I06_014_g_G.fm Seite 14 Samstag, 7.

August 2004 2:31 14

6/14 Description
Overload relays

Moeller HPL0211-2004/2005

ZEV – the revolutionary overload relay for motor currents from 1 – 820 A
Overload relays

General
Technological advances require completely new approaches: the application of
newly developed sensor systems and tripping units has made motor protection
considerably simpler and more economical. All Z overload relays provide the
standard functions: protection in the event of phase failure, overload, or current
imbalance. The innovative ZEV motor-protective system from Moeller can now do
all these things and much more:
Application
Even the most severe starting situations can be dealt with by the ZEV motor-
protective system. The enhanced tripping classes (up to CLASS40) provide reliable
protection for motors with starting times of up to 40 seconds. Protection for any
motor starting situation can be optimally set by preselecting one of the eight
tripping classes between 5 and 40 seconds. An earth fault is quickly detected by the
external core-balance transformers. The integrated thermistor connection allows
the relay to be upgraded to provide a full motor-protective system.
Engineering
The multi-voltage module automatically adapts to different voltages from
24 – 240 V, 50/60 Hz, and 24 – 240 V DC, thus enabling flexible application with all
conventional control voltages.
Mounting
Ring-type sensors enable the innovative ZEV motor protection system to be used
also for small motors. With large motor currents and cable cross-sections, the sensor
cables are simply wound round the incomers.
A main current wiring system and complex cable matching for an additional device
are no longer necessary, neither is the drilling of the mounting plate. Instead, the
sensors are simply fastened with a Velcro fastener.
This saves mounting time and expense. The volume of 58 times less than
conventional transformers enables the saving of valuable mounting space in the
control panel.

Operation
The LCD display guides the user through the setting menus and ensures straight-
forward operation. In the event of a fault, the display shows the cause of the fault
and enables rapid fault identification.
Additional signal cables can be implemented via the freely configurable auxiliary
contacts 05-06 and 07-08.
They can each be assigned one of the following functions:
• Early warning of overload
• Earth fault
• Thermistor tripping
• Internal fault
 I06_016-017_h_G.fm Seite 16 Samstag, 7. August 2004 2:31 14

6/16 Overload relays

Selection aids

Moeller HPL0211-2004/2005

L1 Meny
L2
L3
N
Class
Z1
5 10 15 20
Till Från
25 30 35 40
Overload relays

Z2

C1 C2 Y1 Y2 A1 A2 95 97 05 07
Fri
Reset ~ = e parameter
1
0 – 820 A
Fel !
e > 105%
L1 L2 L3
IF 1)
l µP Fri Reset
% parameter 1
Class Fri
Fri Hand Auto
parameter
parameter 2
2
T1 Mode Up !
M e > 105%
Test Down
3~ T2 Reset
Till Från IF 1)

96 98 06 08

1) IF: internal fault

Inputs Outputs
A 1/A 2 Rated control voltage 95/96 Break contact overload/thermistor
T 1/T 2 Thermistor sensor 97/98 Make contact overload/thermistor
C 1/C 2 SSW core-balance transformers 05/06 Break contact freely assignable
Y 1/Y 2 Remote reset 07/08 Make contact freely assignable

Switchgear and cable sizing corresponding to the respective starting inertia (CLASS)

The switchgear is designed for “CLASS 10” in normal and overload operation. To ensure that the switchgear (circuit-breaker and contactor) as well as the cables are not
overloaded with extended tripping times, they must be over-dimensioned accordingly. The rated operational current Ie for switchgear and cables can be calculated with
the following current factor while taking the tripping class into account:

Tripping class Class 5 Class 10 Class 15 Class 20 Class 25 Class 30 Class 35 Class 40
Current factor for 1.00 1.00 1.22 1.41 1.58 1.73 1.89 2.00
rated operational
current Ie

Relays with integrated sensor

With the ZEV-XSW-25 to ZEV-XSW-145 push-through sensors, the motor incomer cables for each phase are pushed through the respective push-through openings. On
motor currents which are less than 1 A, the motor incomer cables with the ZEV-XSW-25 are inserted in loops. The number of loops depends on the rated motor current
involved.
Number of loops n 4 3 2
Rated motor current IN A 0.31 – 0.4 0.41 – 0.62 0.63 – 1.24
Current settings on relay IE A 1.24 – 1.6 1.23 – 1.86 1.26 – 2.48
between lowest and highest value

