Warner Electric 375, 475, 650, 825, 1000 User Manual
...
Electro-Brake 375, 475, 650, 825,
1000, 1225
P-211
819-0043
Installation Instructions
Contents
Installation Instructions . . . . . . . . . . . . . . . . . . .2
Electrical Coil Data . . . . . . . . . . . . . . . . . . . . . .5
Burnishing and Maintenance . . . . . . . . . . . . . .6
Illustration Drawings
EB-375 EB-475 EB-650 . . . . . . . . . . . . . . . .8
EB-825 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
EB-1000 EB-1225 . . . . . . . . . . . . . . . . . . . .14
Bushing Part Number . . . . . . . . . . . . . . . . . . .17
Warranty . . . . . . . . . . . . . . . . . . . . . .Back Page
Failure to follow these
instructions may result in product damage,
equipment damage, and serious or fatal
injury to personnel.
Follow the installation instructions in this
manual carefully to ensure safe, reliable
operation. All stated or implied manufacturer
warranties are voided if this product is not
installed in accordance with these
instructions.
Electro-Brakes
5. Secure the assembly in position by
alternately tightening the two setscrews. Tap
the bushing lightly from time to time during
the tightening process to make certain that it
seats in properly. (Figure 1)
Figure 1
6. Install the torque arm. (See Section C)
B. Motor Mounting
An optional shaft extension is available for
mounting all Electro-Brakes, except EB-825, on
a single shaft extension motor. (Figure 2)
Electro-Brakes may be mounted on either a
thru-shaft or a single shaft extension motor.
Follow the appropriate instructions for each
application.
A. Thru-Shaft Mounting
1. EB-375. This unit has a straight bore and
mounts directly on a thru-shaft. Slide the unit
on the shaft and secure in place by
alternately tightening the two set screws in
the hub.
Mount all other EB units to a thru-shaft with
a tapered bushing as follows:
2. Insert a key in the shaft keyway.
3. Place a tapered bushing in the Electro-Brake.
4. Insert the set screws loosely into the bushing,
and slide the brake assembly onto the shaft.
1. Mount a standard sheave, pulley, or sprocket
on section E of the shaft extension with either
a tapered bushing or a straight bore.
2. Insert the proper tapered bushing into the
Electro-Brake (except EB-375).
3. Assemble the set screws loosely in the
bushing.
4. Mount the Electro-Brake on the end of the
shaft extension.
5. Mount the complete assembly on the motor
shaft and tighten the set screws.
6. Install the belts or chain on the sprocket,
pulley, or sheave.
7. Install the torque arm. (See Section C)
Warner Electric • 800-825-9050 P-211 • 819-0043
2
Motor
Adapter
A
B
D
E
B
C
G
A
I
F
H
(Threaded
Rem
oval Hole)
2
3
1
All dimensions are nominal unless otherwise noted.
Model A Kwy. Part No. 1 B Kwy. Part No. 2 C Kwy. Part No. 3 Size DEFGH I
EB-375 5/8 3/16x * 7/8 3/16x 590-0016 5/8 3/16x 590-0043 None 4.391 2 .391 2 1/4-20 1.125
EB-375 7/8 3/16x * 1-1/4 1/4x 590-0022 5/8 3/16x 590-0043 None 4.578 2-1/4 .516 2-1/4 1.500
EB-475 1-1/8 1/4x * 1-5/8 3/8x 590-0041 1 1/4x ** #1008 4.516 2-3/4 .641 2-3/4 1/2-13 1.750
EB-650 1-3/8 5/16x *21/2x 590-0042 1-3/8 5/16x 590-0044 #1310 5.547 3-3/8 .641 3-3/8 1/2-13 2.125
EB-650 1-5/8 3/8x * 2-1/4 1/2x 590-0042 1-3/8 5/16x 590-0044 #1310 6.172 4 .641 4 2.375
EB-1000 1-5/8 3/8x * 2-15/16 3/4x 590-0052 1-5/8 3/8x ** #1615 8.297 5-1/4 5 3/4-10 2.937
EB-1000 1-7/8 1/2x * 2-15/16 3/4x 590-0052 1-5/8 3/8x ** #1615 2.937
EB-1000 2-1/8 1/2x 590-0062 2-15/16 3/4x 590-0069 1-5/8 3/8x ** #1615 2.937
EB-1225 2-1/8 1/2x * 3-3/4 7/8x 590-0049 2-1/8 1/2x 590-0048 #2517 10.672 7-1/4 6-7/8 7/8-9 3.750
EB-1225 2-3/8 5/8x * 3-3/4 7/8x 590-0049 2-1/8 1/2x 590-0048 #2517 3.750
*Standard Square Key Furnished with Motor. **Special Key Furnished with Bushing.
