SERVICE MANUAL M a g n a S h e a r
Contents
1. ees 18 A Disassembly 18 B Reassembly 19 7 8 REPLACING WEAR SLEEVE 32 20 A Removing Hub 2 From the Motor Shaft 20 B Removing Wear Sleeve 32 20 C Installing Wear Sleeve es 20 7 9 REPLACING OIL SEAL 31 22 7 10 REPLACING BRAKE INDICATOR SWITCH 249 22 7 11 BRAKE REASSEMBLY PROCEDURE 23 Section 8 ILLUSTRATED REPAIR PARTS 8 1 GENERAL INFORMATION enn 24 8 2 DRIVE MOTORS tica dev aS goa Cua 24 8 3 FACTORY REBUILD SERVICE 1 24 8 4 ORDERING REPLACEMENT 24 8 5 NAME PLATE AND MODEL NUMBER 25 REPAIR PARTS Parts List for Figure 8 1 26 Figure 8 1 5 9 and 5 10 MagnaShear Motor Brake 27 Parts List for FIGUIC 8 2 SEVIRIMUS EXE YUXUEENU DTE S EVIRIR 20 Figure 8 2 MSB12 MagnaShear Motor Brake 29 Parts List for Figure 8 3 30 Figure 8 3 Brake Coil Circuit Board and Junction Box 31 Parts List for Figure 8 4 eene 32 Figure 8 4 Brake Release Indicator Switch2. MSB10 3 4 10 x 2 Lg Poly Pak Seal Shoulder Bolt Heli Coil Insert NOTES Indicates parts in Overhaul Kit Indicates parts in Stack Replacement Kit 26 Bronze Bushing Gasket MSB9 1 2 Lockwasher 1 2 8 Lockwasher 3 8 Hi Collar 6 Lockwasher 3 8 2 Eyebolt 1 2 13 2 Shoulder Bolt 4 Soc Hd Screw 1 4 20 x 1 2 Lg 2 Soc Hd Screw 1 2 13 x 1 1 4 Lg 4 Soc Hd Screw 3 8 16 x 1 1 2 Lg 6 Stud 5 911 X 9 LO 4 Dyna Seal 1 2 4 Lockwasher 5 8 4 Dowel Pin 1 2 x 3 1 2 Lg 4 ROW PIN 1 2 X 2 EO 4 Dowel Pin 1 2 x 4 Lg 2 Spacer 2 Brass Shim 1 Manual Release Shaft 2 But Hd Screw 10 24 x 1 4 Lg 2 Flat Washer 9 16 2 Retaining Ring 2 Hex Nut 1 2 13 8 Release Lever 4 Release Handle 1 Drill Bushing 2 Hex Nut 10 24 2 Flanged Locknut 3 8 16 2 Lockwasher 10 2 Lockwasher 3 8 2 Spring 2 Shoulder Bolt 1 4 x 1 Lg 2 Hd Screw 3 8 16 x 1 1 2 Lg 2 Hex Nut 5 8 11 4 Hub Holding Tool 1 FORCE CONTROL INDUSTRIES INC GE Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 SL DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com MSB9 and MSB10 MagnaShear MOTOR BRAKE HUB HOLDING TOOL 2 MSB10 121 60 I 8 155 LON AL i
3. DIN 53 MOTOR SHAFT NS 3 S 7 8 9 SET SCREW HOUSING 8 ADAPTER 7 Figure 7 9 Removing Hub 2 for MSB12 MSB10 Motor Brake Only Insert 3 4 10 Set Screw then 1 8 x 4 Lg Hex Hd Jack Screw into the Hub 2 as shown in Figure 7 8 While holding the Hub 2 with the Hub Holding Tool tighten the Jack Screw to push the Hub 2 off the Collet 110 MSB12 Motor Brake Only Install a 7 87 9 Set Screw into the Collet 110 Determine the length of this Set Screw so there is approx 1 1 2 of exposed thread left in the Hub Then install a 1 8 x 4 Lg Hex Hd Jack Screw into the Hub 2 While holding the Hub 2 with the Hub Holding Tool tighten the Jack Screw to force the Hub 2 off the Collet 110 as shown in Figure 7 9 B Removing Wear Sleeve 32 MSB9 MSB10 and MSB12 Motor Brakes 1 Place the Hub 2 into a V Block Using a chisel the same width as the Wear sleeve 32 make about 5 FORCE CONTROL INDUSTRIES INC GE Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 SL DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com CHISEL Same Width as Wear Sleeve WEAR SLEEVE 32 5 or 6 Notches SUITABLE V BLOCK SUPPORT Figure 7 10 Removing Wear Sleeve 32 or 6 notches in the Wear Sleeve 32 as shown in Figure 7 10 It can now be removed by hand 4 75 DIA 4 126 03 R 4 280 MATERIAL MILD STEEL MagnaShear
4. 442 195 72 60 ventas industrialmagza com Figure 7 13 Installing Wear Sleeve 32 on MSB12 2 Place the Hub 2 into an Arbor Press and with a flat plate as shown in Figure 7 13 on the next page press the Wear Sleeve 32 on to the Hub 2 as far as it will go Clean off any excess Loctite 7 9 REPLACING OIL SEAL 31 MSB9 and MSB10 Only 1 Remove 4 Hex Nuts 392 and 4 Lockwashers 168 Pull the Mounting Flange 8 off of the motor face 2 Press the Oil Seal 31 out of the Mounting Flange 8 with an arbor press 3 Clean out the oil seal bore in the Mounting Flange 28 and lightly coat the bore with Permatex 30 Sealant ARBOR PRESS MOUNTING FLANGE 8 Figure 7 14 Installing Oil Seal for MSB9 and MSB10 CAUTION Be very careful not to get any of the sealant on the rubber parts of the Oil Seal 31 22 4 Press the new Oil Seal 31 into the bore with an arbor press as shown in Figure 7 14 5 Clean off any excess sealant MSB12 Only 1 Remove the 8 Screws 151 and 4 Lockwashers 129 Pull the Housing 8 and the Gasket 121 off of the Motor Adapter Housing 7 Discard the Gasket 121 2 Remove 8 Screws 166 and 8 Lockwashers 168 Pull the Motor Adapter Housing 7 away from the motor face 3 Press the Oil Seal 31 out of the Motor Adapter Housing 7 4 Clean out the oil seal bore in the Motor Adapter Housing 7 and lightly c
5. 32 Manual Revision amp Printing History 33 GE Nacza MEX 55 53 63 2331 81 83 54 10 18 SL DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com GE Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com Section 1 DESCRIPTION and OPERATION 1 1 UNIT DESCRIPTION Large MagnaShear Fully Electric Motor Brakes with Oil Shear dependability are available in three sizes which have NEMA standard mounting flanges from 10 1 2 FAK to 16 FAK Spring set torque ratings range from 325 Ft Lbs to 1250 Ft Lbs A spring set brake stack is released when 120 230 VAC power is supplied to the Brake Control logic is made simple by use of the motor starter auxiliary contactors Back EMF effect from the motor windings is eliminated The units are ideal for a wide variety of applications including winches transfer conveyors and other heavy duty start stop devices Applications requiring the brake to be released on an average of more than 50 of the time or for long durations must be reviewed and approved by our engineering department MagnaShear MSB9 Motor Brake P FORCE CONTROL INDUSTRIES INC E MagnaShear MSB10 Motor Brake 1 2 The OIL SHEAR PRINCIPLE Conventional brakes depend on the friction between solid surfaces operating in air to transmit torque Friction does the job but produces a
6. 46 becomes dirty it should also be removed and cleaned The oil should be changed more frequently when used in harsh environments or high cyclic applications 1 Replace the Drain Plugs and Sight Gauge if they were removed 2 Remove Pipe Plug 73 at the top of the End Housing 9 Fill with oil to the center of Sight Gauge 46 See Page 3 for Oil Capacity 3 Replace Pipe Plug 73 Do not overfill the brake unit Excess oil will cause the brake to over heat 4 4 TYPE OF OIL Use only Mobil Automatic Transmission Fluid ATF 210 Type or Mobil Multi Purpose Automatic Transmission Fluid for most brakes Other fluids may be specified for special applications Consult Force Control factory Always use the type of oil specified on the Name Plate MSB12 PIPE PLUG 73 REMOVE TO FILL SONT PIPE PLUG 64 SIGHT GAUGE 46 REMOVE TO DRAIN FORCE CONTROL INDUSTRIES INC GE Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 SL DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com Section 5 OPERATIONAL CHECKS Make these Operational Checks with the MagnaShear Motor Brake shut down and completely assembled with the drive motor attached Provisions for manual operation checks must be made if the drive unit has been removed for service and repair 120 VAC or 230 VAC 60 Hz electrical service is required to release the brake See Figure 5 1 below for the Test Set Up
7. LUBRICATION 7 8 REPLACING WEAR SLEEVE 32 A Removing Hub 2 From The Motor Shaft MSB9 and MSB10 Motor Brake Only 1 Use the same procedure as described in the com plete previous Section 7 5 A and Steps 1 and 2 in Section 7 5 to remove the End Housing Assembly and the Brake Stack MSB12 Motor Brake Only 1 Use the same procedure as described in the com plete previous Section 7 5 A and Steps 1 and 2 in Section 7 5 C to remove the End Housing Assembly and the Brake Stack MSB9 MSB10 and MSB12 Motor Brakes 2 Hold the Hub 2 with the Hub Holding Tool 601 20 024 and remove the Collet Locking Bolt 94 and the Copper Washer 81 from the Hub 2 Discard the Copper Washer 81 MSB9 Motor Brake Only Insert 5 8 11 Set Screw then a 3 4 10 x 4 Lg Hex Hd Jack Screw into the Hub 2 as shown in Figure 7 8 While holding the Hub 2 with the Hub Holding Tool tighten the Jack Screw to push the Hub 2 off the Collet 110 20 DRIVE MOTOR SHAFT HUB 42 WITH SCREW 494 AND COPPER WASHER 81 REMOVED SET SCREW MSBO 5 8 11 x 1 1 4 MSB10 1 8 x 1 1 4 HEX HD JACK SCREW MSB9 3 4 10 x 4 MSB10 1 8 x 4 COLLET 110 WEAR SLEEVE 32 OIL SEAL 31 Figure 7 8 Removing Hub 2 for MSB9 and MSB10 APPROX 1 1 2 FROM SET SCREW TO INSIDE FACE OF THE HUB 2 COLLET 110 Ns HUB 2 HEX HEAD JACK SCREW