The current setting IE of the device is calculated as: IE = n
IN

I06_016-017_h_G.fm Seite 17 Samstag, 7. August 2004 2:31 14

Overload relays 6/17

Selection aids

Moeller HPL0211-2004/2005

Tripping times for ZEV electronic motor-protective relay

Tripping class, CLASS 5 10 15 20 25 30 35 40
can be selected
Tripping time in s (g20 %) With 3-pole symmetric loading from cold state
Setting current IE
3 11.3 22.6 34 45.3 56.6 67.9 79.2 90.5

4 8 15.9 23.9 31.8 39.8 47.7 55.7 63.6

Overload relays

5 6.1 12.3 18.4 24.6 30.7 36.8 43 49.1

6 5 10 15 20 25 30 35 40

7.2 4.1 8.2 12.3 16.4 20.5 24.5 28.6 32.7

8 3.6 7.3 10.9 14.6 18.2 21.9 25.5 29.2

10 2.9 5.7 8.6 11.5 14.4 17.2 20.1 23

Recovery time after overload trip

(Overview of the recovery time in min)
CLASS 5 10 15 20 25 30 35 40
trecovery 5 6 7 8 9 10 11 12
[min]

With unbalance > 50 % and with phase failure the trip occurs in 2.5 s

Thermistor tripping
Rated trip resistance R = 3200 O g15 %
Recovery resistance R = 1500 O +10 %
Total PTC thermistor resistance S RK F 1500 O
at RK F 250 O per sensor: 6 sensors
at RK F 100 O per sensor: 9 sensors
Ready to respond after trip at 5 K under response temperature
Test button tripping time: 5 s
EC prototype test certification number: PTB 01 ATEX 3233
For protection of motors in EEx e area, also order
AWB2300-1433G “ZEV motor-protective system, Overload monitoring of motors in EEX e areas”.
I06_022-023_e_G.fm Seite 23 Samstag, 7. August 2004 2:32 14

Technical data 6/23

Tripping characteristic

Moeller HPL0211-2004/2005

These tripping characteristics are mean values of the tripping time of the overload relay reduces to approx.
spread at 20 °C ambient temperature in a cold state. 25 % of the read off value. Specific characteristics for
Tripping time depends on response current. With each individual setting range can be found in the
devices at operating temperature the manual on a page 6/20.

Overload relays
2h 2h 2h 2h With a phase failure or
100 ZB12, ZB32, 100 Z5 100 ZW7
100
ZEV 3-pole unbalance > 50 %, the ZEV will
60 ZB65, 60 60
40 40 40 trip within 2.5 seconds.
ZE, Z00, Z1
20 20 20
Minutes
Minutes

Minutes

Minutes
10 10 10 15
6 6 6 10
4 4 4 5
2 CLASS 40
2 2 35
2
1 1 1 Highest level 30
40 40 40 1 25
3-phase 3-phase
20 20 20
20
Seconds
Seconds
Seconds

10 10 10 Lowest level 20

Seconds
6 6 6 10 15
4 4 7 10
4 2-phase 2-phase 5
2 2 2 3 CLASS 5
1 1 1 2
0.6 0.6 0.6 1
1 1.5 2 3 4 6 8 10 15 20 1 1.5 2 3 4 6 8 1015 20 1 1.5 2 3 4 6 8 10 15 20 1 2 3 4 5 6 7 8 910
x Setting current x Setting current ⫻ Rated current x Setting current
 I06_028-030_e_G.fm Seite 28 Samstag, 7. August 2004 2:33 14

