Stearns 1 056 X00 User Manual To The Dc1abf01 0066 4de1 Afe2 2daf3aa89901

User Manual: Stearns 1-056-X00 to the manual

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P/N 8-078-905-60

Spring-Set Disc Brakes

effective 03/16/06

Installation and Service Instructions
for 1-056-X00* Series (all revisions)
Manual Adjust Brakes
*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.

For replacement parts refer to sheets:
Series
Sheet Part No.
1-056-000
8-078-906-00
1-056-100
8-078-906-01
1-056-200
8-078-906-02
1-056-300
8-078-906-03
1-056-400
8-078-906-04
1-056-500
8-078-906-05
1-056-600
8-078-906-06
1-056-900
8-078-906-09
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.

1-056-000
1-056-400
1-056-500

b) Use a vacuum cleaner or a soft
brush to remove dust from the
brake. When brushing, avoid causing the dust to become airborne.
Collect the dust in a container, such
as a bag, which can be sealed off.

1-056-200
1-056-900

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

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).

General Description
Typical Nameplate

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.
4. Make certain power source conforms
to the requirements specified on the
brake nameplate.

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 incorrectly. For definition of limited warranty/liability, 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.
2. Do not operate the brake in
atmospheres containing explosive
gases or dusts.

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 operation 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 contain burnt and degraded friction material dust. This dust must be removed
before servicing or adjusting the
brake.
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.

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.

BRAKE MOUNTING (Manual Adjust) 1-056-X00






Place hub on motor shaft.

Position hub on shaft as shown.



Tighten set screws to motor shaft.

.188”
(4.77mm)





Remove brake housing.
Housings vary by series number.
See page 1.

Slide endplate over hub noting position
of stabilizer clips, if used.
(Refer to Friction Disc
Replacement, view 3 and 3A.)
Tighten mounting screws.

counterclockwise

*For vertical assembly of 20 &
25lb-ft brakes, refer to page 3.





Connect coil leadwires to
power supply. Refer to
nameplate for voltage rating.*
Caution: Keep wiring away
from pinch points and moving
components.

Replace brake housing and tighten to torque specified below:

Brake series
Torque
1-056-000 1-056-300
8 lb-in
1-056-400 1-056-500
1-056-100 1-056-200
12 lb-in
1-056-600 1-056-900

clockwise

* For DC voltages see
sheet 8-078-950-00.

FRICTION DISC REPLACEMENT SERIES 1-056-X00




Remove support plate screws and
lift support from brake



Remove and discard old friction disc.



Install new friction disc(s) and
stationary disc(s) as shown.

For brakes
with vertical
springs see
Figure 5A
or 5C.

counterclockwise

NG
W RO

3A



* Stabilizer clips
are for use on
single disc units
only. Position
clips opposite
set screw holes.

Reposition support plate on endplate and
tighten mounting screws to 55 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
3/16 hex wrench, or flat screwdriver on older models.

56,X00 Series Air Gap* (REV A & B)



To decrease air gap, turn both adjusting
screws (10) clockwise.

Disc
Torque
Torque
1
2
3

Min/Max
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
Min/Max
3, 6,
2
.45” ± .69”
10 & 15
3
20 & 25 .50” ± .69”

3/16 hex wrench

3/16 hex wrench
counter-clockwise

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.





Discard coil.



Lift plunger/solenoid
lever assembly
out of coil.

A) Insert new coil. (Lead wires
in same position as old coil.)
B) Insert plunger guide.





Remove plunger guide.

A) Re-insert plunger into coil; drop
pivot pin into cradle of support plate.
B) Remove screwdriver.

A
B

B

A

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

VERTICAL SPRING ASSEMBLY 1-056-X00
Vertical Brake Assembly
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.

Figure 5A

Installation Procedure for 20 and
25 lb-ft brakes if mounted vertical
to motor shaft (These brakes are
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.
Reassemble the disc pack with the
stationary discs in the proper arrangement
shown in Figure 5C.

3

Mount support plate and torque screws
evenly to 55 lb-in.

Figure 5B

Figure 5C

TORQUE ADJUSTMENT
TABLE A

Torque Adjustment
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.
The torque on the 1-1/2 lb-ft brake may not
be reduced.

