e-stop brakes - industrial magza
Contents
1. 17 Large E Stop Brake Repair Parts List 18 Figure 6 2 Large E Stop Brake Repair Parts Illustration 19 GE Nacza MEX 55 53 63 28 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com Section 1 DESCRIPTION AND OPERATION 1 1 DESCRIPTION See Figure 1 1 Force Control s E Stop Brakes are fast acting multi ple surface spring activated and pressure released brak ing units The brake uses a multiple surface brake stack design which is sealed against normal environmental contamination The brake stack friction material is a dry facing with heavy duty performance capability They are basically designed to stop and hold loads in position in the event of an emergency stop command loss of air pressure to the brake or loss of power to the driven machinery Braking Torque is available in a wide range from 10 400 In Lbs to 236 000 In Lbs 1 2 OPERATION When air pressure is interrupted to the brake a heavy duty spring pack presses against the Piston 8 and Thrust Plate 5 which in turn compresses the brake stack The brake stack consists of alternating Drive Plates 13 which are pinned to the housing and Friction Discs 12 which are locked to the splined Hub 11 The Hub 11 is keyed to the output shaft When the plates and discs are pressed together by the force of the springs friction between them locks them tog2. Providing todays industries with Oil Shear Clutch and Brake Drives that delivers Flexibility e Efficiency Endurance e Performance Dependability Built to Last Guaranteed to Perform FORCE CON TROL FORCE CONTROL INDUSTRIES INC MAIN OFFICE P O Box 18366 Fairfield Ohio 45018 3660 Dixie Highway Fairfield Ohio 45014 Tel 513 868 0900 Fax 513 868 2105 E Mail info forcecontrol com Web www forcecontrol com Worldwide Leader in Oil Shear Technology CESS Nacza MEX 55 53 63 2331 MTY 81 83 54 10 18 SE DIST AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com
3. See Figure 5 7 BRAKE STACK e LONG STACK Shown 10 DRIVE PLATES 13 9 FRICTION DISCS 12 e SHORT STACK 6 DRIVE PLATES 13 5 FRICTION DISCS 12 HUB 11 S uu UL NZZ DUM ae n HUB CENTERING SPACER 601 43 003 3 DOWEL PINS 210 Figure 5 7 Installing the Brake Stack 11 MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO ORO 442 195 72 60 ventas industrialmagza com INDUSTRIAL 18 SPRINGS 20 SPRINGS Figure 5 8 Large E Stop Brake Spring Placement 6 Install the Brake Stack onto the 3 Pins 210 and the splined Hub 11 Start with a Drive Plate 13 then a Friction Disc 12 then another Drive Plate 13 etc Ending with a Drive Plate 13 NOTES If you have a Long Stack there will be 10 Drive Plates 13 and 9 Friction Discs 12 There will be 6 Drive Plates 13 and 5 Friction Discs 12 for a Short Stack 7 Place the Piston Housing and Piston Sub Assembly onto the Main Housing 9 Make sure the 3 Driver PIns 210 are aligned with the 3 mating holes in the Piston Housing Attach with 6 Screws 66 and 6 Lockwashers 74 Torque to 60 Ft Lbs 8 Set the End Housing on the work bench with the Spring Pins 54 pointed up Place the correct num ber of Springs 40 over the spring pins See Figure 5 8 above for correct placement of these springs 9 Turn the Main Brake Assembly over and remove the Hub Centering Spacer Lowe
4. Installing Piston 3 into Piston Housing 8 12 SPRINGS Install the Brake Stack into position onto the Pins 210 Start with a Drive Plate 13 then a Friction Disc 12 then another Drive Plate 13 etc Ending with a Drive Plate 13 Be sure to align the spline teeth in the Friction Discs 12 up with each other Horizontal Installation If Filler Plates 380 are used they will be installed at the opposite end of the Brake Stack from the Piston Vertical Installation If Filler Plates 380 are used they will be installed at the lower or down end of the Brake Stack NOTES Depending on which Assembly Configuration you have there will be 9 Drive Plates 13 and 8 Friction Discs 12 or 6 Drive Plates 13 and 5 Friction Discs 12 Filler Plates 380 are used with a L long housing for Ass y Configurations S F through S M Place the Brake Stack and Adapter Plate Sub Assembly onto the Main Housing 9 aligning the 10 Studs with the holes in the Adapter Plate 7 Make sure the 3 Pins 210 align up with the 3 holes in the Thrust Plate 5 Attach with 10 Lockwashers 122 and 10 Screws 121 Torque to 30 Ft Lbs 6 If the 10 Studs 120 was removed from the Piston 10 Attach the Hub 11 and Brake Assembly with the Housing 8 install them at this time Use Blue Loctite 242 on the threads 7 Place the Main Housing 9 on the Pi
