DUAL DISK BRAKE CATALOG

Transcription

1 DOVR FLXO LCTRONICS, INC. ISO 900 CRTIFID DUAL DISK BRAK CATALOG NO SQUAL WARRANTY 5 YAR WARRANTY

2 HAVY DUTY DUAL DISK BRAKS Dover's heavy-duty Dual Disk Brake is a pneumatic tension brake available in six size ranges with a variety of options and accessories. The brake was designed for industrial unwind applications in the converting, web printing and paper processing industries. DF has a patent pending on the proprietary new anti-squeal feature of the brake design. Braking force is applied between the two disks on opposing sides of the brake by Dover's unique Universal Actuator. ach actuator is comprised of twin brake cylinders which can be activated independently. The actuator is called universal because of its simple interchangeability between dual disk brakes of different sizes. It is also interchangeable with the pneumatic cylinder assemblies on some of the standard dual disk brakes of other manufacturers. Advantages of the Dual Disk brake with Universal Actuatorä design include hassle-free friction pad removal and installation--no tools are required to change brake pads, a patented quick-change pad release lock, a limited travel actuator piston that prevents disk scoring, and a return spring that cannot puncture the actuator diaphragm. FATURS / BNFITS Heavy duty brake for unwind applications. Wide torque range. Large heat dissipation capacity Cylinders can be actuated individually--valving configured as desired. Any cylinder (two pistons) can be deactivated in seconds. Replace worn brake pads in seconds, without tools. Limited travel actuator piston prevents disk scoring and blown diaphragms. DF No-Squeal Warranty. Dover Flexo lectronics, Inc. (DF) warrants our dual disk and single disk tensioning brakes against annoying squealing noises when installed according to our instructions. This warranty shall be void if non-df parts are used in the brake or if the brake has been contaminated with liquid, solid, or powder applied to the brake disks or friction pads. This warranty is in addition to our standard warranty. DF 5 Year Warranty Dover Flexo lectronics, Inc. warrants its' products to be free of defects in material and workmanship for 5 years from date of original shipment. TABL OF CONTNTS Changing Friction Pads... 0 through 800 Series Brakes...to Brake Sizing and Selection Worksheet.... Torque Capacity & Heat Dissipation Charts... Options & Accessories... Brake Cylinder Piping Worksheet...5 Replacement Parts... Installation Checklist & Ordering Instructions.. 7

3 RPLAC A WORN BRAK PAD IN UNDR 0 SCONDS. Press the release button, then the torque post over the friction pad you wish to change.. Slide the friction pad out.. Slide the new friction pad in.. Press down release button to lock friction pad in place.

4 0 The 0 Series Dual Disk Brake, named for its six inch diameter disks, offers high performance in a torque range from lb-inches up to,00 lbinches. The 0 Series Brake delivers the precise torque range needed for a particular application by allocating actuation of just the number of cylinders needed, from one up to six. OPTIONS Metric Mounting Bolt (MMB). Metric mounting bolts for the actuators. Non-Standard Key (NSK). For shafts having a different sized key other than the standardized ones usually used. ACCSSORIS Mounting Plate - Flat plate for mounting the brake and guard if used. Guard - Safety device to prevent people or objects from touching brake when in motion or hot. Guard Blocks - Allows installation of guard without mounting plate. Valve Assembly - Controls air supply for actuators. SPCIFICATIONS: Disk/Hub Inertia Max. Torque Disk/Hub Weight Max. Ship Wt. Min. Shaft Length.5 Slug-in,00 in-lbs 9. lbs..5 lbs.. in. BRAK SIZ 0 TORQU CAPACITY, LB-IN (N-M) Torque Capacity at 75psi (5.7 bar) #OF CYLINDRS 5 PAD COFFICINT OF FRICTION 0.0 (#) 0.0 (#) 0.5 (#) LB-IN (N-M) LB-IN (N-M) LB-IN (N-M) 0 (5) 80 (9) 70 (9) 80 (9) 50 (7) 0 (8) 0 () 0 () 500 (5) 50 (7) 00 () 70 (7) 90 () 80 () 80 (95) 0 () 0 (5) 00 () KY DPTH D 0 S R I S STANDARD HUB BOR AND KY DIMNSIONS NGLISH BOR KY DPTH (D) 0.5 / / / / / / /..0 /.78.5 /..88 /.0.50 /.7. 5/ /.58 MTRIC BOR KY DPTH (D)

