Dynaspede CAT NO.

BR9334
September 2007

INSTRUCTION MANUAL

MAGNETIC PARTICLE CLUTCH AND BRAKE

DYNASPEDE INTEGRATED SYSTEMS (P) LIMITED

136 A, SIPCOT INDUSTRIAL COMPLEX
HOSUR - 635 126, TAMIL NADU. INDIA.
Phone : + 91-4344-276915/276243/276813
Fax : + 91-4344-276841
Email : mail@dynaspede.com
Website : www:dynaspede.com
 CONTENTS
1.0 Introduction:.................................................................................1
1.1 Unpacking. ....................................................................................1
1.2 Storage. ........................................................................................1
2.0 Principle Of Operation:..................................................................2
3.0 Installation: ..................................................................................8
3.1 Location. .......................................................................................8
3.2 Mounting. ......................................................................................8
3.3 Coupling........................................................................................8
3.4 Electrical connections. .....................................................................9
4.0 Start-Up Procedure: ....................................................................10
5.0 Maintenance:...............................................................................11
6.0 Trouble Shooting:........................................................................12
6.1 General. ...................................................................................... 12
6.2 To find fault in Controller: .............................................................. 13
6.3 To find fault in Particle device: ........................................................ 13
6.4 To find fault in Magnetic powder: .................................................... 13
7.0 Disassembly Procedure: ..............................................................14
7.1 Disassembly procedure of magnetic particle brake ............................. 14
7.1.1 Powder replacement: .................................................................. 15
7.1.2 Bearing replacement: ................................................................. 15
7.1.3 Coil replacement:....................................................................... 16
7.2 Disassembly procedure of magnetic particle clutch ............................. 16
7.2.1 Powder replacement: .................................................................. 16
7.2.2 Bearing replacement: ................................................................. 17
7.2.3 Coil replacement:....................................................................... 17
8.0 Reassembly Procedure:...............................................................18
8.1 Proximity sensor Assembly procedure: ............................................. 18
9.0 List of recommended spares: ......................................................19
10.0 List of illustrations: ...................................................................19

WARRANTY:

Dynaspede warrants the goods against defects in design, materials and

workmanship as per our standard warrantee terms or (in the case of third party
components/sub-systems) by the counter guarantee terms, of the respective
manufacturers.

IMPORTANT:

Magnetic particle devices are dispatched after due inspection and routine tests.
Immediately on receipt, inspect for any outward damage in transit, before
unpacking the individual parts & components from their packing cases. Ensure that
the units are received in good order & condition and promptly notify us and your
insurance agency in case of any transit damage or shortages. Repack the units in
the original packing case until required to be opened for inspection or installation.

Dynaspede reserves the right to change the content and product specification
without notice.
Dynaspede BR9334

1.0 Introduction:

Dynaspede magnetic particle clutches and brakes offer a neat and simple
approach for applications involving accurate control of rewinding and
unwinding torque/tension. This high torque, low inertia devices are to be
used with the Dynaspede Automatic Torque/Tension Controllers. These
latest electronic tension controllers and Tension Sensors or Load Cells,
form an excellent closed loop feedback control system, meeting today’s
industry demands for dead on precision and near zero maintenance.
Alternatively Dynaspede Magnetic Particle Devices can be used with
Dynaspede Manual Tension Controller where manual operation is desired.

1.1 Unpacking.

Immediately on receipt, inspect for any outward damage in transit,

before opening the packing case. Ensure that the units are received in
good order and condition and promptly notify us in case of any transit
damages or shortages. Repack the units in the original packing case until
required to be opened for inspection or installation.

1.2 Storage.

Store in a cool, dry place. Dampness of powder may significantly degrade

performance. Do not store with the units tilted or vertical for long
periods of time or subject them to shocks.

Ο Caution

€ Avoid jerks and shocks while un-packing or by dropping the

units.

€ The units contain rotating parts needing standard installation

practices and safety measures prescribed to avoid injury to
the operating personnel.

€ The units have to be mounted in a horizontal position only,

with an inclination not exceeding 20° from horizontal.

€ The temperature rise during operation at rated values may be

high enough to cause burn injury. Provide protection against
accidental body contact with the unit in operation.

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Dynaspede BR9334

2.0 Principle of Operation:

The operating principle of Dynaspede Magnetic Particle Brake is

explained with reference to drawing no. HGSL 93158, and Particle clutch
is explained with reference to drawing no. HGSL 93159. Major functional
elements of the Magnetic Particle brake/clutch are shown in these
drawings.

A shaft, carrying the brake disc rotates concentric to a stationary

housing. The angular space between the disc and housing forms the
active powder gap, responsible for developing the braking torque. As the
direct current through the coil is increased, the strength of the magnetic
field and therefore the powder within the gap become progressively
dense with a corresponding increase in the torque developed.