11

11

10

10

Turn both spring adjustment screws (11),
Figure 6, equal amounts counterclockwise
to decrease torque. See Table A for torque
reduction permissible amounts.

Nominal
Static
Torque
(lb-ft)
1-1/2
3
6
10
15
20
25

Figure 6

Original Maximum
Spring CounterHeight clockwise
(inches)
Turns
1.56”
1.50”
1.50”
1.56”
5-1/2
1.56”
1.56”
1.50”

% Torque
Reduction
per
Turn
-

9%

TROUBLESHOOTING
COIL FAILURE
SUPPLY VOLTAGE CAUSE

SUPPLY VOLTAGE CORRECTION

Line voltage >110% of coil rating

Reduce voltage or replace with
proper rated coil

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.

WIRING CAUSE

WIRING CORRECTION

Leadwires interfering with plunger Reroute wiring away from plunger
pull-in
and other moving components.
Excessive voltage drop during
inrush time
Coil leadwire shorted to ground

SOLENOID ASSEMBLY CAUSE

Increase leadwires size from power
supply

Excessive wear of solenoid link
arm and/or shoulder bolt

CYCLE RATE CORRECTION
Reduce cycle rate or consider
alternate control method

Thermal capacity is being
exceeded

Reduce cycle rate, use alternate
control method or increase brake
size

ALIGNMENT CAUSE

ALIGNMENT CORRECTION

Motor shaft runout is excessive

Must be within .002”; runout;
consult motor manufacturer

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

WORN PARTS CAUSE
Friction disc excessively worn
(disc can wear to 1/2 original
thickness or .093”)
Endplate, stationary disc or
pressure plate warped
Linkages and/or pivot pins worn

WORN PARTS CORRECTION
Replace friction discs.

Motor shaft endfloat excessive

Endfloat must not exceed .020”;
consult motor manufacturer

HUB CAUSE
Burr on hub interfering with disc
“float”

HUB CORRECTION
File off burr

Set screw backed out and
interfering with disc

Retighten set screw; use Loctite®
242 to help secure

Replace solenoid assembly
WORN PARTS CORRECTION
Replace link arm and link bolt; also
inspect plunger thru-hole for
elongation
Replace guides

Use Class H rated coil and /or find
alternate method of cooling brake

Brake coil wired with windings of
an Inverter motor or other
voltage/current limiting device

Wire coil to dedicated power source
with instantaneous coil rated voltage

Excessive air gap

CYCLE RATE CAUSE
Brake “jogging” exceeding coil
cycle rate

SOLENOID ASSEMBLY
CORRECTION

High ambient temperature
(>110%) and thermal load
exceeding coil insulation rating

Wrong or over tightened torque

Inspect endplate, hub and discs for
dirt, burrs, wiring and other sources
of interference preventing disc “float”

Replace coil or leadwire and protect
with wire sleeving

Plunger guides worn down and
interfering with plunger
movement
APPLICATION CAUSE
APPLICATION CORRECTION
Machinery cycle rate is exceeding Reduce brake cycle rate or use
brake rating
alternate control method

MISCELLANEOUS CAUSE

Disc pack dragging

Motor register must be within
.004” on concentricity.

Loosen solenoid mounting screws
and reposition frame to allow full
face contact
Plunger cocked in coil preventing Realign solenoid frame
pull-in
Excessive solenoid/plunger wear Replace solenoid assembly
at mating surface

WORN PARTS CAUSE

AIR GAP CORRECTION
Reset air gap (refer to Air Gap
Adjustment)

Broke endplate not concentric to
motor C-Face

Plunger not seating flush against
solenoid frame

Broken shading coils

EXCESSIVE WEAR / OVERHEATING
AIR GAP CAUSE
Low solenoid air gap

MISCELLANEOUS CORRECTION
Replace with proper spring or refer
to Installation section for proper
spring height
Reset, refer to Installation Section 4

MISCELLANEOUS

Replace warped or worn component
Replace all worn components

MISCELLANEOUS

Solenoid plunger not pulling
completely

Check line voltage (±10% of
nameplate rating) or replace worn
solenoid assembly

Wiring is restricting disc pack
movement
Excessive stop time
(2 seconds or greater)

Reroute wiring

High Ambient temperature
(in excess of 110°F)

Reduce cycle rate or use alternate
method of cooling

Increase brake size/torque or use
alternate control method

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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