Electrically Released Brake ER-825, ER-1225
Contents
1. INDUSTRIAL MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com 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 7 32 Hex key wrench for mounting screws Tube Grade 242 Loctite Snap ring pliers external Torque wrench minimum 200 Ib ft reading ER 825 Torque wrench minimum 400 Ib ft reading ER 1225 3 steel shims equal thickness not less than 1 16 not greater than 1 8 Small hammer approximately 8 ounce Brass Drift Flat blade screwdriver Loctite grade 242 INSTALLATION FOR ER 825 BRAKE WITH OUTSIDE ARMATURE HUB Technical Information Static TOIQUG nuanua nauan aaa 125 Ib ft Max RPM bois udsupa ashe ed ea ee oh re 3600 Voltage 4 uri ch bad ware eae 4 90 VDC Total Weigh i ca dbeadocaes ny eanarss 15 6 Ib Current draw Nominal 0 295 amp 90 Volts Resistance at 20 degrees C 305 ohms 10 Step 1 Remove the ER brake from its shipping carton The carton contains a magnet Item 11 and armature Item 3 plus mounting hardware and a conduit box See Figure 1 Inspect the components to make sure they have not been dam aged in shipping Step 2 Wipe the magnet and its mounting sur face clean and remove any burrs ACAUTION No solvents on friction face Step 3 Assemble the conduit2. See Figure 7 Inspect the components to make sure they have not been dam aged in shipping Step 2 Wipe the magnet and its mounting sur face clean and remove any burrs ACAUTION No solvent on friction face Step 3 Assemble the conduit box to the mag net in accordance with the instructions included with the conduit box Step 4 Insert an aluminum or other non mag netic material spacer into the magnet bore and align the holes in both com ponents This spacer must be machined to pilot on the motor and magnet pilot mounts and align within the tolerances specified in the intro duction to this manual See Figure 8 8 Warner Electric e 800 825 9050 9 Magnet Armature ms Working Surface See Detail A Taperlock M 1il Bushing Set Screw HR Detail A Detent Cup 6 3 Armature 4 Drive SH o Retainer 9 Follow Up Cup ae Hub 1 Figure 7 Assembled brake showing numbered components Item numbers shown will be referenced throughout this installation procedure Figure 8 Aluminum Spacer installed 819 0466 INDUSTRIAL MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 7260 ventas industrialmagza com Step 5 Position the magnet spacer assembly on the motor pilot and align the holes in the magnet with the spacer and mounting surfa
3. box to the mag net in accordance with the instructions furnished with the conduit box Warner Electric e 800 825 9050 3 Armature Working Surface See Detail A ree Mounting Surface Set Screw Taperlock Bushing we Armature 3 Detent 7 fin K Pin 4 ad Yellow Spring 5 Detent Cup 6 Detail A Fe Serna Figure 1 Assembled brake showing numbered compo nents Item numbers shown will be refer enced throughout this installation procedure Step 4 Insert an aluminum or other non mag netic material spacer into the magnet bore and align the holes in both com ponents This spacer must be machined to pilot on the motor and magnet pilot mounts and align within the tolerances specified in the intro duction to this manual See Figure 2 Figure 2 Aluminum spacer installed 819 0466 5 INDUSTRIAL MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 7260 ventas industrialmagza com Step 5 Position the aluminum spacer magnet assembly on the motor pilots and align the holes in the spacer with the holes in the motor and magnet Following the manufacturer s instructions apply grade 242 Loctite to the threads of each furnished cap screw add a lock washer and fasten the spacer brake assembly on the motor Tighten these screws to 25 to 28 lb ft torque with a
4. magnetic material keep all body parts clear of the possible contact area to avoid injury Magnetic attraction can be overcome by applying approximately 90 volts DC to the size 1225 magnet To prevent accidents follow the proper Montgomery Kone instructions to lock the escalator in place when installing or replacing a brake ACAUTION Each brake is preburnished at the factory amp shipped with its mated compo nents Do not exchange armature or magnet with any other brake as the non mated com ponents may produce less than rated torque and may cause the escalator to fail When either component is replaced the complete brake must be replaced ACAUTION if the magnet mounting surface is magnetic material the magnet must be isolated approximately 1 4 inch from that sur face with a plate or spacers of non magnetic material This helps to reduce stray magnetic force flux which may impair the brake s operation In order to minimize stray flux the brake should be as exposed as possible or if enclosed it must be placed in a housing of non magnetic material such as 302 304 stainless steel or aluminum 4 Warner Electric e 800 825 9050 MEX 55 53 63 2331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 7260 ventas industrialmagza com The mounting pilot diameter must be concen tric to the shaft within 010 T I R The magnet mounting surface must be square with the shaft within 006 T I R measured at the bolt cir