6/28 Technical data

ZEV electronic motor-protective relay

Moeller HPL0211-2004/2005

ZEV ZEV

General Standard screwdriver mm 0.8 x 5.5

Standards IEC/EN 60947, VDE 0660, UL, Auxiliary circuit rated Ui V AC 250
CSA insulation voltage
Climatic proofing Damp heat, constant, to IEC
60068-2-78; Damp heat, cyclic, Rated operational Ue V AC 240
Overload relays

to IEC 60068-2-30 voltage

Ambient temperature Open1) °C -25/608) Safe isolation to VDE 0106 Part 101 and Part
101/A1
Enclosed1) °C -25/408) Between the auxiliary contacts V AC 2405)
Conventional thermal Ith A 6
Storage °C 40 – 80 current
Rated operational current
Temperature compensation Continuous AC–15
Mounting position As required Make contact 120 V Ie A 36)
Weight kg a page 20/22
Mechanical shock resistance g 15 240 V Ie A 36)
half-sinusoidal shock 10 ms 415 V Ie A –
to IEC 60068-2-27
500 V Ie A –
Degree of protection IP20
Break contact 120 V Ie A 3
Protection against direct contact when Finger- and back-of-hand proof
actuated from front (IEC 536)
240 V Ie A 3
415 V Ie A –
Main contacts 500 V Ie A –
Overload relay setting range A 1 – 8207) DC-13 24 V Ie A 1
L/R F 15 ms2) 60 V Ie A –
Temperature compensation %/K –
residual error > 20ºC 110 V Ie A –
220 V Ie A –
Short-circuit protection rating maximum fuse With overload relay in Power consumption Pmax. W 2.5
conjunction with a transformer as Short-circuit rating without welding
required for the contactor
Terminal screw M3.5 Max. fuse2) A gG/ 6
Tightening torque Nm 0.8 Pick-up and drop-out
Tools values
Pozidriv screwdriver Size 1 AC operated x Uc 0.85 – 1.1
Standard screwdriver mm 0.8 x 5.5
DC operated x Uc 0.85 – 1.1
Auxiliary and control circuit connections
Rated impulse withstand Uimp V 4000
voltage Thermistor protection
Overvoltage category/pollution degree III/3
Total resistance (cold) O 1500
Terminal capacity
Response value O 2720 – 3680
Solid mm2 1 x (0.5 – 2.5)
2 x (0.5 – 1.5)4)
Reset range O 1500 – 1650
Flexible with ferrule mm2 1 x (0.5 – 2.5)
2 x (0.5 – 1.5)4)
Recovery time
Solid or stranded AWG 1 x (18 – 14)
Overload a page 6/17
Terminal screw M3.5
Thermistor tripping 5 K under response temperature
Tightening torque Nm 0,8
Earth-fault protection Immediate
Tools
Pozidriv screwdriver Size 1

Notes 1) Ambient temperature: open and enclosed operating range to IEC/EN 60947, PTB: -5°C to +50°C
2) Rated operational current: Making and breaking conditions to DC-13, L/R constant as stated
3) See overlay “Fuses” for short-circuit rating time/current characteristic (please enquire)
4) Terminal capacities auxiliary and control circuits, solid, flexible with ferrules: With connection of 2 conductors only the following combinations are
permissible: 0.5 and 0.75 mm2, 0.75 and 1 mm2, 1 and 1.5 mm2
5) Safe isolation: Up to 240 V depending on contact assignment between mains and outputs no potential isolation to thermistor and summation current
transformer input and current sensor (neighbouring contacts: Us = 127 V)
6) Rated operational current AC-15: contacts 95/96 and 97/98 3 A (contactor control), contacts 05/06 and 07/08 1.5 A (auxiliary contacts)
7) Overload relay main contact setting range: setting range dependant on current sensor
8) Ambient temperature open and enclosed: limited readability of the LCD display at < -15 ºC
9) Main contacts terminal capacity solid and stranded conductors with ferrules: When using 2 conductors use identical cross-section
I06_028-030_e_G.fm Seite 29 Samstag, 7. August 2004 2:33 14

Technical data 6/29

Current sensors

Moeller HPL0211-2004/2005

ZEV-XSW-25 ZEV-XSW-65 ZEV-XSW-145 ZEV-XSW-820

General
Standards IEC/EN 60947, VDE 0660, UL, CSA
Climatic proofing Damp heat, constant, to IEC 60068-2-78;
Damp heat, cyclic, to IEC 60068-2-30

Overload relays
Ambient temperature
Open °C -25/60 -25/60 -25/60 -25/60
Enclosed °C -25/40 -25/40 -25/40 -25/40
Storage1) °C -40/80 -40/80 -40/80 -40/80
Temperature compensation Continuous Continuous Continuous Continuous
Mounting position As required As required As required As required
Weight kg a page 20/22 a page 20/22 a page 20/22 a page 20/22
Mechanical shock resistance half-sinusoidal g 15 15 15 15
shock 10 ms to IEC 60068-2-27
Degree of protection IP20 IP20 IP20 IP20
Protection against direct contact when actuated from front Finger- and back-of-hand proof
(IEC 536)
Main contacts
Rated impulse withstand voltage Uimp V AC –2) –2) –2) 8000
Overvoltage category/pollution degree –2) –2) –2) III/3

Rated insulation voltage

AC Ui V AC –2) –2) –2) 1000
Rated operational voltage Ue V AC –2) –2) –2) 1000
Safe isolation to VDE 0106 Part 101 and Part 101/A1
Between busbar and sensor V AC – – – 500
Overload relay setting range A 1 – 25 3 – 65 10 – 145 40 – 820
Short-circuit protection rating maximum fuse With overload relay in conjunction with a transformer as required for the contactor

Push-through opening o mm 6 13 21 110

Notes 1) Ambient temperature: operating range to IEC/EN 60947, PTB: -5°C to +50°C
2) The main current parameters are defined by the main current wiring which is used.
 I06_034-035_f_G.fm Seite 34 Samstag, 7. August 2004 2:33 14

6/34 Dimensions
Overload relays

Moeller HPL0211-2004/2005
Overload relays

ZEV

29
Overload relays

59.2

103
78
93

37

7.2 4.5 75
45

Current sensors

ZEV-XSW-...

4.5
103
78
35
37
93

a1 c

a
8

ZEV-XSW-... 25 65 145
a 45 70 90
d2

a1 24 49 68
c 50 58 65
35

d1 6 13 21
d2

d2 11.2 19 26

d1
I06_034-035_f_G.fm Seite 35 Samstag, 7. August 2004 2:33 14

Dimensions 6/35
Overload relays

Moeller HPL0211-2004/2005
Overload relays

ZEV + ZEV-XSW-...

ZEV + ZEV-XSW-... 25 65 145

Overload relays
c1 120 128 134

c1

Current sensor

ZEV-XSW-820
~150

35

125 3
37
26

Core-balance transformer

SSW40-...
SSW65-...
SSW120-...
a
a1
a2
SSW40-... SSW65-... SSW120-...
a 64 75 86.5
a1 50 60 70
a2 38 43 54.5
d

b 100 124 200

e
b1 80 100 170
b1
b

c 86 112 205
d 4.5 4.5 4.5
e 40 65 120

c
Product Listing
Model Number: 56T17F5348
Product Type: SQ CAGE IND RUN Normally Stocked: YES
Enclosure: TEFC
Frame: 56 C
Dimensional Drawing A-104406-606
PDF
Dimensional Drawing A-104406-606
DXF
HP: .33/.25
Speed (RPM): 1800/1500
Phase: 3
Volts: 208-230/460
F.L. Amps: 1.5-1.6/.8
Service Factor: 1.15
Bearing: BALL/BALL
DE Bearing: NONE
OPE Bearing: NONE
Footnotes: Bolt-on, removable
base for footless mounting option
Performance/Certification Data
Fail-safe, spring set Stearns
brake for holding or stopping
Manual release lever on rear
of brake housing
Brake coil voltage matches
motor voltages, (see mod
section for other brake coils)
Ball bearings, mechanically
locked on shaft end
Catalog Number: D450
List Price: $405
Multiplier Symbol: E5
Connection Diagram
A-EE7308 PDF
Connection Diagram
A-EE7308 DXF
Frequency (HZ): 60
Mounting: RIGID
Motor Wt:
Insulation Class: B
Duty: CONTINUOUS
Max. Ambient: 40
F.L. Eff.: 68
Thermal Protection: NONE
KVA Code: N
Hazardous Location:
NONE
Brake has manual wear adjustment
up to 10 ft./lbs., automatic
adjustment 25 ft./lbs. and greater
Vertical or horizontal mounting up
to 15lb.-ft, (see mod section for
larger brakes)
Bolt-on, removable rigid base on 56
and 145T frame
1.15 Service factor, 1.0 Service
factor where footnoted
 CR200 Corona resistant magnet
Nameplated 60/50 Hz at next wire (motor can be operated 10:1
lower horsepower variable torque and 2:1 constant
torque)
Brake has manual wear
Brake leads routed through motor
adjustment 15 ft./lbs. and
conduit box (TENV only)
greater
UL Recognized and CSA
Certified
 P.O. Box 8003
Wausau, WI 54401-8003
PH:(715) 675-3311

