dover flexo electronics, inc. iso 9001 certified dual disk brake … · 2019-01-17 · advantages...

DOVER FLEXO ELECTRONICS, INC.ISO 9001 CERTIFIED

DUAL DISK

BRAKE CATALOG

NO

SQUEAL

WARRANTY

5YEAR

WARRANTY

TABLE OF CONTENTS

Changing Friction Pads . . . . . . . . . . . . . . . . . . . . 1

60 through 1800 Series Brakes . . . . . . . . . 2 to 11

Brake Sizing and Selection Worksheet . . . . . . . 12

Torque Capacity & Heat Dissipation Charts . . . 13

Options & Accessories . . . . . . . . . . . . . . . . . . . 14

Brake Cylinder Piping Worksheet . . . . . . . . . . . 15

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . 16

Installation Checklist & Ordering Instructions . . 17

Dover's heavy-duty Dual Disk Brake is a pneumatictension brake available in six size ranges with avariety of options and accessories.

Designed for industrial unwind applications in theconverting, web printing and paper processing indus-tries, the brake includes patented anti-squeal technol-ogy in the Silencer friction pads.

™

Braking force is applied between the two disks onopposing sides of the brake by Dover's uniqueUniversal Actuator . Each actuator is comprised of

™

twin brake cylinders which can be activated independ-ently. The actuator is called because of itsuniversal

simple interchangeability between dual disk brakes ofdifferent sizes. It is also interchangeable with thepneumatic cylinder assemblies on some of the stan-dard dual disk brakes of other manufacturers.

Advantages of the Dual Disk brake with Universal

Actuator design include hassle-free friction pad�

removal and installation--no tools are required tochange brake pads, a patented quick-change padrelease lock, a limited travel actuator piston thatprevents disk scoring, and a return spring that cannotpuncture the actuator diaphragm.

HEAVY DUTY DUAL DISK BRAKES

FEATURES / BENEFITS� 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.� A pair of Silencer pads with each new brake

™

ensures squeal-free performance.

� DFE No-Squeal Warranty. Dover FlexoElectronics, Inc. (DFE) warrants our dual disk andsingle disk tensioning brakes against annoyingsquealing noises when installed according to ourinstructions. This warranty shall be void if non-DFEparts are used in the brake or if the brake has beencontaminated with liquid, solid, or powder appliedto the brake disks or friction pads. This warranty isin addition to our standard warranty.� DFE 5 Year Warranty Dover Flexo Electronics,

Inc. warrants its' products to be free of defects in

REPLACE A WORN BRAKE PAD IN UNDER 30 SECONDS

1. Press the torque post over the friction padyou wish to change.

4. Older brakes may have two (2) buttons todepress to remove pads as show in the figureabove. Press the release button, then thetorque post over the friction pad you wish to,change. After inserting the pad you will needto press the release button to make the torquepost snap back through the pad’s backing hole.

2. Slide the friction pad out.

3. Slide the new friction pad in.

1

Inside Torque Post

Notch

METRICBORE KEY DEPTH (D)

0.625 3/16 0.709

0.688 3/16 0.773

0.750 3/16 0.837

0.813 3/16 0.900

0.875 3/16 0.964

0.938 1/4 1.051

1.000 1/4 1.114

1.063 1/4 1.178

1.125 1/4 1.241

1.188 1/4 1.304

1.250 1/4 1.367

1.313 5/16 1.455

1.375 5/16 1.518

60

SERIES

13 5 15.3

14 5 16.3

16 5 18.3

18 6 20.8

19 6 21.8

20 6 22.8

23 8 26.3

25 8 28.3

28 8 31.3

30 8 33.3

32 10 35.3

35 10 38.3

BORE KEY DEPTH (D)

ENGLISH

STANDARD HUB BORE AND KEY DIMENSIONS

# OFCYLINDERS

0.10 (#1)LB-IN (N-M)

TORQUE CAPACITY, LB-IN (N-M)Torque Capacity at 75psi (5.17 bar)

BRAKE SIZE PAD COEFFICIENT OF FRICTION

SERIES

1

2

3

4

5

6

60

60 SERIES

The , named for its60 Series Dual Disk Brake sixinch diameter disks, offers high performance in atorque range from 3 lb-inches up to 1,010 lb-inches.The 60 Series Brake delivers the precise torque rangeneeded for a particular application by allocatingactuation of just the number of cylinders needed, fromone up to six.

OPTIONS� Non-Standard Key (NSK). For shafts having a

different sized key other than the standardized onesusually used.

ACCESSORIES�Mounting Plate - Flat plate for mounting the brake

and guard if used.�Metric Mounting Bolt - Metric mounting bolts for

the actuators.� 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.