5. no assembly or installation difficulties should be encountered The Warner Electric warranty does not apply to any unit which is not installed used operated and maintained in accordance with Warner Electric s instructions 2 Warner Electric e 800 825 9050 ER 1225 Brake with Pin Drive ER 825 Brake with Outside Armature Hub ER 825 Brake with Inside Armature Hub and Taperlock Bushing ER 825 Brake with Inside Armature Hub and no Taperlock Bushing ER 1225 Brake with Inside Armature Hub P 269 INDUSTRIAL MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 7260 _ ventas industrialmagza com Introduction Warner Electric Electrically Released Brakes function on the same principle of response to magnetic attraction that operates other Warner Electric brakes and clutches Braking torque in the Electrically Released Brake depends on per manent magnets rather than electromagnets With the power off the unit produces full brak ing torque The brake is released by reversing the direction of flux flow in an electromagnetic coil thus opposing the field produced by the permanent magnets The cancellation of electromagnetic force which releases the brake occurs at one nominal value of ampere turns Autogap Assembly Poles This ampere turn value can vary among brakes because of allowable manufacturing tolerances Release voltage varies mainly because of the coil tole
6. 0 P 3 Armature H En RVO Magnet Working See Detail A Surface H Mounting Surface a C Taperlock _ Bushing Set Screw 3 Armature Detail A lt lt ial 4 Pin Yellow Spring Hub 2 Follow Up Cup 8 Red e Spring Detent 7 Detent Cup 6 Figure 18 Assembled brake showing item numbered components Item numbers shown will be referenced throughout this installation procedure Step 5 Position the magnet on the adapter pilot and align the holes in the magnet with the adapter holes Following the manufacturer s instructions apply grade 242 Loctite to the threads of each furnished cap screw add a lock washer and fasten the magnet on the adapter Tighten these screws to 25 to 28 b ft torque with a torque wrench Make electrical connection The positive and negative of the power lead must be connected to the positie and negative lead wires or termi nals of the brake respectively follow Montgomery Kone s instructions to set the release voltage of the brake 819 0466 INDUSTRIAL Step 6 Place the armature hub assembly ona flat surface with the armature working face up Push down on each detent cup Item 6 with your fingers pushing the armature down until the armature will not move down any further See Figure 19 Figure 19 Posi
7. 600 Voltage cavedaguiaagi sacra ewe ta ees 90 VDC Total weight 0 eee eee 16 Ib Current draw 0 295 amp 90 Volts Resistance at 20 degrees C 305 ohms 10 Step 1 Remove the ER brake from its shipping carton The carton contains a magnet Item 10 and armature Item 2 See Figure 13 Inspect the components to make sure they have not been dam aged in shipping Step 2 Wipe the magnet and its mounting Surface clean and remove any burrs Careful No solvents on friction face Step 3 Insert an aluminum or other non mag netic material spacer into the magnet bore and align the holes in both com ponents This spacer must be machined to pilot on the motor and magnet pilot mounts and align within the tolerances specified in the introduction to this manual See Figure 14 Warner Electric e 800 825 9050 Mounting Armature fe Surface Working Surface See Detail A Detail A Armature C a Blue Spring a 3 j Drive Pi five PINS 9 Retaine Ring 8 Follow Up Cup Le Figure 13 Assembled brake showing item numbered components Item numbers shown will be referenced throughout this installation procedure Figure 14 Aluminum spacer installed 819 0466 11 INDUSTRIAL MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 7260 ventas industrialmagza com Step 4 Position the magnet spacer assembly on the transmission pilot and align