3/32 3/32 3/32 4.359 .359 UNC
3/32 1/8 3/32 4.742 .484
1/8 3/16 1/8 1" 4.484 .609 UNC
5/32 1/4 5/32 1-3/8" 5.515 .609 UNC
3/16 1/4 5/32 1-3/8" 6.140 .609
3/16 7/16 7/32 1-5/8" 8.265 UNC
7/32 7/16 7/32 1-5/8"
1/8 5/16 7/32 1-5/8"
7/32 7/16 9/32 2-1/8" 10.640 UNC
9/32 7/16 9/32 2-1/8"
Figure 2
Dodge
Key Key Key Bushing
C. Installing the Torque Arm
The Electro-Brake magnet is bearing-mounted
on the hub and is provided with a torque tab to
prevent the magnet from rotating. When the
brake is de-energized, the tab need only resist
the bearing drag; however when the brake is
energized the full braking torque is applied to
the tab and restraining mechanism. Since the
brake torque is usually substantial, the
customary restraining method is to use a rod
with a ball joint, as furnished with the
Warner Electric • 800-825-9050 P-211 • 819-0043
Electro-Brake. This torque arm should be
sufficiently long for any normal application and
should be mounted so the rod is in tension
rather than compression when brake torque is
applied. Consult the factory for a
recommendation if a longer arm is needed.
The threaded shaft can be cut to any desired
length.
3
EB-375, 475, 650, 825
1. Secure the rod end bearing to the torque arm
shaft. (Figure 3)
Figure 3
2. Secure the rod end of the torque arm
assembly to the tab on the Electro-Brake.
5. Secure the torque arm to the brake so that
the ball joint is inside the tab and the jam nut
is on the outside (Figure 5). Rotate the ball
joint to facilitate this operation. Simply loosen
the jam nut on the shaft, and reposition the
jam nut to the desired position. Retighten the
jam nut to 90-95 ft. lbs. torque.
Figure 5
3. Secure the other end of the torque arm to a
base. Refer to Figure 6 to determine the
correct position for securing the tab and
torque arm. Although the arm may be
mounted in either direction, installing it as
illustrated is important to good bearing life.
EB-1000, 1225
4. Assemble the ball joints to both ends of the
threaded shaft. At least one inch of the shaft
must be threaded into each ball joint.
(Figure 4)
6. Secure the other end of the torque arm to a
base. Refer to Figure 6 to determine the
correct position for securing the tab and
torque arm. Although the arm may be
mounted in either direction, the bracket must
be parallel to the torque rod.
D. Electrical Installation
A wiring diagram showing the electrical
connections that must be made is furnished
with each Warner Electric control. Service
Manual P-239 includes complete information on
all standard power supplies.
E. Wearing Parts
The magnet and armature, the two main wearing
parts, wear at nearly the same rate. When these
parts are worn out, Warner Electric recommends
that the entire brake be replaced.
