CBC-300 & CBC-300-1 Series
Dual Channel Adjust Clutch/Brake Controls
Installation & Operating Instructions
P-2105-WE
819-0549
An Altra Industrial Motion Company
Contents
Introduction .................................2
Specifications ...............................3
Mounting ...................................4
Electrical Connections .....................5, 6, 7
Internal Adjustments ..........................8
Troubleshooting Checklist ......................9
Warranty ...........................Back Page
Failure to follow these instructions
may result in product damage, equipment damage,
and serious or fatal injury to personnel.
Introduction
Warner Electric’s CBC-300 and CBC-300-1 are constant
current, solid state electronic power supplies designed
to operate any of the Warner Electric 90 Volt clutches
and brakes, including fail safe designs. They can operate
a single clutch or brake, two clutches, two brakes,
a combination clutch and brake, or a combination
clutch and fail safe brake, depending on the switching
arrangement used and the application requirements.
The CBC-300 series controls operate from 120 VAC
single-phase input power. They provide constant current
output as set by the torque adjustment potentiometers
on the front panel or remote potentiometer. On the CBC300 series both outputs are adjustable. Output current
ranges are selectable for the adjustable output channels
in one of five ranges by the DIP switches located on the
control’s printed circuit board.
Two versions of the CBC-300 are provided to handle
a wide range of applications. The standard version
is offered the same as before. The CBC-300-1
version is available where an external limit adjustment
potentiometers are required.
Operations of both units are identical except for the
method of the control potentiometer mounting. The
CBC-300-1, external potentiometer option, has terminal
blocks mounted on the PC boards for connection of the
potentiometers.
The potentiometers used can be supplied either as
optional accessory items or be obtained from a local
electronic supply house.
An internal 1.5A FA fuse is provided for line to ground
shorts.
Two LED indicators are provided on the front panel of
the control for “POWER” and “SHORT” indications.
The green indicator marked “POWER” is illuminated
whenever the AC input power is applied to the control. A
red indicator marked “SHORT” is illuminated whenever
a short circuit condition occurs in either of the outputs.
To reset, power must be removed, the shorted condition
cleared, and the AC input power reapplied to the control.
The enclosed version may be used with or without the
cover. Removal of the plastic cover when the control
is used in an enclosure will increase the operating
temperature range of the control.
2 Warner Electric • 800-825-9050 P-2105-WE 819-0549 5/17
Specications
Input Power: 120 VAC, +10%, -15%, 50/60 Hz, single
phase, 215 VA maximum.
Current Ranges:
Switch Setting 1 2 3 4 5
Max Output, ma 60 175 245 305 533
Output: Pulse-width modulated full wave rectified DC.
Constant current, switch selectable ranges designed
for 90 volt DC clutches and brakes.
Ambient Temperature: -32°F to + 113°F (0°C to + 45°C)
with plastic cover installed. -32°F to +150°F (0°C
to + 66°C) with plastic cover removed, or board
assembly only.
Circuit Protection: Internal short circuit protection
on outputs. An internal fuse is provided for AC
ground faults. It is rated at 1.5A FA replaceable
(5mm X 20mm).
Control Adjust: CBC-300 via front panel potentiometer for
current adjustment.
CBC-300-1 via external mounted potentiometer for
current adjustment.
Status Indicators: “POWER” – green LED indicating AC
power is applied to the control.
“SHORT” – red LED indicating that a short
circuit condition exists on one or both of
the outputs.
Internal Adjustments: Current Range Selection via
DIP switches, SW1 for Channel 1 and SW2 for
Channel2.
External Switching: Mechanical or Electro-mechanical
Switching: Customer supplied, 1 amp, 125 V
minimum rating.
Solid-state NPN isolated transistor
Customer supplied, 2 amp, 250V minimum
rating. Maximum off state leakage current < 1 ma.
External Pots:
Remote current adjust pot
Customer supplied: 10,000 ohm, 2 watt, linear,
maximum distance from control to
potentiometer not to exceed 10 feet.
Optional Accessory Pot Kit;
part number, 6011-101-002
Wiring Entrance: Two 7/8” diameter entrance holes
located on the bottom of the control chassis on
enclosed units. No conduit entrances are on chassis
mount versions.