8. 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com INSTALLATION FOR ER 1225 BRAKE WITH INSIDE ARMATURE HUB Technical Information Static TOrquUe 44 oo 4anee ne 64 044 ea 400 Ib ft Max RPM stcacee a betanveddaewns sai 3600 Voltage beta kw sca eae ea ae eens 45 70 VDC Total Weight ita ane a bus Few ade gh e ee 4 60 Ib Current draw 0 256 amp 60 volts Resistance at 20 degrees C 235 ohms 10 Step 1 Remove the ER brake from its shipping carton The carton contains the magnet Item 11 and armature Item 3 plus mounting hardware and conduit box See Figure 18 Inspect the compo nents to make sure they have not been damaged in shipping Step 2 Wipe the magnet and its mounting sur face clean and remove any burrs Careful No solvent on friction face Step 3 Assemble the conduit box to the mag net per instructions included with the conduit box Step 4 Position the aluminum adapter on the motor pilot Align holes in the adapter with holes in the motor Following the manufacturer s instructions apply grade 242 loctite to the threads of each furnished cap screw add a lockwasher and fasten the adapter on the motor Tighten these screws 25 to 28 lb ft torque with a torque wrench The adapter must be machined to pilot on the motor and magnet pilot mounts and align within the tolerences specified in the introduction to this manual 14 Warner Electric 800 825 905
9. CES MNaacza MEX 55 53 63 2331 MTY 81 83 54 10 18 SE DIST AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com Electrically Released Brake ER 825 ER 1225 with Pin Drive Armatues tor MONGOMEY KONG P 230 819 0466 Warner Electric INDUSTRIAL MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 7260 _ ventas industrialmagza com Contents EMOOCUICUION gu aay cn cau npe e a Beek ee ee 3 Installation for ER 825 amp 1225 Brakes with Pin Drive 0000 ees 4 Installation for ER 825 Brake with Outside Armature Hub ww ee 5 Installation for ER 825 Brake with inside Armature Hub amp taperlock Bushing 8 Installation for ER 825 Brake with Inside Armature Hub amp no Taperlock Bushing 10 Installation for ER 1225 Brake with Inside Armature Hub 4 caw we bw oe ee ew ws 13 Operating Instructions 005 16 Warnanty naga k Gare ta oa ba ee nae Back Page Failure to follow these instruc tions may result in product damage equip ment damage and serious or fatal injury to personnel General Information This service manual tells how to install adjust and maintain your Warner Electric brake Warner Electric Electrically Released Brakes are high performance high torque units To obtain the required performance and life the brake must be installed exactly in accordance with the instructions of this service manual After care fully reading these instructions
10. 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 specific legal rights and you may also have other rights which vary from state to state Changes in Dimensions and Specifications All dimensions and specifications shown in Warner Electric catalogs are subject to change without notice Weights do not include weight of boxing for shipment Certified prints will be furnished without charge on request to Warner Electric 815 389 3771 Fax 815 389 2582 www warnerelectric com AW ar n er ee South Beloit IL 61080 Electric P 230 819 0466 7 05 Printed in USA
11. away from this area Figure 12 Setting the airgap If the brake includes temperature and wear sensor wires follow Montgomery Kone s instructions to make proper connections Color coding Is as follows Yellow wires temperature sensor Red wire 90 wear sensor Black wire 70 wear sensor Burnish the brake as follows Start and Stop the escalator 30 times Allow 5 10 seconds delay between each start and Stop With power off check brake static torque which must be at least 125 lb ft If less repeat Step 15 If the brake does not meet the torque requirement after two burnishings replace it 819 0466 INDUSTRIAL MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com Step 17 When the armature is released and rotating freely the armature working face should not rub on the magnet working face and the armature working face axial runout wobble should not exceed 015 inch If the armature rubs or wobbles excessively remove the armature assembly and reassemble it as instructed in Steps 11 amp 12 If the problem persists replace the brake Step 18 Brake installation is complete Follow Montgomery Kone s instructions to install the remainder of the system INSTALLATION FOR ER 825 BRAKE WITH INSIDE ARMATURE HUB amp NO TAPER LOCK BUSHING Technical Information Static TOMUCG gaa xeea carte ihusdass 125 b ft Mex RPM rererere eta eee eee sd we 3
