table of contents - wildeck

TABLE OF CONTENTS SAFETY…………………………………………………………………………………… 1 Electrical Safety Precautions EQUIPMENT ARRIVAL & UNPACKING………………………………………………. 2 EQUIPMENT OVERVIEW………………………………………………………………. 3 Equipment Components PRE-INSTALLATION CHECKLIST…………………………………………………….. 5 INSPECTION OF SITE………………………………………………………………….. 6 Tools Required for VRC Installation INSTALLATION OVERVIEW…………………………………………………………… 7 INSTALLATION INSTRUCTIONS……………………………………………………… 8 PROXIMITY SENSOR ARRANGEMENT……………………………………………... 13 STARTUP CHECKLIST………………………….……………………………………… 15 OPERATING INSTRUCTIONS…………………………………………………………. 16

APPENDIX CARRIAGE LEVELING ADJUSTMENTS……………………………………………... A1 SERVICE/MAINTENANCE……………………………………………………………… A3 LIFTING CHAIN MAINTENANCE……………………………………………………… A4 MAINTENANCE SCHEDULE…………………………………………………………... A5 BRAKE AIR GAP ADJUSTMENT……………..……………………………………….. A6 INVERTER LONG-TERM STORAGE…………………………………………………. A11 POWER-STUD+ INSTALLATION SPECIFICATIONS……………………………….. A12 TROUBLE SHOOTING………………………………………………………………….. A14 SPARE PARTS DRAWINGS…………………………………………………………… B ELECTRICAL…………………………………………………………………………...... C

1

SAFETY To ensure your safety and the safety of those around you, it is important that you read, understand and follow all the safety precautions. Safety precautions in this manual are labeled DANGER, WARNING or CAUTION.

DANGER HIGH VOLTAGE. Failure to follow proper procedures when performing electrical installation or service may result in serious injury or death.

DANGER DO NOT ride this equipment. Riding may result in injury or death. VRCs are NOT elevators.

DANGER DO NOT walk or work under a raised platform.

DANGER Where applicable, if you can open a gate when the unit is not at that level or the unit will operate with the gate open, a safety device is not working and could result in serious injury or death.

CAUTION DO NOT exceed rated capacity.

ELECTRICAL SAFETY PRECAUTIONS

DANGER Always assume that a circuit is not safe until you are sure that it is dead. Make sure that it cannot be energized after you start working on it. Follow OSHA procedures for locking out the control panel anytime maintenance or service is being performed on the unit. Put a lock and tag on disconnects, breakers and/or pulled fuses per OSHA requirements. Safety precautions when working on live circuits or equipment: When electrical repair or maintenance work is required that prohibits de-energizing the circuits, extreme measures of safety must be used. The work should be accomplished only by well-supervised personnel who are fully aware of the dangers involved. Every care should be taken to protect the person performing the work and to use all practical safety measures, such as correct PPE (Personal Protection Equipment).

2

EQUIPMENT ARRIVAL AND UNPACKING A fork truck with a minimum lifting capacity of 2000 lb. (or alternative) will be required to off-load the delivery truck. Material is typically delivered on a flatbed trailer. Verify the number of items on the Bill of Lading agrees with the number of items delivered. Check all pieces to determine if damage has occurred during transit. The carrier agent is responsible for, and should be notified immediately of any visible damage that has occurred. If damaged, the shipment must be signed for as such. All hidden damage must be reported directly to the freight carrier. Contact Wildeck, Inc. immediately if new components need to be sent out to replace the damaged components. Completion time of the installation may be affected by the delivery of the new components. Wildeck warranty does not cover lost time and/or additional trips due to damaged components. Carefully unpack the VRC. Identify and match all parts with the parts list provided with the shipment. Each component is tagged. Call Wildeck, Inc. if any parts are missing or not specified on the parts list. Do not proceed with installation until all parts and quantities are accounted for and are accurate.

3

EQUIPMENT OVERVIEW General Operation The VRC is designed for the movement of freight only and is not intended for riders/passengers. The carriage is guided between two main vertical support columns and is raised and lowered via roller chain and sprockets driven by a drive assembly. EQUIPMENT COMPONENTS NOTE: see next page for component location. Carriage The carriage is the moveable platform where material is loaded for transport between levels. A roller conveyor is typically mounted to the carriage for transferring material to and from conveyor levels. Guide Columns The guide columns consist of high strength steel tubing used to support and guide the carriage during operation. Slides The slides are made of high performance plastic that guide the carriage within the guide columns. Drive Assembly The drive assembly consists of lifting chain and sprockets attached to a common drive shaft driven by a gearmotor assembly. The gearmotor assembly consists of a gearbox and an electric brakemotor. The gearbox decreases the motor’s output speed while increasing the motor’s output torque.

Chain Tensioners Each lifting chain is attached to the carriage through a spring-loaded chain tensioner. The tensioners keep the chain tight and in the event of slack or broken chain shut down the unit through the detection of proximity sensors. Safety Enclosures Where applicable, enclosures and tunnels are located around all access points of the carriage to provide protection from inadvertent contact with the moving equipment. The enclosures surround the VRC unit on the non-operating sides while the tunnels provide protection on the operating sides. Carriage Positioning The carriage stops at a level when the floor level proximity sensor detects the carriage has arrived at that level. The brakemotor stops and holds the carriage in position until the system controls call it to another level. An overtravel proximity sensor is provided and is present in the event the upper floor level sensor fails or malfunctions stopping the unit immediately, preventing it from running into the drive assembly. For high speed applications (typically greater than 40 fpm), deceleration sensors are provided at each level to reduce the carriage speed prior to reaching its destination. Control Panel When provided by Wildeck, Inc., the remotely mounted control panel contains the transformer and other components required for lift operation.