5. Absolutely no work should be performed on the E Stop Brake devices until adequate safety precautions are taken and the machinery is safe to work on 3 2 INSTALLING E STOP BRAKE See Figure 6 1 for Small E Stop Brake and Figure 6 2 for Large E Stop Brake 2 Remove the 5 mounting screws and lockwashers Small E Stop Brake and take the old brake off the drive output shaft 1 First check the output shaft and brake mounting sur NOTE There are 5 3 8 24 mounting screws face for any nicks or burrs Clean up and deburr if 3 1 REMOVING OLD BRAKE 1 If this Installation is to be a retrofit then disconnect the pneumatic air lines to the old brake for the Small E Stop Brake and 12 5 8 11 mounting screws for the Large E Stop Brake 3 Take the old Hub and Key off the output shaft NOTE Th e Small E Stop Brake has only 1 key and the Large E Stop Brake has 2 keys SHOP AIR Va VALVING TO BE 3 8 NPT MINIMUM FOR THE SMALL E STOP BRAKE AND 1 2 NPT FOR THE LARGE E STOP BRAKE LOCATE THE VALVE AS CLOSE TO THE BRAKE AS POSSIBLE Figure 3 1 Pneumatic Control Circuit 4 INDUSTRIAL DIST AUTORIZADO necessary 2 Attach Key 72 to the output shaft with Screw 76 3 Lubricate the output shaft with white grease and slide the Hub 11 on to it Align the set screw hole in the hub with the indent in the key Tighten Set Screw 107 Use Blue Loctite 242 on Set Screw BRAKE RELEASE PRESSURE TO E STOP BRAKE PO
6. from the carrier Whenever possible describe the prob lems you are having with your E Stop Brake on the ship ping papers Return to Force Control Industries Inc 3660 Dixie Highway Fairfield Ohio 45014 Phone 513 868 0900 Fax 513 868 2105 E Mail info forcecontrol com FORCE CONTROL INDUSTRIES INC INDUSTRIAL REPAIR PARTS 6 3 ORDERING REPLACEMENT PARTS When ordering replacement parts please specify all of the following information 1 Brake Model Number On the Name Plate 2 Brake Serial Number On the Name Plate 3 Part Reference Number From the parts list or exploded view drawing 4 5 6 Failure to include information for items 1 through 6 will only delay your parts order Unless another method is specified for item 6 parts weighing less than 150 Lbs will be shipped United Parcel Service Parts weighing more than 150 Lbs will be shipped Motor Freight Air freight and other transportation services are available but only if specified on your order Part Name From the parts list Quantity From the parts list Complete Shipping Information 6 4 NAME PLATE INFORMATION This Name Plate is located on the Piston Housing Force Control Industries Inc Fairfield Ohio For Service Parts Call 513 868 0900 FORCE CONTROL Model No Serial No See next page for Model No Info 13 MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 72 60
7. leaking See below Air valve regulator not functioning properly Improper or loose mounting to Cymonic or Machine Drive Brake not disengaging properly Causing excessive slippage 4 2 CHECKING PISTON SEALS FOR Disassemble to extent necessary and inspect for damaged parts Replace as needed Check air valve and exhaust muffler and replace if necessary Check parts for wear and replace if necessary Increase air pressure See Section 2 Disassemble to extent necessary and inspect for damaged parts Disassemble to extent necessary and inspect for damaged parts Check valve operation and replace if necessary Check mounting and correct If partial disassembly is required see Section 3 Installation Refer to Trouble B E STOP BRAKE f PRESSURE REGULATOR 1 Connect the Pneumatic Testing Setup as shown in Figure 4 1 to the 1 4 NPT or 3 8 NPT Brake Pressure Port Crack the shut off valve until the air pres sure reads about 80 PSI on the pressure gauge and then quickly shut the air off Observe the pressure gauge to see if the air pressure stays the same or drops If the air pressure stays the same or drops slowly the piston seals are okay If the pressure drops rapidly more than 5 PSI in 5 seconds the piston seals are leak ing and will need to be replaced 1 4 P SET 60 TO 80 PSI PRESSURE GAUGE SHOP AIR QUICK ACTING SHUT OFF VALVE Figure 4 1 Check
8. of the brake WARNING Petroleum based cleaning sol vents are extremely flammable Open flames or smoking by any personnel in the vicinity of these solvents is extremely hazardous and MUST NOT BE PERMITTED Pay particular attention to the following 1 Check the Friction Discs 12 wear surfaces for scor ing galling or any evidence of uneven wear 2 Check the Drive Plates 13 for scoring or galling Make sure they are flat If a perceptible ridge is worn in the drive plate where it mates with a friction disc it should be replaced 3 Carefully check the piston and bore surfaces for nicks scratches scoring or other damage which would affect the operation or cause leakage 4 Look for grooves in the Hub 11 and Dowel Pins 210 5 3 SMALL E STOP BRAKE DISASSEMBLY PROCEDURE The Small E Stop Brake must first be removed from the Cymonic Drive before the brake can be disassembled See Figure 5 1 1 Remove the 5 Mounting Bolts and Lockwashers from the Adapter Plate 7 that holds the Brake to the Cymonic Drive MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com 5 CUSTOMER FURNISHED MOUNTING BOLTS 8 WASHERS E STOP BRAKE ASSEMBLY Figure 5 1 Removing the Small E Stop Brake Assembly 2 Pull the Brake Assembly away from the Cymonic Drive and the Hub 11 which will stay on the output shaft To remove the Hub 11 from the output shaft just loosen the Set Scre