12. card all the brake components and do not use any of them with the new brake After completing an inspection with the machine turned off perform the normal burnish proce dure used during installation of a new brake Check the static torque of the brake If the torque is below the rated level perform the bur nish procedure again and check for rated torque If torque falls below the rated level replace the brake Warner Electric 800 825 9050 Check the air gap When the armature is rotat ing freely in a released mode the armature working face should not rub on the magnet working face Armature working face axial runout wobble should not exceed 015 inch If any of the above conditions are present remove the armature assembly from the motor brake and reassemble it on the motor as explained in the installation procedure If problem persists replace the brake Wear pattern Wear grooves will appear on the friction surfaces This is a normal wear condi tion and does not impair the performance of the unit Never machine the friction surfaces to remove grooves or score marks resulting from normal wear 819 0466 17 CSS MNacza MEX 55 53 63 2331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 7260 ventas industrialmagza com 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 w
13. ce axial runout wobble should not exceed 015 inch If the armature rubs or wobbles excessively remove the armature assembly and reassemble it as instructed above If the problem persists replace the brake Brake installation is complete Follow Montgomery Kone s instructions to install the remainder of the system 819 0466 INDUSTRIAL MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com MAINTENANCE INSTRUCTIONS All Brakes Once an electrically released brake is properly installed periodic checks of the brake for worn out conditions are required Experience will determine the proper inspection interval Furthermore in order to refresh the mating sur faces it is recommended that burnishing as described in the installation procedure be per formed once a month Check for worn out conditions as follows Figure 23 Measure dimension X to determine worn out condition Turn off power to the brake The armature must contact magnet all around the circumference and there should be no airgap between arma ture amp magnet If there is partial or no engage ment replace the brake Check the combined thickness of the armature and magnet as shown in Figure 23 dimension X If this dimension ts less than or equal to 2 420 2 27 64 for size ER 825 or 2 875 2 7 8 for size ER 1225 then the brake is worn out and should be replaced immediately Dis
14. ce holes Following the manufacturer s instructions apply grade 242 Loctite to the threads of each furnished cap screw add a lock washer and fasten the spacer magnet assembly on the motor Tighten these screws to 25 to 28 lb ft torque with a torque wrench Make the electrical connection The positive and negative of the power lead must be connected to the positive and negative lead wires or termi nals of the brake respectively follow Montgomery Kone s instructions to set the release voltage of the brake Step 6 Place the armature hub assembly ona flat surface with the armature working face up Push down on each detent cup Item 6 with your fingers sliding the armature down until the armature will move no further See Figure 9 Armature working Surface afer ae Figure 9 Positioning the detent cups in the armature Step 7 Insert the taper lock bushing Item 1 into the hub Item 2 Align the two half drilled holes in the taper lock bushing with the two half threaded holes in the hub Insert two set screws Item 12 into the aligned holes and screw them in loosely to maintain alignment during assembly Warner Electric 800 825 9050 ACAUTION During steps 8 9 and 10 han dle the armature hub assembly by the hub Item 2 or the drive pins Item 4 only making sure the armature Item 3 is as close to the retainer ring Item 10 as possible Any move ment of the armature on the pins Item 4 will
15. cle The spacer or mounting adapter used in installa tion of the brake must be machined to toler ances specified above ACAUTION New armatures shipped from the factory are flat to within 0 005 inches and must stay flat within this tolerance to main tain full torque Any attempt to pry the arma ture loose from the magnet will distort the armature When adjusting the armature posi tion apply any required force only to the hub not to the outer edge of the armature Moreover be careful not to drop the arma ture for this may also cause distortion ACAUTION For proper operation of the brake apply only DC voltages If AC power is ever applied to the brake the magnets will set partially demagnetized and the brake will have to be replaced The positive amp negative of the power lead must be connected to positive amp negative lead wires or terminals of the brake respectively Heat Excessive heat and high operating tem peratures are cuases of rapid wear Air should circulate around the unit as freely as possible especially if the application requires fast repeti tive cycling If a choice of armature shaft material exists it Should be non magnetic Materials such as type 302 304 stainless have been used very suc cessfully Please follow these instruc tions carefully to ensure proper operation Failure to comply with these instructions can result in damage to property and injury or even death to personnel 819 0466
