Hollister-Whitney Elevator Corporation Repair and Maintenance Manual – Mayr Brakes GL100, GL115, GL130, GL170 & GL171 AC Permanent Magnet, Gearless Machines

Bulletin 1158 Page 1 of 15

Hollister-Whitney Elevator Corporation #1 Hollister-Whitney Parkway Quincy, IL 62305 Phone: 217-222-0466

Fax: 217-222-0493 e-mail: [email protected] www.hollisterwhitney.com

Table of Contents I. Brake Removal II. Replacement and Wear Items. III. Brake Install – Repair or Replacement IV. Brake Service – After Repair or Replacement a. Manual Brake Release Adjustment (if so equipped) b. Brake Burnishing c. Brake Adjustment

BEFORE PERFORMING ANY MAINTENANCE ON THE MACHINE BRAKES, TAKE ALL THE NECESSARY SAFETY PRECAUTIONS TO IMMOBILIZE THE CAR AND COUNTERWEIGHT TO PREVENT ANY UNINTENDED MOVEMENT DURING THE MAINTENANCE PERIOD THAT MAY RESULT IN INJURY OR DEATH! READ THE ENTIRE BRAKE REPLACEMENT PROCEDURE BEFORE BEGINNING ANY OF THE STEPS OUTLINED BELOW. CONTACT HOLLISTER-WHITNEY WITH ANY QUESTIONS PRIOR TO BEGINNING THE BRAKE REPLACEMENT. BEFORE OPENING ANY ELECTRICAL ENCLOSURES ON THE MACHINE, REMOVE ALL ELECTRICITY FROM THE MACHINE AND BRAKES TO PREVENT ELECTRICAL SHOCK THAT MAY RESULT IN INJURY OR DEATH DURING THE MAINTENANCE PERIOD!

Bulletin 1158 Page 2 of 15

Hollister-Whitney Elevator Corporation #1 Hollister-Whitney Parkway Quincy, IL 62305 Phone: 217-222-0466

I.

Fax: 217-222-0493 e-mail: [email protected] www.hollisterwhitney.com

Brake Removal • • •

Tools required - Flat, small screwdriver (for terminal blocks), pliers or flat, large screwdriver (for conduit nut), 1/4” x 5” long bolt (for holding brake open), 3/16" hex key, 3/8" hex key, 3/8" wrench, 11/16" wrench (or adjustable wrench), hammer and punch. Before removing the old brake from the machine, verify the new brake is the same model and voltage as the brake that is being replaced. If the new brake is different than the brake being replaced, contact Hollister-Whitney. For machines equipped with the Hollister-Whitney manual brake release cable, begin by removing jam nut "A", nut "B" and washer "C." Then, undo nut "D." Refer to Figure 1.

D

C B A

Figure 1 Bulletin 1158 Page 3 of 15

Hollister-Whitney Elevator Corporation #1 Hollister-Whitney Parkway Quincy, IL 62305 Phone: 217-222-0466

•

Fax: 217-222-0493 e-mail: [email protected] www.hollisterwhitney.com

Once the manual brake release cable hardware has been removed and loosened, slide the brake release cable out of the brake. Refer to Figure 2.

Figure 2 •

Energize the brake needing service (unlock brake from machine rotor). Insert Bolt across mounting flanges to hold brake open while removing from machine. Refer to Figure 3.

Bolt

Figure 3 •

After brake has been “bolted open” remove power to machine before opening electrical enclosure.

BEFORE OPENING ANY ELECTRICAL ENCLOSURES ON THE MACHINE, REMOVE ALL ELECTRICITY FROM THE MACHINE AND BRAKES TO PREVENT ELECTRICAL SHOCK THAT MAY RESULT IN INJURY OR DEATH DURING THE MAINTENANCE PERIOD! BEFORE REMOVING ANY WIRES FROM THE ELECTRICAL ENCLOSURE, WRITE DOWN THE WIRE COLORS AND TERMINAL BLOCK DESIGNATIONS FOR FUTURE REFERENCE! THIS INFORMATION WILL BE NECESSARY WHEN CONNECTING THE WIRES FOR THE NEW BRAKE! Bulletin 1158 Page 4 of 15

Hollister-Whitney Elevator Corporation #1 Hollister-Whitney Parkway Quincy, IL 62305 Phone: 217-222-0466 •

Fax: 217-222-0493 e-mail: [email protected] www.hollisterwhitney.com

After writing down the wire colors and terminal block designations, remove the proper brake wires from the terminal blocks “A” and the corresponding conduit nut "B." Refer to Figure 4.

A

B

Figure 4 •

B

Loosen all 4 brake mount bolts. Remove the bottom 2 and 1 of the top bolts. When removing mounting bolts take note to catch the 3/8” thick brake blocking pads, see “A” Figure 6.(if applicable) With brake and mounting assembly held remove last bolt and blocking pad. Move brake assembly to a working area. “B” in Figure 5 shows location of 2 bolts on top and 2 (not shown) under mount.