As the brake disc slips past the frictional medium of magnetic powder,
the braking energy dissipated, manifests as heat. This results is a
gradual temperature rise of the unit which reaches a final steady-state
value. In order to restrict this value to within safe limits, the heat energy
has to be effectively carried away to the surroundings. The final steady-
state temperature poses a limit on the maximum continuous power
dissipation capabilities of powder brakes, as specified for each rating.
Under these conditions the body temperature is expected to be within
75° C.

In force-cooled model, the body

Housing
temperature relates to the
temperature of the actual brake Drum Coil
body accessible through the Shaft Follower
openings on the force-cooling
jacket.

Magnetic Particle Clutch consists of

two rotating member called drum
Toothed
and a stationary member called
Wheel
pole fixed concentrically
maintaining close air gap between
each other. Same operational
principle as applied to the Brake is
also applicable here.

The main features of the magnetic particle devices are listed below.
• Develops smooth, accurate and infinitely variable torque
• Maintains the set torque independent of slip speed.

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Dynaspede BR9334

• Simple operating principle and construction ensures a long trouble

free operation. No friction elements to cause wear and tear.
• Low device inertia to output torque ratio resulting in excellent
dynamic response and ultra fast operation.
• Heavy-duty construction to withstand severe shock loading without
distortion.
• Silent and maintenance free.
• Available in wide range of torque rating from 0.06kgm. to 40kgm.

The standard Dynaspede Magnetic Particle Brakes and Clutches are air-
cooled self-ventilated and suitable for flange mounting applications. Also
these devices are offered with suitable brackets for foot mounting
applications. For applications where high power dissipation is envisaged
Dynaspede Particle Devices i.e. Brakes and Clutches are offered in forced
cooled version.

Both ends of the excitation coil are brought out and terminated on a
terminal block. The terminal block is placed inside the terminal box,
which is mounted on the housing of the device.

Force Cooled (Axial fan) Force Cooled Particle Clutch

Particle Brakes Force Cooled Particle
Brakes

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Dynaspede BR9334

Magnetic particle clutch (0.06 to 0.6kg.m rating):

MODEL (Series) 200 201 202
RATING PC 0.06 PC 0.3 PC 0.6
RATED TORQUE kg.m 0.06 0.3 0.6
COIL RESISTANCE ±10%@ 25°C Ohms 43 33.3 17.3
RATED EXCITATION VOLTAGE V DC 24 24 24
EXCITATION CURRENT FOR RATED TORQUE
Amps (DC) 0.5 0.6 1.0
(MAX)
TIME CONSTANT TORQUE (measured to
reach 63% of rated value after a step
ms 110 130 134
function of voltage applied at 100RPM
speed of rotating member)
TIME CONSTANT CURRENT (measured to
reach 63% of rated value after a step ms 12.4 35 37
function of voltage applied)
GD2 OF INPUT MEMBER kgm2 6.5 X 10-4 1.6 X 10-3 2.9 X 10-3
GD2 OF OUTPUT MEMBER kgm2 1.76 X 10-4 4.56 X 10-4 1.13 X 10-3
EXCITATION COIL INSULATION Class - F (Temperature rise limited to 90°C)
NON EXCITED DRAG TORQUE (measured
< 1% of rated torque
at 100RPM speed of rotating member)
AMBIENT TEMPERATURE 30°C
MAXIMUM ALLOWED SURFACE/BODY
90°C
TEMPERATURE
6000 ZZ 6201 ZZ 6203 ZZ
Drive end
6000 ZZ 6201 ZZ 6202 ZZ
BEARINGS
6000 ZZ 6201 ZZ 6202 ZZ
Load end
6000 ZZ 6201 ZZ 6203 ZZ
MOUNTING HORIZONTAL - Shaft(s) parallel to ground
SELF COOLED MODEL
POWER DISSIPATION AT 100 RPM SLIP Watts 20 55 60
MAXIMUM ALLOWED SLIP AT RATED
RPM 324 162 97
TORQUE
ALLOWABLE MAXIMUM SPEED AT EXCITED
1200 RPM
CONDITION
ALLOWABLE MAXIMUM SPEED AT NON-
3000 RPM
EXCITED CONDITION
WEIGHT (kg): Flange mounted kg 2.1 4.0 5.3
WEIGHT (kg): Pedestal mounted kg 2.4 5.3 7.5

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 Dynaspede BR9334

Magnetic particle clutch (1.25 to 40kg.m rating):

MODEL (Series) 203 204 205 206 207 208
RATING PC 1.25 PC 2.5 PC 5 PC 10 PC 20 PC 40
RATED TORQUE kg.m 1.25 2.5 5 10 20 40
COIL RESISTANCE ±10%@ 25°C Ohms 13.8 10.76 10.7 6.7 5.5 3.8
RATED EXCITATION VOLTAGE V DC 24 24 24 24 24 24
EXCITATION CURRENT FOR RATED Amps
1 1.6 1.88 2.55 3.2 4.5
TORQUE (MAX) (DC)
TIME CONSTANT TORQUE (measured to
reach 63% of rated value after a step
ms 212 228 280 320 430 520
function of voltage applied at 100RPM
speed of rotating member)
TIME CONSTANT CURRENT (measured to
reach 63% of rated value after a step ms 69 77 82 89 138 276
function of voltage applied)
GD2 OF INPUT MEMBER kgm2 8.0 X 10-3 2.8 X 10-2 5.2 X 10-2 1.6 X 10-1 4.2 X 10-1 7.84 X 10-1
GD2 OF OUTPUT MEMBER kgm2 3.9 X 10-3 1.36 X 10-2 2.72 X 10-2 6.0 X 10-2 1.8 X 10-1 6.36 X 10-1
EXCITATION COIL INSULATION Class - F (Temperature rise limited to90 Deg.C)
NON EXCITED DRAG TORQUE (measured
< 1% of rated torque
at 100RPM speed of rotating member)
AMBIENT TEMPERATURE 30°C
MAXIMUM ALLOWED SURFACE/BODY
90°C
TEMPERATURE
Drive 6003 ZZ 6005 ZZ 6206 ZZ 6207 ZZ 6208 ZZ 6309 ZZ
end 6003 ZZ 6205 ZZ 6206 ZZ 6207 ZZ 6308 ZZ 6309 ZZ
BEARINGS
Load 6003 ZZ 6205 ZZ 6206 ZZ 6207 ZZ 6308 ZZ 6309 ZZ
end 6003 ZZ 6005 ZZ 6206 ZZ 6207 ZZ 6208 ZZ 6309 ZZ
MOUNTING HORIZONTAL - Shaft(s) parallel to ground
SELF COOLED MODEL
POWER DISSIPATION AT 100 RPM SLIP Watts 100 110 150 250 375 550
MAXIMUM ALLOWED SLIP AT RATED
RPM 58 31 26 18 13 9
TORQUE
ALLOWABLE MAXIMUM SPEED AT EXCITED
1200 RPM
CONDITION
ALLOWABLE MAXIMUM SPEED AT NON-
3000 RPM 2000 RPM
EXCITED CONDITION
WEIGHT (kg) : Flange mounted kg 7.7 12.0 22.0 41.0 62.0 108.0
WEIGHT (kg) : Pedestal mounted kg 8.7 12.5 26.0 48.0 72.0 112.0
FORCED AIR (BLOWER) COOLED MODEL
POWER DISSIPATION AT 100 RPM SLIP Watts NA NA 350 525 850 1250

ALLOWABLE MAXIMUM SPEED AT EXCITED

1200 RPM
CONDITION
ALLOWABLE MAXIMUM SPEED AT NON-
4000 RPM 3000 RPM
EXCITED CONDITION
WEIGHT (kg) : Flange mounted kg NA NA 26.0 47.0 69.0 122.0
WEIGHT (kg) : Pedestal mounted kg NA NA 34.4 58.6 83.6 130.8
BLOWER DETAILS POWER: 230V AC, 0.8Amps; AIRFLOW: 450m3/Hr

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Dynaspede BR9334

Magnetic particle brake (0.06 to 0.6kg.m rating):

MODEL (Series) 100 101 102
RATING PB 0.06 PB 0.3 PB 0.6
RATED TORQUE kg.m 0.06 0.3 0.6
COIL RESISTANCE ±10%@ 25°C Ohms 43 33.3 17.3
RATED EXCITATION VOLTAGE V DC 24 24 24
EXCITATION CURRENT FOR RATED Amps
0.5 0.6 1.0
TORQUE (MAX) (DC)
TIME CONSTANT TORQUE (measured
to reach 63% of rated value after a
ms 110 130 134
step function of voltage applied at
100RPM speed of rotating member)
TIME CONSTANT CURRENT (measured
to reach 63% of rated value after a ms 12.4 35 37
step function of voltage applied)
GD2 OF ROTATING MEMBER kgm 2
6.5 X 10 -4
1.6 X 10 -3
2.9 X 10-3
EXCITATION COIL INSULATION Class - F (Temperature rise limited to 90°C)
NON EXCITED DRAG TORQUE
(measured at 100RPM speed of < 1% of rated torque
rotating member)
AMBIENT TEMPERATURE 30°C
MAXIMUM ALLOWED SURFACE/BODY
90°C
TEMPERATURE
6000 ZZ 6201 ZZ 6203 ZZ
BEARINGS
6000 ZZ 6201 ZZ 6202 ZZ
MOUNTING HORIZONTAL - Shaft(s) parallel to ground
SELF COOLED MODEL
POWER DISSIPATION AT 100 RPM
Watts 20 55 60
SLIP
MAXIMUM ALLOWED SLIP AT RATED
RPM 324 162 97
TORQUE
ALLOWABLE MAXIMUM SPEED AT
1200 RPM
EXCITED CONDITION
ALLOWABLE MAXIMUM SPEED AT
3000 RPM
NON-EXCITED CONDITION
WEIGHT (kg) : Flange mounted kg 1.8 3.75 5.0
WEIGHT (kg) : Pedestal mounted kg 2.3 6.4 8.0