16. e reposition the armature hub assembly as described in Steps 11 amp 12 otherwise go to Step 13 Figure 5 Seating the taperlock bushing Step 11 Apply power 90 VDC to release the brake Remove the taperlock bushing and armature assembly Items 1 2 3 from the motor shaft To remove arma ture assembly using a hex key wrench remove both set screws Item 12 from the taperlock bushing Item 1 Insert one set screw into the previously vacant hole in the taperlock 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 plastic hammer ACAUTION Do not pry the armature away from the magnet This can distort the arma ture and require complete brake replace ment Step 12 Repeat Steps 6 7 8 9 and 10 Warner Electric e 800 825 9050 Step 13 Keep fingers away from this area Step 14 Step 15 Step 16 Step 17 Apply power 90 VDC to the brake and remove the shims Set the airgap by pressing the armature into contact with the magnet and then releasing as Shown in Figure 6 The armature should Spring back approximately 3 64 045 Inch Figure 6 Setting the airgap If the brake includes temperature and wear sensor wires follow Montgomery Kone s instructions to make proper connections Color coding Is as follows Yellow wires temperature sensor Red wire 90 wear sensor Black wire 70 wear sensor B
17. e Figure 11 Repeat this alternate tapping and re tightening until the Specified torque no longer turns the screws after tapping Tighten the screws to 15 Ib ft torque The gap between armature and magnet must be 0 062 to 0 125 inch If the gap Is out side of that range reposition the armature hub assembly as described in Steps 11 amp 12 otherwise go to Step 13 Figure 11 Seating the taperlock bushing Step 11 Apply power 90 VDC to release the brake Remove the taperlock bushing and armature assembly Items 1 2 3 from the motor With a hex key wrench remove both set screws Item 12 from the taperlock bushing Item 1 Insert one set screw into the previously vacant hole in the taperlock 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 ACAUTION Do not pry the armature away from the magnet This can distort the arma ture and require complete brake replace ment Step 12 Repeat Steps 6 7 8 9 amp 10 10 Warner Electric e 800 825 9050 Step 13 Step 14 Step 15 Step 16 Make the electrical connections Apply power 90VDC to the brake and remove the shims Set the airgap by pressing the armature into contact with the magnet and then releasing as Shown in Figure 12 The armature Should spring back approximately 3 64 045 inch when power Is applied to the magnet Keep fingers
18. e bushing is loosened in the hub Item 2 If the bushing does not loosen tap on the hub with a plastic hammer ACAUTION Do not pry the armature away from the magnet This can distort the arma ture and require complete brake replace ment Step 12 Repeat Steps 6 7 8 9 and 10 Step 13 Make the electrical connections if they have not been made Apply power 60 VDC to the brake and remove the shims Set the airgap by pressing the armature into contact with the magnet and then releasing as shown in Figure 22 The armature should spring back approximately 3 64 045 inches Figure 22 Setting the airgap 16 Warner Electric e 800 825 9050 Step 14 Step 15 Step 16 Step 17 Step 18 If the brake includes temperature and wear sensor wires follow Montgomery Kone s instructions to make proper connections Color coding Is as follows Yellow wire s temperature sensor Red wire 90 wear sensor Black wire 70 wear sensor Burnish the brake as follows Start and Stop the escalator 30 times Allow 5 10 seconds delay between each start and stop With power off check brake static torque which must be at least 400 lb ft excluding system drag If less repeat Step 15 If the brake does not meet the torque requirement after two burnishings replace it When the armature is released and rotating freely the armature working face should not rub on the magnet working face and the armature working fa
19. ithin 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 notified 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