Figure 4
Warner Electric • 800-825-9050 P-211 • 819-0043
4
Electrical Coil Data
ROTATI ON
ROTATI ON
TORQ UE ARM M AY BE MOUNTED
IN A NY D IRE CTION
CLOCKWISE ROTATI O N
COUNTER-CLOCKWISE ROTATION
IF DIRECTION OF
BELT PULL
THEN LOCATE
TORQ UE ARM TA B
IF DIRECTION OF
BELT PULL
THEN LOCATE
TORQ UE ARM TA B
IF DIRECTION OF
BELT PULL
THEN LOCATE
TORQ UE ARM TA B
IF DIRECTION OF
BELT PULL
THEN LOCATE
TORQ UE ARM TAB
ELECTRO-BRAKE
VIEWED FROM ARMATURE SIDE
EC/EB-375 EC EC EB EB
Voltage — DC 90 6 90 6
Resistance @ 20°C — Ohms 453.5 2.10 446.8 1.96
Current — Amperes .198 2.85 .201 3.07
Watts 17 17 18 18
Coil Build-up — Milliseconds 62 59 50 52
Coil Decay — Milliseconds 13 15 8 10
EC/EB-475 EC EC EB EB
Voltage — DC 90 6 90 6
Resistance @ 20°C — Ohms 368.9 2.32 443.1 2.05
Current — Amperes .244 2.58 .203 2.93
Watts 22 16 18 18
Coil Build-up — Milliseconds 92 90 80 70
Coil Decay — Milliseconds 18 16 89
EC/EB-650 EC EC EB EB
Voltage — DC 90 6 90 6
Resistance @ 20°C — Ohms 225 1.16 257.2 1.24
Current — Amperes .4 5.19 .35 4.84
Watts 36 31 32 29
Coil Build-up — Milliseconds 120 110 112 105
EC/EB-825 EC EC EB EB
Figure 6
Voltage — DC 90 6 90 6
Resistance @ 20°C — Ohms 221 1.098 223.3 1.27
Current — Amperes 407 5.464 .4 4.74
Watts 37 33 36 28
Coil Build-up — Milliseconds 225 180 170 170
Coil Decay — Milliseconds 130 115 80 70
EC/EB-1000 EC EC EB EB
Voltage — DC 90 6 90 6
Resistance @ 20°C — Ohms 248.7 1.23 248.7 1.23
Current — Amperes .36 4.87 .36 4.87
Watts 33 29 33 29
Coil Build-up — Milliseconds 250 220 235 205
Coil Decay — Milliseconds 70 80 70 80
EC/EB-1225 EC EC EB EB
Voltage — DC 90 6 90 6
Resistance @ 20°C — Ohms 207.3 1.04 261.7 1.33
Current — Amperes .43 5.79 .34 4.5
Watts 39 35 31 27
Coil Build-up — Milliseconds 500 480 460 435
Coil Decay — Milliseconds 220 240 190 140
Warner Electric • 800-825-9050 P-211 • 819-0043
5
Burnishing and Maintenance
Burnishing
Intimate metal to metal contact is essential
between the armature and the metal rings
(poles) of the magnet or rotor. Warner Electric
clutches and brakes leave the factory with the
friction material slightly undercut to assure good
initial contact.
Normally, the desired wearing-in process occurs
naturally as the surfaces slip upon engagement.
The time for wear-in, which is necessary to
obtain the ultimate torque of the unit, will vary
depending on speed, load, or cycle duty.
If maximum torque is required immediately after
installation, the unit should be burnished by
slipping the friction surfaces together at reduced
voltage. It is recommended that the burnishings
be done right on the application, if at all
possible.
Burnishing at high speed will result in a
smoother wear-in pattern and reduce the time
for burnishing. The voltage should be set at
approximately 30% or 40% of the rated value.
The unit should be cycled on and off to allow
sufficient time between slip cycles to prevent
overheating.
When a Warner Electric brake or clutch is
properly assembled and installed, no further
servicing, lubrication, or maintenance should be
required throughout the life of the unit.
Maintenance
Re-machining the face of a worn armature is not
recommended. If a replacement armature is to
be used with a used magnet, it is necessary to
re-machine the worn magnet face. In refacing a
magnet: (1) machine only enough material to
clean up the complete face of the magnet;
(2) hold the face within .005" of parallel with the
mounting plate; and (3) undercut the molded
facing material .001" - .003" below the metal
poles.
Heat: Excessive heat and high operating
temperatures are causes of rapid wear. Units,
therefore, should be ventilated as efficiently as
possible, especially if the application requires
fast, repetitive cycle operation.
Foreign Materials: If units are used on
machinery where fine, abrasive dust, chips or
grit are dispelled into the atmosphere, shielding
of the brake may be necessary if maximum life
is to be obtained.
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.
Oil and grease accidentally reaching the friction
surfaces may be removed by wiping with a rag
dampened with a suitable cleaner, which leaves
no residue. In performing this operation, do not
drench the friction material.
If the friction materials have 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
boil to the surface, resulting in further torque
loss.
Wear Pattern: Wear grooves appear on the
armature and magnet surfaces. This is a normal
wear condition, and does not impair functioning
Torque Loss: If a brake or clutch slips or loses
torque completely, the initial check should be
the input voltage to the magnet as follows:
of the unit. Normally, the magnet and armature,
as a mating pair, will wear at the same rate. It is
the usual recommendation that both
components be replaced at the same time.
Warner Electric • 800-825-9050 P-211 • 819-0043
6
90-Volt Series: Connect a DC voltmeter with a
range of 0-100 or more directly across the
magnet terminals. With the power on and the
Loading...