
assembled on each new pin (item 4) at
the factory. Ensure that each detent
ring is approximately 7/8 inch away
from the shoulder of the pin. If it is
not, slide the detent ring into position
as shown in Figure 2.
Figure 2
Step 2: Assemble each new detent cup (item
6) with concave side towards the
detent ring (item 7) and each new yellow spring (item 5) onto each new pin
(item 4) as shown in Figure 2. Make
sure the small end of the yellow spring
is on the 5/8 inch diameter as shown
in Figure 2.
Step 3: Following the manufacturer’s instruc-
tions, apply Grade 242 Loctite to each
of the new pin threads (item15) and,
using the hex key wrench, screw the
four new pins (item 4) into the hub
(item 2). Tighten each pin to 45-50
lb.ft. of torque using a torque wrench.
During Steps 4, 5, 6, 7 and 8, do
not slam the armature down on the detent
cups. Slamming the armature on the detent
cups can deform the cups and cause the
armature to rub during operation.
Step 4: Slide the previously saved armature
(item 3) onto the pins, and gently
push down on the armature towards
the hub (item 2) until it bottoms out.
Step 5: Assemble each new red straight
spring (item 8) onto each armature
boss (item 13) as shown in Figure 3,
Detail B.
Detent RIng
7
Pin
4
Yellow
Spring
5
.875 ± .030
5/8 Diameter
Detent Cup
6
Pin Groove
16
Threads
15
Face of the
Armature
Armature
3
See Detail B
Hub
Magnet
Taper Lock
Bushing
2
11
1
3
10
4
9
8
5
2
7
6
Armature
Retainer
Ring
Pin
Follow
Up Cup
Armature
Boss
Red
Spring
Detent Ring
Detent Cup
Yellow Spring
Hub
Detail B
13
Figure 3
5
Warner Electric • 800-825-9050 P-230-1
Step 6: Assemble each new follow up cup
(item 9) over the pin and over the red
spring (item 8) as shown in Figure 3,
Detail B.
Do not expand retainer ring
(item 10) more than needed to slide over the
pin (item 4). Expanding the retainer ring too
far can cause it to yield or break.
Step 7: Assemble each retainer ring in the pin
groove (item 16) as shown in Figure 2.
Make sure the retainer ring is
fully seated in the groove.
Step 8: Place the armature/hub assembly on a
flat surface with the armature working
face up and push down on each
detent cup with fingers to slide the
armature down until the armature
can't be pushed down any further, as
shown in Fig. 4.
Figure 4
During steps 9 through 11, handle the armature/hub assembly by the hub
(item 2) only, making sure the armature (item
3) is as close to the retainer ring (item 10) as
possible. Any movement of the armature on
the pins will reduce available armature travel
and may cause improper setting of the running air gap.
Note: Steps 9-15 below are to be performed at
the installation site.
.062 inch thick shims are rec-
ommended. Do not use shims thicker than
0.125 inch or you will shorten brake life by
reducing available armature travel.
Keep fingers clear of the area
between the magnet (item 11) and the armature (item 3) as the armature will be pulled
sharply toward the magnet after the gap
between them is closed to approximately 1/8
inch. See Figure 3. Injury can result if fingers
are pinched between the armature and magnet.
Step 9: Turn off power to the brake. Place
three steel shims 120 degrees apart
on the magnet as shown in Figure 5.
Insert the taper-lock bushing (item 1)
into the hub (item 2). Align the two half
drilled holes in the taper-lock bushing
(item-1) with the two half threaded
holes in the hub (item-2). Insert the
two set screws into the above aligned
holes & screw them loosely in by hand
to maintain the alignment during
assembly.
Slip the armature hub assembly onto
the brake shaft until the armature
makes contact with the shims. Place a
drift at several points around the circumference against the large end of
the taper lock bushing (item 1) and tap
it lightly with a small hammer (approximately 8.oz), until it does not slide farther on the shaft.
Figure 5
Apply Downward
Pressure on the
Detent cup.
Armature Working
Face up
3
2
11
1
Armature
Press two places
on armature to
set air gap
Hub
Magnet
Three shims 120° apart
Push
Taper Lock
Bushing
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Warner Electric • 800-825-9050 P-230-1
Step 10: Using a hex key wrench, tighten the
hub bushing screws (item 12) alternately and evenly until tight. Using a
drift, tap lightly at several points
around the circumference against the
large end of the bushing with a small
hammer. Repeat this alternate tapping
and re-tightening until the specified
wrench torque no longer turns the
screw after tapping. Tighten the screw
to 15 lb.ft. torque using a torque
wrench.