8. No 398 400 405 410 415 416 417 418 NOTES REPAIR PARTS LIST BRAKE COIL CIRCUIT BOARD amp JUNCTION BOX MSB9 and MSB10 MagnaShear Brake Figure 8 3 Knockout Seal Circuit Board But Hd Screw 10 24 x 1 4 lg Electric Box Pan Hd Screw 48 32 x 1 2 Lg Indicator Lamp But Hd Screw 1 4 20 x 1 2 Lg Electrical Fitting Washer Nylon Heceptical 5 Pin Lockwasher 1 4 Receptical Nut Stand off Sealing Ring Indicates parts in Overhaul Kit REPAIR PARTS LIST BRAKE COIL CIRCUIT BOARD amp JUNCTION BOX MSB12 MagnaShear Brake Figure 8 3 E ee o 400 405 410 415 416 417 418 420 425 426 NOTES Circuit Board Soc Hd Screw 10 24 x 3 4 Lg 1 Electric Box Pan Hd Screw 8 32 x 1 2 Lg 3 Indicator Lamp But Hd Screw 1 4 20 x 1 2 Lg 3 Electrical Fitting Washer Nylon 3 Heceptical 5 Pin Lockwasher 1 4 3 Receptical Nut Lockwasher 10 1 Sealing Ring Flat Washer 10 1 External Heat Sink Stand off 3 But Hd Screw 10 24 x 1 4 Lg Indicates parts in Overhaul Kit 30 FORCE CONTROL INDUSTRIES INC GE Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 SL DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com BRAKE COIL CIRCUIT BOARD amp JUNCTION BOX MSB9 and MSB10 MagnaShear Brake 428 CIRCUIT BOARD 428 427 405 431 3 434 CIRCUIT BOARD a
9. ON OFF FUSE SWITCH INDICATOR LIGHT SEE NOTE BELOW AND SECTION 3 7 L1 115 VAC or 230 VAC 60 Hz CIRCUIT BOARD NOTE 7 Amp Fuse for MSB9 amp MSB10 10 Amp Fuse for MSB12 Figure 5 1 Test Set Up Electrical Schematic 5 1 CHECKING THE BRAKE OPERATION To check the Brake Operation electrical power is not required to energize the coil since the Magna Shear Motor Brake has a spring applied brake when the coil is de energized FORCE CONTROL INDUSTRIES INC INDUSTRIAL Disconnect the load to the motor Install a torque wrench on the motor shaft and apply torque The brake should slip at or higher than the static torque rating of the brake Refer to page 3 for torque ratings 9 2 CHECKING THE BRAKE COIL OPERATION 1 Remove the cover from the Conduit Box 405 2 Disconnect the black and white power leads from the Brad Harrison Cable Connector 416 to AC In on Terminal Strip J1 located on the Circuit Board 400 3 Connect the test power leads to AC In on J1 Turn the On Off Switch to ON The Power Indicator Light should come on and indicate the brake is released 4 Manually turn the Drive Motor Output Shaft If the shaft turns then the Brake Coil and Control Circuit is operating properly If it is not able to be turned then the Brake Coil or Circuit Board is not functioning properly See section 6 Trouble Shooting CAUTION Physical damage or mal function in the motor or bra
10. 400 435 e d gt 429 9 418 432 d NUT ON INSIDE OF JUNCTION BOX Figure 8 3 Electric Box and Circuit Board FORCE CONTROL INDUSTRIES INC 31 INDUSTRIAL 55 53 632331 MTY 81 83 54 10 18 RE DIST AUTORIZADO 442 1 95 7260 ventas industrialmagza com REPAIR PARTS LIST BRAKE RELEASE INDICATOR SWITCH Figure 8 4 Ref No 106 Poly Pak Seal 113 Lock Screw 117 Drill Bushing Nut Nylon Fitting 159 Switch Actuating Pin Sealing Ring 203 Spring Nylon Strain Relief Fitting 204 Retaining Ring Button Hd Screw 1 4 20 x 1 2 Lg 249 Electrical Switch 1 4 Lockwasher 251 Switch Enclosure PEM Standoff 328 Pan Head Screw NOTES Indicates parts in Overhaul Kit BRAKE RELEASE INDICATOR SWITCH 419 REF FRONT OF END HOUSING 9 Figure 8 4 Brake Release Indicator Switch 32 FORCE CONTROL INDUSTRIES INC 55 53 63 23 31 MTY 81 83 54 10 18 SB DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com Manual Revision amp Printing History MSB9 MSB10 amp MSB12 MagnaShear Motor Brake REVISION PRINTING REVISION REVISION DATE DATE REVISION ACTION DESCRIPTION Mo Yr Mo Yr REVISION NUMBER e Compressed all images Created new PDF file e Converted all source documents and images over to Jerry Jerry 502 MSB9 001 02 1 04 Windows platform and loaded them on the network
11. 5 2 CHECKING THE BRAKE COIL OPERATION 11 Section 6 TROUBLE SHOOTING 6 1 TROUBLE SHOOTING CHART eene 12 6 2 TROUBLE SHOOTING COILS 13 Sizes MSB9 and MSB10 MagnaShear Motor Brake A Coil Resistance Check eene 13 B Coil Current Leakage Test 13 Sizes MSB12 MagnaShear Motor Brake A Coil Resistance Check esee 14 B Coil Current Leakage Test ee 14 TABLE OF CONTENTS Section 7 REPAIR and REPLACEMENT 7 1 GENERAL INFORMATION eene 15 Tips For Handling Circuit Board 15 7 2 CLEANING AND INSPECTION eene 15 7 3 REPAIR OR REPLACEMENT een 15 7 4 MEASURING STACK HEIGHT 15 7 5 REPLACING BRAKE STACK eee 16 A General Instructions For All Sizes 16 Sizes MSB9 and MSB10 Motor Brake 16 C Size MSB12 Motor 16 7 6 REPLACING CIRCUIT BOARD eene 17 A Sizes MSB9 and MSB10 Motor Brake 17 B Size MSB12 Motor Brake ss 17 7 7 REPLACING HOLDING COIL
12. Brooks Brooks e Added Revision History 3 10 Corrected Collet Bolt Sizes for MSB10 zm Jerry Vonderhaar Brooks FORCE CONTROL INDUSTRIES INC 33 INDUSTRIAL 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com FORCE CONTROL INDUSTRIES INC Worldwide Leader in Oil Shear Technology Providing Todays Industries with Oil Shear Clutch amp Brake Drives and Electronic Drive Systems That Delivers Flexibility e Efficiency Endurance Performance Dependability Built to Last Guaranteed to Perform FOHCE 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 CESS Nacza MEX 55 53 63 2331 81 83 54 10 18 DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com
13. EN QU E are 81 94 Pd 62 jj 7 12 315 7 21 Mea L 9 5 F MN 7 BR 7 BRAKE COIL CIRCUIT BOARD ASSEMBLY See Figure 8 3 BRAKE RELEASE INDICATOR SWITCH ASS Y See Figure 8 4 Figure 8 1 Repair Parts MSB9 and MSB10 MagnaShear Motor Brake FORCE CONTROL INDUSTRIES INC 27 INDUSTRIAL MEX 55 53 63 2331 MTY 81 83 54 10 18 DIST AUTORIZADO 442 1 95 72 60 ventas industrialmagza com Ref CO N O1 N TJ 2 TE 3 se 7 31 32 36 45 46 49 52 53 56 59 62 64 73 81 94 10 110 116 5121 122 127 128 129 130 137 138 NOTES REPAIR PARTS LIST MSB12 MagnaShear MOTOR BRAKE Part Name Armature Ring Housing Motor Adapter Housing End Housing Drive Plate Friction Disc Separator Springs Oil Seal Wear Sleeve Air Breather Sight Gauge Pipe Plug 1 8 Threaded Insert 3 8 16 Threaded Insert 5 8 11 Pipe Plug 1 NPT Pipe Plug Magnetic 1 4 NPT Pipe Plug Sq Hd 2 NPT Copper Washer Gasket Hex Hd Screw 7 8 9 x 6 Lg Poly Pak Seal Lockwasher 5 8 Lockwasher 5 16 Lockwasher 5 8 O Ring Eye Bolt 5 8 11 Shoulder Bolt 3 8 16 x Lg Indicates parts in Overhaul Kit Indicates parts in Stack Replacement Kit 28 INDUSTRIAL M ED mm m Shoulder Bolt 1 2 13 x 2 1 2 Lg Soc Hd Cap Screw 1 4 20 x 1 2 Lg Soc Hd Cap
14. in an arbor press and measure the Stack Height to determine whether or not the Brake Stack 12 needs replaced See Section 7 4 and Figure 7 1 If the old Brake Stack 12 needs replaced then take the new Brake Stack 12 and remove the 4 Retaining Rings on the 4 Shoulder Bolts that holds the whole stack together Discard these Retaining Rings they will not be needed Install the new Brake Stack 12 and Reassembly of the Brake with the same procedure given in Section 3 5 A Steps 11 thru 20 16 INDUSTRIAL M MOUNTING FLANGE 8 END HOUSING ASSEMBLY WITH MANUAL RELEASE BRAKE STACK 12 IN UP POSITION 176 UNSCREW 4 SHOULDER BOLTS GASKET 121 Figure 7 2 Replacing the Brake Stack MSB9 amp MSB10 C Size MSB12 Motor Brake See Figures 7 3 7 4 8 2 1 Remove the 8 Screws 149 and 8 Lockwashers 127 from the Housing 8 Pull the End Housing Assembly away from the Housing 8 Remove the Gasket 122 and dis card it Unscrew the 4 Shoulder Bolts 138 from the Housing 8 but do not pull them out of the Brake Stack Pull the complete Brake Stack including the 4 Shoulder Bolts 138 off the 4 Pins 176 and the Hub 2 Spline See Figure 7 3 HOUSING 8 AR SHIMS 986 32 SEPARATOR SPRINGS 17 4 SHOULDER BOLTS 138 DISCS 13 9 DRIVE PLATES 12 8 LOCKWASHERS 127 8 SCREWS 149 END HOUSING ASSEMBLY WITH BRAKE RELE
15. 3 1 These tools are supplied but spares or replacement tools can be ordered from Force Control with their given part number See Figures 8 1 and 8 2 Q zzz Brake Stack Guide Pins MSB9 amp MSB10 Part Ref 412 MSB12 Part Ref 4901 Hub Holding Tool MSB9 MSB10 amp MSB12 Part Ref 900 NOTE The 2 Guide Pins for the MSB9 amp MSB10 are included in Brake Stack Assembly 12 See Figure 8 1 Figure 3 1 Special Assembly Tools 3 3 SCREW TORQUE REQUIREMENTS uu 9 7 Lb Ft DADA a es 14 Lb Ft Pd M 25 Lb Ft WAG 40 Lb Ft 60 Lb Ft DIU ll 555225299599 2533 992225255259 120 Lb Ft Lu 200 Lb Ft 302 Lb Ft It is very important that all screws are torqued with a torque wrench to the specified torque Also torque screws in an opposite 180 pattern as shown in the Example Figure 3 2 Start with the screws nearest the locating dowel pins Figure 3 2 Torque Pattern Example MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com 3 4 VERIFYING MOTOR SPECIFICATIONS The Motor Manufacturer s Specifications must be verified first to ensure the Motor Brake Oil Seal Reliability 1 Motor Shaft Runout 2 Mounting Face Runout and 3 Motor Shaft to Pilot Diameter Eccentricity need to be checked with a Dial Ind
