Installation Instructions • Addax® Cooling Tower Brake System (Page 1 of 3)

WARNING! • Because of the possible danger to person(s) or property from accidents that may result from improper use or installation of products, it is extremely important to follow the proper selection, installation, maintenance and operational procedures. • All rotating power transmission products are potentially dangerous and can cause serious injury. They must be properly guarded in compliance with OSHA, ANSI and any other local standards for the speeds and applications in which they are used. It is the responsibility of the user to provide proper guarding.

1. Sandwiched Brake Disc Installation

Figure 1

1.1. Figure 1 shows the brake disc installed between the hub and the flex element on the motor end.

CAUTION – Do not install the disc between the flex element and the spacer drive shaft flange.

1.2. Reference Addax® drive shaft Installation Instructions for end opposite the brake disc and a complete description of the components.

Fully Machined Surface Towards Hub Face Flex Element Washer

3 x Long Bolts Into Small Hub Holes

Nuts

3 x Short Bolts Into Large Hub Holes Figure 2 Overload Bushing

Rexnord, 6040 Fletcher Ave., Lincoln, NE 68507 CP3-003 Telephone: 402-325-6000 Fax: 402-325-6406 June 2013 www.rexnord.com Rev A Installation Instructions • Addax® Cooling Tower Brake System (Page 2 of 3)

2. Installation Procedure a. Recommend using ½” thick plate steel. b. Machine, at minimum, four (4) holes; two (2) on 2.1. Loosen set screws and move hub back on shaft towards top and two (2) on bottom at Ø.66 for 5/8-18 bolt. the motor shaft bearing by ½ inch (12.5mm). (Figure 3) 2.2. Position the disc with the fully machined surface against Note: Do NOT use two (2) consecutive holes the hub face. Unmachined disc surface must be on the per row. flex element side. c. Verify mounting fixture assures proper height of 2.3. Install the 3 long bolts through the bolt hole of the brake in relation to motor shaft (Figure 3). Bottom of hub, the bolt hole of the disc, through the element and brake pads should be aligned to bottom of rotor. clearance hole of the flange (Figure 2). d. Mount brake to mounting fixture with minimum of 2.4. Install the 3 shorter bolts through the clearance holes four (4) 5/8-18 bolts with lock washers and nuts. of the hub, through the element and through the bolt hole of the flange. Overload bushings and washers are e. The bracket design should have slotted holes in the installed as shown in Figure 2. base to allow for flexibility when mounting on the tower. 2.5. Torque lock nuts and set screws according to Addax 3.2. Center rotor between brake pads (Figure 4). A 0.020” drive shaft Installation Instructions. feeler gauge should move freely between the rotor and both brake pads through one full rotation (Rotor run-out 2.6. Check alignment according to Addax drive shaft shall be less than 0.02” relative to mounting bracket). Installation Instructions. Note: The ½” thick brake rotor centered within brake pads will have a .56” nominal total clearance. One side 3. Caliper Installation and Service Instructions may have a greater clearance.

The Addax Cooling Tower Brake can be mounted in the 3 or 9 3.3. Permanently mount brake assembly. o’clock position, as well as, the 6 o’clock position (Figure 3). 3.4. Modify cover/shield as necessary for proper brake actuation handle clearance. 3.1. A mounting surface and bracket will need to be constructed in order to support brake assembly.

5.29 .50 5.29 .50 From Shaft End CL Motor Shaft From Shaft End to Hub Face CL Motor Shaft Brake Disc to Hub Face Brake Disc 14.17 14.17 Shaft End Shaft End

10.83 10.83

Disc Safety Pin 2.25 Disc Safety Pin 2.25 2.10 2.10 4.20 4.20 5.50 .75 Shaft End Actuation Handle Bracket 8 x 0.66 5.50 6.30 .75 Shaft End 2.29 Actuation Handle Bracket 8 x 0.66 Mounting Holes 6.30 8.40 2.29 Mounting Holes 8.40 10.00 10.00 10.50 Center of Disc/Motor 10.50 Center of Mounting Plate Center of Disc/Motor Center of Mounting Plate .35 .35

Figure 3

CP3-003 Rexnord, 6040 Fletcher Ave., Lincoln, NE 68507 June 2013 Telephone: 402-325-6000 Fax: 402-325-6406 Rev A www.rexnord.com Installation Instructions • Addax® Cooling Tower Brake System (Page 3 of 3)

4. Actuating the Addax Cooling Tower Brake Brake Pads

4.1. Verify power to motor is off and locked out. Rotor 4.2. Use a 15/16” socket or wrench and turn clockwise to engage brake or counter-clockwise to disengage. 4.3. To fully engage the brake and assure proper braking torque, turn clockwise until you hit the set mechanical stop (≈50 lb-in). Do not over-tighten. 4.4. To fully disengage the brake, turn counterclockwise until you hit the release mechanical stop. Note: Verify brake is fully disengaged before starting motor/fan or undue wear on brake pads will result, as well as, undue stress on the motor. 4.5. For added safety, it is recommended to use the rotor safety pin attached by a chain. a. To align rotor safety pin, fully engage brake so that rotor stops rotating. b. If necessary, disengage the brake until you can rotate the disc by hand to align safety pin holes. 0.56 Nominal Distance Between c. Set rotor safety pin in place securing with Brake Pads cotter pin. Figure 4 d. Engage the brake to full torque.

5. Maintenance

5.1. The Addax Cooling Tower Brake is manufactured with 316 stainless steel components. Brake pads should last the lifetime of the cooling tower if used properly. 5.2. Recommend actuating brake once per year to verify brake moves freely. 5.3. Visually inspect brake for any unusual damage. 5.4. Check brake pad clearance as described in installation instructions. 5.5. Lubrication – Annual PM – Apply some grease to the threads on the actuator bolt using a high temperature grease with Teflon.

Rexnord, 6040 Fletcher Ave., Lincoln, NE 68507 CP3-003 Telephone: 402-325-6000 Fax: 402-325-6406 June 2013 www.rexnord.com Rev A