9. parts if the operation or sealing action of the part is not affected The use of coarser abra sives or other machining methods should not be attempt ed Otherwise damaged parts should be replaced A Replacement is recommended for the following parts when needed 1 Replace all O Rings and Liners removed during dis assembly 2 Replace Friction Discs and Drive Plates as a com plete set B Note the following general reassembly instruc tions as applicable 1 Lubricate O Rings with a light coat of vaseline or equivalent immediately before assembly and installa tion of mating parts 2 Use Royal Purple synthetic lubricant or equivalent sparingly on the Liners 51 and 50 and mating surfaces of the End Housing 16 and Piston 3 at reassembly 5 2 CLEANING AND INSPECTION Clean metal parts in a suitable solvent and dry with low pressure compressed air The Drive Plates 13 can be cleaned in a solvent but do not clean Friction Discs 12 in solvent Solvent will damage the friction mate rial used on the Friction Discs Use only a clean dry and FORCE CONTROL INDUSTRIES INC INDUSTRIAL MEX 55 53 63 23 31 lint free rag to clean the Friction Discs 12 Clean drive plates and friction discs one at a time keeping them in the same order as they were when removed After clean ing inspect parts for cracks distortion scoring nicks burrs or any other damage that would affect the operation
10. ventas industrialmagza com 6 5 SMALL E STOP BRAKE MODEL NUMBER Force Control Industries Inc Fairfield Ohio FORCE TRED For Service Parts Call 513 868 0900 Model No __ES 035 344 1 Example Small E Stop Brake with a Short Serial No o 1 Stack with 34 900 Lb Ins of Torque Ass y d Configuration L G and with a Bore Diameter of 3 4375 SS E Stop 1 2 Brake Size 3 Im Small Brake Long Stack Ss Small Brake Short Stack Revision 10 By Force Control Torque 4 5 6 Lb Ins x 1000 66 700 Ass y Configuration S A 55 800 Ass y Configuration S B Bore Dia 7 8 9 50 200 Ass y Configuration S C Inch 44 700 Ass y Configuration S D ajojo 4 000 Max 33 500 Ass y Configuration S E ERIE 3 875 04 41 900 Ass y Configuration S F EFIE 3 4375 INE 34 900 Ass y Configuration S G gag _ 3250 5 NJE 31 400 Ass y Configuration S H E Other Bore Diameters are 0 2 27 900 Ass y Configuration S J available upon reguest e a gt OPA 20 900 assy Configuration s MIER 13 900 Ass Configuration S L ofi 10 400 Ass y Configuration S M 14 FORCE CONTROL INDUSTRIES INC CSS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com 6 6 LARGE E STOP BRAKE MODEL NUMBER Forc
11. with Royal Purple synthetic lubricant or equivalent and insert the Piston 3 into the Piston Housing 8 Be very careful not to damage the Teflon Liners 50 and 51 when inserting the piston PISTON HOUSING 8 LINER 51 PISTON 3 COAT SURFACES A B C AND D WITH ROYAL PURPLE SYNTHETIC LUBRICANT OR EQUIVALENT Figure 5 5 Installing Piston 3 into Piston Housing 8 FORCE CONTROL INDUSTRIES INC 3 Attach the Thrust Plate 5 with 4 Lockwashers 73 and 4 Screws 65 to the Piston 3 Torque to 25 Ft Lbs Set this assembly aside until the brake stack is installed 4 Set the Main Housing 9 on a smooth work surface with the 3 Driver Pins 210 facing up Place the Hub Centering Spacer 601 43 003 into the Main Housing bore See Figure 5 6 for dimensions to machine the Spacer lt can also be ordered from Force Control with the Part No 601 438 003 fo X 45 CHAMFER 8 5 510 n 8 508 DIA 125 NE Sueno RAD wwe BREAK ALL SHARP CORNERS UNLESS OTHERWISE SPECIFIED ALL SURFACE FINISH TO BE 250 MATERIAL MILD STEEL HUB CENTERING SPACER FORCE CONTROL PART No 601 43 003 Figure 5 6 Hub Centering Spacer 5 Manually place the Hub 11 into the Hub Centering Spacer This is very important so that all the spline teeth in the Friction Discs 12 are aligned with each other and are centered when the whole assembly is clamped down
12. 4 Lg 6 Adapter Plate c PL 1 Piston Housing Lockwasher 3 8 3 Main Housing Lockwasher 3 8 6 Soc Hd Cap Screw Friction Disc 3 25 Bore 5 16 16 x 5 8 Lg 1 Long Stack 3 44 3 88 amp 4 00 Bore 3 8 16 x 1l Lg 1 Short Stack Soc Set Screw 1 Drive Plate Stud 3 8 16 x 6 1 2 Lg 10 Long Stack Hex Nut 3 87 16 10 Short Stack Lockwasher 3 8 10 aeu M 2 DowelDriver 5 Dowel Pin 3 8 x 1 Lg 2 FreezePlug 6 Liner Teflon I D Sealing 380 Filler Plate S F thru S M Ass y Config Liner Teflon O D Sealing with L Long Housing 8 Roll Pin Parts included in Overhaul Repair Kit AR As Required See Page 2 for Quantity Used 16 FORCE CONTROL INDUSTRIES INC C amp S MNacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com Small E Stop Brake Y NS 5 3 8 24 BOLTS 380 CUSTOMER FURNISHED En d TORQUE SPECIFICATIONS N 22 REF CUSTOMER S ea E 25 Lb Ft 21 OUTPUT SHAFT 66 25 Lb Ft HEX NUT 121 30 Lb Ft NJ Figure 6 1 Small E Stop Brake Repair Parts FORCE CONTROL INDUSTRIES INC 17 CESS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 RE DIST