The airgap between armature and
magnet must be .062 to .125 inch. If
the airgap is outside of that range,
reposition the armature hub assembly
by repeating steps 1 and 2 of the disassembly procedure and steps 8, 9,
and 10 of the assembly procedure.
Step 11: Apply power to the brake and remove
shims. Set the airgap by pressing the
armature into contact with the magnet
and then releasing as shown in Figure
5. The armature should spring back
approximately 1/32- 3/64 (.031-.045)
inch. If the airgap is outside of that
range, reposition the armature hub
assembly by repeating steps 1 and 2
of the disassembly procedure and
steps 8, 9, and 10 of the assembly
procedure.
Step 12: Burnish the brake as follows: Start
and stop the escalator 30 times.
Allow 5-10 seconds delay between
Start and Stop.
Step 13: Attach torque wrench to the end of the
motor shaft. Hold the wrench at the
handle, and pull it in the direction of
motor rotation in one continuous
motion (without any jerky motion) until
shaft movement is detected. The highest reading on the dial is the static
torque of the brake. This torque without any system drag must be at least
400 lb.ft. for ER-1225 and 125 lb.ft. for
ER-825. If less, burnish the brake
again, repeating step 12. If the brake
does not meet the torque requirement
after two burnishing procedures,
replace the brake.
The brake installation procedure is now complete. If the brake is equipped with a
tachometer, then reposition pulley if necessary and reinstall the belt. For electrical
adjustments, see Montgomery Kone's
Instructions. If any other components of the
system were repositioned or disassembled,
use appropriate instructions for their proper
assembly or adjustments.
7
Warner Electric • 800-825-9050 P-230-1
Warranty
Warner Electric LLC warrants that it will repair or replace (whichever it deems advisable) any
product manufactured and sold by it which proves to be defective in material or workmanship
within a period of one (1) year from the date of original purchase for consumer, commercial or
industrial use.
This warranty extends only to the original purchaser and is not transferable or assignable without
Warner Electric LLC’s prior consent.
Warranty service can be obtained in the U.S.A. by returning any defective product, transportation
charges prepaid, to the appropriate Warner Electric LLC factory. Additional warranty information
may be obtained by writing the Customer Satisfaction Department, Warner Electric LLC, 449
Gardner Street, South Beloit, Illinois 61080, or by calling 815-389-3771.
A purchase receipt or other proof of original purchase will be required before warranty service is
rendered. If found defective under the terms of this warranty, repair or replacement will be made,
without charge, together with a refund for transportation costs. If found not to be defective, you
will be notied and, with your consent, the item will be repaired or replaced and returned to you
at your expense.
This warranty covers normal use and does not cover damage or defect which results from
alteration, accident, neglect, or improper installation, operation, or maintenance.
Some states do not allow limitation on how long an implied warranty lasts, so the above limitation
may not apply to you.
Warner Electric LLC’s obligation under this warranty is limited to the repair or replacement of the
defective product and in no event shall Warner Electric LLC be liable for consequential, indirect,
or incidental damages of any kind incurred by reason of the manufacture, sale or use of any
defective product. Warner Electric LLC neither assumes nor authorizes any other person to give
any other warranty or to assume any other obligation or liability on its behalf.
WITH RESPECT TO CONSUMER USE OF THE PRODUCT, ANY IMPLIED WARRANTIES WHICH
THE CONSUMER MAY HAVE ARE LIMITED IN DURATION TO ONE YEAR FROM THE DATE OF
ORIGINAL CONSUMER PURCHASE. WITH RESPECT TO COMMERCIAL AND INDUSTRIAL
USES OF THE PRODUCT, THE FOREGOING WARRANTY IS IN LIEU OF AND EXCLUDES ALL
OTHER WARRANTIES, WHETHER EXPRESSED OR IMPLIED BY OPERATION OF LAW OR
OTHERWISE, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so
the above limitation or exclusion may not apply to you. This warranty gives you specic legal
rights and you may also have other rights which vary from state to state.
Changes in Dimensions and Specifications
All dimensions and specications shown in Warner Electric catalogs are subject to change without
notice. Weights do not include weight of boxing for shipment. Certied prints will be furnished
without charge on request to Warner Electric.
Warner Electric LLC
31 Industrial Park Road • New Hartford, CT 06057
815-389-3771 • Fax: 815-389-2582
www.warnerelectric.com
P-230-1 819-0376 6/05 Printed in USA
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