5 0 DIMNSIONS (Model shown) /8 NPT (typ air inlet) x /8 - UNC x.5 (M8 x.5 x 90mm) 0.9 (7.5).5 (5.) R.0 (0. R) R.7 (9. R).5 (.) 5.0 (8.5) MIN / MAX 0.5 /.75 ( / 5) 0. (5.75).50 (5.) 7.5 (8.) 5. (8.).7 (9.) 0.58 (.7).9 (88.7) MOUNTING PLAT DIMNSIONS (Accessory) x 0. (8.) Hole Diam. x M x.0 x mm DP Std (9.) air tube access 0.50 (.7) 5.0 (8.5).5 (.) 0.8 (9.7) Ø.50 (8.) Ø 9.5 (.95).7 (9.) 5. (8.) Ø.85 (97.7) (Hole Pattern Diam. Custom hole patterns are available) BRAK GUARD DIMNSIONS (Accessory) THRU-SHAFT HOL.00 (50.8) Diam. RQUIRS RMOVAL OF NAM PLAT MOUNTING SCRW HOL: x 0.8 (7.) 9.0 (.8) x 0.5 (.) 5. (0.)

6 90 The 90 Series Dual Disk Brake, named for its nine inch diameter disks, offers high performance in a torque range from lb-inches up to,000 lbinches. The 90 Series Brake delivers the precise torque range needed for a particular application by allocating actuation of just the number of cylinders needed, from one up to four. OPTIONS Metric Mounting Bolt (MMB). Metric mounting bolts for the actuators. Non-Standard Key (NSK). For shafts having a different sized key other than the standardized ones usually used. Reduced Area Piston (RA). Reduces torque produced to % of normal. ACCSSORIS Mounting Plate - Flat plate for mounting the brake and guard if used. Guard - Safety device to prevent people or objects from touching brake when in motion or hot. Guard Blocks - Allows installation of guard without mounting plate. Valve Assembly - Controls air supply for actuators. SPCIFICATIONS: Disk/Hub Inertia Max. Torque Disk/Hub Weight Max. Ship Wt. Min Shaft Length 7.9 Slug-in,000 in-lbs. 8. lbs. 5 lbs. 7. in. TORQU CAPACITY, LB-IN (N-M) Torque Capacity at 75psi (5.7 bar) BRAK SIZ 90 #OF CYLINDRS PAD COFFICINT OF FRICTION 0.0 (#) 0.0 (#) 0.5 (#) LB-IN (N-M) LB-IN (N-M) LB-IN (N-M) 70 (9) 0 (8) 750 (85) 0 (7) 70 (7) 500 (9) 500 (5) 000 () 50 (5) 0 (7) 0 (5) 000 (9) KY DPTH D 9 0 S R I S STANDARD HUB BOR AND KY DIMNSIONS NGLISH MTRIC BOR KY DPTH (D) / / / / /..0 /.78.5 /..88 /.0.50 /.7. 5/ /.58 BOR KY DPTH (D)