13. ACK BORE DIAMETER 6 10 SHORT STACK SPECIFIED AT TIME OF ORDER 13 05 LONG STACK ae 17 03 SHORT STACK FORCE CONTROL INDUSTRIES INC 3 CESS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 MSS DIST AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com Section 3 INSTALLATION IMPORTANT SAFETY PRECAUTIONS The E Stop Brake Units described in this manual must not be installed in any manner except as spec ified herein and must not be operated at speeds torque loads or temperatures other than those spec ified in this manual Failure to limit operation of the brakes to the conditions specified could damage the brake units and may cause malfunction or damage to interconnecting equipment injury to per sonnel and void the warranty Before attempting any adjustments removal or repair of E Stop Brake Units be sure to disconnect and lock out all power to the machinery to which they are connected The devices are spring set pressure released and were designed to stop and hold loads in position in the event of an emer gency stop command or loss of power to the machinery Some machines may have stopped condi tions where the spring set brake is holding a vertical or inclined load in a raised or partially raised posi tion Members of the machinery that could free fall if the brake is released or disconnected should be pinned mechanically in place and blocked or supported with cribbing to prevent movement of the machinery
14. AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com Repair Parts Large E Stop Brake S mm lanl RE O Ring lees 1 Thrust Plate O RING sou ca EE AE EE s N 2 Adapter Plate Liner Teflon 1 Piston Housing Liner O D Sealing 1 Main Housing FOU PU Pr AR Soc Hd Cap Screw 3 8 16 x 1 1 2 Lg 4 Friction Disc Soc Hd Cap Screw 1 2 13 x 2 Lg 6 Long Stack Soc Hd Cap Screw 1 2 13 x 2 1 4 Lg 6 Short Stack KEY EE EE EE A 2 Drive Plate Lockwasher 3 8 4 Long Stack Lockwasher 1 2 12 Short Stack Soc Hd Cap Screw 3 8 16 x 1 1 2 Lg 2 End Housing Soc Set Screw 3 8 16 x 5 8 Lg 2 DowelDriver 5 Parts included in Overhaul Repair Kit AR As Required See Page 3 for Quantity Used 18 FORCE CONTROL INDUSTRIES INC C amp MNacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com Large E Stop Brake AND LOCKWASHERS 12 FOR SHORT STACK 24 FOR LONG STACK CUSTOMER FURNISHED X TORQUE SPECIFICATIONS us SCREWS 66 AND 67 60 Ft Lbs Figure 6 2 Large E Stop Brake Repair Parts FORCE CONTROL INDUSTRIES INC 19 INDUSTRIAL MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com FORCE CONTROL INDUSTRIES INC
15. E Stop Brake 4 Section 4 TROUBLE SHOOTING 4 1 Trouble Shooting Chart 6 4 2 Checking Piston Seals for Leakage 6 Section 5 REPAIR and REPLACEMENT 5 1 Generallinformation 7 5 2 Cleaning and Inspection 7 5 3 Small E Stop Brake Disassembly Procedure 7 5 4 Small E Stop Brake Reassembly Procedure 8 5 5 Removing Large E Stop Brake 10 5 6 Large E Stop Brake Disassembly Procedure 10 5 7 Large E Stop Brake Reassembly Procedure 11 5 8 Mounting Hub and Large E Stop Brake On Machine Output Shaft 12 Section 6 ORDERING REPAIR PARTS 6 1 Generalinformation 13 6 2 Factory Rebuild Service 13 6 3 Ordering Replacement Parts 13 6 4 Name Plate Information 13 6 5 Small E Stop Brake Model Number 14 6 6 Large E Stop Brake Model Numbers 15 Repair Parts Small E Stop Brake Repair Parts List 16 Figure 6 1 Small E Stop Brake Repair Parts Illustration
16. RT FORCE CONTROL INDUSTRIES INC MEX 55 58 63 23 31 MTY 81 83 54 10 18 QRO 442 195 72 60 ventas industrialmagza com 4 Visually check to see if the teeth in the Friction Discs 12 are aligned with each other Apply 50 to 60 PSI to the brake port to release the brake stack and align the teeth if necessary Attach a 1 2 13 eye bolt into the top of the brake and attach an overhead hoist to it Slide the Brake Assembly on to the Hub 11 and align the 2 Dowel Pins 211 in the Adapter Plate 7 with the dowel pin holes in the mounting face Attach with the 5 3 8 16 mounting bolts and 5 3 8 Lockwashers which are customer furnished Use Red Loctite 262 or 282 Thread locker Torque to 34 Ft Lbs CAUTION Be very careful not to damage the spline teeth in the Friction Discs 12 when engaging the Hub 11 spline Hook up pneumatic valve and piping See Figure 3 1 for Pneumatic Control Circuit Large E Stop Brake 1 First check the output shaft and brake mounting sur face for any nicks or burrs Clean up and deburr if necessary Attach 2 Keys 72 to the output shaft with 2 Screws 76 FORCE CONTROL INDUSTRIES INC INDUSTRIAL MEX 55 53 63 23 31 Lubricate the output shaft with white grease and slide the Hub 11 on to it Align the 2 set screw holes in the hub with the indent in each Key 72 Tighten both Set Screws 107 Use Blue Loctite 242 on bot
17. SSS TOR F7 7TT V VAN 902 ESB 001 02 INSTALLATION AND SERVICE MANUAL FOR E STOP BRAKES WARNING Read this manual before any FORCE installation maintenance and operation CONTROL MANUFACTURERS OF MECHANICAL AND FORCE CONTROL INDUSTRIES INC ELECTRICAL POWER TRANSMISSION EQUIPMENT CESS Nacza MEX 55 53 63 2331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com Limited Warranty Force Control Industries Inc Force Control warrants its products to be free from defects in mate rial and workmanship under normal and proper use for a period of one year from the date of ship ment Any products purchased from Force Control that upon inspection at Force Control s factory prove to be defective as a result of normal use during the one year period will be repaired or replaced at Force Controls option without any charge for parts or labor This limited warranty shall be void in regard to 1 any product or part thereof which has been altered or repaired by a buyer without Force Control s previous written consent or 2 any product or part thereof that has been subjected to unusual electrical physical or mechanical stress or upon which the original identifica tion marks have been removed or altered Transportation charges for shipping any product or part thereof that the buyer claims is covered by this limited warranty shall be paid by the buyer If Force Control determines that any
18. Y PROCEDURE 1 Reinstall a new O Ring 43 and Liner 50 back into the Piston Retainer 8 Lubricate the O Ring with Vaseline or equivalent first Lubricate the 2 O Rings 44 with Vaseline or equivalent and install them into the Piston 8 Install the O D Liner 51 on the Piston 3 2 Coat the surfaces indicated in Figure 5 3 with Royal Purple synthetic lubricant or equivalent and insert the Piston 8 into the Piston Retainer 8 3 Attach the Thrust Plate 5 with 3 Lockwashers 73 and 3 Screws 65 to the Piston 3 Torque to 25 Ft Lbs FORCE CONTROL INDUSTRIES INC MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com 3 SPRINGS 4 SPRINGS TOP TO TOP P 6 SPRINGS 9 SPRINGS 10 SPRINGS Figure 5 2 Small E Stop Brake Spring Placement 4 Place the correct number of Springs 40 over the 8 Pins 54 in the End Housing 16 for your desired Torque See Figure 5 2 for correct spring placement White grease can be used to hold them in place 5 Attach the End Housing 16 to the Piston Housing 8 with the 6 Lockwashers 74 and 6 Screws 66 Tighten in an even manner to compress the springs properly Torque to 25 Ft Lbs LINER 51 PISTON HOUSING 8 9 COAT SURFACES A B C AND D WITH ROYAL PURPLE SYNTHETIC LUBRICANT OR EQUIVALENT Figure 5 3
19. cs 12 Plate 5 5 Friction Discs 12 pn Long hien Small E Stop Brake Dimensional Specifications 1 2 13 LIFTING EYE HOLE MAX SHAFT LENGTH 5 105 With L Housing 3 662 With S Housing 12 19 AEN mi DIA 2 375 DIA DOWEL PIN ON 9 25 B C 1 4 NPT BRAKE RELEASE PORT 6 50 With t Hsng POREAND KEYWAY SIZES 6 406 DIA MOUNTING ORE UNES SPECIFIED AT TIME OF HOLES ON 9 250 DIA B C 5 00 with S Hsng ORDER 4 00 DIA MAX TE L LONG HOUSING S SHORT HOUSING 2 FORCE CONTROL INDUSTRIES INC CSS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 Ds DIST AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com 12 00 APPROX L HOUSING 10 50 APPROX S HOUSING Large E Stop Brake Torgue Specifications ASSEMBLY pig PRESSURE CYCLIC PISTON 2 CONFIGURATION TORQUE TO RELEASE WK VOLUME Lb In PSI Lb Ft Cu In sen 5 ase Ss a 718 Gore 6 Bore 5 Bore 6 35 LONG STACK 5 N cc e e Ref Thrust Ref Thrust Plate 5 9 Friction Discs 12 Plate 5 5 Friction Discs 12 1 2 13 LIFTING HOLE MAX SHAFT LENGTH 866 DIA MOUNTING 6 20 LONG STACK HOLES ON 20 B C 4 20 SHORT STACK 12 HOLES SHORT STACK 24 HOLES LONG STACK KEYWAY FOR 1 25 SQ KEY 2 PLACES 21 50 sore DIA 3 8 18 NPT AIR INLET 1 44 BRAKE REL di 8 12 LONG ST
20. e Control Industries Inc Fairfield Ohio C Ga For Service Parts Call 513 868 0900 Model No ES M 216 600 1 Example Large E Stop Brake with a Long SerialNo O oO o Stack with 216 300 Lb Ins of Torque Ass y Configuration L B and with a Bore Diameter of 6 000 NEN E Stop 1 2 Brake Size 3 M Large Brake Long Stack Large Brake Short Stack Revision 10 By Force Control Torque 4 5 6 Lb Ins x 1000 236 000 Ass y Configuration L A 216 300 AssYy Configuration L B Bore Dia 7 8 9 196 600 Ass y Configuration L C Inch 177 000 Ass y Configuration L D nnm 6 000 Dia Max 157 300 Ass y Configuration L E EFIE 5 000 Dia 137 600 Ass y Configuration L F 4 7 15 4 750 Dia LONG STACK 118 800 Ass y Configuration L G Aan 38755 Dia 103 900 Ass y Configuration L H x MEM Other Bore Diameters are tc 74 200 Ass y Configuration L K Consult factory for Thru Shaft N 59 400 Ass y Configuration L L FORCE CONTROL INDUSTRIES INC 15 CESS Nacza MEX 55 53 63 2331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com Repair Parts Small E Stop Brake KEY KEY NO PART NAME NO PART NAME QTY Soc Hd Cap Screw 3 8 16 x 1 Lg 3 Thrust Plate Soc Hd Cap Screw 3 8 16 x 1 3