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 Dynaspede BR9334

Magnetic particle brake (1.25 to 40kg.m rating):

MODEL (Series) 103 104 105 106 107 108
RATING PB 1.25 PB 2.5 PB 5 PB 10 PB 20 PB 40
RATED TORQUE kg.m 1.25 2.5 5 10 20 40
COIL RESISTANCE ±10%@ 25°C Ohms 13.8 10.76 10.7 6.7 5.5 3.8
RATED EXCITATION VOLTAGE V DC 24 24 24 24 24 24
EXCITATION CURRENT FOR Amps
1 1.6 1.88 2.55 3.2 4.5
RATED TORQUE (MAX) (DC)
TIME CONSTANT TORQUE
(measured to reach 63% of
rated value after a step function ms 212 228 280 320 430 520
of voltage applied at 100RPM
speed of rotating member)
TIME CONSTANT CURRENT
(measured to reach 63% of
ms 69 77 82 89 138 276
rated value after a step function
of voltage applied)
GD2 OF ROTATING MEMBER kgm2 8.0 X 10-3 2.8 X 10-2 5.2 X 10-2 1.6 X 10-1 4.2 X 10-1 7.84 X 10-1
EXCITATION COIL INSULATION Class - F (Temperature rise limited to 90°C)
NON EXCITED DRAG TORQUE
(measured at 100RPM speed of < 1% of rated torque
rotating member)
AMBIENT TEMPERATURE 30°C
MAXIMUM ALLOWED
90°C
SURFACE/BODY TEMPERATURE
6003 ZZ 6205 ZZ 6206 ZZ 6207 ZZ 6308 ZZ 6309 ZZ
BEARINGS
6003 ZZ 6005 ZZ 6206 ZZ 6207 ZZ 6208 ZZ 6309 ZZ
MOUNTING HORIZONTAL - Shaft(s) parallel to ground
SELF COOLED MODEL
Power Dissipation @ 100 RPM slip Watts 100 110 150 250 375 550
MAXIMUM ALLOWED SLIP AT
RPM 58 31 26 18 13 9
RATED TORQUE
ALLOWABLE MAXIMUM SPEED
1200 RPM
AT EXCITED CONDITION
ALLOWABLE MAXIMUM SPEED
3000 RPM 2000 RPM
AT NON-EXCITED CONDITION
WEIGHT (kg): Flange mounted kg 7.0 11.5 18.5 34.0 52.0 92.0
WEIGHT (kg): Pedestal mounted kg 9.0 16.5 24.0 46.0 68.0 125.0
FORCED AIR (BLOWER) COOLED MODEL
Power Dissipation @ 100 RPM slip Watts NA NA 350 525 850 1250
ALLOWABLE MAXIMUM SPEED
1200 RPM
AT EXCITED CONDITION
ALLOWABLE MAXIMUM SPEED
4000 RPM 3000 RPM
AT NON-EXCITED CONDITION
WEIGHT (kg): Flange mounted kg NA NA 21.5 40.0 59.0 106.0
WEIGHT (kg): Pedestal mounted kg NA NA 30.1 52.5 74.5 132.6
BLOWER DETAILS POWER: 230V AC, 0.8Amps; AIRFLOW: 450m3/Hr
FORCED AIR (Axial fan) COOLED MODEL
Power Dissipation @ 100 RPM slip Watts NA NA 600 830 1090 1440
ALLOWABLE MAXIMUM SPEED
1200 RPM
AT EXCITED CONDITION
ALLOWABLE MAXIMUM SPEED
4000 RPM 3000 RPM
AT NON-EXCITED CONDITION
WEIGHT (kg): Flange mounted kg NA NA 24.7 49.7 62.7 107.0
WEIGHT (kg): Pedestal mounted kg NA NA 30.2 62.2 78.7 140.0
3 3
BLOWER DETAILS POWER: 230V AC, 50Hz 740m /h 900m /h 1610m3/h

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Dynaspede BR9334

3.0 Installation:

Personnel: Installation, operation and maintenance of the equipment

should be carried out by qualified personnel. A qualified person is
someone who is technically competent and familiar with all safety
information and established safety practices; with the installation
process, operation and maintenance of this equipment; and with all the
hazards involved.

3.1 Location.

Unless rated for special duty, Dynaspede Magnetic Particle Devices

should be located to confirm to our following specification.

• The atmosphere to be clean and dry and free of inflammable or

combustible vapors, excessive moisture or dust.
• There should be room around the equipment to
i. Provide accessibility for inspection and adjustments.
ii. Provide non-restricted airflow to the intake and from the
exhaust vents on both sides of the device.
• There should be no restriction in the airflow or any possibility of
recirculation of the heated exhaust air, back into the intakes.
• Ambient temperature to be within -6 to 30°C.
• Altitude to be below 1,000 meters.