16. Dimension A 6 Measure the new Brake Stack in an Arbor Press as shown in Figure 7 f This gives Dimension B 7 Use the formula A 026 B Air Gap 8 Use 020 Shim 986 to attain 07 09 Air Gap if necessary COIL LEADS COMPRESSION CHASSIS GROUND 9 Install the new Brake Stack and Reassemble the Brake with the same procedure as described in Section 3 5 B Steps 11 thru 20 7 6 REPLACING CIRCUIT BOARD 400 A Sizes MSB9 and MSB10 Motor Brake See Figure 7 5 1 Take the cover off the Conduit Box 405 amp remove the Brad Harrison Cable 2 Disconnect all the wires from the 2 Terminal Strips J1 and J2 on the Circuit Board 400 3 Disconnect the wire on the Ground Screw 426 4 Remove the 3 Screws 428 and 3 Nylon Washers 431 5 Take the old Circuit Board 400 off and replace it with a new one See Section 7 1 for Tips on Handling Circuit Boards 6 Reattach the Circuit Board 400 with the 3 Screws 428 and 3 Nylon Washers 431 7 Reconnect the wires to J1 and J2 Terminal Strips and the Ground Screw 8 Replace the cover on the Conduit Box 405 amp the Brad Harrison Cable B Size MSB12 Motor Brake See Figure 7 6 1 Take the cover off the Conduit Box 405 amp remove the Brad Harrison Cable 2 Disconnect all the wires from the 2 Terminal Strips J1 and J2 on the Circuit Board 400 and the wire on the Chassis Ground Scre
17. HARRISON CONNECTOR INTERNAL SURGE PROTECTION REVERSE CONTACTOR MR1 K INDICATOR LIGHT BRAKE COIL iai FUNCTION RELEASE BRAKING Brake Coil 5 Pin Connector Figure 3 8 Electrical Schematic BRAKE COIL BRAD HARRISON CONNECTOR 41310 1 White AC 5 Black AC IN on Circuit IN on Circuit Board 115 Board 115 VAC 60 Hz VAC 60 Hz NORMALLY COMMON C CLOSED N C NORNALLY OPEN N 0 2 Red 4 0 Not Used 3 Green Ground ENGAGED OPEN RELEASED CLOSED ENGAGED CLOSED RELEASED N C OPEN Figure 3 9 Brad Harrison Connectors 3 Fuse Requirements MSB9 amp MSB10 7 Amp Fuse Bussmann FNA 7 or equivalent MSB12 10 Amp Fuse Bussmann FNA 10 or equivalent B Brake Release Indicator Switch See Figure 3 10 Figure 3 10 Brake Release Indicator Switch Bump the Drive Motor to check for correct rotation If the rotation is incorrect change two of the phase wires and recheck rotation Verify that the Brake Coil Indicator Light on the Conduit Box is ON while the drive motor is 3 8 START UP Verify that the Brake Coil is connected correctly Check to see if the Drive Motor is wired correctly fuses are in place and the motor disconnect is turned on Set up pre liminary settings on positioning switches to insure the brake will stop FORCE CONTROL INDUSTRIES INC INDUSTRIAL running Next complete a cycle to insure that there
18. Housing 8 and Gasket 121 to the Motor Adapter Housing 7 with 8 Screws 151 and 8 Lockwashers 129 Torque to 120 Lb Ft Install and align the Hub 2 and Collet 110 on the motor shaft with the same procedure given in Section 3 INSTALLATION 3 4 B Mounting the MSB12 to the Drive Motor Steps 6 thru 9 Install the Brake Stack with the same procedure given in Section 3 INSTALLATION 3 4 B Mounting the MSB12 to the Drive Motor Steps 10 thru 19 Install the End Housing 9 with the same procedure given in Section 3 INSTALLATION 3 4 B Mounting the MSB12 to the Drive Motor Steps 20 thru 22 Make sure the Manual Release Lever is in the Up Position Sizes Make sure Air Breather Sight Gauge and all pipe plugs are installed Fill with fresh oil to level of the Sight Gauge See Section 4 LUBRICATION MEX 55 53 63 23 31 23 MTY 81 83 54 10 18 DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com Section 8 ILLUSTRATED PARTS LIST 8 1 GENERAL INFORMATION This section illustrates lists and describes all parts for Sizes MSB9 MSB10 and MSB12 MagnaShear Motor Brakes Parts are identified on the exploded views with Part Reference Numbers These Numbers correspond to the Part Reference Number given in the Parts Lists The Part Name and Quantity Used is also given in the Parts List This Part Reference Number Part Name and Quantity should be used when ordering Repl
19. MSB9 amp MSB10 MOTOR BRAKE WEAR SLEEVE 32 INSTALLATION TOOL Part Number 601 16 004 Figure 7 11 Wear Sleeve Installation Tool C Installing Wear Sleeve 32 Sizes MSB9 and MSB10 Only A Special Wear Sleeve Installation Tool must be used to install the Wear Sleeve 32 onto the Hub 2 Dimensions and Specifications are given in the following Figure 7 11 if you prefer to make your own It can be ordered from Force Control with the following Part Number 601 16 004 1 Clean the surface of the Hub 2 with Loctite Primer T and then apply Red Loctite 271 to the hub surface 2 Place the Hub 2 into an Arbor Press and with Surface A of the Installation Tool press the Wear Sleeve 32 on as far as it will go See Step 1 in Figure 7 12 FORCE CONTROL INDUSTRIES INC INDUSTRIAL Step 1 TOOL 601 16 004 ARBOR PRESS INSTALLATION TOOL 601 16 004 Figure 7 12 Installing Wear Sleeve 32 on Sizes MSB9 and MSB10 Turn the Installation Tool over and with Surface B continue pressing the Wear Sleeve 32 until it bot toms out on the shoulder See Step Z2 in Figure 7 11 Clean off any excess Loctite Size MSB12 Only Just a flat plate is required to install the Wear Sleeve 32 on to the Hub 2 1 Clean the surface of the Hub 2 with Loctite Primer T and then apply Red Loctite 271 to the hub surface 21 MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO
20. are no inter ference problems within the system Set up Position Switches as required 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com Section 4 LUBRICATION 4 1 CHECKING THE OIL LEVEL When the brake is installed and weekly thereafter or until experience dictates otherwise check the oil level Always check the oil level with the brake at room tem perature and while Hub is not rotating The MagnaShear Motor Brake has an Oil Sight Gauge 46 located on the side of the End Housing See Figure 4 1 The oil level is to be at the center of the sight gauge with the motor turned off or brake is set 4 2 OPERATING TEMPERATURES A Ambient Temperature The standard oil used in the MagnaShear Brake is designed to operate between 40 F and 125 F If the ambient temperature will fall outside of this range please contact Force Control Industries Inc for specific recom mendations on proper lubricant B Sump Temperature The maximum recommended oil sump temperature is 200 F 4 3 CHANGING THE OIL IMPORTANT Always open the disconnects to the drive motor before changing the oil MSB9 and MSB10 BREATHER PIPE PLUG 73 45 REMOVE TO FILL REMOVE TO DRAIN SIGHT GAUGE 46 Figure 4 1 Lubrication Horizontal Mounting 10 Every three months completely drain the oil from the brake by removing Drain Plug 64 If the Sight Gauge
21. be paid by the buyer If Force Control determines that any 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 OUTABOVE FORCE CONTROL DOES NOT GRANTANY WARRANTIES EITHER EXPRESSED OR IMPLIED INCLUDING IMPLIED WARRANTIES OF MERCHANTABIL ITY OR FITNESS FOR USE The warranty obligation set forth above is in lieu of all oblig ations 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 QUENTIAL DAMAGES THE BUYER MAY SUSTAIN IN CONNECTION WITH THE DELIVERY USE OR PERFORMANCE OF FORCE CONTROL PRODUCTS Under no circumstances shall any liability 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 writing signed by a duly authorized officer of the company This limited warranty applies exclusively to Force Control products war ranties for motors and gear reducers and other component parts may be provided by their respective manufactures Any legal action for breach of any Force Co