7 90 DIMNSIONS (Model 9 shown) R5.59 () R. ().0 (.8) x /-0UNC x.0 (M0 x.5 x 50mm) 0.8 (0.) 8.5 (7.) MIN / MAX 0.75 /.75 (9 / 5) Ø 9. (.5).00 (5.) SCOND ACTUATOR ONLY USD ON UB9 & UB9 BRAKS 7.9 (8.).0 (0.9).75 (0.7) MOUNTING PLAT DIMNSIONS (Accessory) x 0.5 (.) (Hole Diam.) x M x.0 x mm DP Std (9.) air tube access 0.75 (9.) 8.5 (7.).8 (08.7) 0.8 (9.5) Ø.50 (.5) Ø.75 (9.).59 (9.) 7.9 (8.).5 (07.95) (Hole Pattern Diam. Custom hole patterns are available) BRAK GUARD DIMNSIONS (Accessory) THRU-SHAFT HOL.50 (8.) Diam. RQUIRS RMOVAL OF NAM PLAT MOUNTING SCRW HOL: x 0.8 (7.).0 (58.) x 0.5 (.5) 8. (9.) 5

8 0 The 0 Series Dual Disk Brake, named for its eleven inch diameter disks, offers high performance in a torque range from 9 lb-inches up to,0 lbinches. The 0 Series Brake delivers the precise torque range needed for a particular application by allocating actuation of just the number of cylinders needed, from one up to six. OPTIONS Mounting Adapter (MA). A plate connecting adjacent actuator assemblies. Reduces the quantity of mounting bolts needed. Metric Mounting Bolt (MMB). Metric mounting bolts for the actuators. Non-Standard Key (NSK). For shafts having a different sized key other than the standardized ones usually used. Reduced Area Piston (RA). Reduces torque produced to % of normal. ACCSSORIS Mounting Plate - Flat plate for mounting the brake and guard if used. Guard - Safety device to prevent people or objects from touching brake when in motion or hot. Guard Blocks - Allows installation of guard without mounting plate. Valve Assembly - Controls air supply for actuators. SPCIFICATIONS: Disk/Hub Inertia Max. Torque Disk/Hub Weight Max. Ship Wt. Min. Shaft. Length KY DPTH D. Slug-in,0 in-lbs. 5.9 lbs. 80 lbs. 7. in. TORQU CAPACITY, LB-IN (N-M) Torque Capacity at 75psi (5.7 bar) BRAK SIZ 0 S R I S 0 #OF CYLINDRS 5.50 /.7. 5/ /.58.8 / /8.9.5 /8.7.5 / / /8.9.8 / / / /..0 /.87.5 / /..50 /.77. 5/ / /8.7 PAD COFFICINT OF FRICTION 0.0 (#) 0.0 (#) 0.5 (#) LB-IN (N-M) LB-IN (N-M) LB-IN (N-M) 0 () 0 (5) 00 (7) 0 (5) 90 (0) 070 () 90 (78) 80 (5) 0 (5) 90 (0) 80 (08) 0 (8) 50 (0) 00 (0) 580 (58) 80 (5) 70 () 0 (70) STANDARD HUB BOR AND KY DIMNSIONS NGLISH MTRIC BOR KY DPTH (D) BOR KY DPTH (D)

9 0 DIMNSIONS (Model shown) R.58 R7.5 (7.) THIS CYLINDR NOT USD (8.7) ON UB AND UB.0 (.8) / Step in actuator is on the outside x /-0UNC x.0 (M0 x.5mm x 50mm) 0.8 (0.).8 (.) 8.5 (7.) MIN / MAX.5 /. ( / ) Ø.75 (98.5) SCOND ACTUATOR ONLY USD ON UB & UB 0 WITH MOUNTING ADAPTRS (Option - Model shown) R 7.5 (9.) R 8.7 (.).00 (5.) 0.5 (.).0 (.8) 5.8 (.7) x /-0UNC x.0 (M0 x.5mm x 50mm) / Step in actuator is on the inside.0 (.7) MIN / MAX.5 /. ( / ) Ø.75 (98.5) Mounting Adapter BOLTS, QUALLY SPACD MOUNTING PLAT DIMNSIONS B 0.75 (9.) A x M x.0 x mm DP Std. 0.8 (9.5) air tube access 0.75 (9.).00 (5.) BRAK GUARD DIMNSIONS MOUNTING SCRW HOL: x 0.8 (7.).09 (5.) 5.8 (.7) A THRU-SHAFT HOL: C Diam. RQUIRS RMOVAL OF NAM PLAT x 0.5 (.5) x 0.5 (.) (Hole Diam.) C (Hole Pattern Diam. Custom hole patterns are available) B MOUNTING PLAT DIMS. (0 Series) Models - Models 5- with adapters in mm in mm A B C BRAK GUARD DIMS. (0 Series) Models - Models 5- with adapters in mm in mm A B C