Certification Data Sheet

(DATA IS BASED ON 460 VOLTS)

Model #:56T17F5348 Outline Drawing: A-104406-606

Winding: ZT412 - FR Connection Diagram: A-EE7308

NP HP: 0.33 DESIGN: B Frame: 56 C

Max Load
NP VOLTS: 460 FREQ: 60 HZ Inertia: 2 (lb ft²)
NP AMPS: 0.8 LR CODE: N Approx Mtr Wgt:
NP RPM: 1725 95% PF Corr: Rotor Inertia: 0.04 (lb ft²)
NP EFF: 68% Sound @ 1M: 62 dBA Starts/Hour: 2 (NEMA WK2)
NP PF: 61.9% Ambient 40 C Stall Time: 15 Sec
GTD EFF: 64% Service Factor: 1.15 Insulation: B
Thermal
Protection: NONE Duty: CONTINUOUS

EQUIVALENT WYE CKT. PARAMETERS (OHMS PER PHASE)

R1 R2 X1 X2 XM
23.994 18.232 27.864 18.576 489.34

RM ZREF XR TD TD0
22.8 860 1.6 0.005 0.074

AMPS KW RPM TQ(lb-ft) EFF(%) PF(%) R/R(C)

No LD .05 1800 0 0 12.5 0

N/A 1 .2 1770 .5 66.5 40 0

N/A 1 .25 1750 .75 67.5 51 0

1.0 LD 1 .33 1725 1 68 61.9 25

1.15 LD 1 .38 1720 1.2 70 65 30

MTR AMPS NEMA AMPS MTR TQ NEMA TQ PF (%)

L.R. 5 625 400 % 43000 % 70
B.D. 3.6 450 500 % 53000 % 80.5
Mechanical Information
Shaft Material: STANDARD Mounting: RIGID
Enclosure: TEFC Electrical Type: STANDARD
Frame: 56 C Spaceheaters: NONE
 Frame Material: ROLLED STEEL Orientation: HORIZONTAL
Shaft: STANDARD 56 Conduit Assembly: F1
Grease: STANDARD Bearings DE: NONE
Hazardous Location: NONE Bearings ODE: NONE

FORM 4118 8-20-2002 Date Printed: 3/19/2007

The Above is Typical, Sinewave Power Data Unless Stated Otherwise.

