CBC-700 Series Overexcitation Clutch/Brake Controls Installation Instructions P-272A 819-0527 An Altra Industrial Motion Company Contents Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Reorder Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Connection Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Dimensional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Template for Mounting . . . . . . . . . . . . . . . . . . . . . . . . . 6 System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 7 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . back cover Failure to follow these instructions may result in product damage, equipment damage, and serious or fatal injury to personnel. Introduction Warner Electric's CBC-700 clutch/brake The CBC-700's sophisticated coil suppression control is a basic overexcitation control for circuitry allows extremely short time delays and electromagnetic clutches and brakes. quick response. Optically isolated switching Overexcitation, a momentary high voltage spike, inputs promote full switching flexibility. builds up electromagnetic flux very quickly in the clutch and/or brake coil for quick The CBC-700-90 incorporates several new engagement and superior accuracy. The features: CBC-700 works on the capacitive discharge A short circuit protection for the clutch and principle, boosting AC input voltage and storing brake outputs. If a short is present, an amber a high voltage pulse. No torque adjustment is L.E.D. will illuminate and the outputs will be provided, so full torque is available from the isabled. The short circuit L.E.D. is reset by "on" clutch (or brake) by providing it with full turning off the power to the control for 10 rated voltage. Two models of the CBC-700 are seconds. available: • An O.E.X. on/off switch allows the user to CBC-700-90 90 volt magnets turn off the O.E.X. pulse for custom CBC-700-24 24 volt magnets applications. The CBC-700 requires only two adjustments. • Two output L.E.D.s indicate when the brake Overexcitation pulse duration is adjustable in (red) or clutch (green) is on. seven ranges to custom tailor control function for each application and to minimize coil temperatures. A time delay between clutch/brake engagement is also adjustable between 0 and 100 milliseconds for the CBC-700-90, and 0 to 50 milliseconds for the CBC-700-24, by providing a rest period between brake and clutch engagement. This eliminates overlap and reduces heating and wear of the clutch and brake units. 2 Warner Electric • 800-234-3369 P-272A • 819-0527 Specifications Input: CBC-700-90: 120 VAC ± 10%, 50/60 Hz CBC-700-24: 24 VAC ± 10%, 50/60 Hz Output Voltage: Steady State: CBC-700-90: 90 VDC CBC-700-24: 24 VDC Overexcitation: CBC-700-90: 340 VDC CBC-700-24: 105 VDC Output Current: (per channel, alternately) CBC-700-90: 0.5 Amps max.* CBC-700-24: 3.5 Amps max. Circuit Protection: (fusing) CBC-700-90: 1.6 Amp, 250 Volt, 5 x 20 mm, F/A CBC-700-24: 5 Amp, 250 Volt, 5 x 20 mm, F/A * Caution: It will not work with the SF1525HT-90 OEX Pulse Duration: (current model–with OEX on/off switch) 700-24 Switch Position 1 & 2 1 2 & 3 2 3 & 4 34 700-90 Switch Position 1 & 2 1 2 & 3 23 4 All Open Time (milliseconds) 8 11 15 22 34 50 100 OEX Pulse Duration: (early model–without OEX on/off switch) Switch Position 1 & 2 1 2 & 3 2 3 & 4 34 Time (Milliseconds) 7 10 15 22 34 51 100 Anti-Overlap Adjustment: CBC-700-90: 0 - 100 ms CBC-700-24: 0 - 50 ms Switching Inputs: Two optically isolated, 10-30 VDC Min. and Max. current input 3.1 - 9.5mA Maximum off-state