A

Figure 5

Figure 6

B

Bulletin 1158 Page 5 of 15

Hollister-Whitney Elevator Corporation #1 Hollister-Whitney Parkway Quincy, IL 62305 Phone: 217-222-0466 •

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After placing brake assembly on a work surface slide brake off to service, replace, or make repairs. See Figure 7.

Figure 7

II.

Replacement and Wear Items

(See Figures 9 for reference)

a. Replacement Friction Pad Assembly Matrix (lining glued on adaption plate) Mayr Mayr Part # HW Part # Qty (sold as set) RSD6 #8180880/each 146-004/(Set = 2 pads) 1 RSD8 #8193719/each 144-004/(Set = 2 pads) 1 RSD10 #8197142/each 143-004/(Set = 4 pads) 1 b. Replacement Release Monitoring Assembly Matrix (switch on adaption plate) Mayr Mayr Part # HW Part # Qty RSD6 TBD 146-005 1 RSD8 #8195278 144-005 1 RSD10 #8195278 144-005 1

SWITCH

PADS Figures 9 Bulletin 1158 Page 6 of 15

Hollister-Whitney Elevator Corporation #1 Hollister-Whitney Parkway Quincy, IL 62305 Phone: 217-222-0466

III.

Fax: 217-222-0493 e-mail: [email protected] www.hollisterwhitney.com

Brake Install – Repair or Replacement • •

If replacing old brake with a new brake, check to make sure brake is of same make and model. If not consult Hollister-Whitney Engineering. New brake will come shipped de-energized, brake open, and bolted open to allow for mounting on machine. NOTE: Do not remove bolt as this will release brake and you will not be able to fit the brake over machine rotor.

BOLT

•

Slide brake onto guide rods. Refer to Figure 10.

Figure 10 Bulletin 1158 Page 7 of 15

Hollister-Whitney Elevator Corporation #1 Hollister-Whitney Parkway Quincy, IL 62305 Phone: 217-222-0466

•

Fax: 217-222-0493 e-mail: [email protected] www.hollisterwhitney.com

Loosely install 1 top bolt, “A” through brake base to hold brake assembly on housing. Figure 11.

A

Figure 11 •

• • • •

Install bottom bolts, with Brake Blocking Pad, (if applicable) between brake base and housing. Loosely tighten these. Remove temporary top bolt, slide brake blocking pad between brake base and housing, install both bolts loosely, after all bolts have been started, you can tighten all bolts to attach brake assembly to housing. Make sure Brake blocking Pads are used if necessary. If not, brakes will not be mounted at correct distance from center of rotor. Brakes will not perform as designed. After the brake is attached, route the new brake wires into the electrical enclosure. Be sure to place the conduit nut “B” on the conduit fitting before securing the brake wires into the terminal block. Refer to Figure 13. Once the conduit fitting is secure, cut wires to the desired length and secure them into the terminal block using the wire color and terminal block designations that were written down during the brake removal phase. After everything has been re-installed in the electrical enclosure, and the electrical enclosure closed, remove bolt holding brake in “open” position. After that it is now time to re-apply electricity to the system. See Figure 12 for bolt removal.

Bulletin 1158 Page 8 of 15

Hollister-Whitney Elevator Corporation #1 Hollister-Whitney Parkway Quincy, IL 62305 Phone: 217-222-0466

Fax: 217-222-0493 e-mail: [email protected] www.hollisterwhitney.com

Figure 12 • • • •

If the machine is equipped with the Hollister-Whitney manual brake release cable, re-install the manual brake while referring to Figure 1. For adjusting brake see Section IV.a. – Manual Brake Release Adjustment. Once brake has been restored, and the cars counterweight is free to move, follow Section IV.b. Brake Burnishing, to ensure the brake will achieve the full stopping torque. Once the brake has been burnished and adjusted, See Section IV.c. – Brake Adjustments, be sure to test the brake function in accordance with all applicable code requirements to ensure full functionality

B

Figure 13 Bulletin 1158 Page 9 of 15

Hollister-Whitney Elevator Corporation #1 Hollister-Whitney Parkway Quincy, IL 62305 Phone: 217-222-0466

Fax: 217-222-0493 e-mail: [email protected] www.hollisterwhitney.com

IV Brake Service – After Repair or Replacement a. Manual Brake Release Adjustment (if so equipped). See Figure 14 • • • • •

Tools required – 18mm & 3/8" wrench (or adjustable wrench) Leave the manual brake release handle in the "at-rest" position. With the brake release handle un-actuated, adjust nut, "D" to allow enough cable to protrude through brake arm to attach washer and 2 nuts. Adjust nut “B” to allow about 1/16” space between brake arm and washer, then tighten jam nut “A” against “B”. Actuate the manual brake release handle to ensure the brake opens manually, and returns to the clamped position when the handle is returned to the "at-rest" position.