4

Guide Column, LH

NOTE: see pages 13 and 14 forproper prox. sensor arrangement.

Slack Chain Tensioners(located at base of columns)

General Location of Components

Drive Assembly

Support Braces Brace Crossmember

Guide Column, RH

Carriage Slides

Carriage

Carriage Chain Tensionerswith Sensors

5

PRE-INSTALLATION CHECKLIST A pre-installation visit is recommended and considered to be included in the responsibility of the mechanical installer. Mechanical Installer Responsibilities - Complete mechanical erection of the

equipment as sold by Wildeck, Inc., called out on the general arrangement drawing and in accordance with all instructions within this manual.

- Return trip upon completion of the

electrical installation for final checkout, adjustments and training.

Customer Responsibilities - Unloading and transportation of the

equipment to the installation area, unless coordinated with mechanical installer.

- If unit requires storage, consult

Wildeck, Inc. for storage procedures required to keep warranty in effect.

- All necessary site work to prepare for

the installation such as pit, floor opening, adequate bracing locations and shaftway openings.

- Any site/building modifications

necessary to get the equipment to the installation area.

- Adequate pick point or lifting

mechanism capable of lifting the heaviest load. If weight of load is in question, please contact Wildeck, Inc.

If you have any questions or concerns, please contact Wildeck, Inc. prior to start of work. □ Can the equipment pass through all

doorways, hallways, etc.? □ Can you use the customer’s fork

truck? Is the truck’s capacity sufficient?

□ Is there a pick point capable of lifting the necessary components?

□ Are safety meetings required? □ Are there any work procedure/safety

guidelines particular to the job site? □ What hours are you allowed to work

on site? □ Who is the authorized site contact? □ Is this a union or non-union site? □ Bracing requirements - will additional

materials be required? □ Is welding permitted? Is a “hot

permit” required? Is a fire watch required?

□ Special welding requirements if you have special coatings, i.e. hot galvanized, etc.

□ Is temporary power available near the installation area?

□ Do you have a well-lit area to work in?

□ Is the installation area ready (pit complete, floor opening cut and/or finished, etc.)?

□ Are shaftway openings complete? □ Are there any discrepancies between

the site dimensions/application and the Wildeck general arrangement drawing? Had this information been provided to Wildeck?

□ Will customer doors and/or shaftway openings be completed prior to your arrival?

□ Will other trades or in-plant production cause conflict with your proposed work schedule?

6

INSPECTION OF SITE - Compare the dimensions as called

out on the general arrangement drawing to the actual site conditions. Report any discrepancies to Wildeck immediately.

- Some areas to look for that could be

a problem include: - pit size and/or out of square - overhead clearance - floor-to-floor clearance - floor opening size and/or out of square - proper alignment of floor opening and pit

- Check for any protrusions that could

interfere with either the installation or operation of the VRC.

TOOLS REQUIRED FOR VRC INSTALLATION The following is a list of tools Wildeck considers necessary to install a VRC in a professional and expedient manner. Individual sites and applications may require additional items as needed. If you have any questions regarding these items, contact Wildeck, Inc. - 2000 lb. capacity fork truck or

alternative - Chain fall (2000 lb. capacity

minimum) or Come-A-Long - Cables or hook chain with 2000 lb. or

greater capacity - “C” clamps - Drift pin

- Carpenter’s square - 4 ft. level - Socket set – sockets to 1 ½” - Hammer drill and bits - Hack saw, reciprocating saw or

portable band saw - Drill and bits - Extension cords - Portable light - Sledge hammer - Allen wrenches - Open or box end wrenches to 1 ½” - Chalk line - Plumb bob - Grease gun - 25 ft. measuring tape - Rags Optional Tools - Welding machine and equipment

(helmet, rods, gloves, etc.)

- Cutting torch with full tanks - Disc grinder - Fire extinguisher

7

INSTALLATION OVERVIEW There are two methods of installing a Wildeck, Inc. XpressLift™ VRC. Either method is recommended and equally efficient. Please review the following outline of each method as related to the skill and preference of the installers, availability of necessary installation tools and equipment and working space available. Method 1

1. Review the General Arrangement drawing for position and layout of VRC unit.

2. Make accurate measurements of

the position of the VRC at all levels and mark floor(s) as necessary.

3. Position the carriage at the ground floor according to the General Arrangement drawing.

4. Raise guide columns into position on either side of carriage.

5. Hoist and bolt drive assembly into position on top of columns.

6. Measure columns for proper placement and plumb accuracy.

7. Secure columns to floor.

8. Re-check measurements and plumb accuracy, proceed with bracing and final adjustments.

Method 2 This method will be used when site conditions provide ample working space near the installation site to assemble VRC unit on the floor or when unit is shipped assembled from the factory.

1. Assemble VRC unit on floor (horizontally) per Method 1.

2. Temporarily secure carriage and columns.

3. Hoist VRC unit into position as complete unit.

4. Re-check measurements and plumb accuracy before securing to floor then proceed with bracing and final adjustments.

NOTES: A. The VRC unit can be assembled

on top of saw horses if deemed helpful for assembly and hoisting of complete unit.

B. Electrical work is required on site

when VRC unit is shipped assembled from the factory.