SPECIFICATIONS:Disk/Hub Inertia 2.54 Slug-in

2

Max. Torque 1,010 in-lbsDisk/Hub Weight 9.1 lbs.Max. Ship Wt. 22.5 lbs.Min. Shaft Length 4.6 in.

KEY DEPTHD

2

0.45 (#4)LB-IN (N-M)

40

80

110

150

190

230

(5)

(9)

(12)

(17)

(21)

(26)

170

340

500

670

840

1010

(19)

(38)

(56)

(76)

(95)

(114)

60 SERIES DIMENSIONS (Model 66 shown)

inches (mm)

BRAKE GUARD DIMENSIONS (Accessory)inches (mm)

MOUNTING PLATE DIMENSIONS (Accessory)inches (mm)

3

5.06(128.5)

2.53(64.3)

2.72(69.1)

5.44(138.2)

4x 3/8 - 16UNC x 3.5(M8 x 1.25 x 90mm)

R 4.10(104.1 R)

R 3.71(94.2 R)

1/8 NPT (typ air inlet)

0.69 (17.5)

2.15(54.6)

6.50(165.1)

7.25(184.2)

MIN / MAXØ Ø0.625 / 1.375

(16 / 35)

0.658 (16.7) 3.49(88.7)

0.62(15.75)

9.60(243.8)

MOUNTING SCREWHOLE: 4x 0.28 (7.1)

4x 0.25 (6.4)

5.13(130.3)

THRU-SHAFT HOLE (50.8)2.00 Diam.REQUIRES REMOVAL OF NAME PLATE

0.50(12.7)

Ø 9.25(234.95)

Ø 1.50(38.1)

Ø 3.85 (97.7)(Hole Pattern Diam.Custom hole patternsare available)

6x (8.4)0.33Hole Diam.

0.75(19.1)

0.38(9.7)

air tube access

2.53(64.3)

5.06(128.5)

2.72(69.1)

5.44(138.2)

4x M6 x 1.0 x 12mm DP Std.

90 SERIES

# OFCYLINDERS

0.10 (#1)LB-IN (N-M)



SERIES

1

2

3

4

90

The , named for its90 Series Dual Disk Brake nineinch diameter disks, offers high performance in atorque range from 14 lb-inches up to 3,000 lb-inches.The 90 Series Brake delivers the precise torque rangeneeded for a particular application by allocatingactuation of just the number of cylinders needed, fromone up to four.







without mounting plate.� Valve Assembly - Controls air supply for actuators.


2

Max. Torque 3,000 in-lbs.Disk/Hub Weight 28.4 lbs.Max. Ship Wt. 45 lbs.Min Shaft Length 7.1 in.

19 6 21.8

20 6 22.8

23 8 26.3

25 8 28.3

28 8 31.3

30 8 33.3

32 10 35.3

35 10 38.3

0.750 3/16 0.837

0.813 3/16 0.900

0.875 3/16 0.964

0.938 1/4 1.051

1.000 1/4 1.114

1.063 1/4 1.178

1.125 1/4 1.241

1.188 1/4 1.304

1.250 1/4 1.367

1.313 5/16 1.455

1.375 5/16 1.518

90

SERIES

ENGLISH METRIC

BORE KEY DEPTH (D)BORE KEY DEPTH (D)


4

KEY DEPTHD

0.45 (#4)LB-IN (N-M)

750 (85)

1500 (169)

2250 (254)

3000 (339)

170 (19)

330 (37)

500 (56)

660 (74)


inches (mm)



2.40(60.9)

4.75(120.7)

Ø 9.31(236.5)

4x 3/4-10UNC x 6.0”(M20 x 2.5 x 150mm)4.40

(111.8)

0.81(20.6)

1.00(25.4)

MIN / MAX/Ø Ø0.75 1.375

(19 / 35)

R6.34(161)

R5.59(142)

8.56(217.4)

7.19(182.6)

SECOND ACTUATORONLY USED ON

UB93 & UB94 BRAKES

0.75(19.1)

Ø 13.75(349.3)

Ø 2.50(63.5)

6x 0.52 (13.2)(Hole Diam.)