21. e on which the breach is or should have been discovered A Return Goods Authorization RGA number must be obtained from the factory and clearly marked on the outside of the package before any equipment will be accepted for warranty work Force Control will pay the shipping costs of returning the owner parts that are covered by warranty Force Control believes that the information in this document is accurate The document has been carefully reviewed for technical accuracy In the event that technical or typographical errors exist Force Control reserves the right to make changes to subsequent editions of this document without prior notice to holders of this edition The reader should consult Force Control if errors are sus pected In no event shall Force Control be liable for any damages arising out of or related to this document or the information contained in it GE Nacza MEX 55 53 63 28 31 MTY 81 83 54 10 18 MSS DIST AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com E Stop Brake SERVICE MANUAL Table of Contents Section 1 DESCRIPTION AND OPERATION let Di ei ei ei Wi III N EE OE he oe 1 Ne es ALPE OR ER NE ER OE EE OE EE GE 1 Section 2 SPECIFICATIONS Small E Stop Brake Specifications 2 Large E Stop Brake Specifications 3 Section 3 INSTALLATION 3 1 Removing Old E Stop Brake 4 3 2 Installing
22. ers 73 out of the Thrust Plate 5 and take it off of the Piston 3 Push the Piston 3 out of the Piston Housing 8 TYPICAL LIFT AND CARRY MACHINE 2 SET SCREWS 107 SPLINED HUB 11 10 FORCE CONTROL INDUSTRIES INC MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com INDUSTRIAL 8 Pry the Piston Liner 51 and the 2 O Rings 44 out of the piston groove Also remove the Liner 50 and O Ring 43 from the Piston Housing 8 Discard the Liners and O Rings They will need to be replaced with new ones at Reassembly 5 7 LARGE E STOP BRAKE REASSEMBLY PROCEDURE If you did not remove the whole brake from the machine then complete Steps 1 2 and 3 to reassemble the Piston Housing and Piston Sub Assembly A new Brake Stack can just be installed on the Hub 11 which is still attached to the machine output shaft See Step 6 Attach the Piston Housing 8 to the Main Housing 9 See Step 7 Attach the End Housing 16 with the proper amount of Springs 40 to the Piston Housing 8 See Step 10 1 Reinstall a new O Ring 43 and Liner 50 back into the Piston Housing 8 Lubricate the O Ring with Vaseline or equivalent first Lubricate the 2 O Rings 44 with Vaseline or equivalent and install them into the Piston 8 Install the O D Liner 51 on the Piston 8 2 Coat the surfaces indicated in Figure 5 5
23. ether stopping any shaft rotation When air pressure is restored the air pressure forces the Piston 3 back releasing the pressure on the brake stack allowing the output shaft to rotate LIFTING EYE HOLE TEFLON PISTON SEALS 50 amp 51 VALENS NI r BARN TEEF SS NE END HOUSING 16 YA A N AN SS PISTON 3 APP A MS HEAVY DUTY SPRING PACK THRUST PLATE 5 N RANNI SIE hi IS N NEE SPRING LOADED BRAKE STACK SPLINED HUB 11 ST pH N S INN Ua UMMM A L L D LMM Lip WL a CUSTOMER S OUTPUT SHAFT ADAPTER FLANGE 7 AIR PRESSURE TO RELEASE DRIVE PLATES 13 BRAKE STACK PISTON HOUSING 8 Figure 1 1 Cross Section through E Stop Brake FORCE CONTROL INDUSTRIES INC FRICTION DISCS 12 CESS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 MSS DIST AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com Section 2 SPECIFICATIONS Small E Stop Brake Torgue Specifications NOMINAL ASSEMBLY STATIC PRESSURE CYCLIC PISTON 2 CONFIGURATION TORQUE TO RELEASE WK VOLUME Lb In PSI Lb Ft Cu In 8 599 4 ors With Long Housing SG 3590 ith Short Housing Mann Housing Small E Stop Brake Torque Assembly Configurations 9 Drive Plates 13 6 Drive Plates 13 E v S e ml SHORT STAGK LONG STAGK 8 Filler Plates 380 Plate 5 8 Friction Dis
24. g upward 12 OR 24 CUSTOMER FURNISHED 20 mm DIA MOUNTING BOLTS AND LOCKWSHERS CUSTOMER S OUTPUT SHAFT 2 KEYS 72 ATTACHED TO SHAFT WITH 2 SCREWS 76 Figure 5 4 Removing Large E Stop Brake From Machine 2 Evenly loosen and remove the 6 Screws 67 and 6 Lockwashers 74 that holds the End Housing 16 to the Piston Housing 8 CAUTION This End Housing is under spring pressure so use caution in removing these screws to avoid personal injury 3 Lift the End Housing 16 off and remove the Springs 40 The Pins 54 will remain in the End Housing 16 which will tell you where the springs go at Reassembly Correct Spring Placement is also shown in Figure 5 5 if you wish to change the Braking Torque in your shop 4 Remove the 6 Screws 66 and 6 Lockwashers 74 from the Piston Housing 8 5 Insert 3 1 2 13 x approx 5 Lg Jack Screws into 3 of the tapped holes in the Piston Housing 8 There are 6 tapped holes Use every other one Tighten down evenly to release the Piston Housing from the 3 Driver Pins 210 in the Main Housing 9 Lift the Piston Housing and Piston Sub Assembly up and off the Main Housing 9 6 The Brake Stack can now be removed from the Main Housing 9 and the 3 Driver Pins 210 The Piston 3 and the Thrust Plate 5 need to be taken apart to replace the Piston Seals and O Rings 7 Take the 4 Screws 65 and 4 Lockwash
25. h Set Screws Visually check to see if the teeth in the Friction Discs 12 are aligned with each other Apply 50 to 60 PSI to the brake port to release the brake stack and align the teeth if necessary Attach a 1 2 13 eye bolt into the top of the brake and attach an overhead hoist to it Slide the Brake Assembly on to the Hub 11 The brake will require either 12 or 24 20 mm mounting bolts depending on the brake torque Check the brake adapter plate for the quantity required Attach the brake with the correct quantity of mounting bolts and lockwashers which are both customer furnished Use Red Loctite 262 or 282 Thread locker Torque to 287 Ft Lbs CAUTION Be very careful not to damage the spline teeth in the Friction Discs 12 when engaging the Hub 11 spline Hook up pneumatic valve and piping See Figure 3 1 for Pneumatic Control Circuit MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com Section 4 TROUBLE SHOOTING 4 1 TROUBLE SHOOTING CHART TROUBLE POSSIBLE CAUSE CORRECTION A Brake fails to engage properly B Brake fails to disengage properly C Noise and vibration D Unit overheats Temp over 200 F LEAKAGE See Figure 4 1 Piston sticking or binding Weak or broken spring Air pressure not exhausting or slow in exhausting Worn friction surfaces Low air pressure Piston sticking or binding Piston seals
26. ing Piston Seals for Leakage INDUSTRIAL FORCE CONTROL INDUSTRIES INC MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com Section 5 REPAIR and REPLACEMENT IMPORTANT SAFETY PRECAUTIONS Before attempting any adjustments removal or repair of E Stop Brake Units be sure to dis connect and lock out all power to the machinery to which they are connected The devices are spring set pressure released and were designed to stop and hold loads in posi tion in the event of an emergency stop command or loss of power to the machinery Some machines may have stopped conditions where the spring set brake is holding a vertical or inclined load in a raised or partially raised position Members of the machinery that could free fall if the brake is released or disconnected should be pinned mechanically in place and blocked or supported with cribbing to prevent movement of the machinery Absolutely no work should be performed on the E Stop Brake devices until adequate safety precautions are taken and the machinery is safe to work on 5 1 GENERAL INFORMATION Unless the brake is to be completely overhauled it should be disassembled only to the extent necessary to gain access to the worn or damaged parts Refer to Figure 6 1 for a visual reference to all parts to be disassembled replaced and reassembled A fine stone or crocus cloth may be used to remove minor surface defects from
27. nished Use Red Loctite 262 or 282 Thread locker Torque to 287 Ft Lbs CAUTION Be very careful not to damage the spline teeth in the Friction Discs 12 when engaging the Hub 11 spline Hook up pneumatic valve and piping See Figure 3 1 for Pneumatic Control Circuit FORCE CONTROL INDUSTRIES INC MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com Section 6 ORDERING 6 1 GENERAL INFORMATION This section illustrates lists and describes all parts for the E Stop Brake Parts are identified on the exploded view drawings Figure 6 1 and Figure 6 2 with Part Reference Numbers These numbers correspond to the Part Reference Number given in the parts list The Part Name and Quantity Used is also given in the parts list The Part Number Part Name and Quantity should all be used when ordering parts 6 2 FACTORY REBUILD SERVICE Reconditioning Service is offered by Force Control Industries Inc at the factory Contact Force Control Industries Inc for authorization and shipping instructions before returning a brake for this service Force Control cannot be responsible for units returned to the factory without prior notice and authoriza tion Care must be given to the packing of returned brakes Always protect mounting feet and flanges by attaching to a suitable skid Shipment damaged units always delay repairs It is usually impossible to recover damage costs