22. great amount of heat and wear The MagnaShear Motor Brake is an Oil Shear Brake with the friction surfaces operating in a constant ly replenished film of oil The oil molecules cling to each other and to the friction surfaces As moving and sta tionary elements are brought together a thin but positive film of oil is maintained between them which is con trolled by the clamping pressure and carefully designed grooves in the friction discs Torque is transmitted from one element to the other through the viscous shear of the oil film As long as there is relative motion between the elements they are protected by the oil thus greatly reducing wear The replenished oil film also effectively transmits heat away from the friction elements MagnaShear MSB12 Motor Brake 16 Mounting Flange The Large MagnaShear Motor Brake is also available as an Assembled Brake Motor ABM in a wide variety of sizes MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com 1 3 OPERATION The cross section in Figure 1 2 shows the MagnaShear Motor Brake in the Stopped position with the brake stack engaged The MagnaShear Motor Brake will default to this position when all power is lost To run the Drive Motor the Brake Coil is energized pulling the Armature Plate Assembly away from the SPLINED HUB WITH INTEGRAL OIL PUMP MOUNTING FLANGE F4 2 DUA
23. plunger is aligned with the Switch Actuating Pin 159 7 Reconnect the electrical leads to the switch terminals 8 Manually activate the brake to make sure the Switch 9 249 operates properly Shim under the mounting tabs of the Bracket 332 if necessary to position the Switch 22249 properly Replace the cover to the Switch Enclosure 251 7 11 BRAKE REASSEMBLY PROCEDURE MSB9 and MSB10 Only 1 Attach the Mounting Flange 8 to the motor face with 4 Hex Nuts 892 and 4 Lockwashers 168 Torque to 120 Lb Ft Install and align the Hub 2 and Collet 110 on the motor shaft with the same procedure given in Section 3 INSTALLATION 3 4 A Mounting the MSB9 and MSB10 to the Drive Motor Steps 7 thru 10 FORCE CONTROL INDUSTRIES INC INDUSTRIAL Install the Brake Stack 12 with the same proce dure given in Section 3 INSTALLATION 3 4 A Mounting the MSB9 and MSB10 to the Drive Motor Steps 11 thru 19 Install the End Housing 9 with the same procedure given in Section 3 INSTALLATION 3 4 A Mounting the MSB9 and MSB10 to the Drive Motor Steps 201 thru 22 Make sure the Manual Release Lever is in the Up Position MSB12 Only 1 Attach the Motor Adapter Housing 7 to the motor face with 8 Screws 166 and 4 Lockwashers 158 Torque to 120 Lb Ft Place a new Gasket 121 onto the Motor Adapter Housing 7 Do not use any gasket sealant on this gasket Attach this
24. 4 4 625 538 2 5 15 MSB12 3 625 6 938 807 158 000 2 068 12 ra 1 4 8 1250 1075 bs 60 Minimum Collet Bore For Given Static Torque Motor Brake Weight GIVEN MINIMUM STATIC COLLET TORQUE BORE Lb Ft Inches FORCE CONTROL INDUSTRIES INC 3 INDUSTRIAL 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com 2 2 Dimensional Specifications MSB9 and MSB10 MagnaShear Brake Dimensions Inches BRAKE COIL FLUID LEVEL SIGHT GAUGE 20 00 APPROX BRAKE RELEASE in 5 ELECT INDICATOR SW 7 96 APPROX 137 CONNECTOR CONDUIT BOX 22 AIR BREATHER MANUAL RELEASE LEVER 4 5 8 11 MOUNTING LIFT TO RELEASE BRAKE STUDS ON AJ DIA B C STANDARD MOTOR REGISTER TOLERANCES 10 1 2 AK 000 003 12 1 2 000 005 16 AK 000 005 STANDARD MOTOR SHAFT DIAMETER TOLERANCES 000 001 BRAKE COIL CONDUIT BOX 9 38 BRAKE RELEASE INDICATOR SWITCH AIR BREATHER 5 PIN ELECTRICAL CONNECTOR 3 00 MIN SHAFT 5 12 MAX SHAFT 13 40 17 DIA MIN 2 125 MAX 3 625 DIA BORE 10 94 APPROX 8 5 8 11 MNTG BOLTS ON 14 DIA BC DRAIN FLUID LEVEL GAUGE MANUAL RELEASE LEVER LIFT TO RELEASE BRAKE Dimensions are subject to change without notice Certified Installation Drawings are available upon request 4 FORCE
25. 502 5 9 001 02 SERVICE MANUAL FOR MSB9 MSB10 MSB12 Magna Shear FULLY ELECTRIC OIL SHEAR MOTOR BRAKE ISO 9001 CERTIFIED WARNING Read this manual before any installation maintenance or operation FORCE ZLIN MANUFACTURERS OF MECHANICAL AND FORCE CONTROL INDUSTRIES INC ELECTRICAL POWER TRANSMISSION EQUIPMENT INDUSTRIAL MEX 55 53 63 2331 MTY 81 83 54 10 18 EES DIST AUTORIZADO 442 1 95 72 60 ventas industrialmagza com Limited Warranty Force Control Industries Inc Force Control warrants its products to be free from defects in material and workmanship under normal and proper use for a period of one year from the date of shipment Any products purchased from Force Control that upon inspec tion 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 elec trical physical or mechanical stress or upon which the original identification marks have been removed or altered Transportation charges for shipping any product or part there of that the buyer claims is covered by this limited warranty shall
26. 8 2 MSB12 Motor Brake Figure 8 3 Brake Coil Circuit Board and Junction Box Figure 8 4 Brake Release Indicator Switch 7 5 REPLACING BRAKE STACK A General Instructions for all Sizes 1 4 First drain all the oil from the unit into a suitable con tainer See Section 4 LUBRICATION for location of drain plugs Save or discard as condition warrants Disconnect the 5 Pin Brad Harrison Cable from the Conduit Box 405 See Figure 8 3 Hemove the cover from the Junction Box 251 and disconnect the wires from the Brake Indicator Switch 249 Loosen the Compression Nut on the Strain Relief Fitting 419 and pull the cable out of the box See Figure 8 4 Lift the Manual Release Lever to release the Brake B Sizes MSB9 and MSB10 Motor Brakes See Figures 7 2 and 8 1 1 Remove the 8 Hex Nuts 261 and 8 Lockwashers 127 off of the 8 Studs 72 Pull the End Housing 9 off the Mounting Flange 8 Hemove the Gasket 121 and discard it NOTE On the MSB10 there will be another Gasket 121 and a Spacer 60 between the End Housing 9 and the Mounting Flange 8 Discard this Gasket 121 also The Brake Stack 12 can now be removed by unscrewing the 2 Shoulder Bolts that attaches the Drive Plates to the Mounting Flange 8 Pull the whole Brake Stack 12 off the Hub 2 spline and the 4 Pins 176 See Figure 7 2 Take the 2 Shoulder Bolts out and place the Brake Stack 12
27. ASE LEVER IN UP POSITION Figure 7 3 Removing MSB12 Brake Stack NOTE The complete Brake Stack consists of 9 Drive Plates 12 8 Friction Discs 13 Shims 986 if required 32 Separator Springs 17 and 4 Shoulder Bolts 138 MEX 55 53 63 23 31 FORCE CONTROL INDUSTRIES INC MTY 81 83 54 10 18 DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com 3 Place all the Drive Plates 12 and Friction Discs 13 into an arbor press and measure the Stack Height to determine whether or not the Brake Stack needs replaced See previous Section 7 4 and Figure 7 1 If the Brake Stack needs replaced then the new Brake Stack consisting of 9 Drive Plates 412 and 8 Friction Discs 13 needs to be measured to determine whether or not any 020 Shims 986 are required in the stack to attain an Air Gap of 07 09 The Air Gap is the space between the front face of the Coil 59 and the back face of the Armature Plate 56 with the Brass Shim 184 attached to it See Figure 7 4 A 026 B AIR GAP ARMATURE RING 5 END HOUSING 9 026 GASKET 122 2 700 REF STACK HEIGHT 2 776 REF ARMATURE PLATE 56 NOTE COIL ENERGIZED Figure 7 4 Checking Air Gap for MSB12 4 Energize the Coil 5 Measure the distance from the face of the Armature Plate 56 to the back mounting face of the End Housing 9 with Gasket 122 removed This gives
28. CONTROL INDUSTRIES INC GE Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 SL DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com Section 3 INSTALLATION IMPORTANT SAFETY PRECAUTIONS The MagnaShear Motor Brake units described in this manual must not be installed in any manner except as specified and must not be operated at speeds horsepower loads or temperatures other than those specified in this manual Failure to limit the operation of the drive to the con ditions specified could damage the unit or damage interconnected equipment and void the Warranty WARNING BEFORE INSTALLATION OR ATTEMPTING ANY REPAIRS TO THE MOTOR BRAKE OPEN THE DISCONNECTS TO THE DRIVE MOTOR LOCK IT OUT TO AVOID THE POSSIBILITY OF PERSONAL INJURY 3 1 RECEIVING THE MagnaShear MOTOR BRAKE Check the brake for shortage or damage immediately upon arrival Prompt reporting to the carrier s agent with notations made on the freight bill will expedite satisfac tory adjustment by the carrier Force Control is not responsible for damage in shipment A Assembled Brake Motor ABM If your MagnaShear Motor Brake is shipped pre assembled to a drive motor it is filled with oil and ready to run except for installing the Air Breather 45 and electrical wiring See Figures 3 7 3 8 and 3 9 for Electrical Wiring Diagram and information NOTE Before shipment the Air Breather 45 is removed and a plastic pipe plug put in its pl
