II. Electrical Connection of Brake


		55,000 and 55,400 Series					55,500; 55,300 and 57,500 Series
		Remove housing nuts (15) by unscrewing					Remove housing nuts (15) by unscrewing
		from housing studs (150), remove					from housing studs (150), remove
		housing (7) by pulling back.					housing (7) by pulling back.

55,200 Series

Remove wraparound sheet metal housing (7) by turning wing-nut on latch counterclockwise until latch releases.

Figure 2

4.If installing pulley or sprocket on brake shaft, do not use excessive force during installation. Maximum overhung load at center of keyway length is 150 lbs.

5.After alignment, dowels are suggested to maintain alignment.

6.Remove housing (7). Continue with Step D.

D.For all sizes

1.Refer to solenoid air gap, Table 2 in Section IV-A. Follow Steps 1 and 2 for checking and air gap adjustment, if necessary.

2.See Section II, Electrical Connection of the Brake, for coil connection.

3.Replace housing. On 55,300; 55,500 and 57,500 Series Brake, tighten housing nut (15) 3/4 to 1 turn (8 in-lb) beyond contacting the housing surface. On 55,000 and 55,400 Series standard enclosure brake, tighten housing nut 1/4 turn (30 in-lb) beyond contacting housing. On 55,000 and 55,400 Series DTWP enclosure brake, housing nut gaskets are provided. Tighten housing nut 1/2 to 3/4 turn (20 in-lb) beyond contacting gasket on housing.

Note 2: Check face of motor, machine or foot mounting bracket to which brake is to be mounted to be sure NEMA dimensions of 0.004” T.I.R. on concentricity and face run out are met. Shaft run out is to be 0.002” T.I.R. Maximum shaft end float is 0.020”. On foot mounted brakes, dowels are recommended for bracket.

2.Use a key (not supplied) tight fitting and full axial length of hub (16). Slide hub on shaft positioning inboard face of hub about 3/16” from mounting face or at 5/16” for 57,500 Series. See Figure 3. Securely tighten both hub set screws (16S) with torque of 78 in-lbs on 1/4” and 156 in-lbs on 5/16”. Recommended practice is to drill a set screw dimple into shaft, especially on vertical installation.

Figure 3

3.Attach brake to mounting face by sliding brake friction disc(s) (4) over hub, engaging without force. Brake endplate

(2) face is to be tight against mounting face.

Note 3: If motor or assembly is to be ceiling or horizontally wall mounted, orient brake so that plunger will be above solenoid frame at final installation.

4.Install 3/8” – 16 cap screws (not supplied) or 1/2” size for 57,500 Series to attach endplate to mounting surface. Tighten to

manufacturer’s recommended torque. Continue with Step D.

B. Method of installing 55,000 and 55,400 Series with waterproof, dust-tight enclosure:

1.Remove screws (142S) and support plate assembly (142).

2.Remove stationary disc(s) (3) and friction disc(s) (4).

Note: Vertically mounted multi-disc brakes have special pins which guide vertical mounting springs. Observe color coded sequence of springs from reinstallation.

See Notes 1, 2 and 3 in Method I-A of Installing Brakes with Standard Enclosure.

3.Attach endplate (2) to mounting face and tighten 3/8” – 16 cap screws (not supplied) to manufacturer’s recommended torque.

4.Use a key (not supplied) tight fitting and full axial length of hub (16). Slide hub on shaft positioning square inboard face of hub 1/32” to 1/16” from unfinished cast surface of endplate (2). See Installation Procedure, A, Step 2 for set screw tightening.

5.Reassemble friction disc(s) (4) and stationary disc(s) in the same order, being sure all slide freely without binding. If vertical mounting springs are used, be sure to reassemble in original sequence or refer to Sheet 301.4.

6.Mount support plate assembly (142) and torque screws (142S) evenly to 43 in-lbs. Be sure plunger is above frame on horizontal brakes. Continue with Step D.

C.Method of installing 55,200 Series:

1.Do not disassemble brake.

2.Bolt foot mounting bracket to a suitable base.

3.For in-line coupling, follow coupling manufacturer’s suggestions on alignment.

Note: If brake is upside down for later ceiling mount, turn brake upright before installing housing.

CAUTION: Inverter Motor and Special Control Systems. This brake contains either a single phase AC coil or DC coil that requires instantaneous power within ± 10% of rating at the coil. A separate power source is required when this brake is used in conjunction with a motor or control system that limits voltage or current input (i.e. inverter motors) or causes a ramping of the power supply.

Note 1: Brake coil connections described here cover common motor connections. For nonstandard motor or control connections contact respective supplier or Stearns Division.

Note 2: On brakes with space heater, connect to appropriate power source. Heater is to be energized continuously, even during storage, if rust may occur.

Note 3: Be sure lead wires to coil are not tight or pinched, and that leads will not be rubbed by friction disc, trapped between solenoid plunger and frame, caught between lever arm and endplate, or by linkage.

A. AC coils – single and dual voltage

1.All Stearns AC coils are single-phase. Connect single voltage coils to any two wires of single or three-phase power source, or, for operation with motor control, to any two motor leads of proper voltage.

Method of connecting dual voltage coil for use on high or low voltage is shown in Figure 4. Observe the lead numbering sequence for proper connection as shown in next column.

2.To use a 230 volt coil (or a dual voltage coil connected for 230 volts) with a 230/460 dual voltage three-phase motor, the brake leads are connected across two

500, 300, 0, 200, 55 specifications

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Stearns 55, 300, 200, 500 manual II. Electrical Connection of Brake

Models: 500 300 0 200 55

55,000 and 55,400 Series

55,500; 55,300 and 57,500 Series

55,200 Series

D.For all sizes

C.Method of installing 55,200 Series: