MCS-103-1 Adjustable Torque Controls Adjustable Torque Control The MCS-103-1 is an enclosed control • Torque control for one 90 VDC clutch or brake complete with a cover and mounting provisions. A brake and clutch may be • Operates up to four units, two operated separately with this control – on at a time or up to four units, two at a time. The • Easy-to-install. Compact. external wiring is connected to the 120 VAC input terminal strip located behind the cover. • Convenient terminal strip behind an easy-to-remove • cover • • Can be used with electrically released brakes Dimensions Specifications .50" CONDUIT SIZE BOTH SIDES MCS-103-1 Part No. 6010-448-002 2.75" Input 120 VAC, 50/60 Hz 1.00" 1.25 Amp Output 90 V full wave rectified for one unit and adjustable from 0-90 volts full wave rectified for second unit .50" .19" DIA. MTG. HOLES (4) Circuit Protection Fused 1.5 Amp, 250 V Ambient -20° to 113°F (-29° to 45°C) Temperature Maximum Cycle Rate Limited by the clutch or brake and will vary with application. 4.38" Mounting Mounting centers 5-1/2" wide, 3" high. Knockouts for 1/2" conduit 3.00" External Switches Double pole, double throw maintained contact. Minimum contact (User furnished) rating: 10 Amp, 28 VDC resistive or 10 Amp, 120 VAC inductive. .69" Contact ratings given will operate all Warner Electric brake and clutch units. However, switches with ratings less than those given may be used with fractional horsepower units provided the rating is equal to or 2.75" .56" 5.50" greater than the coil current. 6.63" All dimensions nominal unless otherwise specified. Connection Diagrams Energize K , 1 (NEUT) 1 (NEUT) 1 1 Brake released 120 VAC 120 VAC 120 VAC Energize K & K , 1 2 50/60 Hz 50/60 Hz 50/60 Hz Softstop Brake (HOT) (HOT) 2 2 2 Full Brake On as shown (USER FURNISHED) (USER FURNISHED) SWITCH SWITCH STOP +90V +90V 3 3 3 +90V +ADJ. 4 4 ADJ. 4 ADJ. OUTPUT VOLTAGE VOLTAGE START 5 5 + CLUTCH 5 RHEOSTAT CLUTCH 1000Ω + BRAKE 50W 6 6 6 + 6010-101-002 ELECTRICALLY TORQUE CONTROL (not included) ELECTRICALLY RELEASED K K 2 1 RELEASED BRAKE BRAKE 90 VOLT UNIT 7 7 7 - 90 VOLT UNIT Normal Clutch/Brake Operation Clutch/Electrically Released Soft Stop for (One unit on at a time) Brake Operation Electrically Released Brake (Both units on at a time) 150 Warner Electric 800-234-3369 Power Supply MCS-805-1, MCS-805-2 The DC voltage required to release the Warner Electric ER-1225 Brake is supplied by the MCS-805-1 or MCS-805-2 Power Supply. The correct brake release voltage— approximately 35-75 volts DC—is set by adjusting the power supply at the time of brake installation. Temperature compensating circuits provide proper operation over the entire operating range of 0°F to 150°F. Switching may be provided on either the AC or DC side of the power supply. The MCS-805-1 may be mounted on its back panel or on 1/2" conduit. The MCS-805-2 has a torque adjustment capability for soft stop applications. The MCS-805-2 requires two switching circuits when used for those applications requiring soft engagement. Specifications MCS-805-1 MCS-805-2 Part No. 6090-448-006 6090-448-007 Input 115/230 VAC, 50/60 Hz ±10% 115/230 VAC, 50/60 Hz ±10% Output 0.4 Amp, 35/75 VDC 0.4 Amp, 35/75 VDC Ambient -20° to 150°F (-29° to 65°C) -20° to 150°F (-29° to 65°C) Temperature Maximum Limited by the clutch or brake and will vary with application. Cycle Rate Consult factoryfor specifics. External Switches For DC switching: single pole, single throw. (User furnished) Minimum contact rating 1 amp, 120 volts DC resistive. For AC switching: single pole, single throw. Minimum contact rating 1 amp, 120 volts AC. Circuit Protection .75 Amp 250V Slow Blow 3 AG 0.28 Diameter (4) Mtg Holes Dimensions Clearance for .25" Screw FRONT SIDE BACK TOP AND BOTTOM 3.44 7.125 6.0 1.125 0.875 Diameter 2.625 Knockouts for 0.50 Conduit Both Ends Typical 0.56 0.53 3.75 5.0 3.44 4.81 5.0 Connection Diagram Connect the MCS-805-1 or MCS-805-2 Power Supply per the following diagram and instructions: MCS 805-1 MCS 805-2 12 3 4 12 3 4 12 3 4 12 3 4 S1 S1 Open – brake engaged S1 S2 Closed – brake released 120 VAC 230 VAC 120 VAC 230 VAC or tq. adj. mode per S1 12 3 4 5 6 7 8 9 1 2 3 45 67 89 –+ –+ S1 S1 AC INPUT AC INPUT GND GND 120/230 VAC 120/230 VAC Brake Brake DC Switching 50/60 Hz 50/60 Hz DC Switching (Jumper if not used) Closed – brake release Open – brake in tq. adj. mode For AC switching, switch may be in series with input supply. For DC switching, use terminals 7 and 8 as shown. DO NOT put switch in series with load on terminals 5 and 6. Warner Electric 800-234-3369 151 CBC-200, CBC-300 Adjustable Torque Controls Single or Dual Channel Adjustable Torque Control The CBC-200 and CBC-300 Controls provide single/dual torque control when connected to any of Warner Electric’s 90 volt clutches and brakes. Common features • and • Current monitored output maintains consistent torque regardless of CBC-200 CBC-300 variation in coil temperature. Dual channel/Single channel Dual channel/Dual channel • Switch selection tunes control to torque adjust torque adjust exactly match power requirements The CBC-200 is a dual channel control The CBC-300 has two adjustable and operating characteristics of each with one adjustable current and one current channels. clutch or brake. fixed voltage. • Individual torque adjust allows preset maximum torque tailored to applica- Specifications tion requirements. CBC-200 CBC-300 • Short circuit protection, line to line. Part No. 6011-448-001 6021-448-001 • Torque limiting protects machine Input Power 120 VAC +10% -15%, 50/60 Hz, single phase, 215 VA max. components from damage. Pulse-width modulated full wave rectified D.C. Constant current, Output • Can be used with electrically released switch selectable ranges, 0-90 volt brakes. Ambient +32°F to +113°F (0°C to 45°C) with plastic cover installed Temperature +32°F to +150°F (0°C to 66°C) with plastic cover removed Dimensions Internal line to line short circuit protection Circuit Optional customer supplied fusing on A.C. line, 1.5 Amps, 250 VAC. 2.500" Protection 2.250" ± .010" (63.5) Fast-acting fuse recommended .620" (57.2 ± .254) NOM. 1.095" (15.7) (27.8) Current Adjust 1.183" REF. REF . (46.1) (via front panel Single adjustable channel Dual adjustable channels NOM. potentiometers) “POWER”—green LED indicates A.C. power is applied to the Status control. “SHORT”—red LED indicates a short circuit condition exists on one indicators or both outputs. 5.187" ± Set DIP switches SW1 and SW2 to suit the current draw of the connected (131.7 ± .508) connected clutch/brake coil: Internal 6.500" Switch Range 1 2 3 4 5 (165.1) Adjustments Max Current NOM. Draw (mA) 60 175 245 305 533 .020" Mechanical or electromechanical—customer supplied: External 1 Amp, 125 V minimum rating Switching Solid-state, NPN isolated transistor—customer supplied: 2 Amp, J250 V minimum rating. Maximum off state leakage current <1 mA 2.063" 4.460" (52.4) .180" (113.3) NOM. NOM. (.46) DIA. MTG. HOLE Connection Diagram CH-1 CH-2 TB1 1 2 3 4 5 6 7 8 9 .750" ± .020" (19.1 ± .508) +-+- G CBC-300 IS 120 H ADJUSTABLE BOTH VAC 1.750" ±.010" 1.345" ± .020" CHANNELS. 