10 0 The 0 Series Dual Disk Brake, named for its thirteen inch diameter disks, offers high performance in a torque range from lb-inches up to 9,80 lbinches. The 0 Series Brake delivers the precise torque range needed for a particular application by allocating actuation of just the number of cylinders needed, from one up to eight. OPTIONS Mounting Adapter (MA). A plate connecting adjacent actuator assemblies. Reduces the quantity of mounting bolts needed. Metric Mounting Bolt (MMB). Metric mounting bolts for the actuators. Non-Standard Key (NSK). For shafts having a different sized key other than the standardized ones usually used. Reduced Area Piston (RA). Reduces torque produced to % of normal. ACCSSORIS Mounting Plate - Flat plate for mounting the brake and guard if used. Guard - Safety device to prevent people or objects from touching brake when in motion or hot. Guard Blocks - Allows installation of guard without mounting plate. Valve Assembly - Controls air supply for actuators. SPCIFICATIONS: Disk/Hub Inertia Max. Torque Disk/Hub Weight Max. Ship Wt. Min. Shaft Length KY DPTH D 5.9 Slug-in 9,80 in-lbs 9. lbs. 0 lbs. with adapter 7. in. BRAK SIZ 0 S R I S 0 TORQU CAPACITY, LB-IN (N-M) Torque Capacity at 75psi (5.7 bar) #OF CYLINDRS PAD COFFICINT OF FRICTION 0.0 (#) 0.0 (#) 0.5 (#) LB-IN (N-M) LB-IN (N-M) LB-IN (N-M) 70 (0) 550 () 0 (9) 550 () 090 () 0 (78) 80 (9) 0 (85) 90 () 090 () 90 (7) 90 (555) 70 (55) 70 (0) 50 (9) 0 (85) 80 (7) 780 (8) 90 () 80 () 80 (97) 90 (7) 70 (9) 980 () STANDARD HUB BOR AND KY DIMNSIONS NGLISH BOR KY DPTH (D).75 5/.58.8 / /8.9.5 /8.7.5 / / /8.9.8 / / / /..0 /.87.5 / /..50 /.77. 5/ / / / / / / /8.0 MTRIC BOR KY DPTH (D)

11 0 DIMNSIONS (Model 8 shown) R8.5 (07) R7.0 (87).00 (5.).0 (.8) / Step outside 8x /-0UNC x.0 ( M0 x.5mm x 50mm) 8.5 (7.5) MIN / MAX.8 /.75 (5 / 70) 0.8 (0.) Ø.7 (9.).0 (0.). ().88 (7.8) 0 WITH MOUNTING ADAPTRS (Option - Model8 shown) R9.50 (.) R0. (0.).00 (5.).0 (.8) x /-0UNC x.0 (M0 x.5mm x 50mm) / Step inside. (.) Mounting Adapter MIN / MAX.8 /.75 (5 / 70) Ø.7 (9.) 0.5 (.). (.) MOUNTING PLAT DIMNSIONS 0.75 (9.) x 0.5 (.) (Hole Diam.) x M x.0 x mm DP Std. air tube access 0.75 (9.). () BRAK GUARD DIMNSIONS MOUNTING SCRW HOL: x 0.8 (7.).88 (7.8) A THRU-SHAFT HOL C Diam. RQUIRS RMOVAL OF NAM PLAT B A 0.8 (9.5) x 0.5 (.5) C (Hole Pattern Diam. Custom hole patterns are available) B MOUNTING PLAT DIMS. (0 Series) Models -8 Models 5-8 with adapters (800 Series MP) in mm in mm A B C BRAK GUARD DIMS. (0 Series) Models -8 Models 5-8 with adapters (800 Series Guard) in mm in mm A B C