29. L LIP OIL SEAL AND WEAR SLEEVE V KEYLESS V COLLET 2247 L1 A AME dee 8 Y Sr Brake Stack which allows the splined hub and drive motor to rotate independently from the motor brake To stop the Drive Motor the Brake Coil is de energized This allows the brake springs to push the Armature Plate Assembly against the Brake Stack clamping it and stop ping the splined hub and drive motor BRAKE COIL CONDUIT BOX amp CIRCUIT BOARD BRAKE RELEASE INDICATOR SWITCH BRAKE RELEASE COIL ARMATURE AND THRUST PLATE SPRING LOADED WAIN N AMES MANUAL RELEASE SPRING SET BRAKE STACK Figure 1 2 MagnaShear Motor Brake Cross Section INDUSTRIAL MEX 55 53 63 23 31 BRAKE SPRINGS FORCE CONTROL INDUSTRIES INC MTY 81 83 54 10 18 DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com Section 2 SPECIFICATIONS 2 1 Technical Specifications With Pulse Width Modulation MAX BRAKE AVAILABLE MAX No STATIC DYNAMIC KE per INERTIA FILOT COLLET SPRINGS TORQUE TORQUE ENGMT Inches Inches Lb Ft Lb Ft Ft Lbs Lb Ft Qts VAC Amps 10 50 115 6 18 MSB9 2 2375 8000 0992 3 Y 5 8 650 559 10 50 4 450 387 115 6 18 MSBI0 2375 6 675 581 69 000 1 244 pepe pee _8 900 77
30. Lockwashers 127 and Screws 149 into the Housing 8 and position the Gasket 122 on the face of the Housing 8 19 Slide the End Housing 9 into place and attach with 8 Lockwashers 127 and 8 Screws 149 Torque these 8 Screws 149 to 120 Lb Ft 20 Lower the Manual Release Lever to engage the brake 3 6 FINAL INSTALLATION 1 Make sure all pipe plugs Sight Gauge 46 and Air Breather 45 is installed properly in the housings 2 Remove the Pipe Plug 73 in the top of the End Housing 9 3 Fill the brake unit with fresh oil to the center of the Sight Gauge 46 as described in Section 2 Lubrication 3 7 WIRING SPECIFICATIONS See Figures 3 8 3 9 and 3 10 A Brake Coil NOTES 1 Coils may be driven independently 2 Circuit Breaker Requirements MSB9 amp MSB10 120 VAC Type 10 AC high in rush current Motor Starter 7 Amp MSB12 120 VAC Type 10 AC high in rush current Motor Starter 10 Amp FORCE CONTROL INDUSTRIES INC GE Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 SL DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com 115 7 FUSE FOR LINE MOTOR STARTER MSB9 amp MSB10 AUXILIARY CONTROLS BUSSMANN FNA 7 OR EQUIV 10 AMP FUSE FOR FOWARD CONTACTOR MF1 BRAKE CIRCUIT idis MSB12 BUSSMANN 10 OR EQUIV BRAKE COIL CUSTOMER FURNISHED 5 PIN BRAD
31. NC GE Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 SL DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com Section 7 REPAIR and REPLACEMENT WARNING SHUT OFF AND LOCK OUT ALL ELECTRICAL POWER BEFORE ATTEMPTING TO MAKE ANY REPAIRS TO THE BRAKE UNIT 7 1 GENERAL INFORMATION Unless the Motor Brake is to be completely overhauled it should be disassembled only to the extent necessary to gain access to the worn or damaged parts An overhead crane and soft sling is recommended to be used to remove any heavy parts Tips For Handling Circuit Board 1 Only touch the outer edges of the Circuit Board Do not touch any components on the Circuit Board 2 Make sure you always remove all static electricity from your body before handling any Circuit Boards Use a Static Wrist Strap if available or always ground yourself first by holding on to a non painted surface on the brake unit 7 2 CLEANING AND INSPECTION Clean metal parts in a suitable solvent and dry with low pressure compressed air After cleaning inspect parts for cracks distortion scoring nicks burrs or any other damage that would affect the operation of the brake Pay particular attention to the Wear Sleeve 32 on the Hub 2 and the Oil Seal 31 located in the Mounting Flange 8 for the MSB9 amp MSB10 for the MSB12 it is ARBOR PRESS PRESS DOWN FIRMLY SS 25 SPACER Figure 7 1 Measuring Stack Height FORCE C
32. NTROL INDUSTRIES INC INDUSTRIAL B Coil Current Leakage Test Remove the cover from the Junction Box 405 and disconnect the 2 Coil Leads from both terminals on the Terminal Strip J1 located on the Circuit Board 400 Connect 1 alligator clip to both Coil Leads and the other one to Chassis Ground Screw 426 See Figure 6 2 A reading of 10 Meg Ohms or greater indicates that the Coil is fine and does not need to be replaced Anything much less would indicate that there is a short to ground and the Coil would need to be replaced See Section 7 for Coil Replacement MEG OHMETER SET TO MEG 0HM POSITION CHASSIS REMOVE COIL LEADS FROM TERMINALS ON J1 TWIST THEM TOGETHER amp CLIP A MEG OHMMETER TO THEM AS SHOWN JUNCTION BOX WITH COVER REMOVED Figure 6 2 Coil Current Leakage Testing NOTE A Hi Pot Tester can be used for this test but do not exceed 1250 VDC 13 MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com Size MSB12 MagnaShear Motor Brake Pulse Width Modulation PWM Board With External Heat Sink A Coil Resistance Test Remove the cover from the Junction Box 405 and disconnect the 2 Coil Leads from both terminals on the Terminal Strip J1 located on the Circuit Board 400 Hook Up Meg Ohmmeter to both coil leads as shown in Figure 6 3 Set the Meg Ohmmeter to Ohm range and test Resistance at 500 VDC T
33. ONTROL INDUSTRIES INC INDUSTRIAL located in the Motor Adapter Housing 7 Check for nicks scratches or any damage that would cause leakage 7 3 REPAIR OR REPLACEMENT A fine stone or 600 Grit Paper may be used to remove minor surface defects from parts if the operation or seal ing action of the part is not affected The use of coarser abrasives or other machining methods should not be attempted and damaged parts should be replaced Recommended Spare Parts 1 Replace all Gaskets O Rings Oil Seals and Wear Sleeves removed at disassembly 2 Replace Brake Stack as a complete Assembly 3 The Circuit Board 400 is a common replacement part 7 4 MEASURING STACK HEIGHT The Stack Height must be measured to determine whether or not the Brake Stack needs to be replaced If it measures under the Minimum Worn Stack Height then the Brake Stack needs to be replaced See Figure 7 1 Section 8 shows exploded view drawings for each size of MagnaShear Motor Brake Refer to these illustra tions for all disassembly and reassembly procedures CALIPERS MINIMUM WORN STACK HEIGHT 5 9 1 96 5 10 2 80 MSB12 2 59 BRAKE W O SHIM 986 STACK NEW STACK HEIGHT 5 9 2 113 2 103 MSB10 2 960 2 950 MSB12 APPROX 2 70 15 MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com Figure 8 1 MSB9 MSB10 Motor Brakes Figure
34. Screw 5 8 11 x 2 1 2 Lg soc Hd Cap Screw 5 8 18 x 2 3 4 19 Soc Hd Cap Screw Soc Hd Cap Screw 5 16 18 x 1 1 4 Lg Dowel Pin 3 8 x 1 Hex Hd Screw 5 8 11 x 2 Lg Seal Washer 5 8 Lockwasher 5 8 Dowel Pin 5 8 x 4 1 2 Roll Pin 3 8 x 1 3 4 Dowel Pin 5 8 x 4 Brass Shim Manual Release Shaft But Hd Screw 1 4 20 x 3 8 Lg Flat Washer 1 2 Retaining Ring Flat Washer 5 16 Release Lever Helease Handle Drill Bushing Hex Nut 10 Flanged Locknut 3 8 16 Lockwasher 10 Lockwasher 3 8 Spring Bronze Bushing Shoulder Bolt Hex Hd Screw 3 8 16 x 1 1 2 Lg Hub Holding Tool Stack Guide Pin Aluminum Shim 02 FORCE CONTROL INDUSTRIES INC MEX 55 58 63 2831 81 83 54 10 18 DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com MSB12 MagnaShear MOTOR BRAKE 110 e bi Sua 158 168 129 151 HUB HOLDING TOOL 137 901 2 900 4 STACK GUIDE PINS SHOWN IN 2 121 STORAGE POSITION 17 986 BRAKE STACK 198 BRAKE COIL CIRCUIT BOARD ASSEMBLY SEE FIGURE 8 3 BRAKE RELEASE INDICATOR SWITCH ASSEMBLY SEE FIGURE 8 4 OTN Figure 8 2 Repair Parts MSB12 MagnaShear Motor Brake FORCE CONTROL INDUSTRIES INC 29 INDUSTRIAL MEX 55 53 63 2331 MTY 81 83 54 10 18 DIST AUTORIZADO 442 1 95 72 60 ventas industrialmagza com Ref
35. Stack in exactly the same order as they were assembled There are 2 Separator Springs 17 between each Drive Plate 12 Be careful so not to lose track of them 6 Attach the Motor Adapter Housing 7 and Housing 8 to the motor mounting face with the 8 Hex Hd Screws 166 and 8 Lockwashers 168 Torque to 120 Lb Ft 7 Apply a light coat of White Grease or equivalent to the Wear Sleeve 32 located on the Hub 2 and the lip of the Oil Seal 31 located in the Motor Adapter Housing 7 8 Slide the Hub 2 and Collet 110 onto the motor shaft Be very careful not to damage the lip of the Oil Seal 31 or Wear Sleeve 32 9 Position the Hub 2 as shown in Figure 3 6 Measure the distance from the end of the Hub 2 to the face of the Motor Adapter Housing 7 This distance should be 3 37 1 32 Figure 3 6 is on the next page 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com 8 HEX HD SCREWS 166 8 LOCKWASHERS 168 4 DOWEL PINS 176 ANUN m 2 2 SCREW 94 WASHER 81 HUB 2 3 37 1 32 HOUSING 7 FACE OF HOUSING 8 Figure 3 6 Installing Motor Adapter Housing 7 and Positioning The Hub 2 and Collet 110 on The Motor Shaft 10 Use the Hub Holding Tool 900 to hold the Hub 2 Apply Blue Loctite 242 and torque the Collet Locking Bolt 94 t
36. ace This is done to prevent oil spillage during shipment In most cases this will be a red plas tic plug This plug must be removed and the Breather 45 installed to prevent damage to the brake The breather is taped to the motor shaft for shipment Always check the oil level to see if the oil level is in the center of the Sight Gauge 46 See Section 4 LUBRICATION B MagnaShear Motor Brake The standard MagnaShear Motor Brake has been par tially assembled at the factory for ease of shipment The Motor Brake is completely assembled except for the Hub and Collet Sub assembly which is packaged sepa rately and also the motor mounting bolts or studs and lockwashers Partial disassembly will be necessary to mount the brake to the drive motor FORCE CONTROL INDUSTRIES INC INDUSTRIAL During Installation refer to Section 8 for a visual reference to parts MSB9 Motor Brake Figure 8 1 MSB10 Motor Brake Figure 8 1 MSB12 Motor Brake Figure 8 2 Electric Box amp Circuit Board Figure 8 3 Brake Release Indicator Switch Figure 8 4 3 2 SPECIAL ASSEMBLY TOOLS 2 Guide Pins 12 are required for the MSB9 amp MSB10 while 4 Guide Pins 901 are required for the MSB12 to install the Brake Stack A Hub Holding Tool 900 is required to torque the Collet Locking Bolt The Tools and Part Ref Numbers are shown in the following Figure
37. acement Parts 8 2 DRIVE MOTORS The Drive Motors used with these MagnaShear Motor Brakes are standard motors and may be repaired or replaced by any qualified Motor Re build Facility or Supplier 8 3 FACTORY REBUILD SERVICE Reconditioning Service is offered by Force Control Industries Inc at the factory A complete factory rebuild will be 5096 the cost of a new unit if the housings are reusable If Housings need to be replaced there will be an additional cost Contact Force Control Industries Inc for authorization and shipping instruction before returning a drive unit for this service Force Control cannot be responsible for units returned to the factory without prior notice and authorization Care must be given to the packing of returned drives Always protect mounting feet by attaching to a skid Shipment damaged drives always delays repairs It is 24 usually impossible to recover damage costs from the carrier When possible describe the problem experi enced on your shipping 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 Web www forcecontrol com 8 4 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
38. and tighten down evenly to compress the Springs 36 Use Blue Loctite 242 and Torque to 25 Lb Ft MSB12 Motor Brakes 1 Place a new Holding Coil 59 into the End Housing 9 pushing the coil leads up through the Electrical Fitting 415 2 Attach the Coil 59 with 4 Seal Washers 167 and 4 Screws 150 IMPORTANT Torque the 5 8 11 Screws to 60 Lb Ft 1 FORCE CONTROL INDUSTRIES INC INDUSTRIAL MSB9 and MSB10 HOLES FOR 2 SHOULDER 4 PINS BOLTS 144 H amp D 177 4 SPRINGS 36 LOCATION A GE amp SPRINGS 36 LOCATION B C amp G 8 SPRINGS 36 LOCATION A B C D E F G amp H 2 PINS 179 G amp C 8 PINS 4 SPRINGS 36 LOCATION A C E amp G SPRINGS 36 LOCATION F amp G 8 SPRINGS 36 LOCATION A B C D E G amp H Figure 7 7 Correct Placement of Brake Springs 36 3 Setthe End Housing 9 so the Coil 59 is facing upright 4 Place the correct number of Springs 36 over the Pins 177 as shown in Figure 7 7 5 Set the Armature Plate 56 and Thrust Plate 5 in position on the Springs 36 Insert the 4 Shoulder Bolts 144 and tighten down evenly to compress the Springs 36 Use Blue Loctite 242 and torque to 25 Lb Ft MSB9 and MSB10 Motor Brakes Only 6 Attach the 2 Lockwashers 129 and 2 Flange Nuts 315 to the 2 Manual Rele
39. and START UP IMPORTANT SAFETY PRECAUTIONS eee 5 3 1 RECEIVING THE MagnaShear MOTOR BRAKE 5 A Assembled Brake Motor ABM 5 B MagnaShear Motor 5 3 2 SPECIAL ASSEMBLY 0015 0 5 3 3 SCREW TORQUE REQUIREMENTS 5 3 4 VERIFYING MOTOR SPECIFICATIONS 6 3 5 MOUNTING THE MagnaShear MOTOR BRAKE TO THE DRIVE MOTOR een 6 A Sizes MSB9 and MSB10 Motor Brake 6 B Size MSB12 Motor Brake ss 7 3 6 FINAL 8 3 6 WIRING SPECIFICATIONS eene 8 Brake Coil erani rr e 8 B Brake Release Indicator Switch 9 38 STARFUP uL enne 9 Section 4 LUBRICATION 4 1 CHECKING THE OIL LEVEL nenne 10 4 2 OPERATINGTEMPERATURES eee 10 A Ambient Temperatures eene 10 B Sump Temperature eee 10 4 3 CHANGING THE 00 2 0 00 2 2002474744 10 10 Section 5 OPERATIONAL CHECKS 5 1 CHECKING THE BRAKE OPERATION 11
40. ase Shafts 189 Torque to 25 Lb Ft MSB12 Motor Brake Only 6 Attach the 2 Flat Washers 274 and 2 Flange Nuts 315 to the 2 Manual Release Shafts 189 Use Blue Loctite 242 and torque to 25 Lb Ft MSB9 MSB10 and MSB12 Motor Brakes 7 Place the rubber seal on the coil leads and pull the wires through taking up all the slack in the wires Seat the rubber seal into the threaded part of the 19 MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com Electrical Fitting 415 Tighten down the compres sion nut See Figure 7 5 or 7 6 8 Attach the coil leads to Terminal Strip J1 on the Circuit Board 400 and replace the Conduit Box cover See Figure 7 5 or 7 6 MSB9 and MSB10 Motor Brakes Only 9 Position a new Gasket 121 on Mounting Flange 8 mounting face Do not use any gasket sealant on this gasket 10 Attach the End Housing Assembly with 4 Hex Nuts 261 and 4 Lockwashers 127 Torque to 60 Lb Ft MSB12 Motor Brake Only 9 Position a new Gasket 122 on the Housing 8 mounting face Do not use any gasket sealant on this gasket 10 Attach the End Housing Assembly with 4 Screws 148 and 4 Lockwashers 127 Torque to 120 Lb Ft MSB9 MSB10 and MSB12 Motor Brakes 11 Replace Drain Plug 64 in bottom of End Housing 9 Fill with fresh oil to center of Sight Gauge 46 as specified in Section 4
41. evenly and very carefully Note the quantity and position of Springs 36 Make a sketch of their location to help you at reassembly or as shown in Figure 7 7 12 Remove the 4 Screws 150 and 4 Seal Washers 167 from the End Housing 9 Lift the Holding Coil 59 out of the End Housing 9 B Reassembly MSB9 and MSB10 Motor Brakes 1 Place a new Holding Coil 284 into the End Housing 9 pushing the coil leads up through the Electrical Fitting 415 2 Attach the Coil 59 with 4 Seal Washers 167 and 4 Screws 150 IMPORTANT Torque the 4 1 2 13 Screws to 45 Lb Ft 3 Set the End Housing 9 so the Coil 59 is facing upright Install the Brake Springs 36 as described below and shown in Figure 7 7 NOTE There are 4 Pins 177 amp 2 Pins 179 installed in the End Housing 9 and also 2 3 8 16 tapped holes for the 2 Shoulder Bolts 144 The Pins 177 179 and Shoulder Bolts 144 are all used for the installation of the required number of Brake Springs 36 4 Install 3 8 16 x 3 Lg Set Screw any of the shoulder bolt holes that will require a Brake Spring 36 This will insure that the Brake Springs 36 stays in position when the Armature Plate 56 and Thrust Plate 5 is placed on the springs 5 Set the Armature Plate 56 and Thrust Plate 5 in position on the Springs 36 Remove any set screws Insert the 2 Shoulder Bolts 144
42. ews 149 and 8 Lockwashers 127 from the Housing 8 Pull the End Housing 9 off the Housing 8 5 Remove the Gasket 122 and discard it MSB9 MSB10 and MSB12 Motor Brakes 6 Take the cover off of the Conduit Box 405 and dis connect the coil leads from J1 terminal strip located on the Circuit Board 400 Also remove the com pression nut from the Electrical Fitting 415 and pry the rubber seal out of the fitting and off of the coil leads See Figures 7 5 or 7 6 7 Lower the Brake Manual Release Lever 8 Turn the End Housing 9 over with the Armature Plate 56 and Thrust Plate 5 in an Up position Do not rest the end housing on the Conduit Box 251 MSB9 and MSB10 Motor Brakes Only 9 Remove the 2 Hex Nuts 4315 and 2 Lockwashers 129 from the 2 Manual Release Shafts 189 MSB12 Motor Brake Only 9 Remove the 2 Hex Nuts 315 and 2 Flat Washers 274 from the 2 Manual Release Shafts 189 MSB9 MSB10 and MSB12 Motor Brakes 10 Loosen and remove the 2 Shoulder Bolts 144 that holds the Armature Plate 56 in place Lift the FORCE CONTROL INDUSTRIES INC CESS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 SL DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com Armature Plate 56 and Thrust Plate 5 up and out of the End Housing 9 CAUTION This Armature Plate 56 is under spring pressure so loosen the 2 Shoulder Bolts