IMPORTANT:

The performance of the device shall be poor, if the powder

becomes moist. Particular care should therefore be taken to
prevent entry of water or oil into the unit. When the device is
installed near a gearbox, complete sealing should be provided to
prevent oil from seeping into the unit along with the shaft.

3.2 Mounting.

Dynaspede Magnetic particle devices are to be mounted in horizontal

position with an inclination not exceeding 20 degrees from
horizontal. No other mounting positions are permitted. The mounting
surfaces should be rigid and vibration free.

3.3 Coupling.

In direct coupling standard engineering practices should be followed to

ensure correct alignment.

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Dynaspede BR9334

If Magnetic Particle device is coupled using gears or chain, care has to be

taken so that no undue stress is applied on bearings of Particle device
due to misalignment.

NOTE: In the case of Particle clutch, the input (driving) shaft and output
driven shaft are labeled as “MOTOR SIDE” and “LOAD SIDE” respectively.
It is not recommended to use the clutch by reversing input and output
sides, as it would impair the torque characteristics and reduce the
powder life. In case the device is to be used other than our
recommendations, prior consultation with Dynaspede representative is
recommended.

3.4 Electrical connections.

All electrical connections are clearly indicated in the respective terminal

blocks and associated control equipments. For details refer to the
catalogues on the control equipment. For force cooled models, blower to
be connected to the suitable motor starter. In this model interlock to be
provided such a way that controller gets supply only when the blower is
ON. Refer drawing nos. P31242813 & P31242693 for blower
connection.

IMPORTANT:

*Before starting the system, it is necessary to ensure that the

blower is started (for force cooled devices) and found operating
satisfactory. The tension controller should be interlocked with
the blower motor starter in order to prevent starting of the
controller without starting blower motor.

Initial checks before applying the power:

 Mains power supply is correct.

 Check all external wiring circuits – power, control, particle device
and earth connections.

NOTE: Completely disconnect the equipment before point to point

checking with a buzzer or when checking insulation with a Meggar.

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Dynaspede BR9334

 Check for damage to equipment.

 Check for loose ends, clippings, drilling swarf etc lodged in the
equipment and system.
 Check whether the particle device can be turned free from
obstruction.

Ensure the safety of the complete system before equipment is

ON:

 Ensure that rotation of the device in either direction will not cause
damage.
 Ensure that nobody else is working on another part of the system,
which will be affected by powering up.
 Ensure that other equipment will not be adversely affected by
powering up.

WARNING!

Ensure that all wiring is electrically isolated and cannot be made

“live” unintentionally by other personnel.

The magnetic particle device must be connected to a safety earth.

This equipment can endanger life through rotating machinery.

The user must provide guarding and/or additional safety system
to prevent risk of injury.

4.0 Start-Up Procedure:

Before the unit is put into normal operation, the following pre-running
procedures have to be strictly followed. In “as received condition”, the
magnetic device within the unit will be scattered about in the interior of
the unit, due to shocks and vibrations in transit. The pre-running
procedure outlined below will re-orient the powder in proper locations for
normal operation thereafter. Failure to observe the pre-running
procedure can drastically impair the torque transmission and may
result in torque fluctuations.

¾ With the unit in a non-excited condition, run the shaft at 10rpm for 5
minutes and then run the shaft at the highest possible speed (not
exceeding 1500rpm) for about 5 minutes. The centrifugal action due
to this pre-running, will help relocate the powder within the working
gaps of the unit.

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Dynaspede BR9334

¾ With the unit under running condition, set the excitation current to
about 25% of the rated value and switch the excitation periodically
ON (for 5sec.) and OFF (10sec.) for 25 to 30 times, taking care that
the unit does not over heat. In case the body temperature rises
beyond 30°C above the ambient, allow the unit to cool off, before
continuing this procedure.
¾ Allow the unit to cool off completely before normal operation.
Don’t operate the device above the maximum temperature (given in
specifications), which reduces the service life of the device.

Start-up procedure and adjustments

For start-up and adjustment procedure follow step-by-step procedure
given in the catalogue of control equipment.

5.0 Maintenance:

Dynaspede magnetic particle devices are well protected against ingress

of moisture or external contaminants. Although they need virtually no
routine maintenance, the following precautions during installation or
periodic inspection can greatly increase the service life of these units.

Performance will be poor if moisture or oil is allowed to enter the unit. A

leaky gearbox or oil flowing along the shaft can adversely affect the
service life of units.
Since the service life of the magnetic device depends on the application, no
periodic replacement of powder is prescribed. In practice, powder
replacement is recommended when the torque transmission falls below
70% of the initial value. A drop in torque transmission can be
compensated by increasing the value of excitation up to about 130% of
initial value, which set during commissioning.
Although powder service life varies according to the operating conditions, the service life of the
powder is estimated to be 5000 to 8000 hours when the device is used under allowable slip-heat
dissipation rate.

For more details of settings on control equipments, refer to relevant

catalogue.
The following periodic maintenance should be performed to prevent
interruption in the operation.

ƒ Inspect the control cabinets and covers for tightness.

ƒ Check the electrical equipments and terminal blocks of brake for firm
electrical connections and cleanliness.
ƒ Check the bearing noise and bearing temperatures. The permissible
temperature rise of the bearings, over the ambient is less than 50°C.
If the said limits are exceeded the probable causes are deterioration

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Dynaspede BR9334

and caking of the grease or/and undue stresses on bearings due to

improper alignment in coupling.

ƒ In the Magnetic Particle Clutch and Brakes grease packed sealed

bearings are used. It is suggested to replace these bearings once in
every two years.

CHART – 1
Magnetic particle device coil details
BRAKE/CLUTCH COIL
Rating Resistance Normal Setting
kgm. Ohms ±10% VDC
0.06 43 17
0.3 33.3 17
0.6 17.3 16
1.25 13.8 11
2.5 10.76 12
5 10.7 16
10 6.7 14
20 5.5 16
40 3.8 15

IMPORTANT:
ƒ Turn off all input power before cleaning the dust or dirt in the
device.
ƒ Use a vacuum or low-pressure clean air to remove dust and
dirt on the components and housings.

6.0 Trouble Shooting:

6.1 General.

The following are most common causes of Dynaspede Magnetic Particle

Clutch and Brake malfunctioning.
• Discontinuity in a circuit, caused by a broken wire in the power or
control circuit.
• Loose connection at the termination of any of the interconnecting
wires.
• Circuit grounding, caused by faulty or damaged insulation.

If the working system suddenly malfunctions, do not make any

adjustments before first checking all connections.

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Dynaspede BR9334

♦ tightness.
♦ breakage.
♦ faulty or damaged insulation.
If checks do not bring out any faults proceed as follows.
If Magnetic Particle Device (Clutch or Brake) is found not functioning,
first step is to locate where the fault exists whether it is in the control
circuit or Magnetic Particle Device.

6.2 To find fault in Controller:

Switch ON the supply to the Tension Controller. Measure the voltage
across the excitation coil of the Particle Device. A variable voltage of 0 to
maximum VDC (maximum voltage is depends on particle device rating,
which is given in chart-1) depending upon set torque or tension is
expected. If this voltage is found absent fault in the Controller is
suspected. Refer relevant instruction manual for trouble shooting of the
Controller.

6.3 To find fault in Particle device:

If the above said voltage is present and Particle Device is not functioning,
then damage to the excitation coil of the Device is suspected. Measure
the coil resistance. (Refer chart-1 for coil resistance.) If it is found open
or higher than the value mentioned in data sheet, coil needs
replacement. For replacing the coil refer following assembly and
disassembly procedure.

6.4 To find fault in Magnetic powder:

If Tension Controller and excitation coil of the device are in good
condition, and if the Particle Device is not delivering rated torque, then
loss of magnetic powder is suspected.
The powder life is considered indefinite. Powder devices normally do not
require frequent powder changes or replenishments… when operated
within the device limits and ratings specified. Moisture is the greatest
enemy that often impairs the life of powder if the powder cakes due to
moisture or excessive overloading, it may have to be fully flushed out
and replenished. Such a condition manifests in jamming or jerky
operation of the brake.
In most cases, the powder may leak out over prolonged periods of
operation through the minute gaps in sealing. This will manifest in a
corresponding reduction in torque transmission capability. In an
automatic control system, this will be compensated by an increase in the
excitation voltage needed to transmit a given torque. Normally the
device, when shipped in new condition, will have a nominal voltage
across its terminals (specified in each case) to transmit the rated torque.
If the voltage is found to increase beyond certain limits, it might be

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Dynaspede BR9334

advisable to replenish small quantities of powder to make up for lost

powder.

WARNING:

Store spare powder tightly closed in its container away from

moisture. DO NOT store in refrigerator or in moist atmosphere.

If powder replacement/ replenishment is needed, pre-heat the

required quantity of powder to about 110 – 120°C and cool it in
dry atmosphere, before use. A pre-heating oven normally used for
drying welding electrodes before use, will be found ideal for this
drying.

DO NOT keep the powder case open in dusty atmosphere.

Conductive dust is especially harmful and may result in improper
functioning of powder devices.

7.0 Disassembly Procedure:

Magnetic particle devices have a long service life and operate without
any special routine maintenance. Any gradual deterioration or loss of
powder results in a reduction of braking torque. This reduction is
compensated, to an extent by an increase in the excitation current
needed to develop the required torque.
Prolonged usage, accidental overloading or ingress of moisture and other
contaminants may cause gradual deterioration of powder, leading to a
significant reduction in braking torque.
7.1 Disassembly procedure of magnetic particle brake
Refer the constructional drawing HGSL 93158/ HGSL 03192.
While disassembly and reassembly of the Dynaspede Magnetic Particle
Brake note the following points.