12 800 The 800 Series Dual Disk Brake, named for its eighteen inch diameter disks, offers high performance in a torque range from lb-inches up to 7,990 lbinches. The 800 Series Brake delivers the precise torque range needed for a particular application by allocating actuation of just the number of cylinders needed, from one up to ten. OPTIONS Metric Mounting Bolt (MMB). Metric mounting bolts for the actuators. Non-Standard Key (NSK). For shafts having a different sized key other than the standardized ones usually used. Reduced Area Piston (RA). Reduces torque produced to % of normal. KY DPTH D ACCSSORIS Mounting Plate - Flat plate for mounting the brake and guard if used. Guard - Safety device to prevent people or objects from touching brake when in motion or hot. Guard Blocks - Allows installation of guard without mounting plate. Valve Assembly - Controls air supply for actuators. SPCIFICATIONS: Disk/Hub Inertia Max. Torque Disk/Hub Weight Max. Ship Wt. Min. Shaft Length TORQU CAPACITY, LB-IN (N-M) Torque Capacity at 75psi (5.7 bar) BRAK SIZ 800 #OF CYLINDRS Slug-in 7,990 in-lbs 7.8 lbs. lbs. 9. in. PAD COFFICINT OF FRICTION 0.0 (#) 0.0 (#) 0.5 (#) LB-IN (N-M) LB-IN (N-M) LB-IN (N-M) 00 (5) 790 (89) 800 (0) 800 (90) 590 (80) 00 (07) 00 () 00 (7) 500 (0) 00 (8) 90 (0) 700 (8) 000 () 990 (5) 9000 (0) 00 (7) 800 (5) 0800 (0) 800 () 5590 () 590 () 00 () 90 (7) 90 () 00 (07) 700 (8) 90 (89) 990 (5) 7990 (90) 7990 (0) S R I S STANDARD HUB BOR AND KY DIMNSIONS NGLISH BOR KY DPTH (D).000 /..0 /.87.5 / /..50 /.77. 5/ / / / / / / /8.0.8 /..875 / / /..0 /.9.5 / /.5.50 /.58. 7/ / / / / / / / MTRIC BOR KY DPTH (D)

13 800 DIMNSIONS (Model 80 shown) R.98 (0.9) R.50 (85.75) 0.58 (.8) 5.88 (9.5) 5x /-0UNC x 7.5 (M0 x.5mm x 90mm).5 (5.9) MIN / MAX.00 /.00 (50 / 5) Ø 8.00 (57.) Mounting Adapter.00 (5.).8 (8.07) 7.5 (8. MOUNTING PLAT DIMNSIONS (Accessory) x 0.5 (.) (Hole Diam.) x M x.0 x mm DP Std. air tube access 0.75 (9.05) 0.75 (9.05) 0.8 (9.5) OPTIONAL COOLING HOLS Ø 5.00 (7) Ø.90 (.) Ø 8.50 (5.9) (Hole Pattern Diam. Custom hole patterns are available) BRAK GUARD DIMNSIONS (Accessory) THRU-SHAFT HOL. (7.0) Diam. RQUIRS RMOVAL OF NAM PLAT MOUNTING SCRW HOL: x 0.8 (7.) 5. (.) x 0.5 (.5). (95.0)