0.75(19.1)

0.38(9.65)

4.25 (107.95)(Hole Pattern Diam.Custom hole patternsare available)

air tube access

8.56(217.4)

7.19(182.6)

4.28(108.7)

3.59(91.2)


THRU-SHAFT HOLE 1.50 (38.1) Diam.REQUIRES REMOVAL OF NAME PLATE

5

14.10(358.1)

MOUNTING SCREWHOLE: 4x (7.1)0.28

4x (6.35)0.25

8.63(219.2)

110 SERIES

The , named for its110 Series Dual Disk Brakeeleven inch diameter disks, offers high performancein a torque range from 19 lb-inches up to 6,210 lb-inches.The 110 Series Brake delivers the precise torque rangeneeded for a particular application by allocatingactuation of just the number of cylinders needed, fromone up to six.




and guard if used.�Mounting Adapter - A plate connecting adjacent

actuator assemblies. Reduces the quantity ofmounting bolts needed.�Metric Mounting Bolt - Metric mounting bolts for





2

Max. Torque 6,210 in-lbs.Disk/Hub Weight 54.9 lbs.Max. Ship Wt. 80 lbs.Min. Shaft. Length 7.3 in.

# OFCYLINDERS



SERIES

1

2

3

4

5

6

110

1.250 1/4 1.367

1.313 5/16 1.455

1.375 5/16 1.518

1.438 3/8 1.605

1.500 3/8 1.669

1.563 3/8 1.732

1.625 3/8 1.796

1.688 3/8 1.859

1.750 3/8 1.922

1.813 1/2 2.032

1.875 1/2 2.096

1.938 1/2 2.160

2.000 1/2 2.223

2.063 1/2 2.287

2.125 1/2 2.350

2.188 1/2 2.414

2.250 1/2 2.477

2.313 5/8 2.587

2.375 5/8 2.651

2.438 5/8 2.714

110

SERIES

32 10 35.3

35 10 38.3

38 10 41.3

40 12 43.3

42 12 45.3

45 14 48.8

48 14 51.8

50 14 53.8

52 16 56.3

55 16 59.3

58 16 62.3

60 18 64.4

62 18 66.4

METRICENGLISH

BORE KEY DEPTH (D) BORE KEY DEPTH (D)


6

KEY DEPTHD

0.10 (#1)LB-IN (N-M)

0.45 (#4)LB-IN (N-M)

230 (26)

460 (52)

690 (78)

920 (104)

1150 (130)

1380 (156)

1040 (117)

2070 (234)

3110 (351)

4140 (468)

5180 (584)

6210 (702)

BRAKE GUARD DIMENSIONSinches (mm)

MOUNTING PLATE DIMENSIONSinches (mm)


inches (mm)

110 SERIES WITH MOUNTING ADAPTERS (Option - Model 116 shown)inches (mm)

7

THRU-SHAFT HOLE: C Diam.REQUIRES REMOVAL OF NAME PLATE

A

MOUNTINGSCREW

HOLE:4x 0.28

(7.1)

4x 0.25(6.35)

B

Models 111-116

Models 115-116with adapters

inmm

inmm

A B C

16.60 9.13 2.63

421.6 231.9 66.7

18.10 9.88 2.88

459.7 250.95 73.15

BRAKE GUARD DIMS.(110 Series)

13.10(332.7)

R 7.56(192.1)

R 8.37(212.6)

3 BOLTS, EQUALLY SPACED

MountingAdapter

2.09(53.1)

4.40(111.8)

0.56(14.2)

Ø11.75(298.5)

5.38(136.7)

3x 3/4-10UNC x 6.0”(M20 x 2.5mm x 150mm)

MIN / MAX/Ø Ø1.25 2.44

(32 / 62)

1.00(25.4)

1/4” Step in actuatoris on the inside

5.38(136.7)

4.40(111.8)

0.81(20.6)

1.00(25.4)

Ø11.75(298.5)

6x 3/4-10UNC x 6.0”(M20 x 2.5mm x 150mm)

MIN / MAX/Ø Ø1.25 2.44

(32 / 62)

1/4” Step in actuatoris on the outside

4.38(111.3)

8.56(217.4)

SECOND ACTUATORONLY USED ONUB113 & UB114

R6.58(167.1)

R7.35(186.7) THIS CYLINDER NOT USED

ON UB111 AND UB113

Models 111-116

Models 115-116with adapters

inmm

inmm

A B C

16.25 3.00 4.25

412.75 76.2 107.95

17.75 4.50 6.375

450.85 114.3 161.93

MOUNTING PLATE DIMS.(110 Series)

0.75(19.1)

AB

6x (13.2)0.52(Hole Diam.)

0.75(19.1)

0.38(9.65)

C(Hole Pattern Diam. Customhole patterns are available)

air tube access


130 SERIES

# OFCYLINDERS



SERIES

12345678

130

The , named for its130 Series Dual Disk Brakethirteen inch diameter disks, offers high performancein a torque range from 23 lb-inches up to 9,840 lb-inches.The 130 Series Brake delivers the precise torque rangeneeded for a particular application by allocatingactuation of just the number of cylinders needed, fromone up to eight.