Note: In case of force cooled particle devices, first remove blower cover
and fan.

1. While extracting the bearings, it should be removed by force applied

to the outer race when removing from housing or the inner race
when removing from the shaft.
2. Match and identify all parts while removing to avoid confusion while
reassembly.
3. Do not open the Brake in the dusty or humid area.

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4. Spread some sheets of neat, clean and dry paper over the floor or
table. Place the brake over the paper which disassembling.

5. All parts should be kept on a clean wooden board or lintless cloth.

6. Avoid hammer blows during disassembly, particularly while

extracting or refitting bearings. Use proper puller for this purpose or
make use of a hydraulic press.

7. Disconnect all power wires and remove the unit from the machine.

7.1.1 Powder replacement:

1. Support the Brake vertically so that the shaft faces the ground.

2. The Bracket I is fixed to the housing I and Follower by bolts.

Remove these bolts. Using same bolts and two extraction holes,
extract the Bracket I.

3. Remove the screws on drum cover and extract the Drum cover by
using extraction holes.

4. Remove the follower carefully. Care should be taken that the

magnetic powder should not fall out. Now tilt the Brake and collect
the magnetic powder on a clean paper.

5. Keep the powder safely until it is ready for re-filling.

7.1.2 Bearing replacement:

6. Keep the Brake so that shaft points upward.

7. Remove the ring nut and locking washer using a J spanner. Remove
the bracket II complete with drum assembly making use of the
extraction holes and bolts (removed from the bracket).

8. Remove the bracket II using the extraction holes. Now bracket

comes out with bearing. Extract the bearing from the bracket.
Remove the spacer.

9. To remove inside bearing from the shaft, use proper puller.

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7.1.3 Coil replacement:

10. Open the terminal box and disconnect both ends of the excitation
coil connected to the terminal block.

11. Remove the bolts on housing II and extract housing II making use
of the extraction holes and using same bolts.

12. Remove the coil taking care that the coil wires are not damaged.

13. Ensure that packing shims are in place while re-assembly of coil.

7.2 Disassembly procedure of magnetic particle clutch

Refer the constructional drawing no. HGSL 93159.

While disassembly and reassembly of the Magnetic Particle Clutch please

note the following points.

1. While extracting the bearings, it should be removed by force applied

to the outer race when removing from housing or the inner race
when removing from the shaft.

2. Match and identify all parts while removing to avoid confusion while
reassembly.

3. Do not open the clutch in the dusty or humid area.

4. Spread some sheets of neat, clean and dry paper over the floor or
table. Place the Clutch over the paper which disassembling.

5. All parts should be kept on a clean wooden board or lintless cloth.

6. Avoid hammer blows during disassembly, particularly while

extracting or refitting bearings. Use proper puller for this purpose or
make use of a hydraulic press.

7. Disconnect all power wires and remove the unit from the machine.

7.2.1 Powder replacement:

1. Unfasten the bolts and remove the mounting plates. Support the
Clutch vertically so that the output shaft faces the ceiling.

2. Remove ring nut and locking washer using a J spanner or a suitable

tool. Remove the Bracket I making use of special extraction fixture

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for bracket. Mount the fixture on Bracket I of clutch and gradually

tighten the extraction bolts. The Bracket I will come out with outside
bearing. While removing the bearing from Bracket I, take care that
the force is applied in inner race of the bearing only.

3. Remove the screws on drum cover and extract the drum cover by
using extraction holes.

4. Remove the follower carefully. Care should be taken that the

magnetic powder should not fall out. Now tilt the Clutch and collect
the magnetic powder on a clean paper.

5. Keep the powder safely until it is ready for re-filling.

7.2.2 Bearing replacement:

6. Remove circlip on the shaft of Follower assembly. Extract the

Follower using suitable puller. Extract the bearing using suitable
bearing puller.

7. Support the assembly vertically so that input shaft faces the ceiling.
Take care that the machined spigot is not damaged.

8. Remove ring nut and locking washer using a J spanner. Remove the
bracket II complete with drum assembly making use of the
extraction holes and bolts (removed from the bracket).

9. Remove the bracket II using the extraction fixture. Now bracket

comes out with bearing I. Extract the bearing from the bracket.
Remove the spacer.

10. To remove inside bearing, from the shaft, two holes near the inner
race of the bearing inside of which pins are inserted are provided in
the drum. Insert the rods of sufficient length and diameter into these
holes and gently tap over them and remove the bearing.

11. After removing the bearing keep the pins in place. In some of the
Clutches you may find that, bearing extraction holes are not
provided on the drum because the inner bearing can be removed
using a bearing puller.

7.2.3 Coil replacement:

12. Open the terminal box and disconnect the two ends of the excitation
coil connected to the terminal block.

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13. Remove the bolts on housing-II and extract housing-II making use
of the extraction holes and using same bolts.