14 BRAK SIZING & SLCTION WORKSHT INSTRUCTIONS (After completion, you may wish to photocopy this page and fax it to us at (0) To select the proper brake size and number of cylinders required for a particular application, first complete the application data (at right) and perform the calculations below using the formulas given. Record your results in the spaces provided.. You will need to select a brake that has a torque capacity greater than that required by your application. Also, the brake you select must not exceed its maximum heat dissipation capability at the cooling speed of your application. Follow steps below.. Refer to the Heat Dissipation vs. RPM chart on the next page. Identify the brake series which have curves marked above the intersection of Heat (HP) dissipation capacity [calculation #] versus Cooling Speed [calculation #].. Refer to the Torque Capacity chart on the next page to identify brake size and pad options that have torque capacities which are slightly greater than your Torque(Max) [calculation #]. 5. From the Torque Capacity chart select a brake that has adequate torque capacity and heat dissipation for your Torque (Max) and Cooling Speed.. Check to ensure that the brake chosen has a greater torque capacity than your calculated -stop torque [calculation #7]. It may be necessary to use a brake with higher torque capacity and operate some cylinders from a separate air supply to provide -stop torque. NOT: We recommend calling a DF applications engineer at (0) -50 for assistance in sizing a brake for your application. If your application has a low torque limit requirement, please check the Performance Review chart on page to ensure the brake you've chosen has a APPLICATION DATA minimum achievable torque below your requirement.. Full Roll Diameter (D max) inches Note: If you are faced with several acceptable options, keep in mind that smaller brakes are less expensive, but a. Core Diameter (D min) inches larger brake has greater heat dissipation at a given speed.. Web Speed, Max.(S max) ft/min 7. Refer to min. and max. brake shaft dimensions for the brake you have chosen Min.(S min) ft/min (listed on each Series dimension page) to determine the acceptable bore dimension range. Using the Standard Hub Bore and. Rotational Speed, Max. (N max) rpm Key Dimensions table and diagram, Min. (N min) rpm select a bore size (See Note). Specify keyway width only if non-standard is 5. Web Tension, Max.(F max.) lbs. required. 8. To Order: Write the brake size, number Min.(F min.) lbs. of cylinders, bore diameter, key size, and. Web Material options in the space provided below. Refer to the Torque Capacity chart for choice of Thickness inches friction pads. Turn to page 0 to properly specify your brake when ordering. List Width inches accessories separately. 9. Piping of cylinders will be configured in 7. -Stop Time (T) sec. series unless otherwise specified. Specify piping and valving on separate Brake Roll Weight (W) lbs. Cylinder Piping Worksheet.. Max. Torque = Dmax x Fmax (in-lb) CALCULATIONS. Min Torque = Dmin x Fmin (in-lb). Heat (HP) = Fmax x Smax,000. Brake N max* =.8 Smax (RPM) Dmin * for max. cooling speed calculation 5. Brake N min* =.8 (RPM) Smin Dmax * for min cooling speed calculation. Cooling Speed = N min + Nmax (RPM) 7. -Stop Torque = (in-lb) SPCIAL RQUIRMNTS WxDmax x Smax 778 x T BRAK SLCTD BOR AND KY