ACCESSORIES� Mounting Plate - Flat plate for mounting the brake

and guard if used.� Mounting Adapter - A plate connecting adjacent

actuator assemblies. Reduces the quantity ofmounting bolts needed.�Metric Mounting Bolt - Metric mounting bolts for





2

Max. Torque 9,840 in-lbsDisk/Hub Weight 94.6 lbs.Max. Ship Wt. 130 lbs. with adapterMin. Shaft Length 7.3 in.


1.375 5/16 1.518

1.438 3/8 1.605

1.500 3/8 1.669

1.563 3/8 1.732

1.625 3/8 1.796

1.688 3/8 1.859

1.750 3/8 1.922

1.813 1/2 2.032

1.875 1/2 2.096

1.938 1/2 2.160

2.000 1/2 2.223

2.063 1/2 2.287

2.125 1/2 2.350

2.188 1/2 2.414

2.250 1/2 2.477

2.313 5/8 2.587

2.375 5/8 2.651

2.438 5/8 2.714

2.500 5/8 2.778

2.563 5/8 2.841

2.625 5/8 2.905

2.688 5/8 2.968

2.750 5/8 3.032

130

SERIES

35 10 38.3

38 10 41.3

40 12 43.3

42 12 45.3

45 14 48.8

48 14 51.8

50 14 53.8

52 16 56.3

55 16 59.3

58 16 62.3

60 18 64.4

62 18 66.4

65 18 69.4

68 20 72.9

70 20 74.9

METRICENGLISH

BORE KEY DEPTH (D)BORE KEY DEPTH (D)

8

KEY DEPTHD

0.10 (#1)LB-IN (N-M)

0.45 (#4)LB-IN (N-M)

270 (30)

550 (62)

820 (93)

1090 (123)

1370 (155)

1640 (185)

1910 (216)

2190 (247)

1230 (139)

2460 (278)

3690 (416)

4920 (555)

6150 (694)

7380 (833)

8610 (972)

9840 (1111)

BRAKE GUARD DIMENSIONSinches (mm)

MOUNTING PLATE DIMENSIONSinches (mm)


inches (mm)

130 SERIES WITH MOUNTING ADAPTERS (Option - Model138 shown)inches (mm)

9

8.56(217.5)

R7.40(187)

12.06(306.3)

R8.15(207)

MIN / MAX/Ø Ø1.38 2.75

(35 / 70)

1/4” Step outside

4.40(111.8)

8x 3/4-10UNC x 6.0”( M20 x 2.5mm x 150mm)

Ø13.37(339.6)

1.34(34)

6.88(174.8)

1.00(25.4)

0.81(20.6)

13.44(341.3)

13.44(341.3)

R9.50(241.3)

R10.24(260.1)

MountingAdapter

1/4” Step inside

MIN / MAX/Ø Ø1.38 2.75

(35 / 70)

4.40(111.8)

Ø13.37(339.6)

1.34(34)

6.88(174.8)

4x 3/4-10UNC x 6.0”(M20 x 2.5mm x 150mm)

1.00(25.4)

0.56(14.2)

THRU-SHAFT HOLE C Diam.REQUIRES REMOVAL OF NAME PLATE

A

MOUNTINGSCREW

HOLE:

4x 0.28(7.11)

4x 0.25(6.35)

B

Models 131-138in

mm

in

mm

A B CBRAKE GUARD DIMS.

(130 Series)

Models 135-138 withadapters (1800 Series Guard)

18.10

459.7

25.24

641.1

9.88

250.95

11.63

295.4

2.88

73.2

4.63

117.6

0.75(19.1)

AB

6x (13.2)0.52(Hole Diam.)

0.75(19.1)

0.38(9.65)

C(Hole Pattern Diam. Custom hole

patterns are available)

air tube access


Models 131-138

Models 135-138 withadapters (1800 Series MP)

inmm

in

mm

A B C

6.38

161.9

8.50

215.9

MOUNTING PLATE DIMS.(130 Series)

17.75

450.9

24.90

641.1

4.50

114.3

5.00

127

1800 SERIES

# OFCYLINDERS



SERIES

123456789

10

1800

The , named for its1800 Series Dual Disk Brakeeighteen inch diameter disks, offers high performancein a torque range from 33 lb-inches up to 17,990 lb-inches.The 1800 Series Brake delivers the precise torquerange needed for a particular application by allocatingactuation of just the number of cylinders needed, fromone up to ten.









2

Max. Torque 17,990 in-lbsDisk/Hub Weight 172.8 lbs.Max. Ship Wt. 236 lbs.Min. Shaft Length 9.2 in.


50 14 53.8

52 16 56.3

55 16 59.3

58 16 62.3

60 18 64.4

62 18 66.4

65 18 69.4

68 20 72.9

70 20 74.9

72 20 76.9

75 20 79.9

78 22 83.4

80 22 85.4

82 22 87.4

85 22 90.4

88 25 93.4

90 25 95.4

92 25 97.4

95 25 100.4

98 28 104.4

100 28 106.4

102 28 108.4

105 28 111.4

108 28 114.4

110 28 116.4

115 32 122.4

METRICENGLISH

BORE KEY DEPTH (D)

2.000 1/2 2.223

2.063 1/2 2.287

2.125 1/2 2.350

2.188 1/2 2.414

2.250 1/2 2.477

2.313 5/8 2.587

2.375 5/8 2.651

2.438 5/8 2.714

2.500 5/8 2.778

2.563 5/8 2.841

2.625 5/8 2.905

2.688 5/8 2.968

2.750 5/8 3.032

2.813 3/4 3.142

2.875 3/4 3.205

2.938 3/4 3.269

3.000 3/4 3.332

3.063 3/4 3.396

3.125 3/4 3.459

3.188 3/4 3.523

3.250 3/4 3.586

3.313 7/8 3.696

3.375 7/8 3.760

3.438 7/8 3.823

3.500 7/8 3.887

3.563 7/8 3.950

3.625 7/8 4.014

3.688 7/8 4.077

3.750 7/8 4.141

3.813 1 4.251

3.875 1 4.314

3.938 1 4.378

4.000 1 4.441

4.063 1 4.506

4.125 1 4.569

4.188 1 4.632

4.250 1 4.695

4.313 1 4.758

4.375 1 4.822

4.438 1 4.885

4.500 1 4.949

1800

SERIES

BORE KEY DEPTH (D)

10

KEY DEPTHD

0.10 (#1)LB-IN (N-M)

0.45 (#4)LB-IN (N-M)

400 (45)

800 (90)

1200 (136)

1600 (181)

2000 (226)

2400 (271)

2800 (316)

3200 (362)

3600 (407)

3990 (451)

1800 (203)

3600 (407)

5400 (610)

7200 (813)

9000 (1016)

10800 (1220)

12590 (1422)

14390 (1626)

16190 (1829)

17990 (2033)


25.24(641.1)

MOUNTINGSCREW

HOLE:4x 0.28

(7.11)

4x 0.25(6.35)

11.63(295.40)

THRU-SHAFT HOLE 4.63 (117.60) Diam.REQUIRES REMOVAL OF NAME PLATE



inches (mm)

11

5.88(149.35)

5x 3/4-10UNC x 7.5”(M20 x 2.5mm x 190mm)

Ø 18.00(457.2)

7.15(181.61

2.68(68.07)

MIN / MAX/Ø Ø2.00 4.50

(50 / 115)

1.00(25.4)

0.58(14.8)

13.225(335.92)

R11.98(304.29)

R11.250(285.75)

MountingAdapter

4x M6 x 1.0 x 12mm DP Std.6x (13.21)0.52(Hole Diam.)

0.75(19.05)

0.38(9.65)

Ø 8.50 (215.9)(Hole Pattern Diam. Custom hole

patterns are available)

0.75(19.05)

Ø 24.90(632.46)

Ø 5.00(127)

air tube access

OPTIONAL COOLINGHOLES

1. To select the proper brake size andnumber of cylinders required for aparticular application, first complete theapplication data (at right) and perform thecalculations below using the formulasgiven. Record your results in the spacesprovided.

2. You will need to select a brake that hasa torque capacity greater than that requiredby your application. Also, the brake youselect must not exceed its maximum heatdissipation capability at the cooling speedof your application. Follow steps below.

3. Heat Dissipation vs. RPMRefer to thechart on the next page. Identify the brakeseries which have curves marked abovethe intersection of Heat (HP) dissipationcapacity [calculation #3] versus CoolingSpeed [calculation #6].

4. Torque CapacityRefer to the chart onthe next page to identify brake size andpad options that have torque capacitieswhich are slightly greater than yourTorque(Max) [calculation #1].

5. Torque CapacityFrom the chart selecta brake that has adequate torque capacityand heat dissipation for your Torque (Max)and Cooling Speed.

6. Check to ensure that the brake chosenhas a greater torque capacity than yourcalculated E-stop torque [calculation #7].It may be necessary to use a brake withhigher torque capacity and operate some

cylinders from a separate air supply toprovide E-stop torque.

If your application has a low torque limitrequirement, please check thePerformance Review chart on page 16 toensure the brake you've chosen has aminimum achievable torque below yourrequirement.

Note: If you are faced with severalacceptable options, keep in mind thatsmaller brakes are less expensive, but alarger brake has greater heat dissipation ata given speed.

7. Refer to min. and max. brake shaftdimensions for the brake you have chosen(listed on each Series dimension page) todetermine the acceptable bore dimensionrange. Using the Standard Hub Bore andKey Dimensions table and diagram,select a bore size (See Note). Specifykeyway width only if non-standard isrequired.

8. To Order: Write the brake size, numberof cylinders, bore diameter, key size, andoptions in the space provided below. Referto the chart for choice ofTorque Capacityfriction pads. Turn to page 20 to properlyspecify your brake when ordering. Listaccessories separately.

9. Piping of cylinders will be configured inseries unless otherwise specified. Specifypiping and valving on separate BrakeCylinder Piping Worksheet.

NOTE: We recommend calling a DFEapplications engineer at (603) 332-6150for assistance in sizing a brake for yourapplication.

BRAKE SIZING & SELECTION WORKSHEET INSTRUCTIONS(After completion, you may wish to photocopy this page and fax it to us at (603) 332-3758

APPLICATION DATA

1. Full Roll Diameter (D ) __________ inchesmax

2. Core Diameter (D ) _____________ inchesmin

3. Web Speed, Max.(S ) ____________ ft/minmax

Min.(S ) _____________ ft/minmin

4. Rotational Speed, Max. (N ) _______ rpmmax

Min. (N ) ________ rpmmin

5. Web Tension, Max.(F .) ____________ lbs.max

Min.(F .) _____________ lbs.min

6. Web Material __________________________

Thickness _______________________ inches

Width __________________________ inches

7. E-Stop Time (T) ____________________ sec.

Roll Weight (W) ____________________ lbs.

CALCULATIONS

1. Max. Torque = D x Fmax max(in-lb) 2

2. Min Torque = D x Fmin min(in-lb) 2

3. Heat (HP) = Fmax maxx S33,000

4. Brake N * = 3.82max Smax(RPM) Dmin

* for max. cooling speed calculation

5. Brake N * = 3.82min Smin(RPM) Dmax* for min cooling speed calculation

6. Cooling Speed = 2N + Nmin max(RPM) 3

7. E-Stop Torque = W x D x Smax max(in-lb) 7728 x T

SPECIAL REQUIREMENTS

BRAKE SELECTED BORE AND KEY

12

13

CHARTS FOR BRAKE SIZING AND PAD SELECTION

500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500

150

140

130

120

110

100

90

80

70

60

50

40

30

20

10

0

1800 Series - 3900 RPM Max.


RPM

HE

AT

DIS

SP

AT

ION


HP

HEAT DISSIPATION vs. RPM

35

30

25

20

15

10

5

0

KW



# OFCYLINDERS



SERIES

123456123412345612345678123456789

10

1800

0.10 (#1) 0.45 (#4)LB-IN (N-M) LB-IN (N-M)

40 (5) 170 (19)

80 (9) 340 (38)

110 (12) 500 (56)

150 (17) 670 (76)

190 (21) 840 (95)

230 (26) 1010 (114)

170 (19) 750 (85)

330 (37) 1500 (169)

500 (56) 2250 (254)

660 (74) 3000 (339)

230 (26) 1040 (117)

460 (52) 2070 (234)

690 (78) 3110 (351)

920 (104) 4140 (468)

1150 (130) 5180 (585)

1380 (156) 6210 (702)

270 (30) 1230 (139)

550 (62) 2460 (278)

820 (93) 3690 (416)

1090 (123) 4920 (555)

1370 (155) 6150 (694)

1640 (185) 7380 (833)

1910 (216) 8610 (972)

2190 (247) 9840 (1111)

400 (45) 1800 (203)

800 (90) 3600 (407)

1200 (136) 5400 (610)

1600 (181) 7200 (813)

2000 (226) 9000 (1017)

2400 (271) 10800 (1220)

2800 (316) 12590 (1422)

3200 (361) 14390 (1626)

3600 (407) 16190 (1829)

3990 (451) 17990 (2033)

60

90

110

130

PERFORMANCE REVIEW TABLE

MINIMUMBORE

in (mm)

MAXIMUMBORE

in (mm)

0.750(19)

1.250(32)

1.375(35)

2.000(50)

1.375(35)

2.438(62)

2.750(70)

4.000(115)

0.625(13)

1.375(35)