43. ff and replace it with a new one See Section 7 2 for Tips on Handling Circuit Boards 6 Re attach with 3 Screws 428 and 3 Nylon Washers 431 Re connect the wires to J1 and J2 Terminal Strips and the wire on the Chassis Ground Screw 426 7 Place the O Ring 437 back on the External Heat Sink 420 and re attach it with the Bridge Rectifier back onto the Conduit Box 405 with Screw 427 and Flat Washer 434 Replace conduit box cover amp Brad Harrison Cable 7 7 REPLACING HOLDING COIL 59 See Figure 8 1 for Sizes MSB9 and MSB10 See Figure 8 2 for Size MSB12 A Disassembly MSB9 MSB10 and MSB12 Motor Brakes 1 First drain all the oil from the unit into a suitable con tainer See Section 4 LUBRICATION for location of drain plugs Save or discard oil as condition warrants 2 Disconnect the 5 Pin Brad Harrison Cable from the Conduit Box 405 and the wires from the Brake Indicator Switch Box 251 3 Lift the Manual Release Lever to release the brake MSB9 and MSB10 Motor Brakes Only 4 Remove the 8 Hex Nuts 261 and 8 Lockwashers 127 off of the 8 Studs 72 Pull the End Housing 9 off the Mounting Flange 8 5 Remove the Gasket 121 and discard it 18 NOTE On the MSB10 there will be another Gasket 121 and a Spacer 60 between the End Housing 9 and the Mounting Flange 8 Discard this Gasket 121 also MSB12 Motor Brake Only 4 Remove the 8 Scr
44. he Resistance should read as follows MSB12 Coil Resistance 115 7 15 Ohms 10 230 60 Ohms 10 96 A reading outside of this range would indicate that the Coil is bad and needs to be replaced See Section 7 for Coil Replacement MEG OHMETER SET TO OHM POSITION REMOVE COIL LEADS FROM TERMINAL J1 AND CLIP A MEG OHMETER TO THEM Figure 6 3 Coil Resistance Testing NOTE A Hi Pot Tester can be used for this test but do not exceed 1250 VDC 14 B Coil Current Leakage Test Hemove the cover from the Junction Box 405 and disconnect the 2 Coil Leads from both terminals on the Terminal Strip J1 located on the Circuit Board 400 Connect 1 alligator clip to both Coil Leads and the other one to Chassis Ground Screw 426 See Figure 6 4 A reading of 10 Meg Ohms or greater indicates that the Coil is fine and does not need to be replaced Anything much less would indicate that there is a short to ground and the Coil would need to be replaced See Section 7 for Coil Replacement MEG OHMMETER SET TO MEG 0HM POSITION JUNCTION BOX 405 WITH COVER REMOVED CHASSIS GROUND REMOVE COIL LEADS FROM TERMINALS STRIP J1 AND CONNECT THEM TOGETHER Figure 6 4 Coil Current Leakage Testing NOTE A Hi Pot Tester can be used for this test but do not exceed 1250 VDC FORCE CONTROL INDUSTRIES I
45. ia Horizontal Mounting 488 Ft Lbs Torque with Manual Release 2 1 8 Collet Bore Dia 115 and Engineering Revision 1 6 Manual Release 7 Revision 10 By Force Control With Manual Release Collet Bore Motor Shaft Dia 8 1 375 1 625 1 8 5 2 125 2 250 2 3 5 3 625 Eurodrive Motors Voltage 9 EB 5c EB 230 VAC Special Torque 4 5 6 pug 675 Ft Lbs 11252 1250 Ft Lbs 25 INDUSTRIAL 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com Ref 36 545 46 56 59 60 62 64 72 73 75 76 81 94 10 110 114 115 REPAIR PARTS LIST MSB9 and MSB10 MagnaShear MOTOR BRAKE Figure 8 1 ef om e Thrust Plate Mounting Flange End Housing Brake Stack Assembly Oil Seal Wear Sleeve Spring MSB9 325 Ft Lbs Torque MSB9 468 Ft Lbs Torque MSB9 650 Ft Lbs Torque MSB10 450 Ft Lbs MSB10 675 Ft Lbs MSB10 900 Ft Lbs Air Breather Sight Gauge Armature Plate Holding Coil Spacer Ring MSB10 Only Pipe Plug 1 NPT Pipe Plug Mag Sq Hd 1 2 NPT Stud 1 2 13 x Lg MSB9 1 2 13 x 4 Lg MSB10 Pipe Plug 1 2 NPT Pipe Plug 1 1 4 NPT Street Elbow 1 4 NPT Copper Washer MSB9 5 8 MSB10 3 4 Hex Hd Collet Bolt MSB9 5 8 11 x 1 3 4 Lg
46. icator as shown in Figure 3 3 FACE amp SHAFT RUNOUT MOTOR SHAFT TO PILOT DIAMETER ECCENTRICITY SHAFT RUNOUT X DIAL INDICATOR T LARGE MNTG FACE SHAFT FACE RUNOUT Figure 3 3 Verifying Motor Specifications MAXIMUM ALLOWABLE T I R Inches As Per NEMA MG 1 Standard Maximum Maximum 2 Dia Allowable Allowable Allowable Shaft Runout Face Runout Eccentricity CU CAE 1E NE 12 amp Larger 00 05 009 07 007 CAUTION in excess of this maximum will result in a potential leak condition 3 5 MOUNTING THE MagnaShear MOTOR BRAKE TO THE DRIVE MOTOR First check the motor shaft and pilot diameter for any nicks scratches or burrs Clean up and de burr if necessary De grease motor shaft Collet 110 amp Hub 2 IMPORTANT Do not use any Molybdenum Disulfide or any other similar lubricant on the motor shaft The collet locking element is keyless and depends on friction to transmit torque from the brake to the motor shaft A Sizes MSB9 and MSB10 Motor Brake See Figure 8 1 1 Pull up the Manual Release Lever to release the brake 2 Remove the End Housing 9 from the Mounting Flange 8 by taking off the 8 Hex Nuts 261 and 8 Lockwashers 127 Pull the End Housing 9 away from the Mounting Flange 8 3 Remove the Brake Stack 12 from the Mounting Flange 8 by unscrewing the 2 Sho
47. ke stack can also prohibit shaft rotation 11 MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com Section 6 TROUBLESHOOTING 6 1 TROUBLESHOOTING CHART PROBLEM POSSIBLE CAUSE REMEDY 1 Brake fails to engage properly Electrical control circuit Check control circuit Faulty Magna Shear circuit board Replace circuit board Worn friction surfaces Check disc stack for wear and replace if necessary 2 Brake fails to release properly Electrical control circuit Check control circuit Faulty Magna Shear circuit board Replace circuit board Faulty coil Replace coil Low voltage at circuit board Verify control power 3 Brake torque too high Excessive spring force Contact Force Control Low oil level Check oil level and add oil Inspect for oil leak 4 Brake torque too low Inadequate spring force Wrong oil Contact Force Control 5 Noise and vibration Motor mounted on poor foundation Improve installation Tighten mounting bolts 6 Drive overheats Brake fails to engage See 1 and 2 above 200 F max or disengage properly Improper oil level Check oil level Add Drain as req d 7 Oil leakage Worn oil seal Disassemble and replace Gaskets Tighten all external screws Poor ventilation Remove breather and clean 8 Brake does not repeat Electrical control circuit Check control circuit PLC scantime Inconsistent Stopping i Faulty Magna Shear ci
48. list or exploded view drawing 4 Part Name From the parts list 5 Quantity From the parts list 6 Complete Shipping Information 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 FORCE CONTROL INDUSTRIES INC GE Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 SL DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com gt Force Control Industries Inc For Service Parts Call ZEE oW 513 868 0900 Magna4Shear MOTOR BRAKE Model No 01 MSB 9 2 H 488 R C 1 1 SeialNo 0 0 Use Mobil ATF 210 Type F U S PATENTS 5 172 789 5 242 039 5 389 049 5 533 425 5 603 395 OTHER U S amp FOREIGN PATENTS PENDING C 01 MSB gt Size 1 9 MSB9 FU MSB10 E MSB12 Pilot Diameter FAK 2 NEMA SEW IEC 10 500 112 1325 EJ 2500 El vow lt lt Mounting Position 3 EB Horizontal EB Brake Up D Brake Down FORCE CONTROL INDUSTRIES INC 8 5 NAME PLATE AND MODEL NUMBER The Name Plate shown is located on the Brake End Housing The Example shown is a size MSB9 12 1 2 Pilot D
49. ntil all Drive Plates Friction Discs and Separator Springs have been installed ending with a Drive Plate 16 Install the 2 Shoulder Bolts 12 using Blue Loctite 242 thru the two remaining holes in the Drive Plates 12 into the Mounting Flange 8 17 Torque all 4 Shoulder Bolts to 14 Lb Ft 18 Place the Gasket 121 on the mounting face of the End Housing 9 19 Slide the End Housing 9 into place and attach with 8 Lockwashers 127 and 8 Hex Nuts 261 Torque these 8 Hex Nuts 261 to 60 Lb Ft FORCE CONTROL INDUSTRIES INC INDUSTRIAL NOTE There will be an extra Gasket 121 and a Spacer 60 between the End Housing 9 and the Mounting Flange 8 for Size MSB10 20 Lower the Manual Release Lever to engage the brake B Size MSB12 Motor Brake See Figure 8 2 1 Pull up the Manual Release Lever to release the brake 2 Remove the End Housing 9 from the Housing 8 by taking out the 8 Screws 148 and 8 Lockwashers 127 Pull the End Housing 9 away from the Housing 8 3 Remove the Gasket 122 and keep it for reassembly 4 Remove the whole Brake Stack from the Housing 8 by unscrewing the 4 Shoulder Bolts 138 in the Drive Plates 12 Do not remove these 4 Shoulder Bolts 138 from the Brake Stack 5 Set the Brake Stack on a work bench with the threads of the 4 Shoulder Bolts 138 pointing up IMPORTANT Make sure you keep the Brake