The following pages provide step by step instructions for installation of the VRC unit using Method 1.

8

INSTALLATION INSTRUCTIONS Prior to installing a Wildeck, Inc. VRC carefully unpack the unit and match all components to the parts list. Contact Wildeck, Inc. (Phone: 800-325-6939) immediately if any components are missing, damaged or not specified by the parts list. Do not proceed with installation until all components are accounted for. Wildeck, Inc. provides a General Arrangement drawing that includes specific dimensions to insure proper VRC installation and operation. Throughout the rest of these installation instructions the General Arrangement drawing will be referred to as GA drawing.

1. Review GA drawing for position and layout of the VRC.

2. Make accurate measurements of the position of the VRC at all levels and mark floor(s) as necessary.

NOTE: all floor mounted conveyors are to be aligned and plumb with one another. If not do not proceed with VRC installation until conveyors have been repositioned accordingly.

3. If conveyor hasn’t already been installed onto carriage, do so before proceeding with the following steps. Refer to GA drawing for position of conveyor.

4. Position carriage assembly at lower floor aligned with the floor mounted conveyor leaving gap between conveyors as called out on the GA drawing. Block up carriage so it is level and sitting a few feet off the floor.

IMPORTANT

Alignment and spacing between carriage mounted conveyor and floor mounted conveyor are critical.

5. Hoist right hand guide column into position alongside the carriage.

WARNING

It is the responsibility of the installer to properly lift and secure components in a safe manner.

6. Position guide column alongside carriage so upper and lower slides on carriage upright are located between column tubes. There shall be 1/8” gap between flange of slides and column as shown in Figures 1a & 1b.

Figure 1a

9

Figure 1b

WARNING The carriage alone will not support the guide columns. Make sure raised columns are always supported and held in place throughout the installation process.

7. Plumb guide column and verify distance between upper floor edge(s) and guide column (see Figure 2) match dimension called out on the GA drawing.

Figure 2

8. Clamp support brace to mounting angles on guide column as shown in Figure 3 making sure brace is level and end pad is firmly positioned against floor structure.

9. Drill Ø9/16” holes through brace and mounting angles and drill proper size and depth of holes into floor structure.

Figure 3

10. Secure support brace to guide

column and floor structure using supplied hardware. Leave hardware snug tight until drive assembly has been properly installed.

NOTE: if welding is permitted, braces can be welded into place rather than bolted. Temporarily tack weld braces in place until drive assembly has been properly installed then fully weld braces (full penetration welds), use minimum E70 electrode material, low hydrogen.

10

11. Repeat steps 5 – 10 for installation of the left hand guide column.

12. Clamp crossmember to support

braces (end furthest from floor) leaving a minimum of 3” gap between guide column and crossmember (see Figure 4). It is critical to ensure spacing between columns (see Figure 5) is as called out on the GA drawing.

Figure 4

13. Drill Ø9/16” holes through support braces and secure crossmember(s) to support braces using supplied 1/2" hardware. Leave bolts snug tight until drive assembly has been installed. Repeat at all upper levels.

14. Hoist drive assembly on top of guide columns and secure using supplied 3/8” hardware. Refer to the GA drawing for orientation.

15. Before tightening all hardware, double check distances between guide columns (see Figure 5) and guide columns to floor edge (see Figure 2) match dimensions called out on the GA drawing (top to bottom).

16. Anchor guide columns to floor per anchor installation instructions in Appendix A12 & A13.

Figure 5

17. Temporarily remove chain jump

blocks from the drive assembly to allow room to install lifting chain onto sprockets (see Figure 6).

Figure 6

11

18. Drape lifting chain over sprockets located on drive assembly. String one end of chain down inside rear column tube and other end to hang down between column tubes allowing enough chain to attach to carriage assembly.

19. Before attaching chain to carriage check that there are an equal number of links between sprocket and carriage on each strand of chain.

20. Attach chain to carriage connection blocks using supplied connecting links (see Figure 7). Refer to Appendix A1 for further detail on attaching chain.

Figure 7

21. String lifting chain through rear

column tubes, around tensioner idler sprockets at the base of guide columns and attach to carriage connection tabs with supplied connecting links (see Figures 8a & 8b).

Figure 8a

Figure 8b

22. Lifting chain are sent long and

must be cut to length. Measure and cut chain so that:

□ Chain shall not be slack □ Chain shall not rub against

column tubes □ Lower tensioners shall not be

positioned more than 45° from vertical when chain are properly installed (see Figure 9 on next page)

12

Figure 9

23. Remove blocking from underneath carriage so carriage assembly is hanging from the lifting chain.

24. Make necessary carriage leveling

adjustments according to Appendix A1 and A2.

25. After carriage is level, reinstall chain jump blocks onto drive assembly so that there is 1/8” to 1/4” gap between chain and jump block.

26. Attach wire carrier to mounting

bracket on guide column using supplied hardware (see Figure 10).

Figure 10 NOTE: typically the carriage assembly is sent with the wire carrier attached.

27. At this point all required electrical

work shall be performed.

NOTE: refer to pages 13 & 14 for proper setup of proximity sensors. NOTE: route low voltage wiring through wire duct (mounted on guide column) to VRC control panel. High voltage wiring must be routed through the appropriate conduit, refer to the local electrical codes.

13

Proximity Sensor Arrangement All VRC units are equipped with floor level sensors to properly position the carriage at each level and an overtravel sensor in case of sensor malfunction. High speed applications (typically greater than 40 fpm) are also equipped with deceleration sensors at each level to reduce carriage travel speed prior to stopping at the floor level sensor. The distance between the deceleration and floor level sensors shall be the required deceleration distance, typical all levels. Initial Prox. Sensor Setup Position each floor level sensor so carriage stops when carriage mounted conveyor is even with floor mounted conveyor. Position deceleration sensors at the maximum distance (top of unistrut for bottom level and bottom of unistrut for top level) before running the unit in high speed the first time. Then reposition deceleration sensors so unit only runs in ‘Jog’ speed for 1/2 second before turning on the floor level sensor. (see Figures 11 & 12) VRC units with more than 2 levels require the intermediate levels to have floor level sensors for each direction of travel (up and down). High speed applications will also have deceleration sensors for each direction of travel. (see Figure 13 on next page)

Figure 11

Figure 12

14

Figure 13 Proximity sensors will not function properly if the sensors are positioned too close together. Sensors can be set no closer than 1-5/8” from each other (see Figure 14).

Figure 14

15

STARTUP CHECKLIST □ Check that the VRC is properly

braced from front to back and from side to side.

□ Touch up all welds, marks, scrapes,

etc. with paint. □ Make sure that all electrical

connections are properly made. □ Verify all sensors are positioned

within ½” to 1” from flag (see Figure 15)

Figure 15 □ Ensure all proximity sensors are

functioning properly: Green LED on = power on Amber LED on = flag detected NOTE: it is common that the carriage travels past the floor level sensors by a few inches in high speed applications. This distance will stay constant; if this distance varies as the VRC cycles inspect for possible causes, such as a misaligned deceleration sensor.

□ Ensure teeth on tensioner idler sprockets are properly meshing with the lifting chain, add or remove shims as necessary (see Figure 16).

Figure 16 □ Check that the unit stops level with

each floor conveyor. □ Check for excessive noise during

operation. □ Check if carriage “rocks” during

operation. □ Do a full load test. □ Are there any unsafe conditions that

exist? Contact Wildeck, Inc. immediately.

□ Post all operational signs. □ Remove all debris. □ Instruct the customer on the proper

operation. □ Instruct the customer on procedures

for when a problem occurs.

16

OPERATING INSTRUCTIONS Before operating the lift, please read, understand and follow all the safety precautions listed below.

DANGER DO NOT ride this equipment. Riding may result in serious injury or death! VRCs are NOT elevators.

DANGER DO NOT walk or work under a raised platform.

WARNING Only trained persons shall be permitted to operate or maintain this equipment. Improper operation or maintenance may cause serious injury or death!

WARNING If at any time proper operation or performance of the equipment is in question, DO NOT use it. Notify your supervisor or the proper maintenance people immediately.

CAUTION DO NOT allow loads to overhang the sides of the carriage. This will result in damage to the equipment and material.

CAUTION DO NOT exceed the rated capacity.

TO OPERATE: (when VRC controls are provided by Wildeck, Inc.) - Verify all personnel and obstructions

are clear of the unit. - Verify power is on

Automatic Mode - When switched to automatic mode

the main system controls will take over signaling the VRC controls when to call/send the carriage to designated levels.

Maintenance Mode - When switched to ‘Jog’ mode the

main system controls no longer control the VRC unit. Manual operation of the carriage and carriage conveyor are controlled through switches/buttons on the front of the control panel.

- If an emergency occurs push the EMERGENCY STOP button. The button will keep the lift inoperative until the button is pulled back out.

17

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APPENDIX A

A1

Procedure for leveling carriage side-to-side 1. Connect lifting chains to bottom hole on outer flanges of connection blocks. 2. If carriage is unlevel side-to-side by 1/2" or more then the chain on the lower side of the carriage needs to be lifted over sprocket by a tooth or more. 3. If carriage is unlevel side-to-side by less than 1/2" then move the chain connection up to next hole on the connection blocks. Start by moving chain connection on higher side of carriage, alternate as necessary.

CARRIAGE LEVELING ADJUSTMENTS(side to side)

Right SideChain attachedto outer flangewith 3 holesLeft Side

Chain attachedto outer flangewith 2 holes

A2

Procedure for leveling carriage front-to-back Note: leveling blocks are located on inside of uprights andsecured into place using longer 3/8" bolts from upper slides. 1. Thread jackscrew into leveling block with head of jackscrew toward front of carriage. 2. Thread jam nut onto jackscrew between leveling block and rear upright flange. 3. Turn jackscrew clockwise until jackscrew presses against rear upright flange. Jackscrew must contact rear upright flange. 4. If necessary to level carriage, continue to turn jackscrew clockwise to tilt front of carriage up. 5. Thread jam nut up against leveling block to lock into place. Do not leave jam nut loose.

CARRIAGE LEVELING ADJUSTMENTS(front to back)

Jam Nut

Leveling Block Jackscrew

A3

SERVICE/MAINTENANCE MAINTENANCE CHECK

1. Motor – Check that the cooling fins on the motor and area through which air is drawn into the fan guard on the back of the motor are kept clean.

2. Motor – Check that the fan is

operating properly, make an audible check. If a blower is supplied check that it is turning on and off properly.

3. Brake – Check that the brake is holding the fully loaded carriage in position at each level.

4. Gearbox – Check gear lube temperatures; excessive gear lube temperatures reduce the life of the lube and gearbox components.