BRAKESERIES

MAX. # OFCYLINDERS

MIN. TORQUECAPACITY

lb-in. (N-M)

at 5 psiw/ two #1 pads

MAX TORQUECAPACITY

lb-in. (N-M)

at 75 psiw/ max. #4 pads

MAXIMUMRPM

60

90

110

130

1800

4

6

6

8

10

14(1.5)

19(2)

23(2.6)

33(4)

3000(339)

6210(702)

9840(1111)

17990(2033)

4500

3600

3100

3900

1010(114) 6400

3(0.3)

OPTIONS & ACCESSORIES

VALVE DIMENSIONS

A J MK LG H ID E FB C

3.12 2.125 0.22 0.50 0.80 1.00 0.45 2.37 1.00 0.40 4.501/8 NPT 1/8 NPT

79.25 53.98 5.59 12.7 20.32 25.4 11.43 60.2 25.4 10.16 114.301/8 NPT 1/8 NPT

6.38 5.38 0.22 0.50 0.80 1.00 0.45 2.37 1.00 0.40 4.501/8 NPT 1/8 NPT

162.05 136.65 5.59 12.7 20.32 25.4 11.43 60.2 25.4 10.16 114.301/8 NPT 1/8 NPT

in

mm

in

mm

SIZE

1 0R 2VALVE

3 0R 4VALVE

14

Mounting Adapter Assemblies. A plate with shortbolts that connects adjacent actuator assemblies.Reduces the quantity of mounting bolts needed andprovides an optional mounting bolt pattern. Mountingbolts included. Adapters are shown in the dimensionaldrawings for Models 110 through 1800.

613-1318

613-1191

613-1193

110 SERIES - 115 & 116 only

130 SERIES - 135 - 138 only

1800 SERIES - Standard

MODEL PART NUMBERS

Mounting Plates. Flat plate for mounting the brakeand guard if used. Mounting Plates are shown in thedimensional drawings for all models.

60

90

SERIES

ALL

ALL

MODELS PART NUMBERS

213-0305

213-1364

110

130

1800

NO ADAPTERS

with ADAPTERS

NO ADAPTERS

with ADAPTERS

ALL

213-1365

213-1366

213-1366

213-1367

213-1367

External Shut-off Valve Assemblies. Controlsair supply for actuators. Please specify valvingconfiguration as shown on the following page whenordering a complete brake assembly. See diagrambelow for dimensions.

NUMBER OF VALVES

One-Valve Assembly

Two-Valve Assembly

Three-Valve Assembly

Four-Valve Assembly

Replacement Slider Valve

613-0238

613-0240

613-0242

613-0244

119-0007

PART NUMBERS

Guard Assemblies. Safety device to prevent peopleor objects from touching brake when in use. Guardsare shown in the dimensional drawings for all models.

60

90

110

130

1800

SERIES

ALL

ALL

NO ADAPTERS

with ADAPTERS

NO ADAPTERS

with ADAPTERS

ALL

MODELS PART NUMBERS

613-1311

613-1346

613-1316

613-1347

613-1347

613-1349

613-1349

Guard Mounting Blocks. Right angle block with0.344 inch through hole to machine frame. Allowsinstallation of the guard if a mounting plate is notused. All Brake Series require 4 per unit.

213-0310ALL SERIES

KG

F

H

I (NPT)AIR IN

LD

AB

J (NPT)AIR OUT

C DIA. 2 PLACES

E

M1/4” (6MM)AIR TUBING

BRAKE CYLINDER PIPING WORKSHEET

The diagrams below represent the axial views of complete actuator assemblies for each of DFE’s Heavy DutyBrakes. Identify your brake size by the first two digits appearing above each brake. Draw your piping fromeach actuator or pad to the valve required. Piping of cylinders will be completed in series unless otherwisespecified.

15

13 _

18 _ _For: 111 113112 114

9 _

6 _

For: 115116

� 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 byremoving the brake pad. Takes only seconds. Noextra parts to buy, install or remove.� Brake pads having friction coefficients of 0.10 (#1),

and 0.45 (#4). Asbestos free.� Retrofit kits available for dual disk brakes of other

manufacturers.

UNIVERSAL ACTUATOR

16

DIMENSIONSinches (mm)

Actuator Assemblies. May be purchased asreplacement parts, or to increase torque as add-ons,space provided. Specify friction pads and mountingbolt kit separately. Note: Addition of a second actuatorto a 60 Series Brake requires Strap Kit 610-0018

CYLINDERS 60 SERIES 90 - 1800 SERIES

1 Cylinder

2 Cylinders

3 Cylinders

613-0188

613-0190

613-0192

613-0007

613-0005

n/a

Friction Pads. Available in two coefficients. #4(0.45) is standard on DFE brakes.