Enclosure: Rated NEMA 1 only – Control must be kept
clear of foreign materials, dust, grease and oil which
might affect its operation.
Part Numbers:
Enclosed Versions
CBC-300 6021-448-009
CBC-300-1 6021-448-002
Warner Electric • 800-825-9050 P-2105-WE 819-0549 5/17 3
Mounting
Mounting 2 Plcs
Enclosed Units
Any vertical, horizontal, or angled surface is
suitable for mounting the CBC-300 and CBC-300-1.
Follow these procedures to mount your control.
q 1. Remove the front cover by removing the top and
bottom retaining screws.
q 2. Set the control on the mounting surface and mark
for the three mountings holes in accordance with
“Dimensions.” (See Figure 1)
q 3. Install the top two mounting bolts or screws until
they are nearly flush, set the control over the larger
top mounting holes and pull down to position the
control.
q 4. Tighten the top bolts or screws and install the
bottom bolt or screw and tighten.
This completes the mounting of the control. The control
is now ready for final wiring. Refer to the wiring section
for final wiring.
q 1. If the CBC-300-1 control is used, first pre-wire
the external potentiometers. Refer to: External
Potentiometer wiring for CBC-300-1, page 5
2.500
(63.5)
Max.
(165.1)
6.500
Max.
2.062
(52.4)
Max.
4.460
(113.3)
WARNER ELECTRIC
CLUTCH-BRAKE
CURRENT CONTROL
TORQUE ADJUSTMENT
CHANNEL 1
5
6
4
3
2
1
10
0
1.812
(46.02)
Max.
Max.
7
3
2
8
1
9
SHORTPOWER
CHANNEL 2
5
4
0
Ø0.180
(4.57)
Ø0.375
(9.53)
(2 Plcs)
6
7
8
9
10
Slot
Ø0.180
(4.57)
Mounting
2.250
(57.2)
WARNER ELECTRIC
CLUTCH-BRAKE
CURRENT CONTROL
SHORTPOWER
2.220
(56.39)
1.095
(27.81)
0.620
(15.75)
5.185
(131.7)
q 2. If the CBC-300 control is used, refer to: Final
Wiring, page 6
CBC-300
CBC-300-1
CBC-300-1CBC-300
(Figure 1)
4 Warner Electric • 800-825-9050 P-2105-WE 819-0549 5/17
External Potentiometer wiring for CBC-300-1
TB-3
ACCESSORY KIT (1)
q 1. Remove the four screw that hold the bracket
assembly and PC Board to the chassis.
q 2. Route the potentiometer cable(s) through one of
the conduit entrance holes on the bottom of the unit
and wire to the appropriate terminal block on the PC
board. Refer to the wiring diagrams below for the
proper connections.
CBC-300-1 External Current Limit Adjustment
q 1. Wire the external current limit potentiometer to
Terminal Block TB-3 for Channel 1 and TB-4 for
Channel 2 as shown in the diagram. (See Figures 6
& 7)
q 2. If the accessory potentiometer kit is used, wire
the potentiometers per the colors as shown in the
diagram.
q 3. Make sure all terminals are securely fastened and
the wiring cable is secured so that it can’t pull loose
from the terminals.
This completes the preliminary wiring of the remote
potentiometers. The control is now ready for final wiring.
Refer to the wiring section for final wiring, page 6
Note: Be careful not to pinch or crimp the pot wiring to
prevent shorting to the housing or components.
CBC-300-1
External Current
Limit Adjust
10K POT
10 FT MAX
CW
10K, 2W POT
10% TOL, LINEAR OR
6011-101-002
ACCESSORY KIT (1)
(Figure 6)
TB-4
CBC-300-1
External Current
Limit Adjust
10K POT
10 FT MAX
CW
10K, 2W POT
10% TOL, LINEAR OR
6011-101-002
BLK
WHT
RED
BLK
WHT
RED
TB3
1
2
3
TB4
1
2
3
CH1
CH2
(Figure 7)
Warner Electric • 800-825-9050 P-2105-WE 819-0549 5/17 5
CBC-300/CBC-300-1
Channel 1 Channel 2
Final Wiring
Normal Clutch–Brake Wiring
(Power applied clutch or brakes)
Electrical Connections
All electrical current must be off
when making electrical connections to prevent
injury or death which can result from contact with
live wires.