15 CHARTS FOR BRAK SIZING AND PAD SLCTION TORQU CAPACITY, LB-IN (N-M) Torque Capacity at 75psi (5.7 bar) HAT DISSIPATION vs. RPM BRAK SIZ #OF CYLINDRS PAD COFFICINT OF FRICTION 0.0 (#) 0.0 (#) 0.5 (#) LB-IN (N-M) LB-IN (N-M) LB-IN (N-M) 0 (5) 80 (9) 70 (9) 80 (9) 50 (7) 0 (8) 0 () 0 () 500 (5) 50 (7) 00 () 70 (7) 90 () 80 () 80 (95) 0 () 0 (5) 00 () 70 (9) 0 (8) 750 (85) 0 (7) 70 (7) 500 (9) 500 (5) 000 () 50 (5) 0 (7) 0 (5) 000 (9) 0 () 0 (5) 00 (7) 0 (5) 90 (0) 070 () 90 (78) 80 (5) 0 (5) 90 (0) 80 (08) 0 (8) 50 (0) 00 (0) 580 (585) 80 (5) 70 () 0 (70) 70 (0) 550 () 0 (9) 550 () 090 () 0 (78) 80 (9) 0 (85) 90 () 090 () 90 (7) 90 (555) 70 (55) 70 (0) 50 (9) 0 (85) 80 (7) 780 (8) 90 () 80 () 80 (97) 90 (7) 70 (9) 980 () 00 (5) 790 (89) 800 (0) 800 (90) 590 (80) 00 (07) 00 () 00 (7) 500 (0) 00 (8) 90 (0) 700 (8) 000 () 990 (5) 9000 (07) 00 (7) 800 (5) 0800 (0) 800 () 5590 () 590 () 00 () 90 (7) 90 () 00 (07) 700 (8) 90 (89) 990 (5) 7990 (90) 7990 (0) HAT DISSPATION KW HP 800 Series RPM Max. 0 Series - 00 RPM Max. 0 Series - 00 RPM Max. 90 Series RPM Max. 0 Series - 00 RPM Max RPM PRFORMANC RVIW TABL BRAK MAX. # OF CYLINDRS MIN. TORQU CAPACITY lb-in. (N-M) at 5 psi w/ two # pads MAX TORQU CAPACITY lb-in. (N-M) at 75 psi w/ max. # pads MAXIMUM RPM MINIMUM BOR in (mm) MAXIMUM BOR in (mm) 0 (0.) 00 () ().75 (5) 90 (.5) 000 (9) (9).75 (5) 0 9 () 0 (70) ().8 () 0 8 (.) 980 () (5).750 (70) () 7990 (0) (50).000 (5)

16 OPTIONS & ACCSSORIS Mounting Adapter Assemblies. A plate with short bolts that connects adjacent actuator assemblies. Reduces the quantity of mounting bolts needed and provides an optional mounting bolt pattern. Mounting bolts included. Adapters are shown in the dimensional drawings for Models 0 through 800. MODL PART NUMBRS 0-5 & only only Standard -9 Mounting Plates. Flat plate for mounting the brake and guard if used. Mounting Plates are shown in the dimensional drawings for all models. MODLS PART NUMBRS 0 90 ALL ALL NO ADAPTRS NO ADAPTRS -5 - with ADAPTRS with ADAPTRS ALL -7 Guard Mounting Blocks. Right angle block with 0. inch through hole to machine frame. Allows installation of the guard if a mounting plate is not used. All Brake Series require per unit. ALL xternal Shut-off Valve Assemblies. Controls air supply for actuators. Please specify valving configuration as shown on the following page when ordering a complete brake assembly. See diagram below for dimensions. NUMBR OF VALVS PART NUMBRS One-Valve Assembly Two-Valve Assembly Three-Valve Assembly Four-Valve Assembly Replacement Slider Valve VALV DIMNSIONS Guard Assemblies. Safety device to prevent people or objects from touching brake when in use. Guards are shown in the dimensional drawings for all models MODLS ALL ALL NO ADAPTRS with ADAPTRS NO ADAPTRS with ADAPTRS ALL PART NUMBRS I (NPT) AIR IN F K G L D A B C DIA. PLACS H / (MM) AIR TUBING M J (NPT) AIR OUT SIZ 0R VALV 0R VALV in mm in mm A B C D F G H I J K L M /8 NPT /8 NPT /8 NPT /8 NPT /8 NPT /8 NPT /8 NPT /8 NPT

17 BRAK CYLINDR PIPING WORKSHT The diagrams below represent the axial views of complete actuator assemblies for each of DF s Heavy Duty Brakes. Identify your brake size by the first two digits appearing above each brake. Draw your piping from each actuator or pad to the valve required. Piping of cylinders will be completed in series unless otherwise specified. For: 9_ 8 For: 5 5