 ® P/N 8-078-905-60
Spring-Set Disc Brakes
Installation and Service Instructions
for 1-056-X00* Series (all revisions)
Manual Adjust Brakes
*This sheet includes Series 1-056,000; 1-056,100; 1-056,200;
1-056,300; 1-056,400; 1-056,500; 1-056,600 and 1-056,900.
For other series consult factory.
1-056-100
1-056-600
1-056-000
1-056-400
1-056-500
1-056-200
1-056-900
1-056-300
Tools required for installation and servicing:
3/8” hex wrench
5/16” hex wrench
3/16” hex wrench
Typical Nameplate
Important
Please read these instructions carefully
before installing, operating, or servicing
your Stearns Brake. Failure to comply
with these instructions could cause injury
to personnel and/or damage to property if
the brake is installed or operated incor-
rectly. For definition of limited warranty/lia-
bility, contact Rexnord Industries, LLC,
Stearns Division,5150 S. International Dr.,
Cudahy, WI 53110, (414) 272-1100.
Caution
1. Installation and servicing must be
made in compliance with all local
safety codes including Occupational
Safety and Health Act (OSHA). All
wiring and electrical connections must
comply with the National Electric Code
(NEC) and local electric codes in
effect.
2. Do not operate the brake in
atmospheres containing explosive
gases or dusts.
5/16” nut driver
1/4” screwdriver
8” adjustable wrench
3. To prevent an electrical hazard,
disconnect power source before
working on the brake. If power
disconnect point is out of sight, lock
disconnect in the off position and tag
to prevent accidental application of
power.
4. Make certain power source conforms
to the requirements specified on the
brake nameplate.
5. Be careful when touching the exterior
of an operating brake. Allow sufficient
time for brake to cool before
disassembly. Surfaces may be hot
enough to be painful or cause injury.
6. Do not operate brake with housing
removed. All moving parts should be
guarded.
7. Installation and servicing should be
performed only by qualified personnel
familiar with the construction and oper-
ation of the brake.
8. For proper performance and
operation, only genuine Stearns parts
should be used for repairs and
replacements.
9. After usage, the brake interior will con-
tain burnt and degraded friction mate-
rial dust. This dust must be removed
before servicing or adjusting the
brake.
DO NOT BLOW OFF DUST using an
air hose. It is important to avoid
dispersing dust into the air or inhaling
it, as this may be dangerous to your
health.
effective 09/21/06
For replacement parts refer to sheets:
Series
1-056-000
Sheet Part No.
8-078-906-00
1-056-100 8-078-906-01
1-056-200
1-056-300
8-078-906-02
8-078-906-03
1-056-400
1-056-500
8-078-906-04
8-078-906-05
1-056-600 8-078-906-06
1-056-900 8-078-906-09
Also available at www.rexnord.com
a) Wear a filtered mask or a respirator
while removing dust from the inside
of a brake.
b) Use a vacuum cleaner or a soft
brush to remove dust from the
brake. When brushing, avoid caus-
ing the dust to become airborne.
Collect the dust in a container, such
as a bag, which can be sealed off.
10. Caution! While the brake is
equipped with a manual release to
allow manual shaft rotation, the
motor should not be run with the
manual release engaged, to avoid
overheating the friction disc(s).
General Description
These series of brakes are spring-set,
electrically released. They contain one or
more rotating friction discs (4) driven by a
hub (16) mounted on the motor or other
shaft.
Operating Principle
These series contain one or more friction
discs (4) assembled alternately between
the endplate (2) friction surface, stationary
disc(s) (3) and pressure plate (also called
stationary disc) (3). The stationary disc(s)
are restrained from rotating by being keyed
into the endplate. With the brake released,
all disc pack components are free to slide
axially and the friction disc(s) to rotate.
Brake release occurs when the solenoid
coil is electrically energized, causing the
solenoid plunger to travel a specified
distance and through a lever system,
overcoming the pressure spring force.
This action releases the clamping force
on the disc pack, thereby allowing the
friction disc(s) and brake hub to rotate.
Brake sets and torque is produced when
electric current to the solenoid coil is
interrupted, thereby collapsing the
solenoid magnetic field. The solenoid
plunger returns to its original
de-energized position allowing the lever
arm to move forward by virtue of the
compressed torque springs. This action
compresses the disc pack components
which applies a retarding torque to the
brake hub and ultimately restores the
brake to a spring-set static condition.
 BRAKE MOUNTING (Manual Adjust) 1-056-X00

Place hub on motor shaft.

 Position hub on shaft as shown.
 Tighten set screws to motor shaft.

.188”
(4.77mm)

 Remove brake housing.

Housings vary by series number.

 Slide endplate over hub noting position
of stabilizer clips, if used.
(Refer to Friction Disc
See page 1. Replacement, view 3 and 3A.)
Tighten mounting screws.

counter-
clockwise

*For vertical assembly of 20 &

25lb-ft brakes, refer to page 3.

 AC coils are 50/60 Hz, single

phase rated. Power supply to
coil must not have current or
 Replace brake housing and tighten to torque specified below:

Brake series Torque

frequency limiting output that is 1-056-000 1-056-300
less then the coil requirement. 8 lb-in
1-056-400 1-056-500
- Connect leadwires to power 1-056-100 1-056-200
12 lb-in
source. Verify voltage rating* 1-056-600 1-056-900
per nametag on coil.
- Keep wiring away from pinch
points and moving components. clockwise

* For DC voltages see

sheet 8-078-950-00.