50/60 Hz N (44.5 ± .254) (34.2 ± .508) OR CBC-200 IS FIXED VOLTAGE CHANNEL 2 ADJUSTABLE G SW1 SW2 VOLTAGE CHANNEL 1 H 1-1/2 A N 152 Warner Electric 800-234-3369 Adjustable Torque Controls CBC-500 Panel Mounted CBC-500 series Dual torque adjustable power supplies The CBC-500 series is a dual channel adjustable voltage control with optically isolated input switching for 24 and 90 volt electric clutches and brakes. These controls can be set up to energize the two outputs alternately (single) or simulta- neously (dual). Refer to the Appendix for additional setup and switching information. • • Dual adjustable channels • Optically isolated input switching • Single or dual channel operation Specifications • Auxiliary 12V supply CBC-500-90 CBC-500-24 • Can be used with electrically released brakes Part No. 6024-448-003 6024-448-002 Input Voltage 120 VAC 24-30 VAC Output Voltage 0-90 VDC 0-24 VDC Enclosure (Optional) 1 Amp/Channel 5 Amps/Channel Output Current 2 Amps Total 5 Amps Total Auxiliary 12 VDC 250 mA 12 VDC 250 mA Supply Circuit Fused Fused Protection 2.5 Amp, 250 V Fast-blo 6.3 Amp, 250 V Fast-blo Ambient +32° to 122°F (0° to 50°C) Temperature Status Red LED indicates channel is energized. Indicators Two potentiometers for voltage adjustment of channel 1 and channel 2 output from 0 to full rated voltage. Frequency adjustment from 60 to 400 Hz to reduce Adjustments clutch/brake “Hum” associated with machine frequencies. Jumper for single or • Lift off hinge dual operation. See appendix for explanation. • Quick-release latches 3 Optically coupled, 10-30 VDC, 3-9 mA for Channel 1, Channel 2 and Inputs: Channel 2 override (applies full voltage to channel 1 output) • Conforms to NEMA Type 13 • European Standard IEC 529, IP65 Part No. 6042-101-004 Connection Diagram 8"H x 6"W x 4"D Size (203.2 x 152.4 x 101.6 mm) SWITCHING POWER/OUTPUT (CHANNEL 2 LED) (CHANNEL 1 LED) + + 1 8 CHANNEL 2 CHANNEL 2 INPUT Dimensions (CLUTCH OR (10-30 VDC) - - 2 7 BRAKE) + 6.40" + (CHANNEL 2 (CHANNEL 1 3 6 CHANNEL 1 INPUT CHANNEL 1 ADJUST) ADJUST) (10-30 VDC) (CLUTCH OR - 0.20" 6.00" - 4 5 BRAKE) + 5 4 CHANNEL 2 OVERRIDE INPUT FREQUENCY N/C (DO NOT USE) (10-30 VDC) ADJUST } - 6 3 AUXILIARY + • • • • Dual CBC-500-90 7 J2 2 SUPPLY 120 VAC • • • • Single J1 12 VDC, 250 mA - 8 CBC-500-24 1 1.75" 24-30 VAC 3.90" CBC-500 WARNER ELECTRIC All dimensions nominal unless otherwise specified. 0.90" 1.40" 1.15" Warner Electric 800-234-3369 153 CBC-550 Adjustable Torque Controls Panel Mounted CBC-550 series Dual adjustable with power transformer The CBC-550 series is a dual channel ad- justable voltage control with optically coupled switching for 24 and 90 volt electric clutches and brakes. These controls can be set up to energize the two outputs alter- nately (single) or simultaneously (dual). Refer to the Appendix for additional setup and switching information. The CBC-550 series has a power transformer which will operate with a 120, 220, 240, 380, or 480 VAC input. • • Dual adjustable channels • Optically isolated input switching • Single or dual channel operation • Can be used with electrically released brakes Specifications Enclosure (Optional) CBC-550-90 CBC-550-24 Part No. 6024-448-006 6024-448-005 Input Voltage 120/220/240/380/480 VAC Output Voltage 0-90 VDC 0-24 VDC 1 Amp/Channel 4 Amps/Channel Output Current 1.2 Amps Total 4 Amps Total Auxiliary 12 VDC 250 mA 12 VDC 250 mA Supply Circuit Fused Fused Protection 1.5 Amp, 250 V fast-blo 5 Amp, 250 V fast-blo Ambient +32° to 122°F (0° to 50°C) Temperature • Lift off hinge Status Red LED indicates channel is energized. Indicators • Quick-release latches Two potentiometers for voltage adjustment of channel 1 and channel 2 output • Conforms to NEMA Type 13 from 0 to full rated voltage. Frequency adjustment from 60 to 400 Hz to reduce Adjustments clutch/brake “Hum” associated with machine frequencies. Jumper for single or • European Standard IEC 529, IP65 dual operation. See appendix for explanation. 