28. product or part thereof should be repaired or replaced under the terms of this limited warranty it will pay for shipping the repaired or replaced product or part thereof back to the buyer EXCEPT FOR THE EXPRESS WARRANTY SET OUT ABOVE FORCE CONTROL DOES NOT GRANT ANY WARRANTIES EITHER EXPRESSED OR IMPLIED INCLUDING IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR USE The warranty obliga tion set forth above is in lieu of all obligations or liabilities of Force Control for any damages Force Control specifically shall not be liable for any costs incurred by the buyer in disconnecting or re installing any product or part thereof repaired or replace under the limited warranty set out above FORCE CONTROL EXPRESSLY EXCLUDES ALL LIABILITY FOR ANY INDIRECT OR CONSE QENTIAL DAMAGES THE BUYER MAY SUSTAIN IN CONNECTION WITH THE DELIVERY USE OR PERFORMACE OF FORCE CONTROL PRODUCTS Under no circumstances shall any liabil ity for which Force Control is held responsible exceed the selling price to the buyer of the Force Control products that are proven to be defective This limited warranty may be modified only in writ ing signed by a duly authorized officer of the company This limited warranty applies exclusively to Force Control products warranties for motors and gear reducers and other component parts may be provided by their respective manufactures Any legal action for breach of any Force Control war ranty must be commenced within one year of the dat
29. r this Assembly on to the End Housing 10 Insert the 6 Screws 67 and 6 Lockwashers 74 and finger tighten them to just hold the brake together Turn the brake over with the End Housing 16 facing up Tighten the 6 Screws down in an even manner to compress the Springs 40 correct ly Torque to 60 Ft Lbs 11 Manually pull the Hub 11 out of the brake stack 12 INDUSTRIAL 22 SPRINGS 24 SPRINGS 5 8 MOUNTING HUB AND LARGE E STOP BRAKE ON MACHINE OUTPUT SHAFT 1 First check the output shaft and brake mounting sur face for any nicks or burrs Clean up and deburr if necessary Attach 2 Keys 72 to the output shaft with 2 screws 76 Lubricate the output shaft with white grease and slide the Hub 11 on to it Align the 2 set screw holes in the hub with the indent in each Key 72 Tighten both Set Screws 107 Visually check to see if the teeth in the Friction Discs 12 are aligned with each other Apply 50 to 60 PSI to the brake port to release the brake stack and align the teeth if necessary Attach a 1 2 13 eye bolt into the top of the brake and attach an overhead hoist to it Slide the Brake Assembly on to the Hub 11 The brake will require either 12 or 24 20 mm mounting bolts depending on the brake torque Check the brake adapter plate for the quantity required Attach the brake with the correct quantity of mounting bolts and lockwashers which are both customer fur
30. ston Housing 8 using the 2 Pins 139 for positioning FORCE CONTROL INDUSTRIES INC same procedure given in Section 3 INSTALLATION CESS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com 5 5 REMOVING LARGE E STOP BRAKE The Large E Stop Brake does not have to be removed from the machine before the brake can be disassembled If you are not removing the whole brake from the machine go to 5 6 DISASSEMBLY PROCEDURE Steps 2 to Steps 8 and remove the End Housing 16 and the Piston Housing 8 for access to the Piston Liners and the Brake Stack To remove the whole brake from the machine com plete the following 5 Steps See Figure 5 4 1 Install a 1 2 13 eye bolt into the top hole of the Piston Housing 8 Attach an overhead crane to the eye bolt 2 Remove the 12 mounting bolts and lockwashers that attaches the brake to the machine 3 Pull the Brake Assembly straight back off the machine face and the Splined Hub 11 which will remain attached to the machine output shaft 4 To remove the Hub 11 from the machine output shaft just loosen the 2 Set Screws 107 and pull it off of the shaft 5 The 2 Keys 72 can be taken out of the output shaft by removing the 2 Screws 76 5 6 LARGE E STOP BRAKE DISASSEMBLY PROCEDURE See Figure 6 2 for a reference to all parts 1 Set the brake on a work bench with the End Housing 16 facin
31. w 107 and pull it off the shaft Remove the 10 Hex Nuts 121 and 10 L ockwashers 122 from the 10 Studs 120 Lift the Outer Brake Assembly off The Main Housing 9 can just be lifted off the Brake Stack and the Adapter Plate 7 The Brake Stack can now be removed from the 5 Dowel Driver Pins 210 that are pressed into the Adapter Plate 7 Back the 6 Screws 66 out of the End Housing 16 in an even and consistent manner CAUTION This End Housing is under spring pressure so use caution in removing these 6 screws to avoid any personal injury Lay the brake with the Piston Housing 8 in an up position Lift the Piston Housing 8 off the End Housing 16 Make a sketch of the placement of the Springs 40 This will help at Reassembly Remove the Springs 40 Correct spring placement is also shown in Figure 5 2 for torque adjustment in the field INDUSTRIAL CUSTOMER S OUTPUT SHAFT 9 Remove the 3 Screws 65 and 8 Lockwashers 73 from the Thrust Plate 5 and separate the Thrust Plate 5 from the Piston 3 Push the Piston out of the Piston Housing 8 10 If the Piston Seals need replaced then pry the Liner 51 and 2 O Rings 44 out from the Piston 8 Remove the Liner 50 and O Ring 43 from the Piston Retainer 8 Discard the Liners and O Rings They will need to be replaced with new ones at reassembly 5 4 SMALL E STOP BRAKE REASSEMBL
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