50. ntrol warranty must be commenced within one year of the date on which the breach is or should have been discovered A Return Goods Authorization RGA number must be obtained from the factory and clear ly marked on the outside of the package before any equipment will be accepted for war ranty 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 typo graphical 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 suspected 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 23 31 MTY 81 83 54 10 18 SL DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com Section 1 DESCRIPTION and OPERATION 1 1 UNIT DESCRIPTION erre 1 1 2 THE OIL SHEAR PRINCIPLE eee 1 1 3 OPERATION eere 2 Section 2 SPECIFICATIONS 2 1 TECHNICAL SPECIFICATIONS 3 2 2 DIMENSIONAL SPECIFICATIONS 4 Section 3 INSTALLATION
51. o 515 Lb Ft NOTE The Hub 2 will move approx 1 32 further on to the shaft as the screw is tightened The final position of the Hub 2 is 1 64 Installing Brake Stack HOUSING 8 4 GUIDE PINS 901 4 PINS 176 4 SEPARATOR SHIMS 986 SPRINGS 17 REQUIRED INSTALLED ON GUIDE PINS HUB 2 PLATE 12 FIRST FRICTION NEXT DRIVE DISC 13 PLATE 12 Figure 3 7 Installing MSB12 Brake Stack 11 Remove the 4 Guide Pins 901 from the stored position See Figure 8 2 and install them into the Housing 8 as shown in Figure 3 7 12 Shims 986 were required install them first 13 Take the First Drive Plate 12 from the Brake Stack and place it over the 4 Pins 176 and the 4 Guide Pins 901 14 Place the First Friction Disc 13 on the Hub 2 spline 15 Place a Separator Spring 17 on each of the 4 Guide Pins 901 16 Repeat Steps 12 13 and 14 until all Drive Plates 12 Friction Discs 13 and Separator Springs 17 have been installed ending with a Drive Plate 12 17 Remove the Guide Pins 901 one at a time while keeping pressure on the stack with your hand This will keep the Separator Springs 17 in place Replace each of the 4 Guide Pins 901 with Shoulder Bolts 138 Use Blue Loctite 242 on the bolts and torque to 25 Lb Ft Replace the 4 Guide Pins 901 back into the 4 storage position holes 18 Insert a couple
52. oat the bore with Permatex 30 Sealant CAUTION Be very careful not to get any of the sealant on the rubber parts of the Oil Seal 31 5 Press the new Oil Seal 31 into the bore with an arbor press as shown in Figure 7 15 MOTOR ADAPTER HOUSING 7 FLAT PLATE ARBOR PRESS INSTALLATION TUBE OIL SEAL 31 Figure 7 15 Installing Oil Seal for MSB12 6 Clean off any excess sealant 7 10 REPLACING BRAKE INDICATOR SWITCH 249 See Figure 8 4 Make sure the electrical power is shut off and locked out to avoid the possibility of any personal injury 1 Remove the cover from the Switch Enclosure 251 2 Disconnect the leads from the switch terminals Take out the 2 Screws 328 Pull the Bracket 332 and the Switch 249 out of the Switch Enclosure 251 FORCE CONTROL INDUSTRIES INC CESS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 SL DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com REF SWITCH ACTUATING PIN 4159 BRAKE RELEASE INDICATOR SWITCH 249 SHIM UNDER MOUNTING TABS IF NECESSARY SWITCH BRACKET 332 Figure 7 16 Brake Release Indicator Switch 4 Pry the Switch 249 up and off the 2 tangs on the Switch Bracket 332 as shown in Figure 7 16 5 Push the 2 tangs up and into the new Switch 249 6 Attach the Bracket 332 to the 2 Standoffs with 2 Screws 328 Use Blue Loctite 242 Make sure the switch
53. rcuit board Replace circuit board Oil temperature change Check temperature Machine resistance changed Lubricate bearings For installations requiring precise starting and stopping operating temperatures are important Operating tempera tures between 115 F and 165 F are recommended 12 FORCE CONTROL INDUSTRIES INC 55 53 63 23 31 MTY 81 83 54 10 18 SB DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com 6 2 TROUBLESHOOTING COILS Sizes MSB9 amp MSB10 MagnaShear Motor Brake Pulse Width Modulation PWM Board A Coil Resistance Test Remove the cover from the Junction Box 405 and disconnect the 2 Coil Leads from both terminals on the Terminal Strip J1 located on the Circuit Board 400 Hook Up a Meg Ohmmeter to both coil leads as shown in Figure 6 1 Set the Meg Ohmmeter to Ohm range and test Resistance at 500 VDC The Resistance should read as follows MSB9 amp 10 Coil Resistance 21 5 Ohms 10 230 VAC 2220 54 0 44 86 Ohms 10 96 A reading outside of this range would indicate that the Coil is bad and needs to be replaced See Section 7 for Coil Replacement MEG OHMETER JUNCTION BOX WITH COVER REMOVED SET TO OHM POSITION REMOVE COIL LEADS FROM TERMINALS ON AND CLIP A MEG OHMMETER TO THEM Figure 6 1 Coil Resistance Testing NOTE A Hi Pot Tester can be used for this test but do not exceed 1250 VDC FORCE CO
54. t 1 5 8 4 STUDS 155 MOUNTING FLANGE 8 2 50 1 32 MSB9 a 3 25 1 32 MSB10 2 2 27 i i HUB 2 NX COLLET BOLT 94 por COLLET 110 OIL SEAL 31 WEAR SLEEVE 32 Figure 3 4 Installing Mounting Flange 8 and Positioning The Hub 2 and Collet 110 on The Motor Shaft FORCE CONTROL INDUSTRIES INC CESS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 SL DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com 10 Use the Hub Holding Tool 900 to hold the Hub 2 Torque the Collet Locking Bolt 2294 to 190 Lb Ft for the MSB9 and 324 Lb Ft for the MSB10 NOTE The Hub 2 will move approx 1 32 further on to the shaft as the screw is tightened The final position of the Hub 22 is 1 64 Installing Brake Stack 11 If needed install the 2 Guide Pins 12 180 apart into the Mounting Flange 8 as shown in Figure 3 5 Use Blue Loctite 242 MOUNTING FLANGE 8 FIRST DRIVE PLATE 2 SEPARATOR SPRINGS ON GUIDE PINS NEXT DRIVE PLATE 2 GUIDE PINS 12 180 FIRST FRICTION DISC Figure 3 5 Installing The MSB9 amp 10 Brake Stack 12 12 Take the First Drive Plate from the Brake Stack 12 and place it over the 4 Pins 176 and the 2 Guide Pins 12 13 Place the First Friction Disc on the Hub 2 spline 14 Place a Separator Spring on each Guide Pin 15 Repeat Steps 12 13 and 14 u
55. ulder Bolts in the Drive Plates The 2 Guide Pins 12 remain 4 Set the Brake Stack 12 on a work bench with the threads of the 2 Shoulder Bolts pointing up There is a Retaining Ring on each Shoulder Bolt Remove both of them and discard them IMPORTANT Make sure you keep the Brake Stack in exactly the same order as they were assembled There are 2 Separator Springs between each Drive Plate Be care ful not to lose track of them 5 Screw the 4 Studs 155 in to the motor mounting face Leave approximately 1 5 8 of exposed thread from the motor face Use Blue Loctite 7242 6 Attach the Mounting Flange 8 to the motor mount ing face with the 4 Hex Nuts 392 and 4 Lockwashers 168 Torque to 120 Lb Ft 7 Apply a light coat of White Grease or equivalent to the Wear Sleeve 32 located on the Hub 2 and the lip of the Oil Seal 31 located in the Mounting Flange 8 8 Slide the Hub 2 and Collet 110 onto the motor shaft being Be careful not to damage the lip of the Oil Seal 31 or Wear Sleeve 32 9 Position the Hub 2 as shown in Figure 3 4 Measure the distance from the end of the Hub 2 to the face of the Mounting Flange 8 This distance should be 2 50 1 32 for the MSB9 and 3 25 1 32 for the MSB10 Apply Blue Loctite 242 and tighten the Collet Locking Bolt 94 enough to take out excess clearance in the Hub Collet Assembly but still able to move i
56. w 426 3 Remove the Screw 427 and Flat Washer 434 which holds the Bridge Rectifier and External Heat Sink 420 to the Conduit Box 405 Remove the External Heat Sink 420 and O Ring 437 and store for reassembly POWER INDICATOR LIGHT 410 CIRCUIT BOARD 400 ELECTRICAL BOX 405 REW 426 2 RUBBER SEAL ELECTRICAL FITTING 415 gt E TP pum 4 E hd y 5 PIN BRAD HARRISON 3 SCREWS 428 CONNECTOR ELECTRICAL 1416 FITTING 415 3 NYLON WASHERS 8431 amp ORANGE WIRES NOT USED Figure 7 5 Conduit Box with Cover Removed for Sizes MSB9 and MSB10 FORCE CONTROL INDUSTRIES INC INDUSTRIAL 17 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO 442 195 72 60 ventas industrialmagza com Brake Coil Circuit Board amp Conduit Box POWER INDICATOR CHASSIS GROUND LIGHT 410 SCREW 426 ELECTRICAL CONNECTOR 415 BRIDGE RECTIFIER l 3 SCREWS 428 3 NYLON WASH 431 EXTERNAL HEAT SINK 420 O RING 437 SCREW 427 WASHER 434 5 PIN BRAD HARRISON CONNECTOR 416 RED amp ORANGE WIRES NOT USED COIL LEADS COMPRESSION NUT END HOUSING BRAKE COIL 59 b Figure 7 6 Conduit Box with Cover Removed for Size MSB12 Motor Brake 4 Remove the 3 Screws 428 and 3 Nylon Washers 431 5 Take the old Circuit Board 400 o
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