3 Optically coupled, 10-30 VDC, 3-9 mA for Channel 1, Channel 2 and Part No. 6006-101-007 Inputs Channel 2 override (applies full voltage to channel 1 output) 6"H x 6"W x 6"D Size (152.4 x 152.4 x 152.4 mm) 154 Warner Electric 800-234-3369 Adjustable Torque Controls CBC-550 Panel Mounted Dimensions 4.60" 4.08" 3.90" 4.72" 4.50" 2.85" 3.50" Connection Diagram SWITCHING OUTPUT AC INPUT (CHANNEL 2 LED) (CHANNEL 1 LED) + + 1 480 CHANNEL 2 8 CHANNEL 2 1 INPUT VAC (CLUTCH OR BRAKE) - (10-30 VDC) - 2 7 380 2 + VAC + 3 CHANNEL 1 6 CHANNEL 1 (CHANNEL 2 (CHANNEL 1 240 INPUT ADJUST) ADJUST) (CLUTCH OR BRAKE) 3 - - 4 (10-30 VDC) 5 VAC 220 CHANNEL 2 + 5 4 4 VAC OVERRIDE FREQUENCY (10-30 VDC) - 120 6 ADJUST 3 5 N/C (DO NOT USE) VAC AUXILIARY + 7 2 SUPPLY } • • • • Dual J2 6 0 VAC 12 VDC, - • • • • 8 Single 1 J1 250 mA CONNECT NEUTRAL TO TERMINAL 6 AND HOT CBC-550 WARNER ELECTRIC TO CORRESPONDING AC INPUT VOLTAGE. All dimensions nominal unless otherwise specified. Warner Electric 800-234-3369 155 CBC-1825R Adjustable Torque Controls Panel Mounted CBC-1825R series The CBC-1825R is designed to provide consistent and repeatable acceleration and deceleration when used with Warner Electric 90 VDC clutches and brakes. Current to each channel is introduced along an adjustable time ramp and monitored continuously. Adjustments include initial pull-in pulse, hold level, maximum torque, and ramp time. LEDs are provided on the circuit board to indicate power is applied to the clutch or brake unit. Note: It is recommended that the auto-gap springs be removed from the clutch and brake for successful accel-decel application. Set-up Specifications CBC-1825R Initial Pulse Part No. 1825-448-001 Adjustment Input Voltage 120 VAC, 50/60 Hz, 100 VA maximum Torque Current driven PWM, compatible with 90 VDC clutch/brake Adjustment Output Current (switch selectable current output) Ramp Time Auxiliary Supply 12 VDC 250 mA Adjustment Input Fused 1.5 Amp, 250 V fast-blo Circuit Protection clutch and brake outputs are short circuit protected Hold Level Adjustment Clutch and brake LEDs indicate output is energized Status Indicators Short circuit LED indicates a fault Time Ambient Temperature 0° to 122°F (-18° to 50°C) Contact rating: 15 mA @ 15 V, open collector NPN 2mA All dimensions nominal unless Switching maximum allowable leakage current and 2 V maximum saturation voltage otherwise specified. 156 Warner Electric 800-234-3369 Current Adjustable Torque Controls CBC-1825R Panel Mounted Dimensions 5.00" (127) 0.25" 4.50" (6.4) (114) 0.31" TYP. 6.50" (7.9) (165) 4.25" (108) 5.00" (127) 0.15"R TYP. 0.75" (3.8) 5.00" (19) (127) TOP VIEW BACK VIEW Connection Diagram HOLD LEVEL SET-UP SWITCH (Up: Normal, Down: Set-Up) CLUTCH CLUTCH LED SWITCH BRAKE LED SHORT CIRCUIT LED 4 SELECT OPEN: CLUTCH OUTPUT 3 CLOSED INHIBIT BRAKE COMMON 2 7 +12 VDC 1 BRAKE 6 CLUTCH INITIAL PULSE 5 CLUTCH CLUTCH RAMP 4 TIME CLUTCH HOLD 3 LEVEL CLUTCH 2 TORQUE 120 VAC ADJUST 1 BRAKE RAMP TIME BRAKE HOLD LEVEL F BRAKE U TORQUE S ADJUST E BRAKE INITIAL PULSE FRONT VIEW Warner Electric 800-234-3369 157