COEFFICIENT 60 SERIES 90-1800 SERIES

#1 (0.10)

#4 (0.45)

613-3544

613-3574

613-3543

613-3573

Silencer Pads.™

100% success rate eliminating brakesqueal. Available in two coefficients. #4 (0.45) isstandard on DFE brakes.

COEFFICIENT 60 SERIES 90-1800 SERIES

#1 (0.10)

#4 (0.45)

610-3741

610-3009

610-3250

610-3433

Cylinder Kit. Addition or replacement of cylinderscan be done with the following kits. Friction pads andmounting bolt kit not included.

60 SERIES

90-1800 SERIES

613-1305

613-1317

Mounting Ki .t Used to mount brakes to machine.For additional actuator assemblies or replacementpart. Metric sizes available. Kit contains bolt,washers, and spacer.

1800SERIES

90-130SERIES

UNIT60

SERIES

610-3610

610-3632

610-3612

610-3630

610-3625

610-3645

inch

metric

REPLACEMENT PARTS

0.75(19)

10.06(256)

0.50(13)

2x 1/8 NPT PORTS

2.50(64)2.78

(71)

8.56(217)

2.52(64)

3.53(90)

4.12(105)

1.34 (34)

2x (21)Ø0.812

3.25(83)

1.16(30)

In order to obtain the best brake performance andensure trouble-free operation, you must ensure that theinstallation environment and related machinerycomply with the following conditions. Compliancewith these requirements is necessary to validate the 5Year Warranty No-Squeal Warrantyand .

1. The brake mounting surface must be rigid andstrong enough so it doesn’t deflect when loaded bybrake torque.

2. The shaft must be straight. (Bent shafts cause diskrun-out, resulting in vibration and noise)

3. The shaft must not have noticeable end play.

4. The shaft bearing must be in good condition, withno noticeable free-play or noise.

5. The shaft diameter must be properly matched tothe brake bore. (A loose fit can cause balanceproblems and disk run-out)

6. The shaft must be perpendicular to the brakemounting surface to within 0.040" (1 mm),measured at the end of the shaft.

7. The set screws must be tight so the disk assemblydoes not move on the shaft.

8. The actuator plates must be centered between thedisks and be parallel to the brake mountingsurface.

9. All mounting bolts and set screws must be tight.

10. The friction surfaces of the disks and friction padsmust be clean and free of oil or any other lubricantor substance.

11. The friction pads must be installed with thefriction surface against the disk, and the steel backplate against the air cylinder.

12. Actuator plates must be parallel to the disks.(Crooked actuators cause uneven wear and noise.)

INSTALLATION CHECKLIST FOR DUAL DISK BRAKES

HOW TO ORDEROrder your brake using the Dual Disk product code below.

1. Specify the brake series and the quantity of cylinders you require2. Specify bore (standard key is assumed unless otherwise specified).3. Specify any options (if needed).

4. Specify the pad Coefficient of Friction based on your worksheet calculations (page 12), and quantity of eachcoefficient of pad (i.e. 2D93 = 6 pads).

PADSQty of #1 (0.10 coeff.)Qty of #4 (0.45 coeff.)

5. Specify any desired accessories. (Note: SAE mounting hardware is provided if metric mounting hardware isnot specified)

17

Your brake:____________________________________________________________________________

Refer to Brake Sizing and Selection Worksheet in the previous pages for selection of your brake.

ACCESSORIES (See Brake Pages for More Info)Mounting Kit Mounting PlateMounting Adapter Metric Mounting BoltGuard Guard BlocksValve Assembly

2D X X - XXX - OPTIONS

See Bore & KeyCharts on Brake

pages

DUAL DISKBRAKE

SERIES1-6 for 60 Series1-4 for 90 Series1-6 for 110 Series1-8 for 130 Series

1-10 for 1800 Series

# OFCYLINDERS BORE

| |||

OPTIONS= Nonstandard

Key= Specials

NSK

Z

= 60 Series= 90 Series= 110 Series= 130 Series= 1800 Series

69

111318

Examples: 2D1809-1.5002D116-1.125- NSK

217 PICKERING ROADROCHESTER, NH 03867-4630

PHONE: 603-332-6150FAX: 603-332-3758

E-mail: [email protected]: www.dfe.com

CANADA

MEXICO

UNITED KINGDOM

EUROPE

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KOREA

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CHINA

DOC 801-1317 R4Printed in USA

©2017 DOVER FLEXO ELECTRONICS, INCALL RIGHTS RESERVED

DOVER FLEXO ELECTRONICS, INC.

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