5. Drive Components – Inspect lifting chain for wear or breaking, kinking and excessive corrosion. Be sure connections are tight and sprockets (including idler sprockets at base of each guide column) are not worn or damaged. Make an audible check on the flange bearings on either end of the drive shaft.

6. Proximity Sensors – Make sure all sensors are properly secured and have proper clearance between moving carriage and sensors. Nothing shall contact the sensors.

A4

LIFTING CHAIN MAINTENANCE The use of high quality non-detergent oils are recommended. Oil should be applied between the link plates to lubricate the pin/bushing bearing area and between the roller edges and roller link plates to lubricate the roller/bushing bearing area.

Recommended Oil Viscosity vs Operating Temperature GRADE TEMPERATURE SAE 10 -20°F to 80°F (-29°C to 27°C) SAE 20 10°F to 110°F (-12°C to 43°C) SAE 30 20°F to 130°F (-7°C to 54°C) SAE 40 30°F to 140°F (-1°C to 60°C) SAE 50 40°F to 150°F (4°C to 65°C)

Manual Lubrication

DANGER Manual lubrication is to be applied only when the VRC is stopped and power to the VRC is off and locked out. If there is an automated chain lubrication system on the VRC unit then manual lubrication is not required. Oil can be applied with a brush or oil spout can. The amount of oil should be sufficient to prevent a red rust discoloration of the oil. The discoloration suggests that additional oil applied more frequently is required. If this occurs the chain should be cleaned and re-lubricated prior to further use. NOTE: see Maintenance Schedule for frequency of lubrication. Drip Lubrication (where applicable) The rate at which the oil is applied should be sufficient to prevent red rust discoloration of the oil. Adjust drip rate accordingly. Care should be taken to prevent wind from misdirecting the drops. Oil levels should be checked periodically to assure that the reservoir is not dry.

DRIVESYSTEMS

MOTOR BRAKESINSTALLATION & MAINTENANCE

RETAIN FOR FUTURE USE

General Instructions

This manual describes general operating and maintenance guidelines for a majority of brake products shipped by NORD Gear. This instruction manual is not intended to include a comprehensive listing of all details or procedures required for installation, operation and maintenance.

Brakes covered in this manual are manufactured by PRECIMA. Please feel free to contact NORD with any questions about the supplied brake components.

Safety Notice

Only qualifi ed personnel should attempt installation, opera-tion and maintenance of NORD brakes. Read this manual in its entirety before operating, commissioning, servicing, or as-sembling the motor brake. If you have a question about a procedure or are uncertain about any detail, seek clarifi ca-tion and DO NOT PROCEED!

WARNING

• This equipment contains high electrical voltage. Remove and lockout all power from the electric motor and brake before any work is completed on the brake.

• The user is responsible for conforming to all national and local electrical and safety codes. Wiring practices, proper grounding, disconnects, and over current protection, are of particular importance.

• Make certain the load is supported when servicing the brake. Removing power from the brake or removing the brake from the motor will release the load, which may cause severe injury or death.

• Failure to follow proper procedures and precautions may result in severe bodily injury or death.

Motor Brake

The standard NORD motor brake is “spring-set”. When pow-er is removed and the brake is de-energized (power-off), the brake springs exert a force against the armature plate in turn preventing the brake rotor (or brake disc) from rotat-ing. When the brake coil is energized (power-on), a magnetic fi eld builds and pulls the armature plate across the air gap to the brake casing, which releases the brake rotor and allows the motor shaft to rotate.

Figure 1: Basic Brake Operation

NORD brakes are DC voltage brakes and in most instances are supplied with a motor mounted brake rectifi er for easy connections to AC power. AC power is taken directly from the power line or from the terminal block of the motor and converted to DC by the supplied rectifi er.

IMPORTANT NOTEIf the motor is connected to a frequency inverter, soft start, or is a two-speed motor, the AC power must be supplied to the brake rectifi er separately from the motor power.

• Each NORD motor frame size has a number of brake sizes available, with different torque capacities.

• Brake torque adjustments are possible by changing the brake spring combinations. In addition, brake sizes from 5-40 Nm (3.7-30 lb-ft) are typically supplied with an additional spanner-nut adjustment on the back of the brake.

• NORD brakes provide a high degree of safety because when power is removed the brake will automatically set to hold the load.

• The brake rotor or brake disc is environmentally safe and asbestos-free.

• The connection between the rectifi er and the brake coil is completed at the factory and the brake air-gap is factory- set but can be adjusted in the event of wear.

U35000 - 1 of 16

www.nord.com/docs02.11.13

NORD Gear CorporationToll Free in the United States: 888.314.6673

NORD Gear LimitedToll Free in Canada: 800.668.4378

DRIVESYSTEMS


RETAIN FOR FUTURE USE U35000 - 4 of 16




BRAKE SIZE: BRE 5 BRAKE TORQUE: 5 Nm (3.7 lb-ft) max. BRAKE SIZE: BRE 10 BRAKE TORQUE: 10 Nm (7.4 lb-ft) max.NORD Brake P/N