AC Input Power Connections
q 1. Connect Earth Ground wire to Terminal 1 and
tighten securely.
q 2. Connect the Hot side of the 120 VAC line to
Terminal 2 and tighten securely.
q 3. Connect the neutral side of the 120 VAC line to
Terminal 3 and tighten securely.
q 4. Determine which clutch/brake arrangement is
to be used and proceed to the appropriate wiring
section (Normal wiring or Electrically Released
Wiring, page 7).
q 1. Connect either the clutch or brake magnet to
Terminals 4 and 5. Tighten Terminal 4 securely.
q 2. Connect the other magnet, either brake or clutch
to Terminals 7 and 8. Tighten Terminal 7 securely.
q 3. Connect switching for Channel 1 to Terminals 5
and 6. Tighten both terminals securely.
q 4. Connect switching for Channel 2 to Terminals 8
and 9. Tighten both terminals securely.
q 5. Set DIP Switch, SW1 for proper current
setting before applying power to the control.
See Internal Switch Settings Chart for proper
DIP Switch settings
q 6. If external potentiometers are being used, then
proceed to the external potentiometer wiring
section. If external potentiometers are not used, this
completes the wiring of the control.
q 7. Double check all connections before applying
power.
G
120 VAC
H
N
G
120 VAC
H
N
External switching by
customer, see
specification.
6 Warner Electric • 800-825-9050 P-2105-WE 819-0549 5/17
or
4 5 6 7 8 92 31
+
Clutch
+
-
Brake
-
2 31
Note: CBC-300 Channel 1
and Channel 2 current
output is adjustable.
Note: If Solid-state NPN switching
is used, emitter is connected to
terminal 6 or 9 and collector is
connected to terminal 5 or 8.
(Figure 3)
Clutch – Electrically Released Brake Wiring
(Power on clutch / power off Brake)
q 1. Connect the Brake to Terminals 4 and 5. Observe
the polarity when making
connections. Tighten Terminal 4 securely.
q 2. Connect the Clutch to Terminals 7 and 8. Tighten
Terminal 7 securely.
q 3. Connect the switching for Channel 1 to Terminals
5 and 6. Tighten terminals securely.
q 4. Connect the switching for Channel 2 to Terminals
8 and 9. Tighten terminals securely.
G
120 VAC
H
N
or
2 31
q 5. Set DIP Switch, SW1 for proper current setting
before applying power to the control.
See Internal Switch Settings Chart for proper DIP
Switch settings.
q 6. If external potentiometers are being used, then
proceed to the external potentiometer wiring section.
If they are not used, this
completes the wiring of the control.
q 7. Double check all connections before
applying power.
Channel 1 Channel 2
4 5 6 7 8 92 31
+
Clutch
+
-
ER
Brake
-
120 VAC
G
H
N
External switching by
customer, see
specification.
Note: If Solid-state NPN switching
is used, emitter is connected to
terminal 6 or 9 and collector is
connected to terminal 5 or 8.
(Figure 4)
Warner Electric • 800-825-9050 P-2105-WE 819-0549 5/17 7
Internal Adjustments
The internal DIP Switch on the control circuit board adjusts the control for the proper current range to the clutch and/or
brake coil being used. The Chart below indicates the proper setting based on coil resistance and Warner Electric product.
To adjust for products not listed, obtain coil resistance information and set switches per coil resistance.