leakage < 2 mA Ambient Temperature: 0° to 140° F (-18° to + 60° C) Auxiliary Supply: 12 VDC, 250 mA maximum Enclosure: Rated NEMA 13 with optional enclosure (P/N 6042-101-004 ) Reorder Information Model Part No. CBC-700-24 6042-448-002 CBC-700-90 6042-448-003 CBC-700-90C 6042-448-013 Enclosure 6042-101-004 Note: CBC-700-90C has a right angle terminal strip and is conformally coated. Warner Electric • 800-234-3369 P-272A • 819-0527 3 Installation The voltages in this control can cause serious injury (even death). When installing or wiring this control, make sure the input power is off, and main capacitors discharged. Do not apply voltage to the control until it is securely mounted and completely wired in accordance with local codes and all installation work, including cleanup, has been completed. Connection Diagram Brake Clutch Ch. 2 AuxiliaryC (Ch. 1) Input Input Clutch CBC-700-90: 120 VAC Supply Brake CBC-700-24: 24 VAC (10-30 VDC) (10-30 VDC) (12V) + + - - + - 9 11 1 2 3 4 5 6 7 8 10 Switching Options The control may be operated in either 2-wire (level) or 3-wire (pulse) mode. 2-Wire 3-Wire 3-Wire 2-Wire + 10-30 VDC* + + Open: Brake 10-30 VDC* 10-30 VDC* Closed: Clutch -- - 8 3 6 56 7 8 4 5 7 *Input voltage can be customer supplied or furnished by the 12 VDC auxiliary supply. Example Below is an example of a common approach using an external contact closure for the start signal and a sensor to initiate braking. 2 3 5 8 9 11 1 4 6 7 10 4 Clutch/Start Input Sensor Through External Output NPN Momentary Contact Brake/Stop Input From Sensor (NPN) Powered From Auxiliary Supley Dimensional Diagram The control may be mounted on its base (two mounting slots) or on its back (for mounting slots). All dimensions are nominal. 1.85 (47) 2.50 (63.5) in. (mm) 4.50 (114.3) All dimensions 0.50 (12.7) nominal 3.25 (82.5) 4.65 (118.1) 0.100 R, TYP (2.54) 0.50 (12.7) 6 PLS 0.20 (5.1) 0.95 (24) 0.125R, TYP 5.00 (3.2) (127) 4 Warner Electric • 800-234-3369 P-272A • 819-0527 CBC-700-90 (current model) CBC-700-90 (early model) CBC-700-24 (with OEX on/off switch) (without OEX on/off switch) Clutch/ OEX Switch Overlap Pot Clutch/ OEX Switch Overlap Pot Clutch/ OEX Switch Overlap Pot Brake (CBC-700-24) (CBC-700-24) Brake (CBC-700-90) (CBC-700-90) Brake (CBC-700-90) (CBC-700-90) Model Switches On % Model Switches On % Model Switches On % SF/PB-120 10 SF/PB-120 1&2 0 SF/PB-120 1&2 0 SF/PB-170 1&2 0 SF/PB-170 1&2 0 SF/PB-170 10 SF/PB-250 13 SF/PB-250 15 SF/PB-250 15 SF/PB-400 3 20 SF/PB-400 3&4 20 SF/PB-400 2 10 SF-500 2 16 SF-500 2&3 10 SF-500 2&3 10 PC/PB-500 2&3 15 PC/PB-500 2&3 15 PC/PB-500 2&3 10 SF-650 3&4 18 SF-650 2 15 SF-650 2 15 PB-650 2 15 PB-650 2 15 PB-650 2 16 SF-825 3 30 SF-825 3&4 20 SF-825 4 30 SF-825 brg 4 25 SF-825 brg 3 25 SF-825 BRG 3&4 20 PC/PB-825 3&4 20 PC/PB-825 3&4 15 PC/PB-825 3 20 SF-1000 4 35 SF-1000 3 35 SF-1000 3&4 25 PC/PB-1000 3 30 PC/PB-1000 3&4 30 PC/PB-1000 4 30 SF-1225 All open 60 SF-1225 4 60 PC/PB-1225 3&4 22 PC/PB-1225 3 40 SF-1225 3 40 PC/PB-1225 4 40 SF-1525 All open 70 SF-1525 4 70 PC/PB-1225 3 38 PC/PB-1525 4 60 SF-1525 4 70 PC/PB-1525 All open 60 EC-375 18 EC-375 18 PC/PB-1525 3 45 EB-375 16 SF-1525 HT 4 80 EB-375 16 EC-475 2&3 12 EC-475 2&3 12 EC-375 15 EB-475 2&3 10 EB-375 15 EB-475 2&3 10 EC-650 2 15 EC-650 2 15 EC-475 2&3 12 EB-650 2 15 EB-475 2&3 10 EB-650 2 15 EC-825 4 26 EC-825 3 26 EC-650 3&4 15 EB-825 3&4 20 EB-650 2 15 EB-825 3 20 EC-1000 4 30 EC-1000 3 30 EC-825 3&4 20 EB-1000 3 30 EB-825 3&4 20 EB-1000 4 30 EC-1225 All open 60 EC-1225 4 60 EC-1000 3&4 30 EB-1225 4 55 EB-1000 3&4 30 EB-1225 All open 55 UM/EM-50 15 UM/EM-50 15 EC-1225 3 40 UM/EM-100 2&3 8 EB-1225 3 40 UM/EM-100 2&3 8 UM/EM-180 2&3 8 UM/EM-180 2&3 8 UM/EM-50 1&2 5 UM/EM-210 2 20 UM/EM-100 2&3 5 UM/EM-210 2 20 UM/EM-215 2 20 UM/EM-215 2 20 UM/EM-180 2&3 5 EP-170 1&2 0 UM/EM-210 28 EP-170 1&2 0 EP-250 15 EP-250 15 UM/EM-215 3&4 8 EP-400 3&4 20 EP-250 13 EP-400 3 20 EP-500 2&3 15 EP-500 2&3 15 EP-400 2 10 EP-825 3 25 EP-500 2 16 EP-825 4 25 EP-1000 4 35 EP-1000 3 35 EP-825 3&4 20 EP-1525 4 70 EP-825 HT 4 *0 EP-1525 All open 70 AT-25 3 10 AT-25 3&4 10 EP-1000 3&4 25 AT-55 3&4 20 EP-1525 3 70 AT-55 3 20 AT-115 3 40 AT-115 3&4 40 AT-25 24 AT-55 26 This is a floating-type control and is not refer- AT-115 3&4 14 enced to AC ground. Under no circumstances should any of *For the units with a shuttle armature, the the output wire leads be connected to earth or chassis ground overlap setting should be zero (0). as the unit will be destroyed. Control Adjustments The duration of the OEX Pulse and Anti-Overlap Time Delay can be optimized to a specific clutch/ brake. The chart above designates switch settings for 90 and 24 VDC Warner Electric clutch/brake models. Anti-Overlap Time Delay OEX Duration Settings Potentiometer PI 4 1 2 3 OPEN 0 100 (Example shows 2 & 3 on for 15 ms duration) Warner Electric • 800-234-3369 P-272A • 819-0527 5 Template for Mounting CBC-700 Base Mount Wall Mount 6 Warner Electric • 800-234-3369 P-272A • 819-0527 System Troubleshooting The chart below will be helpful when attempting to isolate problems which may occur in the control system. It will also prove helpful when encountering problems during initial system start-up. Symptom A: No output on either clutch or brake upon power-up. Probable Cause Solution Improper wiring Check wiring and correct if necessary. No power available Check that AC power is available to control. Blown fuse * See Fuse keeps blowing, Symptom C. Faulty control Replace control. Symptom B: Clutch activates upon power-up. Probable Cause Solution Improper wiring Check wiring and correct if necessary. Faulty input switching circuit Check that input switching network is providing proper signal. Symptom C: Fuse keeps blowing. Probable Cause Solution Improper wiring Check wiring and replace fuse. Shorted brake/clutch coil Check coil resistance and replace if necessary. Ground Fault Check coil to earth ground resistance. Improper AC line voltage Check line voltage and correct if necessary. Improper magnet voltage Check magnet voltage rating and replace with correct magnet if necessary. Symptom D: Magnets do not appear to have enough torque. Probable Cause Solution Improper OEX switch setting Set pulse duration switch settings according to setup chart. Magnets incorrectly sized Verify sizing by repeating the selection process. Symptom E: Outputs don't switch; Inputs don't switch. Probable Cause Solution Incorrectly wired inputs Check wiring and correct if necessary. Faulty switching device Check for proper operation and replace if defective. Faulty control Replace control. Symptom F: Switching time too long or too short. Probable Cause Solution Improper overlap pot setting Set overlap according to setup chart. Symptom G: Amber L.E.D. illuminated * Probable Cause Solution Improper wiring Check wiring and correct if necessary. Shorted brake/clutch coil Check coil resistance and replace if necessary. Faulty control Replace control. * Turn off power to control for 10 seconds to turn off amber L.E.D. Warner Electric • 800-234-3369 P-272A • 819-0527 7