FRICTION DISC REPLACEMENT SERIES 1-056-X00


Install new friction disc(s) and
Remove support plate screws and
stationary disc(s) as shown.
lift support from brake
Note: Stabilizer clips should never be located over the set
screws of the hub.

Single disc brakes always use two stabilizer clips, locate at 90°
counter- from each other.
clockwise
Double disc brakes typically will not require stabilizer clips, how-
ever there are some special modifications that will use them.

Rev A & B may have these clips may have these clips located
1 per disc, and should never be positioned in line with each
other.


Rev C will have only one clip, used on the inner-most disc. No
Remove and discard old friction disc. clip will be used on the outer-most disc.

Three disc brakes will never use stabilizer clips on friction discs.

 Reposition support plate on endplate and

tighten mounting screws to 55 lb-in.
clockwise

Note: Friction discs can wear to 1/2 their original thicknes, or .093”

2
 AIR GAP ADJUSTMENT 1-056-X00
As friction disc wear the air gap will increase. When plunger gets to the reset position, the air gap must be adjusted.


To increase air gap, turn both adjusting screws (10) counterclockwise. Use To decrease air gap, turn both adjusting
3/16 hex wrench, or flat screwdriver on older models. screws (10) clockwise.
56,X00 Series Air Gap* (REV A & B)
Torque
Disc Torque Min/Max
1 1.5, 3 & 6 .38” ± .69”
2 10 & 15 .45” ± .69”
3 20 & 25 .50” ± .69” clockwise
*±.03”

56,X00 Series Air Gap* (REV C)

Disc Torque Min/Max
3, 6, 3/16 hex wrench
2 .45” ± .69” 3/16 hex wrench
10 & 15
3 20 & 25 .50” ± .69” counter-clockwise
Maximum gap should not exceed .69”
*±.03”

COIL REPLACEMENT SERIES 1-056-X00

Remove housing and disconnect power and wiring to coil.

Insert screwdriver between support

plate and lever arm and pry forward.  Lift plunger/solenoid
lever assembly
out of coil.
 Remove plunger guide.

 Discard coil.
 A) Insert new coil. (Lead wires
in same position as old coil.)
B) Insert plunger guide.
 A) Re-insert plunger into coil; drop
pivot pin into cradle of support plate.
B) Remove screwdriver.

A B
B

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

VERTICAL SPRING ASSEMBLY 1-056-X00

Vertical Brake Assembly
Single disc brakes are universal mount and
do not require separator springs. Double
disc brakes are universal mount but require
separator springs which are preassembled
to the stationary disc. These discs are
inserted spring first into the brake.
Refer to figure 5A below.
Figure 5A
Installation Procedure for 20 and Mount support plate and torque screws
25 lb-ft brakes if mounted vertical evenly to 55 lb-in.
to motor shaft (These brakes are
factory assembled for horizontal operation.)
Remove support plate by loosening the
three mounting screws.
Remove stationary discs and friction discs.
Using the spring kit provided with this
brake, insert three springs of identical color
into each stationary disc hole. Springs are Figure 5B
inserted from the side opposite the indent
mark (see Figure 5B). Stationary disc
should be placed on a clean flat surface
with a clearance hole to allow the tip of the
spring to extend through the bottom side of
the stationary plate. Using the 1/8” pin
provided and a hammer, drive the spring
until the large coil diameter bottoms out
against the disc.
Reassemble the disc pack with the
stationary discs in the proper arrangement
Figure 5C
shown in Figure 5C.

3
 TORQUE ADJUSTMENT
TABLE A
Torque Adjustment
Nominal Original Maximum % Torque
Brake is factory set for nominal rated static 11 11 Static Spring Counter- Reduction
torque which is maximum torque. Torque Torque Height clockwise per
may be decreased up to 50% for increased (lb-ft) (inches) Turns Turn
stopping times up to 2 second stop time. 1-1/2 1.56” - -
The torque on the 1-1/2 lb-ft brake may not 3 1.50”
be reduced. 10 10 6 1.50”
Turn both spring adjustment screws (11), 10 1.56” 5-1/2 9%
Figure 6, equal amounts counterclockwise 15 1.56”
to decrease torque. See Table A for torque Figure 6 20 1.56”
reduction permissible amounts. 25 1.50”