18 RPLACMNT PARTS Actuator Assemblies. May be purchased as replacement parts, or to increase torque as add-ons, space provided. Specify friction pads and mounting bolt kit separately. Note: Addition of a second actuator to a 0 Series Brake requires Strap Kit CYLINDRS Cylinder Cylinders Cylinders n/a Mounting Bolt A ssemblies. Used to mount brakes to machine. For additional actuator assemblies or replacement part. Metric sizes available. Kit contains bolt, washers, and spacer. UNIT inch metric Friction Pads. Available in three coefficients. # (0.5) is standard on DF brakes. COFFICINT # (0.0) # (0.0) # (0.5) Cylinder Kit. Addition or replacement of cylinders can be done with the following kits. Friction pads and mounting bolt kit not included Reduced Area Piston Kit. For 90 Series brakes and up. Reduces torque produced to % of normal UNIVRSAL ACTUATOR Backed by our No-Squeal Warranty. No disassembly required when changing brake pads. No-Fail cylinder. Return spring can't puncture the diaphragm. Replace worn brake pads in seconds, without tools. Limited travel piston prevents disk scoring and blown diaphragms. Deactivate any cylinder or piston simply by removing the brake pad. Takes only seconds. No extra parts to buy, install or remove. A range of brake pads having friction coefficients of 0.0 (#), 0.0 (#), and 0.5 (#). Asbestos free. Retrofit kits available for dual disk brakes of other manufacturers. DIMNSIONS.5 (90) x Ø0.8 (). () 0.0 (5) x /8 NPT PORTS. (0).78 (7). (05) 0.50 () 0.75 (9).50 ().5 () 8.5 (7).5 (8)

19 INSTALLATION CHCKLIST FOR DUAL DISK BRAKS In order to obtain the best brake performance and ensure trouble-free operation, you must ensure that the installation environment and related machinery comply with the following conditions. Compliance with these requirements is necessary to validate the 5 Year Warranty and No-Squeal Warranty.. The brake mounting surface must be rigid and strong enough so it doesn t deflect when loaded by brake torque.. The shaft must be straight. (Bent shafts cause disk run-out, resulting in vibration and noise). The shaft must not have noticeable end play.. The shaft bearing must be in good condition, with no noticeable free-play or noise. 5. The shaft diameter must be properly matched to the brake bore. (A loose fit can cause balance problems and disk run-out). The shaft must be perpendicular to the brake mounting surface to within 0.00" ( mm), measured at the end of the shaft. 7. The set screws must be tight so the disk assembly does not move on the shaft. 8. The actuator plates must be centered between the disks and be parallel to the brake mounting surface. 9. All mounting bolts and set screws must be tight. 0. The friction surfaces of the disks and friction pads must be clean and free of oil or any other lubricant or substance.. The friction pads must be installed with the friction surface against the disk, and the steel back plate against the air cylinder.. Actuator plates must be parallel to the disks. (Crooked actuators cause uneven wear and noise.) HOW TO ORDR Order your brake using the Dual Disk product code below.. Specify which series brake and how many cylinders you require.. Specify bore (standard key is assumed).. Specify any options.. Assume all pads are the standard 0.5. Describe any variations. xamples: D () RA D-.5- MA,.,. pads (In this example, the remaining cylinder has a 0.5 pad) D X X - XXX - OPTIONS (separate with commas) DUAL DISK BRAK = 0 Series 9 = 90 Series = 0 Series = 0 Series 8 = 800 Series #OF CYLINDRS BOR OPTIONS - for 0 Series - for 90 Series - for 0 Series -8 for 0 Series -0 for 800 Series See Bore & Key Charts on Brake pages x0. = 0.0 coefficient pad (x = qty) x0. = 0.0 coefficient pad (x = qty) MA = Mounting Adapters (0 Series and up) MMB = Metric Mounting Bolts NSK = Nonstandard Key RA = Reduced Area Piston Z = Specials Your brake: Refer to Brake Sizing and Selection Worksheet in the following pages for selection of your brake. 7

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