Half-Wave Full-Wave PC VC IC RC NORD Brake P/N

Half-Wave Full-Wave PC VC IC RC

[VAC] [AAC] [VAC] [AAC] [W] [VDC] [ADC] [Ω] [VAC] [AAC] [VAC] [AAC] [W] [VDC] [ADC] [Ω]19010212 - - - - 22 24 0.92 26.0 19020222 - - - - 28 24 1.17 20.619010912 230 0.09 115 0.19 22 105 0.21 500 19020922 230 0.14 115 0.28 33 105 0.32 33219011902 400 0.05 200 0.11 22 180 0.12 1475 19021902 400 0.07 200 0.15 29 180 0.16 110019011912 460 0.05 230 0.10 22 205 0.11 1900 19021922 460 0.06 230 0.11 26 205 0.13 162019012212 500 0.04 250 0.08 21 225 0.09 2450 19022222 500 0.06 250 0.12 30 225 0.13 170019012512 575 0.04 - - 22 250 0.09 2850 19022522 575 0.05 - - 27 250 0.11 2323

BRAKE SIZE: BRE20 BRAKE TORQUE: 20 Nm (15 lb-ft) max. BRAKE SIZE: BRE40 BRAKE TORQUE: 40 Nm (30 lb-ft) max.NORD Brake P/N




BRAKE SIZE: BRE 60 BRAKE TORQUE: 60 Nm (44 lb-ft) max. BRAKE SIZE: BRE 100 BRAKE TORQUE: 100 Nm (74 lb-ft) max.NORD Brake P/N




BRAKE SIZE: BRE 150 BRAKE TORQUE: 150 Nm (110 lb-ft) max. BRAKE SIZE: BRE 250 BRAKE TORQUE: 250 Nm (185 lb-ft) max.NORD Brake P/N




BRAKE SIZE: BRE 400 BRAKE TORQUE: 400 Nm (295 lb-ft) max. BRAKE SIZE: BRE 800 BRAKE TORQUE: 800 Nm (590 lb-ft) max. NORD Brake P/N



[VAC] [AAC] [VAC] [AAC] [W] [VDC] [ADC] [Ω] [VAC] [AAC] [VAC] [AAC] [W] [VDC] [ADC] [Ω]19092252 - - - - 144 24 6.00 4.0 19094252 - - - - 144 24 6.00 4.019092952 230 0.62 115 1.24 145 105 1.38 76 19094952 230 0.62 - - 145 105 1.38 7619093902 400 0.35 200 0.70 141 180 0.78 230 19095902 400 0.27 - - 108 180 0.60 30019093952 460 0.31 230 0.62 140 205 0.68 300 19095902 460 0.31 - - 140 205 0.68 30019093962 500 0.29 250 0.57 143 225 0.63 355 19095962 500 0.29 - - 143 225 0.63 35519093972 575 0.26 - - 142 250 0.57 440

BRAKE SIZE: BRE 1200 BRAKE TORQUE: 1200 Nm (885 lb-ft) max.

IMPORTANT NOTE NORD Brake P/N


[VAC] [AAC] [VAC] [AAC] [W] [VDC] [ADC] [Ω] The PMG500 rectifi er is required when utilizing the larger 800 Nm (590 lb-ft) - and 1200 Nm (885 lb-ft) twin-rotor brakes. In order to prevent rapid wear, NORD recommends using the PMG500 rectifi er to “overexcite” the brake during its release. The brake coil should be sized utilizing the PMG rectifi er like a half-wave rectifi er.

19099802 230 0.62 - - 145 105 1.38 7619099902 400 0.27 - - 108 180 0.60 30019099902 460 0.31 - - 140 205 0.68 300

Half-Wave [VAC] = AC supply voltage with half-wave rectifi er Pc [W] = Power to brake coil

Half-Wave [AAC] = AC supply current to half-wave rectifi er Vc [VDC] = DC brake coil voltage (range -30% to +10%)

Full-Wave [VAC] = DC supply voltage with full-wave rectifi er Ic [ADC] = DC current top brake coil

Full-Wave [AAC] = AC supply current to full-wave rectifi er Rc [V] = Brake coil resistance (±5%)

When used as a stopping brake, evaluation of brake work is essential. Brake coil data based upon ambient conditions of 20°C (68°F).

Designed as a holding brake or emergency stop brake only.

DRIVESYSTEMS






General Maintenance

Brake Air Gap

In order to obtain optimal brake performance and maximum brake life, it is necessary to periodically check and reset the brake air gap. As the brake rotor wears and decreases in thickness, the air gap will increase. If the air gap is too large, the brake coil may not have enough magnetic force to pull the metal armature disc across the gap and the brake will drag.

IMPORTANT NOTEWhen a complete brake motor is supplied by NORD, the air gap is already set at the factory. If the brake is ordered as a part, the air gap must be set in the fi eld. All brake air gap adjustments must be made with the brake assembled onto the motor and power off (brake engaged).

Hand Release Lever (HL)

It is common to supply the NORD brake with a hand release lever assembly. The hand release lever allows the brake to be manually released without requiring that the brake be ener-gized with voltage. The lever has a spring return that allows the brake to be hand released and returned automatically to its set position. The handle of the hand release lever can be unscrewed for easy removal.

Figure 4

IMPORTANT NOTEWhen a brake motor with hand-lever is supplied by NORD, both the hand lever air gap and brake air gap are set at the factory. When ordered as parts, proper hand-lever and air gap adjustments must be made in the fi eld. Hand-lever adjustments must always be made prior to assembling the brake to the motor. All brake air gap adjustments must be made with the brake assembled to the motor and the power off (brake engaged).