Switch DIP No. 1 2 3 4 5
Coil Resistance
at 20° C (W)
Current Range 0 - 60 ma 0 - 175 ma 0 - 245 ma 0 - 305 ma 0 - 533 ma
Warner Electric SF-120 EC-375 ATC-25 SF-500 ATC-115
Clutch Models SF-170
Warner Electric
Brake Models
1000-1550 350-999 250-349 205-249 100-204
SF-250
SF-400
PB-120
PB-170
PB-250
PB-400
EC-475
EM-50
EM-100
EM-180
UM-50
UM-100
UM-180
UM-50C
UM-180C
EUM-50
EUM-100
EUM-180
EB-375
EB-475
EM-50
EM-100
EM-180
UM-50
UM-100
UM-180
UM-50C
UM-180C
EUM-50
EUM-100
EUM-180
PC-500
SF-825
PC-1000
SF-1225
PC-1225
PC-1525
EC-1000
EM-210
UM-210
UM-215
UM-210C
EUM-210
EUM-215
ATB-25
PB-500
PB-650
PB-1000
PB-1225
PB-1525
EB-650
EB-1000
EB-1225
EMFB-50
UMFB-50
ER/FB-375
EM-210
UM-210
UM-215
UM-210C
EUM-210
EUM-215
SF-650
SF-825BM
PC-825
SF-1000
EC-650
EC-825
EC-1225
ATC-55
EB-825
EMFB-180
UMFB-180
ER/FB-475
ATB-55
ER-825
SF-1525
(Not SF-1525HT
Models)
EMFB-210
UMFB-210
ER/FB-650
ATB-115
Note: Only one switch number is to be set to the “on” position at any time.
8 Warner Electric • 800-825-9050 P-2105-WE 819-0549 5/17
System Troubleshooting
A. Symptom:
Green LED indicator marked “Power” does not come on when power is applied to the CBC-200 Controller.
Probable Cause Solution
No Power is applied to the Control • Check that AC power is applied to the control.
• Incorrect wiring on AC power to the control.
• Check for 120 VAC at Terminals 2 and 3 with an AC Voltmeter.
Internal line fuse is blown • Check for blown fuse – replace.
Indicator LED is defective • Check for 120 VAC at Terminals 2 and 3 of the control.
• Check for output voltage at output terminals for Channel 1 and
Channel 2. If voltage is not present, replace control or board.
B. Symptom: Red LED marked “short” illuminates
Probable Cause Solution
Shorted magnet coil • Check resistance of magnet coil used and replace if necessary.
Wiring between control and magnet shorting • Check for shorted conditions in wiring between the magnets and the
control, and wiring to chassis ground.
Improper magnet coil voltage • Check magnet for proper coil voltage rating.
Transient noise • Check for source of transient noise and suppress. Wire control using
shielded cables. Segregate wiring runs.
C. Symptom: Magnets do not engage when power is applied.
Probable Cause Solution
External switching improperly wired • Check wiring and switch connections and rewire if necessary.
Torque adjust set to zero (0) • Set torque adjustment potentiometer to maximum level.
Current range switch improperly set • Check DIP Switch settings per chart and reset if required.
No power applied to the control • Refer to Symptom A above.
System incorrectly wired • Check wiring per the wiring diagram and rewire if necessary.
Fail safe brake used in place • Check to insure that a fail safe brake is not being used in place of
of power applied brake a power applied brake. Replace brake with correct brake.
D. Symptom: Magnets do not disengage when power is removed
Probable Cause Solution
External switches incorrectly wired • Check wiring of switching circuits and rewire if necessary.
Fail safe brake magnet being used • Check to see if fail safe brake is being used in place of power applied
brake.
Faulty control • Replace control and see if problem is resolved.
E. Symptom: Magnets do not appear to have enough torque
Probable Cause Solution
DIP Switch improperly set • Check DIP switch setting per chart and reset if necessary.
Magnets incorrectly wired • Check wiring between control and magnets and rewire if required.
Torque adjust potentiometer set too low • Check setting of torque adjust potentiometer and set to maximum if
required.
Magnets are incorrectly sized • Verify sizing is correct by repeating selection process.
Warner Electric • 800-825-9050 P-2105-WE 819-0549 5/17 9
Warranty
Warner Electric LLC warrants that it will repair or replace (whichever it deems advisable) any product
manufactured 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 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 Specications
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.
www.warnerelectric.com
31 Industrial Park Road
New Hartford, CT 06057
815-389-3771
Fax: 815-389-2582
P-2105-WE 819-0549 5/17 Printed in USA
An Altra Industrial Motion Company
www.altramotion.com
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