D

1/16” Space between washer and arm

B A

Figure 14

Bulletin 1158 Page 10 of 15

Hollister-Whitney Elevator Corporation #1 Hollister-Whitney Parkway Quincy, IL 62305 Phone: 217-222-0466 b.

Fax: 217-222-0493 e-mail: [email protected] www.hollisterwhitney.com

Brake Burnishing

BRAKES MUST BE BURNISHED TO ACHIEVE FULL STOPPING TORQUE!

• • • • • •

Each new brake, or brake serviced on the machine must be burnished separately. Repeat the following procedure for each brake serviced. Clamp the brake on the rotor. (De-energize the brake circuit.) Run the elevator in the direction of the load at 11 RPM for 1 minute If the overall travel of the elevator will not allow the burnishing time to be met on one pass, open (energize) the brake at the bottom of the hoist way, lift the load back to the top and repeat the run until the full burnishing time has been achieved. Stop occasionally to ensure the rotor and brake do not overheat. After burnishing, re-verify the air gap between the Coil Carrier Assembly and Armature Disk. ***** NOTE: MAX AIR GAP 0.040 inch ******

Max Air Gap Tag on Brake

Bulletin 1158 Page 11 of 15

Hollister-Whitney Elevator Corporation #1 Hollister-Whitney Parkway Quincy, IL 62305 Phone: 217-222-0466

Fax: 217-222-0493 e-mail: [email protected] www.hollisterwhitney.com

c. Brake Adjustments –(Machine shown with Mayr 6 Model Brakes) ***** Brake air gap must be checked with brake de-energized***** BEFORE PERFORMING ANY MAINTENANCE ON THE MACHINE BRAKES, TAKE ALL THE NECESSARY SAFETY PRECAUTIONS TO IMMOBILIZE THE CAR AND COUNTERWEIGHT TO PREVENT ANY UNINTENDED MOVEMENT DURING THE MAINTENANCE PERIOD THAT MAY RESULT IN INJURY OR DEATH! • • • • •

Tools required – 3/8” hex key and 0.020 inch feeler gauge. The air gap on new brakes, are preset from the factory at approximately 0.020 inch. Gap should be equal all the way around. See Figures 16 on next page. Before you check or adjust the brake air gap, clamp the brake on the rotor (de-energize.) All adjustments and measurements will be made with the brake clamped on the rotor (de-energized.) Move rubber dust shield “A” to expose Air Gap “B”. Refer to Figure 13.

2

B

1

A

Figure 15

Bulletin 1158 Page 12 of 15

Hollister-Whitney Elevator Corporation #1 Hollister-Whitney Parkway Quincy, IL 62305 Phone: 217-222-0466

•

Fax: 217-222-0493 e-mail: [email protected] www.hollisterwhitney.com

Check Air Gap (between coil carrier assembly “1” and armature disk “2”) at “B” (Figure 15), approx. 0.020 inch gap should be equal all the way around. (Figures 16)

***IMPORTANT!!! Air gap can surpass 0.020 inch, but must not exceed 0.040 inch. *** If Brake air gap meets or exceeds 0.040 inch see Section V.c. Brake Wear - Check Procedure Bulletin 1146

Figures 16

Bulletin 1158 Page 13 of 15

Hollister-Whitney Elevator Corporation #1 Hollister-Whitney Parkway Quincy, IL 62305 Phone: 217-222-0466

• • • •

Fax: 217-222-0493 e-mail: [email protected] www.hollisterwhitney.com

Side-to-Side air gap adjustment - ONLY AS NECESSARY - With the Brake clamping the rotor (de-energized) Use a 3/8” Hex Wrench to loosen (4 per brake) socket head screws “C”. Shown in Figures 17 After the air gap is set, re-tighten the socket head screws, “C”. NOTE: It may be necessary to lightly tap the brake base to obtain equal air gap. DO NOT USE A STEEL HEAD HAMMER, USE A BRASS, LEAD, OR HARD PLASTIC HEAD. DO NOT HAMMER THE GUIDE RODS! ONLY TAP ON BRAKE BASE!!

C

Figures 17

Bulletin 1158 Page 14 of 15

Hollister-Whitney Elevator Corporation #1 Hollister-Whitney Parkway Quincy, IL 62305 Phone: 217-222-0466

• • • •

Fax: 217-222-0493 e-mail: [email protected] www.hollisterwhitney.com

Top-to-bottom air gap adjustment – ONLY AS NECESSARY – Air gap can be adjusted by shimming under Brake Base. With the Brake clamping the rotor (de-energized) Use a 3/8” Hex Wrench to loosen (2 per side) socket head screws per instructions as follows. If air gap is less near the top of Brake, add shims under back of Brake Base “E” (2 locations) If air gap is less near bottom of Brake, add shims under front of Brake Base “F” (2 locations) See Figures 18

Shim

E

F

Figures 18 Bulletin 1158 Page 15 of 15