14. Remove the coil taking care that the coil wires are not damaged.

15. Ensure that packing shims are in place while re-assembly of coil.

8.0 Reassembly Procedure:

To reassemble the dismantled parts of the Dynaspede particle Brake or

Clutch, follow the preceding, step-by-step, procedure in the reverse
sequence.

8.1 Proximity sensor Assembly procedure:

1. Remove the rubber washer from proximity sensor and bring both nuts
towards cable side of the proximity sensor.

2. Insert the proximity sensor into the nylon

bush provided on the particle device.
Rotate proximity sensor till it touches the
OD of the tooth wheel.

3. Gently rotate the particle device shaft, to

ensure the proximity sensor is not gone
inside the groove the wheel.

4. Rotate the proximity sensor 1 turn

backwards carefully to maintain 1 mm gap
between proximity sensor and tooth
wheel.
A – TOOTHWHEEL (SPACER)
5. Slightly tighten the first nut against the B – NYLON BUSH
nylon bush. Hold the first nut and tighten C – PROXIMITY SENSOR WITH NUT
the second nut. While doing this ensure D – ANABOND LOCATION
E – P-CLIP
that proximity sensor does not rotate. F – BRACKET

6. Give connection to the proximity sensor and switch ON the supply.

Slowly rotate particle device shaft and observe the pulse output of
sensor by multimeter.

7. Once the sensor is found OK, apply small quantity of anabond or

equivalent adhesive on outer surface of the second nut and threaded
portion of the sensor. While doing this, take care so that adhesive does
not flow inside the nylon bush.

8. Clamp the proximity with the bracket by using “P” clip.

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9.0 List of recommended spares:

Sl.no. Description
1. Bearings
2. Drum cover
3. Magnetic power
4. Coil
5. Blower/axial fan – (For force cooling version only)
*For ordering above spares, please mention model number
and nameplate details of the particle device.

10.0 List of illustrations:

Sl.no. Description
1. Dimensional drawing of Magnetic particle brake; 0.06 to HGSL 02207
0.6kgm rating (Air cooled self- ventilated)
2. Dimensional drawing of Magnetic particle brake; 1.25 to HGSL 98186
40kgm rating (Air cooled self- ventilated)
3. Dimensional drawing of Magnetic particle brake; 5 to HGSL 98189
40kgm rating (force cooled)
4. Constructional details of Magnetic particle brake. (Axial HGSL 93158
fan force cooled). HGSL 03192
5. Dimensional drawing of Magnetic particle clutch; 0.06 to HGSL 02208
0.6kgm rating (Air cooled self- ventilated)
6. Dimensional drawing of Magnetic particle clutch; 1.25 to HGSL 00083
40kgm rating (Air cooled self- ventilated)
7. Dimensional drawing of Magnetic particle clutch; 5 to HGSL 00084
40kgm rating (force cooled)
8. Constructional details of Magnetic particle clutch. HGSL 93159
9. Dimensional drawing of Magnetic particle brake; 5 to HGSL 03191
40kgm rating (axial fan force cooled)
10. Interconnection diagram for DOL starters and particle P31242813
brake.
11. Interconnection diagram for DOL starters and particle P31242693
clutch.

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Dynaspede
LIST OF BRANCH
OFFICES
(Sales & Service network)
620, Centre point
R C Dutt Road, Alkapuri
Vadodara-390 005
Telefax:91 265 2339404
Email:baroda@dynaspede.com
203, 2nd Floor, Aarohi
Block No 2, Kapoorthala
Complex, Aliganj
Lucknow-226 024
Ph:0522 2388316
Telefax:91 522 2325726
Email: lucknow@dynaspede.com
First Floor, Dhannur Building
Sir P M Road
Mumbai-400 001
Ph:022 22663675 / 22661291
Fax:91 22 22662358
Email:mumbai@dynaspede.com
24,Krishasawmy Nagar
50 feet Road, Ramanathapuram,
Coimbatore – 641 045
Ph:0422 2582181
Telfax:91 422 2582182
Emai:coimbatore@dynaspede.com
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BR9334
303 Money Chambers
6 K H Road
Bangalore-560 027
Ph:080 22243094 / 22126490
Telfax:91 80 22273608
Email:bangalore@dynaspede.com
4th Floor
Ballygunge New AC Market
46/31/1 Gariahat Road
Kolkata-700 029
Ph:033 24617272
Telefax:91 33 24646855
Email: kolkata@dynaspede.com
S 505, Suryakiran Complex
Sarojini Devi Road
Secunderabad-560 003
Ph: 044 66322018
Telefax:91 40 27810150,
Email:secunderabad@dynaspede.com
1/54-29, Butt Road,
St. Thomas Mount,
Chennai-600 016
Ph:044 66199999
fax:91 44 66199919
Email:chennai@dynaspede.com
508 Pragati Tower
26 Rajendra Place
New Delhi-110 008
Ph:011 25729172, 25731830
Telfax:91 11 25724973
email:delhi@dynaspede.com