20. o the motor Shaft until the armature makes contact with the shims Using a drift lightly tap on the taperlock bushing at several points around the circumfer ence with a small hammer until it will not slide further onto the shaft See Figure 21 Shims Figure 20 Armature installation with shims in place Step 10 Using a torque wrench tighten the hub bushing screws Item 12 alternately and evenly until tight Place a drift against the large end of the bushing at several points around the circumfer ence and tap it lightly with a small hammer See Figure 21 Repeat this alternate tapping and re tightening until the specified torque no longer turns the screws after tapping Tighten the screws to 15 lb ft torque The gap between armature and magnet must be 062 to 125 inch If the gap is outside of that range reposition the armature hub assembly as described in Steps 11 amp 12 otherwise go to Step 13 819 0466 15 CES MaaczAa MEX 55 53 63 2331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 7260 ventas industrialmagza com Figure 21 Seating the taperlock bushing Step 11 Apply power 60 VDC to release the brake Remove the taperlock bushing and armature assembly Items 1 2 3 from the motor shaft With a hex key wrench remove both set screws Item 12 from the taperlock bushing Item 1 Insert one set screw into the previously vacant hole in the taperlock bushing and tighten this screw until th
21. onnections Color coding Is as follows Yellow wires temperature sensor Red wire 90 wear sensor Black wire 70 wear sensor Step 11 Burnish the brake as follows Start and Stop the escalator 30 times Allow 5 10 seconds delay between start and stop Step 12 With power off check brake static torque which must be at least 125 lb ft excluding system drag If less repeat Step 11 If the brake does not meet the torque requirement after two burnishings replace it Warner Electric e 800 825 9050 Step 13 When the armature is released and rotating freely the armature working face should not rub on the magnet working face and the armature working face axial runout wobble should not exceed 015 inch If the armature rubs or wobbles excessively remove the armature assembly and reassemble it as instructed in Steps 15 17 below If the problem persists replace the brake Step 14 Brake installation is complete Follow Montgomery Kone s instructions to install the remainder of the system Steps to disassemble the armature from transmission shaft Step 15 Using socket wrench remove bolt amp washer from the shaft end Step 16 Apply power and slowly slide the arma ture away from magnet ACAUTION Do not pry the armature away from the magnet This can distort the arma ture and require complete brake replace ment Step 17 Follow Steps 5 thru 13 819 0466 13 INDUSTRIAL MEX 55 53 63 23 31 MTY
22. pinched between the armature and the magnet Step 6 Insert the key in the motor shaft key Way Step 7 Make sure no power is applied to the brake Place three steel shims 120 degrees apart on the magnet as shown in Figure 16 ACAUTION __ 062 inch shims are recom mended Do not use shims thicker than 125 inch or you will shorten brake life by reducing available armature travel Slip the armature hub assembly onto the trans mission shaft until the armature hub bottoms out on the shims See Figure 16 The gap between the armature amp magnet must be no more than 125 inch If the gap is larger than 125 inch push on the hub to achieve 125 inch gap Shims Figure 16 Armature installation with shims in place Step 8 Insert the washer and bolt into the threaded hole in the end of the shaft Tighten the bolt to the torque specified by Montgomery Kone 819 0466 INDUSTRIAL MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com Step 9 Apply power 90 VDC to the brake and remove the shims Set the airgap by pressing the armature into contact with the magnet and then releasing as Shown in Figure 17 The armature Should spring back approximately 3 64 045 inch when power Is applied to the magnet Figure 17 Setting the airgap Step 10 If the brake includes temperature and wear sensor wires follow Montgomery Kone s instructions to make proper c
