819-0121_P-251-HIres
Contents
1. 0 31 7 9 Snap Ring Check No 1 Check No 2 The remaining wear life of the friction surfaces can be estimated by checking the step machined on the O D of the brake magnet where the armature and magnet meet This step is approximately equal to the friction material thickness When this step is completely covered by the armature worn down with the brake engaged the brake is worn out and should be replaced Magnet Worn to Step N C Check No 2 Note A new splined hub should also be installed when the armature and magnet are replaced Reusing the old splined hub or armature adapter may prevent the armature from fully engaging the magnet resulting in torque loss Foreign Materials If units are used on machinery where fine abrasive dust chips oil or grit are dis pelled into the atmosphere a protective screen around the unit is necessary Where units are used near gear boxes or transmissions requiring fre quent lubrication means should be provided to protect the friction surfaces from oil and grease contamination contact to prevent serious loss of torque by reducing the coefficient of friction P 251 e 819 0121 9 INDUSTRIAL MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 7260 ventas industrialmagza com and swelling the friction material Small amounts of oil and grease accidentally reaching the friction surfaces may be removed by wiping with a rag dampened with a non p2. T I R 3 If Magnet mounting surface is a magnetic material the magnet is to be insulated approximately 1 2 inch from that surface with a plate or spacer of non magnetic material 12 Warner Electric e 800 825 9050 Shaft Size Keyway Size Warner Electric Browning 1 2 1 8 x 1 16 180 0002 H 1 9 16 1 8 x 1 16 180 0003 5 8 3 16 x 3 32 180 0004 11 16 3 16 x 3 32 180 0005 3 4 3 16 x 3 32 180 0006 13 16 3 16 x 3 32 180 0007 7 8 3 16 x 3 32 180 0008 15 16 1 4 x 1 8 180 0009 1 1 4 x 1 8 180 0010 1 1 6 1 4 x 1 8 180 0011 1 1 8 1 4 x 1 8 180 0012 1 3 16 1 4 x 1 8 180 0013 1 1 4 1 4 x 3 16 180 0014 1 5 16 5 16 x 7 32 180 0015 1 3 8 5 16 x 7 32 180 0016 1 7 16 3 8 x 1 4 180 0017 H 2 1 1 2 3 8 x 7 32 180 0018 3 4 1 2 x 3 8 180 0026 Ql 1 13 16 1 2 x 3 8 180 0027 7 8 1 2 x 3 8 180 0028 15 16 1 2 x 3 8 180 0029 1 2 x 3 8 180 0030 1 1 16 1 2 x 3 8 180 0031 1 1 8 1 2 x 3 8 180 0032 1 3 16 1 2 x 3 8 180 0033 1 1 4 1 2 x 3 8 180 0034 1 5 16 1 2 x 3 8 180 0035 1 3 8 1 2 x 3 8 180 0036 1 7 16 1 2 x 3 8 180 0037 1 1 2 1 2 x 3 8 180 0038 1 9 16 1 2 x 3 8 180 0039 1 5 8 1 2 x 3 8 180 0040 1 11 16 1 2 x 3 8 180 0041 1 3 4 1 2 x 3 8 180 0042 1 13 16 1 2 x 3 8 180 0043 1 7 8 1 2 x 3 8 180 0044 1 15 16 1 2 x 3 8 180 0045 2 1 2 x 3 8 180 0046 Ql 2 2 1 16 1 2 x 3 8 180 0047 2 1 8 1 2 x 3 4 180 0048 2 3 16 1 2 x 23 32 180 0049 2 1 4 1 2 x 11 16 180 0050 2 5 16 5 8 x 5 16 180 00
3. If the above voltage adjustment procedure can not be observed visually the alternate ohmmeter procedure should be used Section IV Step 10 For the ER 1225 the procedure is the same as Step 9 with the exception of the control used The only two controls to be used are the MCS 805 1 or MCS 805 2 the voltage adjust is performed by adjustment screw only located on inside of control 10A Follow Step 9 for adjustment of brake control for ER 1225 10B For MCS 805 2 only Set partial engagement torque using adjusting pot at top of control Switch connected to terminals 7 and 8 must be open to make this adjustment A setting of 10 gives maximum torque After completion of installation procedure and brake control adjustment it may be necessary to burnish wear in the brake in the application P 251 819 0121 INDUSTRIAL MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Note The brake is pre burnished at the factory but during the installation and handling of the brake static torque may have been affected Therefore burnishing on site is recommended Step 11 Burnish the brake as follows This step requires you to run the machine that brake is used in Observe all safety rules and regulations for your facility Using the brake as the primary stop device start and stop the brake 30 times Allow 5 10 seconds delay between Start and Stop MeNe During t
4. 825 H D 2 078 3 546 3 750 6 75 358 6 4 250 3 503 338 3 501 ER 1225 H D 2 50 5 031 3 750 8 79 358 6 7 250 6 378 338 6 376 Warner Electric e 800 825 9050 P 251 e 819 0121 11 BES MNaaza MEX 55 53 63 2331 MTY 81 83 54 10 18 Qe DIST AUTORIZADO QRO 442 1 95 72 60 Technical Ratings ventas industrialmagza com Bushing Part Numbers Browning Bushing Bushing Number Static Max D C Total Size Torque RPM Voltage Weight ER 825 125 Ib ft 3600 90 15 6 Ibs ER 1225 400 Ib ft 3000 35to75 60 3 Ibs ER 825 1225 ER 825 ER 1225 Voltage DC 90 35 75 Resistance 20 C Ohms 304 235 Current Amperes 29 383 Watts 26 35 Coil Built up milliseconds 400 700 Coil Decay milliseconds 20 20 Bore Size ER 825 ER 1225 H D Drive H D Drive Spline Drive Spline Drive Bore Dia Keyway Bore Dia Keyway 500 562 1 8 x 1 16 750 875 3 16 x 3 32 375 625 3 16 x 3 32 937 1 250 1 4 x 1 8 937 1 187 1 4 x 1 8 1 312 1 375 5 16 x 5 32 1 250 1 4 x 1 8 1 437 1 750 3 8 x 3 16 1 312 1 375 5 16 x 5 32 1 812 2 062 1 2 x 1 4 1 437 1 500 3 8 x 3 16 2 125 2 250 1 2 x 1 4 2 312 2 687 5 8 x 5 16 Furnished with key Customer Shall Maintain 1 Squareness of magnet mounting face with armature shaft within 006 T I R 2 Concentricity of magnet mounting pilot diameter with armature shaft within 010
5. and high operating temperatures are causes of rapid wear Air should be allowed to circulate around the unit as efficiently as possible especially if the application requires fast repetitive cycle operation If the above checks indicate that the proper voltage and current is being supplied to the coil mechanical parts should be checked to assure that they are in good operating condition and properly installed See operating instruction under Check No 1 P 251 819 0121 ESS INIAGZAL MEX 55 53 63 2331 DIST AUTORIZADO QRO 442 1 95 72 60 MTY 81 83 54 10 18 ventas industrialmagza com Removable plug in ends for 5 conduit Dimensions and Specifications ER 825 Heavy Duty Drawing I 25578 ER 1225 Heavy Duty Drawing I 25620 ER 825 amp ER 1225 Magnet View A Pilot R G Dia V a H a TA H e At B D J Y t oe E E Mounting holes are within 0 005 of true position relative to pilot S dia T holes diameter y equally spaced L gt i on Udia gt IN lt O e P _ A B Cc D E G ER Size Max Dia 825 H D 8 656 2 5 156 1 250 1 765 5 625 1225 H D 12 671 4 093 234 2 5 2 171 7 671 H l J K L N ER Size Max Min Min 825 H D 531 5 16 18 UNC 3A 1 687 1 546 062 531 1225 H D 546 5 16 18 UNC 3A 1 718 1 546 062 562 O P Q R S T U V Max Max ER
6. apart on the magnet as shown in Figure 3 Insert the taper lock bushing Figure 3 item 5 into the hub Figure 3 item 2 4 Warner Electric e 800 825 9050 Slip the armature hub assembly onto the brake shaft until armature makes contact with shims Step 5 Using a hex wrench tighten the hub bush ing bolts alternately and evenly until tight Using a drift and small hammer tap lightly at several points around the circumference of the taper lock bushing Repeat this alternate tapping and re tightening until the specified torque is reached and wrench no longer turns the screw after tapping Tighten bolts to the following Unit Torque Bushing Type ER 825 87 in Ib Browning Series H ER 1225 290 in Ib Browning Series Q Do not attempt to pull the bushing flange flush with the hub end as there should be 1 8 to 1 4 clearance when tightened The airgap between armature and magnet must be 062 to 125 inch If the airgap is outside of that range reposition the armature hub assembly by repeating steps 1 and 2 of the disassembly proce dure and steps 4 and 5 of the assembly procedure 1 Magnet 062 0 2 Splined Hub Thick O 3 Armature Steel Shims 4 Spiral Retainer Ring 3 5 Bushing aN 5 FrictionO Steel Shim Material Stock 3 Places 120 Apart Figure 3 P 251 819 0121 INDUSTRIAL MEX 55 53 63 23 31 MTY 81 83 54
7. aude aed EE de ees Warranty cacaaces sinss orint aeniea sinana Introduction Warner Electric Electrically Released Brakes function on the same principle of response to magnetic attraction that operates other Warner Electric brakes and clutches Braking torque in the Electrically Released Brake depends on permanent magnets rather than electromagnets With the power off the unit produces full braking torque The brake is released by reversing the direction of flux flow in an electro magnetic coil thus opposing the field produced by the permanent magnets The opposition to and cancellation of electro magnetic force which releases the brake occurs nominally at one value of ampere turns This ampere turn value can vary among brakes because of allowable manufacturing tolerances 2 Warner Electric e 800 825 9050 ER 825 and ER 1225 Release voltage varies mainly because of coil tolerance and autogap spring variations Properly adjusting the power supply voltage is important so the autogap springs will separate the magnet and armature causing full release of the brake Ceramic permanent magnets which are the heart of Electrically Released Brakes are not subject to fatigue losses therefore Warner Electric Electrically Released Brakes are self adjusting Warner Electric Electrically Released Brakes are burnished at the factory to assure rated torque shortly after initial application Very little additional wear in