COIL FAILURE
SUPPLY VOLTAGE CAUSE
Line voltage >110% of coil rating
AC input on a DC coil
Excessive voltage drop during
inrush time
WIRING CAUSE
Leadwires interfering with plunger Reroute wiring away from plunger
pull-in
Excessive voltage drop during
inrush time
Coil leadwire shorted to ground
TROUBLESHOOTING
SUPPLY VOLTAGE CORRECTION
Reduce voltage or replace with
proper rated coil
Replace rectifier or replace with
proper rated coil.
Increase current rating of power
supply.
WIRING CORRECTION
and other moving components.
Increase leadwires size from power
supply
Replace coil or leadwire and protect
with wire sleeving
EXCESSIVE WEAR / OVERHEATING
AIR GAP CAUSE AIR GAP CORRECTION
Low solenoid air gap Reset air gap (refer to Air Gap
Adjustment)
Disc pack dragging Inspect endplate, hub and discs for
dirt, burrs, wiring and other sources
of interference preventing disc “float”
CYCLE RATE CAUSE CYCLE RATE CORRECTION
Brake “jogging” exceeding coil Reduce cycle rate or consider
cycle rate alternate control method
Reduce cycle rate, use alternate
Thermal capacity is being
control method or increase brake
exceeded
size
ALIGNMENT CAUSE ALIGNMENT CORRECTION
Broke endplate not concentric to Motor register must be within
motor C-Face .004” on concentricity.

SOLENOID ASSEMBLY
SOLENOID ASSEMBLY CAUSE Motor shaft runout is excessive Must be within .002”; runout;
CORRECTION
consult motor manufacturer
Plunger not seating flush against Loosen solenoid mounting screws
solenoid frame and reposition frame to allow full Brake is being operated on a Vertical separator springs must be
face contact incline greater than 15° above or used to prevent discs from
below horizontal becoming cocked
Plunger cocked in coil preventing Realign solenoid frame
pull-in WORN PARTS CAUSE WORN PARTS CORRECTION
Excessive solenoid/plunger wear Replace solenoid assembly Friction disc excessively worn Replace friction discs.
at mating surface (disc can wear to 1/2 original
thickness or .093”)
Broken shading coils Replace solenoid assembly
Endplate, stationary disc or Replace warped or worn component
WORN PARTS CAUSE WORN PARTS CORRECTION pressure plate warped
Excessive wear of solenoid link Replace link arm and link bolt; also Linkages and/or pivot pins worn Replace all worn components
arm and/or shoulder bolt inspect plunger thru-hole for
Motor shaft endfloat excessive Endfloat must not exceed .020”;
elongation
consult motor manufacturer
Plunger guides worn down and Replace guides
HUB CAUSE HUB CORRECTION
interfering with plunger
movement Burr on hub interfering with disc File off burr
“float”
APPLICATION CAUSE APPLICATION CORRECTION
Machinery cycle rate is exceeding Reduce brake cycle rate or use Set screw backed out and Retighten set screw; use Loctite®
brake rating alternate control method interfering with disc 242 to help secure
High ambient temperature Use Class H rated coil and /or find MISCELLANEOUS MISCELLANEOUS
(>110%) and thermal load alternate method of cooling brake Solenoid plunger not pulling Check line voltage (±10% of
exceeding coil insulation rating completely nameplate rating) or replace worn
Brake coil wired with windings of Wire coil to dedicated power source solenoid assembly
an Inverter motor or other with instantaneous coil rated voltage Wiring is restricting disc pack Reroute wiring
voltage/current limiting device movement
MISCELLANEOUS CAUSE MISCELLANEOUS CORRECTION Excessive stop time Increase brake size/torque or use
Replace with proper spring or refer (2 seconds or greater) alternate control method
Wrong or over tightened torque
to Installation section for proper
High Ambient temperature Reduce cycle rate or use alternate
spring height
(in excess of 110°F) method of cooling
Excessive air gap Reset, refer to Installation Section 4
Rexnord Industries, LLC., Stearns Division, 5150 S. International Dr., Cudahy, WI 53110, (414) 272-1100 Fax: (414) 277-4364 www.rexnord.com