23. rance and Autogap spring variations Properly adjusting the power supply voltage is important so the autogap springs will separate the magnet and armature causing full release If the release voltage is not set properly the arma ture will rub against the magnet This rubbing action can cause the brake and other compo nents in the system to fail Warner Electric Electrically Released Brakes are burnished at the factory to assure rated torque shortly after initial application Very little additional wear in is required Friction M aterial Armature Magnet Shell The same principle of response to magnetic attraction used in this FB 650 operates the larger ER 825 and ER 1225 Electrically Released Brakes Described in this manual Warner Electric e 800 825 9050 819 0466 3 INDUSTRIAL Installation Instructions for ER 825 amp ER 1225 BRAKES With Pin drive Important Please read the following cautionary notes before starting installation The permanent magnets used in this brake which determine its unique features and operation also demand spe cial consideration when installing and operating it Read the following carefully The brake consists of an armature and magnet The magnet includes permanent magnets which will srongly attract any magnetic material toward it Keep the magnet at least 1 2 inch away from any magnetic material including a steel work bench If the magnet must come closer than 1 2 inch to any
24. reduce available armature travel and may cause improper air gap setting Keep fingers clear of the area between the magnet Item 11 and the arma ture Item 3 because the armature will be pulled sharply toward the magnet after the gap is closed to approximately 1 8 inch Injury can result if fingers are pinched between the armature and the magnet Step 8 Insert the key in the motor shaft key Way Step 9 Make sure no power applied to the brake Place three steel shims 120 degrees apart on the magnet as shown in Figure 10 ACAUTION 0 062 inch shims are recom mended Do not use shims thicker than 0 125 inch or you will shorten brake life by reducing available armature travel Slip the armature hub assembly onto the motor Shaft until the armature makes contact with the shims Using a drift lightly tap on the taperlock bushing at several points around the circumfer ence with a small hammer until it will slide no further onto the shaft See Figure 11 Shims Keep fingers away from this area Figure 10 Armature installation with shims in place 819 0466 9 CES MaaczAa MEX 55 53 63 2331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 7260 ventas industrialmagza com Step 10 Using a torque wrench tighten the hub bushing screws Item 12 alternately and evenly until tight Place a drift against the large end of the bushing at several points around the circunference and tap it lightly with a small hammer Se
25. the holes in the magnet with the spacer and mounting surface holes Following the manufacturer s instructions apply grade 242 Loctite to the threads of each furnished cap screw add a lock washer and fasten the magnet on the transmission Tighten these screws to 25 to 28 Ib ft torque with a torque wrench Make the elecrical connection The positive and negative of the power lead must be connected to the positive and negative lead wires or termi nals of the brake respectively follow Montgomery Kone s instructions to set the release voltage of the brake Step 5 Place the armature hub assembly on a flat surface with the armature working face up Push down on each detent cup Item 5 with your fingers pushing the armature down until the armature will not move down any further See Figure 15 Figure 15 Positioning the detent cups in the armature ACAUTION During steps 7 and 8 handle the armature hub assembly by the hub Item 1 only making sure the armature Item 2 is as Close to the retainer ring Item 9 as possi ble Any movement of the armature on the pins Item 3 will reduce available armature travel and may cause improper air gap set ting 12 Warner Electric e 800 825 9050 Keep fingers clear of the area between the magnet Item 10 and the arma ture Item 2 because the armature will be pulled sharply toward the magnet after the gap is closed to approximately 1 8 inch Injury can result if fingers are
26. tioning the detent cups in the armature Step 7 Insert the taperlock bushing Item 1 into the hub Item 2 Align the two half drilled holes in the taperlock bushing with the two half threaded holes in the hub Insert two set screws Item 12 into the aligned holes and screw them in loosely to maintain alignment during assembly ACAUTION During Steps 8 9 and 10 han dle 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 Item 4 will reduce available arma ture travel and may cause improper air gap setting PNR Keep fingers clear of the area between the magnet Item 11 and the arma ture Item 3 because the armature will be pulled sharply toward the magnet after the gap is closed to approximately 1 8 inch Injury can result if fingers are pinched between the armature and the magnet Step 8 Insert the key in the motor shaft key Way Warner Electric e 800 825 9050 MEX 55 53 63 2331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 72 60 ventas industrialmagza com Step 9 Make sure no power is applied to the brake Place three steel shims 120 degrees apart on the magnet as shown in Figure 20 ACAUTION 062 inch shims are recom mended Do not use shims thicker than 125 inch or you will shorten brake life by reducing available armature travel Slip the armature hub assembly ont