8. is required P 251 819 0121 INDUSTRIAL MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Sizes ER 825 and ER 1225 with Spline Drive Armatures Installation Instructions Failure to follow these instructions may result in product damage equipment damage and serious or fatal injury to personnel Basic Mechanical Considerations Electrically released brakes require special mounting considerations Please review the items listed below prior to starting installation contained in steps 1 12 A If the brake magnet is to be mounted to a surface of magnetic material isolate the brake approximately 1 2 inch from the surface with a plate or spacer of non magnetic material B If a choice of armature shaft material exists this should also be nonmagnetic Materials such as type 302 304 stainless have been used very successfully C In order to minimize stray flux the unit should be exposed as much as possible or if enclosed it should be placed in a housing of nonmagnetic material such as stainless steel or aluminum D ACAUTION must be exercised when the armature is moved close to the magnet assembly since the permanent magnets create a very strong attractive force Injury may result if fingers are in between the armature and magnet when the gap is 1 2 or less E Foreign Materials If units are used on machinery where fine abrasive dust chips oil or gri
9. 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Step 6 Electrical Connections Several different types of controls can be used on the ER 825 However only one control can be used on the ER 1225 electrically released brakes If you are installing an ER 825 brake follow the procedures in Section below When completed with Section proceed to Step 7 If you are installing an ER 1225 follow the procedures in Section II below When completed with Section Il proceed to Step 7 Section For ER 825 Brakes ER 825 brakes require a variable voltage or variable current control to release the brake by offsetting the magnetic force generated by permanent magnets Warner Electric controls such as the CBC 200 single channel or CBC 300 dual channel offer variable output and are suitable for use with ER 825 brakes Connection should be made in accordance with instructions provided with the chosen control Section II For ER 1225 Brakes Connect the MCS 805 1 or MCS 805 2 Power Supply per the following diagram and instructions MCS 805 1 2 3 4 5 6 7 8 4 O Brake Brake 1 115 VAC Ny ad MCS 805 2 2 3 4 5 6 7 8 0 aie 230 VAC Oe of Brake Brake Coil Release ACAUTION ER brakes are polarity sensitive Connect the terminal of the brake to the terminal of the control and
10. 2 The brake is disengaged released when the ohmmeter indicates higher resistance usually greater than one ohm may be as high as 10 000 ohms The difference between ohmmeter readings 1 and 2 must be large enough to reliably indicate armature engagement or disengagement Reliable readings can usually be obtained from a brake mounted on a shaft running on antifriction bearings Coil Data Unit Current Draw amp Resistance ohms Size at 60 Volts D C at 20 C 10 ER 825 308 195 ER 1225 256 235 Dimensional Drawings and Mounting Provisions TOP AND BOTTOM cr ae ee 2 625 0 875 Diameter Knockouts for 0 50 Conduit Both Ends Typical FRONT SIDE A 7 125 ye nt 5 0 gt La 3 44 i 8 Warner Electric e 800 825 9050 0 28 Diameter 4 Mtg Holes Clearance for 25 Screw BACK 4 81 gt 5 0 gt P 251 819 0121 INDUSTRIAL MEX 55 53 63 2331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Operating Instructions When an Electrically Released Brake is properly installed no further servicing lubrication or maintenance should be required throughout the life of the unit A worn out Electrically Released Brake can lose its ability to produce adequate torque Consequently it is imperative that the brake be inspected frequently for wear and to ins
11. 51 2 3 8 5 8 x 5 16 180 0052 2 7 16 5 8 x 5 16 180 0053 2 1 2 5 8 x 5 16 180 0054 2 9 16 5 8 x 5 16 180 0055 2 5 8 5 8 x 5 16 180 0056 2 11 16 5 8 x 5 16 180 0057 P 251 819 0121 INDUSTRIAL Exploded View 1 25578 1 25620 Parts List ER 825 Heavy Duty ER 1225 Heavy Duty MEX 55 53 63 23 31 DIST AUTORIZADO QRO 442 1 95 72 60 Electrically Released Brake Electrically Released Brake ER 825 Heavy Duty MTY 81 83 54 10 18 ventas industrialmagza com Per 25578 Per 25620 ER 1225 Heavy Duty Item Description Part Number Part Number Qty 1 Bushing 180 0002 180 0018 80 0026 180 0057 1 2 to 1 1 2 Bore 3 4 to 2 11 16 Bore 1 2 Retainer Ring 748 0006 748 0005 1 3 Splined Hub 540 0057 540 0064 1 5 Mounting Accessory M 5321 101 001 5321 101 001 1 4 amp 6 Magnet 1 M 90 Volt and Armature sold only in matched pairs 5250 25 5252 4 1 6 1 Terminal Accessory 5311 101 001 5311 101 001 1 7 Conduit Box 5200 101 010 5200 101 010 1 How to order 1 Specify bore size 2 Specify Heavy Duty Example ER 825 Electrically Released Brake per l 25578 Heavy Duty 7 8 bore Warner Electric e 800 825 9050 P 251 819 0121 13 BES MNaaza MEX 55 53 63 2331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Warranty Warner Electric LLC warrants that it will repair or replace whichever it deems advisable any product manufac
12. GES Naaza MEX 55 53 63 2331 MTY 81 83 54 10 18 EY DIST AUTORIZADO QRO 442 1 957260 ventas industrialmagza com Electrically Released Brakes ER 825 and 1225 Heavy Duty Installation Instructions 819 0121 Warner Electric An Altra Industrial Motion Company INDUSTRIAL MEX 55 53 63 2331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com This service manual tells how to install adjust and maintain your Warner Electric brake It also contains information for part replacements when needed Warner Electric Electrically Released Brakes are high performance high torque units To obtain the required performance and life the brake must be installed exactly in accordance with the instructions in this service manual The Warner Electric warranty does not apply to any unit which is not installed used operated and maintained in accordance with Warner Electric s instructions Contents Introd CtHON coc dees beren ence a e Installation Instructions 00 eee Controls Used 0 0 00 eee eee eee Ohmmeter Procedure to Detect Armature Release Coll Data sscacttie cos Senna a eee ete MCS 805 1 MCS 805 2 Mounting Dimensions Operating Instructions 04 Dimensions and Specifications Bushing Part Numbers 210s sae wedeewa eine wie wine Exploded View 0000 cece cece eee eens Parts GiS lt 0 badging aide
13. armature as dropping may also cause distortion Figure 1 Step 3A Place the armature splined adapter assembly on a flat surface segments up Press the splined hub retainer ring end first through the autogap spring and splined armature adapter P 251 e 819 0121 3 INDUSTRIAL MEX 55 53632331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Figure 2 Step 3B Turn the assembly over and insert the retainer ring in the groove Take care not to bend or distort retainer ring Step 3C Turn the assembly over and slide the armature against the retainer ring ACAUTION During steps 4 through 7 handle the armature hub assembly by the hub Figure 3 item 2 only making sure the armature Figure 3 item 3 is as close to the retainer ring Figure 3 item 4 as possible Any move ment of the armature on the splined hub will reduce available armature travel and may cause improper setting of the running air gap ACAUTION 1 16 inch thick steel shims are recommended for shim stock selection Do not use shims thicker than 1 8 inch or you will shorten brake life by reducing available armature travel Shim stock must be clean and free of any contamination oil grease Keep fingers clear of the area between the magnet and the armature as the armature will be pulled sharply toward the magnet after the gap is closed to approximately 1 2 inch Step 4 Place three steel shims 120 degrees
14. e adjustment screw clockwise the voltmeter should indicate a voltage range from approximately 30 to 75 volts for the MCS 805 series and 0 to 90 volts using other variable supplies Wear Pattern NEW BURNISHED Figure 4 10 Warner Electric e 800 825 9050 To determine if there is current flow through the magnet coil further checks may be made as follows a low range 1 to 1 amp amp meter should be connected in series with one wire to the magnet The Coil Data chart pages 8 lists the correct ratings for the various sizes These readings are with the power on and the brake release adjustment turned clockwise until a voltmeter attached to the brake magnet terminals reads 60 VDC If no amperes are read an Ohm reading of the magnet coil should be taken Ohmmeter checks should be made with the power off and circuit open To be certain disconnect one lead wire to the coil Refer to the Coil Data chart page 8 for the specifications of the appropriate unit A very high or infinite resistance reading would indicate an open coil Wear Pattern Figure 4 As the brake is used wear grooves will appear on the friction surfaces This is a normal condition and does not impair functioning of the unit Never machine the friction surfaces to remove grooves or score marks resulting from normal wear There are two main wear parts magnet and armature When either is worn out the complete brake must be replaced Heat Excessive heat
15. etroleum non residue cleaning solution In performing this operation do not drench the friction material If the friction material has been saturated with oil or grease no amount of cleaning will be completely effective Once such a unit has been placed back in service heat will cause the oil to be boiled to the surface resulting in further torque loss This unit should then be replaced Fails to Release If an Electrically Released Brake does not release the initial check should be to verify the electrical connections polarity between the brake coil and power supply If the lead wires are connected properly power supply positive terminal and brake coil terminal and power supply negative terminal and brake coil terminal the next check is to see that the brake release voltage adjustment is properly set in accordance with installation instructions See Table of Contents If readjustment of the control output does not release the brake and an AC input to the control is present a further check should be made to determine if the control is faulty as follows Put machine in a safe condition so that when voltage is applied to control and switch closures are made the brake does not rotate and machine does not run Connect a DC voltmeter across the brake magnet terminals Do not disconnect the leads to the terminals Turn the torque adjustment on the control fully counterclockwise then slowly turn th
16. ill be fully released 3 With switch connected to terminals 7 and 8 and switch closed with AC power removed brake will be fully engaged D ER brakes are polarity sensitive Connect the plus terminal of the brake to terminal 6 on the control and the minus terminal of the brake to terminal 5 on the control P 251 819 0121 5 INDUSTRIAL MEX 55 53 63 2331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Step 7 Apply power to the brake and remove shims Note It may be required at this point to adjust voltage to brake to release the armature and remove shims Set the airgap by pressing the armature into contact with the magnet and then releasing See Figure 3 The armature should spring back approximately 1 32 3 64 031 045 inch If the airgap is outside of that range reposition the armature hub assembly by procedure Section Ill and steps 4 and 5 of the assembly procedure Section l Note If armature does not spring back proceed to voltage adjust procedure Step 8 Brake Release Voltage Adjustment When setting the brake power supply the objective is to achieve armature release by adjusting the coil voltage so it counteracts the permanent magnet to the maximum extent possible Two different release procedures are used depending on whether an ER 825 or ER 1225 is involved For ER 825 brakes follow the procedures outlined in Step 9 below For ER 1225 brakes follow the p
17. or replacement of the defective product and in no event shall Warner Electric LLC be liable for consequential indirect or incidental damages of any kind incurred by reason of the manufacture sale or use of any defective product Warner Electric LLC neither assumes nor authorizes any other person to give any other warranty or to assume any other obligation or liability on its behalf WITH RESPECT TO CONSUMER USE OF THE PRODUCT ANY IMPLIED WARRANTIES WHICH THE CONSUMER MAY HAVE ARE LIMITED IN DURATION TO ONE YEAR FROM THE DATE OF ORIGINAL CONSUMER PURCHASE WITH RESPECT TO COMMERCIAL AND INDUSTRIAL USES OF THE PRODUCT THE FOREGOING WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES WHETHER EXPRESSED OR IMPLIED BY OPERATION OF LAW OR OTHERWISE INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state Changes in Dimensions and Specifications All dimensions and specifications shown in Warner Electric catalogs are subject to change without notice Weights do not include weight of boxing for shipment Certified prints will be furnished without charge on request to Warner Electric 7 815 389 3771 Fax 815 389 2582 Electric www warnerelectric com An Alt
18. orque measurements machine power should be turned off and properly locked out Step 12 With the brake fully engaged attach torque wrench to the end of the brake shaft Hold the wrench at the handle and pull it in the direction of motor rotation in one continuous motion without any jerky motion until shaft movement is detected The highest reading on the dial is the static torque of the brake This torque without any system drag must be at least 400 Ib ft for ER 1225 and 125 Ib ft for ER 825 If less burnish the brake again repeating Step 11 If the brake does not meet the torque requirement after two burnishing procedures replace the brake The brake installation procedure is now complete Warner Electric e 800 825 9050 Section Ill Disassembling the Armature Hub Assembly Figure 3 ACAUTION Do not pry the armature away from the magnet If armature is distorted the entire brake must be replaced Note Steps 1 and 2 are to be performed at the brake Note Make sure power to the brake is turned off See Figure 3 for the following two steps Put machine in a safe condition so that when voltage is applied to control and switch closures are made the brake does not rotate and machine does not run Step 1 Loosen the taper lock bushing item 5 on the brake shaft To loosen remove both hex screws from the taper lock bushing item 5 figure 3 using a hex wrench Insert the hex screws into the previously vacan
19. ra Industrial Motion Company P 251 819 0121 12 07 Printed in USA Warner Warner Electric LLC 449 Gardner Street South Beloit IL 61080
20. rocedures outlined in Step 10 Step 9 For ER 825 Brakes Put machine in a safe condition so that when voltage is applied to control and switch closures are made the brake does not rotate and machine does not run 9A Attach multimeter to brake to monitor DC voltage observing proper procedure for hookup of multimeter per manufacturing instruction 9B Apply power to control and close switch connections that allow DC voltage from control to be applied to brake 9C Depending on variable control used and output channel that brake is hooked up to turn voltage adjust knob or screw counter clockwise to OVDC at this point slowly increase voltage control clockwise until brake armature disengages Releases Record this voltage continue to increase voltage until brake armature engages 6 Warner Electric e 800 825 9050 Note If armature does not engage it may be necessary to manually engage the armature by pressing on the back side of the armature keeping fingers from between armature and magnet 9D After armature is engaged slowly decrease counter clockwise the voltage adjust to the brake until the brake armature releases Record this voltage 9E The final voltage setting for the brake should be the mid point between the voltages recorded in Step 9C and 9D Note If the autogap is not used an external release force of approximately 5 10 pounds should be applied by hand to detect the point of armature release Note
21. t are dispelled into the atmosphere a protective screen over the unit may be necessary Where units are used near gear boxes or transmissions requiring frequent lubrication means should be provided to protect the friction surfaces from oil and grease to prevent serious loss of torque NAGAINA Applications requiring a vertical shaft mounting must be reviewed and approved by Warner Electric Applications Engineering Warner Electric e 800 825 9050 Note Failure to set control voltage using the step by step procedures in this manual may cause overheating and premature failure Section 1 Step 1 Check to insure that the magnet and its mounting surface are clean and free from burrs Step 2 Bolt the magnet in place with capscrews and lockwashers Note The magnet pilot diameter must be concen tric to the shaft within 010 inch T I R The magnet mounting surface must be square with the shaft within 006 inch T I R measured at the bolt circle Step 3 Assemble the splined armature assembly armature splined armature adapter and autogap are preassembled to the hub ACAUTION New armatures shipped from the factory are flat to within 005 inch and this flatness must be retained to maintain full torque Any attempt to pry the armature loose from the magnet will distort the armature When adjusting the armature position apply any required force only to the hub not to the outer edge of the armature Also use care when han dling the
22. t taped holes in the taper lock bushing and tighten these screws until the bushing is loosened in the hub item 2 If the bushing does not loosen tap on the bushing with a drift and small hammer Step 2 Apply power to the brake The armature will then spring away from the magnet If it does not check electrical connections and release voltage Remove taper lock bushing item 5 and armature assembly items 2 amp 3 from the brake shaft Set the bushing aside Do not discard the bushing Note If reinstalling armature assembly follow steps 1 thru 7 in the assembly procedure P 251 e 819 0121 7 INDUSTRIAL MEX 55 53 63 2331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Section IV Ohmmeter Procedure to Detect Armature Release When the brake armature cannot be visually observed during brake voltage adjustment an ohmmeter can be used to determine when the armature disengages One ohmmeter lead should be attached to the armature itself in a manor not to obstruct the movement of the armature the other to the machine base The release point can be determined as follows Put machine in a safe condition so that when voltage is applied to control and switch closures are made the brake does not rotate and machine does not run 1 The brake is engaged when the armature contacts the magnet causing very low resistance less than one ohm MCS 805 1 and MCS 805 2 Power Supply
23. the terminal of the brake to the terminal of the control Plus to plus and minus to minus connections are imperative Put machine in safe condition so that when voltage is applied to the control and switch closures are made the brake does not rotate and machine does not run Warner Electric e 800 825 9050 A 115 VAC supply to terminals 1 and 4 Jumpers to connect terminal 1 with terminal 2 and terminal 3 with terminal 4 Recommended fuse is 3 4A slow blow Or 230 VAC supply to terminals 1 and 4 Jumper to connect terminal 2 with terminal 3 Recommended fuse is 3 4A slow blow B A chassis ground should be provided as a non current conducting ground wire color coded green C Switching Follow instructions per control models listed MCS 805 1 Standard Control Operation 1 For switching DC side Switch connected to terminals 7 and 8 Switch open will allow brake to be engaged Switch closed will enable the release of the brake 2 For switching AC side Line power off will allow brake to be engaged Line power on will release brake A jumper connection must be made between 7 and 8 3 Slower brake actuation will result when switching the AC side MCS 805 2 Two Step Control Operation 1 With switch connected to terminals 7 and 8 and switch is open with AC power applied brake will be partially engaged 2 With switch connected to terminals 7 and 8 and switch is closed with AC power applied brake w
24. tured and sold by it which proves to be defective in material or workmanship within a period of one 1 year from the date of original purchase for consumer commercial or industrial use This warranty extends only to the original purchaser and is not transferable or assignable without Warner Electric LLC s prior consent Warranty service can be obtained in the U S A by returning any defective product transportation charges prepaid to the appropriate Warner Electric LLC factory Additional warranty information may be obtained by writing the Customer Satisfaction Department Warner Electric LLC 449 Gardner Street South Beloit Illinois 61080 or by calling 815 389 3771 A purchase receipt or other proof of original purchase will be required before warranty service is rendered If found defective under the terms of this warranty repair or replacement will be made without charge together with a refund for transportation costs If found not to be defective you will be notified and with your consent the item will be repaired or replaced and returned to you at your expense This warranty covers normal use and does not cover damage or defect which results from alteration accident neglect or improper installation operation or maintenance Some states do not allow limitation on how long an implied warranty lasts so the above limitation may not apply to you Warner Electric LLC s obligation under this warranty is limited to the repair
25. ure that it engages and disengages properly The frequency of inspections is dictated by usage a brake used in a high cycle rate and or heavy load application must be inspected more often than one used less severely Sound maintenance practices will determine proper inspection intervals Torque loss can result if the armature and magnet wear extensively enough to cause the detent to move off the end of the hub spline resulting in a loss of the autogap function The end of normal service will occur when the armature wears through the friction material and into the coil causing an open circuit and failure to release when voltage is applied Brake wear is determined by two checks The first determines whether the brake is about to lose torque the second assures that the armature has not worn through the friction material endangering the coil If either of these checks indicates excessive wear the unit should be replaced Check No 1 Check to insure that the distance from the retaining ring to the splined adapter is less than 5 16 inch see Check No 1 This 5 16 inch dimension can also be exceeded if the splined hub is improperly positioned on the hub at installation If the 5 16 inch dimension is exceeded the armature must be readjusted Disassemble per Section IlI Steps 1 and 2 and relocate brake armature as indicated starting with step 1 7 Warner Electric e 800 825 9050 Wear Step Indicator Armature gt
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819 0121_P 251 HIres