Brake Hand-Lever Installation and Adjustment

Figure 5

Direction ofhand release

Hand lever

Brake Housing

Bolt

Washer

Spring

Pins

y

Hand Lever Air Gap

1. Place the hand-lever over the brake housing (as shown) and align the pins.

2. Screw the bolts with washer and spring into the pins.

3. Using a feeler gage, adjust the hand-lever air gap per Table 5.

Table 5: Hand-Lever Air Gap Setting

BrakeSize

Dimension “y” BrakeSize

Dimension “y” [mm] [in] [mm] [in]

BRE 5 1 0.040 BRE 100 1.2 0.047BRE 10 1 0.040 BRE 150 1.2 0.047BRE 20 1 0.040 BRE 250 1.5 0.059BRE 40 1 0.040 BRE 400 1.5 0.059BRE 60 1 0.040 BRE 800 1.5 0.059

BRE 1200 1.5 0.059

IMPORTANT NOTEWhen setting the hand-lever gap or dimension “y” the magnetic brake coil housing and the anchor plate must be kept uniform all around.

WARNING

• To assure proper assembly and proper functioning of the brake, the hand-lever must be assembled to the brake, and the hand-lever air gap must be adjusted, before the brake is assembled to the motor.

• Once adjusted properly, the hand-lever air gap setting should not be altered, even when readjusting the air gap setting.

Tolerance: + 0.008 in [+ 0.2 mm]

DRIVESYSTEMS






Setting the Brake Air Gap

NORD spring-loaded brakes are virtually maintenance free. However, the air-gap of the brake rotor or brake disc must be periodically checked and adjusted. If necessary, the worn brake rotor must be replaced. Table 6 serves as guide to check and set the brake air gap as needed.

IMPORTANT NOTEWhen a complete brake motor is supplied by NORD, the air gap is already set at the factory. If the brake is ordered as a part, the air gap must be set in the fi eld. All brake air gap adjustments must be made with the brake assembled to the motor and the power off (brake engaged).

The brake air gap is checked by placing a feeler gage be-tween metal anchor plate and the brake coil housing as shown in Figure 6. This procedure is identical even for the larger BRE800 and BRE1200 twin rotor brakes.

Figure 6 – Setting the Brake Air Gap

MOTOREND SHIELD

MOTOREND SHIELD

FIXINGSCREW

SETTING BOLT(HOLLOW SCREW)

COILHOUSING

METALANCHOR PLATE

ARMATUREPLATE

BRAKEROTOR

AIR GAP

AIR GAP

BRAKEHUB

X

Procedure

1. Loosen the fi xing screws that attach the brake to the motor’s end-shield by approximately half a turn.

2. If required, the brake assembly may be loosened slightly from the motor’s end shield by turning the threaded setting bolts (hollow screws) that surround the fi xing screws, counter clockwise, into the brake coil housing.

3. Depending upon whether or not the air gap needs to be decreased or increased, turn the fi xing screws accordingly until the desired nominal air gap (Table 6) is reached, as measured using the appropriate feeler gauge.

• Turning the fi xing screws clockwise allows the brake coil housing to be moved towards the anchor plate and reduces the air gap.

• Turning the fi xing screws counter-clockwise allows the brake coil housing to be moved away from the anchor plate and increases the air gap.

4. If the setting bolts (hollow screws) were adjusted as suggested in Step 2, re-secure the brake coil housing fi rmly against the motor’s end shield by turning the setting bolts (hollow screws) clockwise, out of the brake coil housing.

5. Tighten the fi xing screws to the appropriate torque.

6. Re-check and measure the air gap in multiple locations to check for appropriate spacing. Repeat the steps as needed until the desired air gap spacing is uniform and consistent all the way around the brake.

Table 6: Brake Air Gap Settings

Brake Size

Fixing Screw Tightening Torque

Nominal Air Gap Setting

Maximum Air Gap

[lb-ft] [Nm] [in] [mm] [in] [mm]

BRE 5 2.2 3 0.008 0.2 0.024 0.6

BRE10 4.4 6 0.008 0.2 0.028 0.7

BRE20 7.4 10 0.012 0.3 0.031 0.8

BRE40 7.4 10 0.012 0.3 0.035 0.9

BRE60 18 25 0.012 0.3 0.039 1.0

BRE100 18 25 0.016 0.4 0.043 1.1

BRE150 18 25 0.016 0.4 0.043 1.1

BRE250 37 50 0.020 0.5 0.047 1.2

BRE400 37 50 0.020 0.5 0.047 1.2

BRE800 37 50 0.028 0.7 0.047 1.2

BRE1200 37 50 0.028 0.7 0.047 1.2

Tolerance: + 0.004 in [+ 0.1 mm]

Brake air gap must be re-adjusted before the stated value.

When using the stainless steel friction plate (RG) increase the nominal air gap to 0.6 mm (0.024 in.).

DRIVESYSTEMS






Brake Rotor (Brake Disc) Wear Assessment

Periodically the brake rotor or brake disc must also be checked for wear. If the brake rotors wear approaches the minimum allowed thickness, then the part should be replaced. Use Table 7 to determine whether or not the brake rotor requires replacement.

Table 7: Brake Rotor Thickness

Brake Size Nominal Brake RotorThickness

Minimum Brake Rotor Thickness

[in] [mm] [in] [mm]

BRE 5 0.295 7.5 0.177 4.5BRE10 0.335 8.5 0.217 5.5BRE20 0.406 10.3 0.295 7.5BRE40 0.492 12.5 0.374 9.5BRE60 0.571 14.5 0.453 11.5BRE100 0.630 16 0.492 12.5BRE150 0.709 18 0.571 14.5BRE250 0.787 20 0.650 16.5BRE400 0.787 20 0.650 16.5BRE800 0.787 20 0.650 16.5BRE1200 0.866 22 0.689 17.5

As new condition.

Worn condition - brake rotor replacement is required!

Brake Pad Replacement (reference to parts list on page 8)

When the brake pad is worn the pad should be replaced to maintain proper brake operation and ensure safety.

Required Tools

• Phillips head screw drivers (fan shroud removal)• External snap ring pliers (fan and brake hub removal).• Large fl at head screw driver or small pry bar (fan removal)• Metric T-handle wrenches and open-end wrenches.

Procedure

1. Remove the fi xing screws (946) securing the fan cover (940) to the motor end-shield (932). If the brake has a hand release (937), the lever arm should be removed by unscrewing it.

2. Remove the fan cover (940) and note the position of the hand release slot if applicable.

3. Remove the snap ring holding the cooling fan (939) and carefully remove the cooling fan (939), key and second snap ring (997).

4. If the brake is equipped with a dust boot (992), remove it.

5. Remove the socket head cap screws holding the brake coil (936) to the motor end-shield (932).

6. Remove the brake coil (936), noting the hand release (937) and power cable locations.

7. Slide the brake rotor (993) off the brake hub (938) which is secured to the motor shaft.

8. Clean the brake, install the new brake rotor pad and reassemble the brake in reverse order of the steps outlined.

Optional Brake Accessories

NORD can supply a variety of brake options and accessories, of which some of the most common are noted below.

Hand Release Lever (HL)

The hand release lever allows the brake to be manually re-leased without requiring that the brake be energized with voltage. The lever has a spring return that allows the brake to be hand released and returned automatically to its set posi-tion. The handle of the hand release lever can be unscrewed for easy removal.

Locking Hand Release Lever (FHL)

This option allows the brake to be manually released and locked off without requiring voltage to the brake. The lock mechanism prevents the spring from returning the brake to a closed state without manual action by the user. The hand release lever can be unscrewed for easy removal.

Corrosion Protected Brake (RG)

The brake is fi tted with a stainless steel brake plate to pro-vide additional corrosion protection in severe and wet envi-ronments.

Dust & Corrosion Protected Brake (SR)

A rubber-sealing boot is installed on the brake to provide additional protection in dusty environments. This feature in-cludes the stainless steel brake plate (RG).

IP66 Brake (IP66)

NORD can also provide an IP66 brake option designed for a bigger degree of protection against severe environments.

A14

TROUBLE SHOOTING

A systematic trouble shooting procedure will help reduce downtime should a problem occur. A complete understanding of the equipment and how it works will help make efficient trouble shooting progress. Activated controls do not start lift motor. SITUATION RESPONSE A. Main electrical disconnect off Consult maintenance staff before turning on. B. Thermal overload tripped Press reset button. Determine cause if it trips again. Motor is overheating. C. Blown control fuse Determine cause. Replace fuse. D. Power circuit between WARNING Dangerous high voltage potential disconnect and starter is dead exists. Use extreme care when testing. Check voltage with voltmeter. Repair as needed. Motor starts, carriage raises but both stop before second level is reached. SITUATION RESPONSE A. Object encountered Remove obstruction, repair as required. B. Thermal overload tripped Motor binding. Repair or replace as required. C. Chain interference or chain Determine cause, repair if chain is off sprocket off sprocket correct interference. D. Capacity limit tripped Current sensor set incorrectly. Increase current

sensor via hardware or software, refer to electrical schematics.

A15

Rough or noisy operation. SITUATION RESPONSE A. Travel interference Remove obstructions or correct problem. Make repairs if required. B. Drive component interference Remove obstructions or correct problem. Make repairs if required. C. Carriage is not level Determine cause and correct. D. Interference between chain Determine cause and correct. and columns. E. Inadequate lubrication Determine cause and correct. Carriage does not stop even with the conveyor level. SITUATION RESPONSE A. Misaligned floor level sensor Re-adjust floor level sensor. Motor runs but lift does not operate. SITUATION RESPONSE A. Mechanical failure Examine all drive and lift components for breakage. Brake release is slow. SITUATION RESPONSE A. Air gap too large Check air gap and adjust. B. Voltage to brake coil too small Check connection voltage of brake coil.

A16

Brake does not release. SITUATION RESPONSE A. Air gap too large Check air gap and adjust. If brake discs are

completely worn out, replace brake. B. Brake not receiving electrical Check electrical connection. power C. Failed rectifier Replace rectifier D. Voltage to brake coil too small Check voltage connection of brake coil. E. Rectifier supply voltage from Check voltage to nameplate. inverter Brake engagement is slow. SITUATION RESPONSE A. The brake is actuated with the Brake is to be actuated with the fast brake normal brake action circuit. action circuit. B. Defective relay Replace relay C. Voltage to brake coil too large Check connection voltage of brake windings. D. Brake is switched to AC side Use DC switching. Brake does not engage. SITUATION RESPONSE A. Brake rotor is worn Replace brake. B. Voltage to brake coil too large Check connection voltages of brake windings. C. Hand release is adjusted Adjust to correct air gap. incorrectly D. Anchor plate mechanically remove mechanical blockage. blocked

APPENDIX B

SPARE PARTS DRAWINGS

DRN

BY:

DATE

:

REV:

REV

DATE

:

JOB

#:

QTY:

BRT

33/

10/2

014

4160

10/7

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QTY

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3/8-

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122

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3 1

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per

the

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ase

.

1

2

3

4

APPENDIX C

ELECTRICAL

table of contents - wildeck

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