27. torque wrench Make the electrical connection The positive and negative of the power lead must be connected to the positive and negative lead wires or termi nals of the brake respectively Follow Montgomery Kone s instructions to set the release voltage of the brake Step 6 Place the armature hub assembly ona flat surface with the armature s working face up Push down on each detent cup Item 6 with your fingers sliding the armature down until the armature will move no further See Figure 3 Armature working Surface Figure 3 Positioning detent cups in armature Step 7 Insert the taperlock bushing item 1 into the hub Item 2 Align the two half drilled holes in the taperlock bushing with the two half threaded holes in the hub Insert two set screws Item 12 into the aligned holes and screw them in loosely to maintain alignment during assembly See Figure 1 6 Warner Electric e 800 825 9050 ACAUTION During Steps 8 9 and 10 han dle the armature hub assembly by the hub Item 2 only making sure the armature Item 3 is as close to the hub Item 2 as possible Any movement of the armature on the pins Item 4 will reduce available armature travel and may cause improper air gap setting Keep fingers clear of the area between the magnet Item 11 and the arma ture Item 3 because the armature will be pulled sharply toward the magnet after the gap is closed to approximately 1 8 inch Injury can res
28. ult if fingers are pinched between the armature and the magnet Step 8 Insert the key into the motor shaft key Way Step 9 Make sure no power is applied to the brake Place three steel shims 120 degrees apart on the magnet as shown in Figure 4 ACAUTION 0 062 inch shims are recom mended Do not use shims thicker than 0 125 inch or you will shorten the brake life by reducing available armature travel Slip the armature hub assembly onto the motor Shaft until the armature makes contact with the shims See Figure 4 Using a drift lightly tap on the taperlock bushing at several points around the circumference with a small hammer until it will not slide further onto the shaft See Figure 5 Shims g Keep fingers away from this area Figure 4 Installing armature with shims in place 819 0466 CES MaaczAa MEX 55 53 63 2331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 7260 ventas industrialmagza com Step 10 Using a torque wrench tighten the hub bushing screws Item 12 alternately and evenly until tight Place a drift against the large end of the bushing at several points around the circumfer ence and tap it lightly with a small hammer See Figure 5 Repeat this alternate tapping and re tightening until the specified torque no longer turns the screws after tapping Tighten the screws to 15 Ib ft torque The gap between armature and magnet must be 0 062 inch to 0 125 inch If the gap is outside of that rang
29. urnish the brake as follows Start and stop the escalator 30 times With power off check brake static torque which must be at least 125 lb ft excluding systems drag If less repeat Step 15 If the brake does not meet the torque requirement after two burnishings replace it When the armature is released and rotating freely the armature working face should not rub on the magnet working face and the armature working face axial runout wobble should not exceed 015 inch Additionally if the armature rubs or wobbles excessively remove the armature assembly and reassemble it as instructed in Steps 11 amp 12 If the problem persists replace the brake 819 0466 7 INDUSTRIAL MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 195 7260 ventas industrialmagza com Step 18 Brake installation is complete Follow Montgomery Kone s instructions to install the remainder of the system INSTALLATION FOR ER 825 BRAKE WITH INSIDE ARMATURE HUB AND TAPER LOCK BUSHING Technical Information Static Torque cee eee 125 b ft MAX RPM tay ce pean ee eon ene rrah eens 3600 Voltage a0 oa Ono g deen ean ea 90 VDC Total Weight 000 cece eee 15 6 Ib Current Draw 0 295 amp 90 Volts Resistance at 20 degrees C 305 Ohms 10 Step 1 Remove the ER brake from its shipping carton The carton contains a magnet Item 10 and armature Item 3 plus mounting hardware and a conduit box
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