Warner Electric 5200-101-010 User Manual

Conduit Box Kit No. 5200-101-010

-1391

P
819-0198

Installation Instructions

4

10

8

11

9-1

*7

3

6
5

9

9-1

1

2

2

1

4

Introduction

Components

Conduit box kit No. 5200-101-010 contains all
components needed to assemble a conduit box
for 375, 400, 475, 500, 650, ER-825, and ER-1225
clutches and brakes.

When properly installed, this conduit box is
designed to provide a proper means for field wiring
terminations. It conforms to the requirements of
Underwriters Laboratories.

Do not connect rigid conduit
directly to the conduit box. A minimum of 12” of
flexible liquid tight conduit or other suitable
flexible wiring with appropriate fittings is
required. Flexible wiring is required to prevent
side loading of bearing on bearing mounted
clutches and possible deformation or breakage
of the conduit box or clutch/brake components
during assembly.

Step 1

Assemble a customer supplied flexible wiring
connector into desired end of conduit box (3).
Press protective plug (5) into unused conduit hole.

Thread green washer head hex screw (9) into
round hole in base of conduit box. Place terminal
ring (9-1) over screw before inserting.

Snap two wire grommets (6) into square holes in
conduit box base. The grommet crowns should
be toward the outside of the box and the rubber
flanges should be on both sides of the conduit
box.

Push two terminal spacers (7) through rubber
grommets. Number 6 spacers fit in sizes 375, 400,
and 475. Sizes 500 to 1225 use number 8 spacers.
(See Figure 1)

Figure 1

Warner Electric • 800-825-9050 P-1391 • 819-0198

2

Parts List for kit 5200-101-010

Item Quantity Part Name

11Bracket
21Screw, Hex, Washer Head

and Sems Conical Washer
31Box, Conduit
43Screw, Hex, Washer Head
51Plug, Protective
62Grommet, Wire

*7 2 Spacer No. 8 Thd.

2 Spacer No. 6 Thd.
82Cap terminal
91Screw, Hex, Washer Head,

Green

9-1 3 Terminal, Ring

10 1 Cover
11 2 Screw, No. 8 Brass
12 1 Plug, Protective

*The No. 6 spacers are required on Sizes 375, 400 and 475. All
others use No. 8.

Failure to follow these
instructions may result in product damage,
equipment damage, and serious or fatal
injury to personnel.

Step 2

asten bracket (1) to clutch field/brake magnet

F
with one No. 10-32 hex washer head screw (2).
The screw is self-tapping, threads are not
provided in the magnet bracket adapter. The
square projection on the magnet fits into the
square hole in the bracket. The curved side of
the bracket mounts toward the magnet. The
bracket flange is toward the flange side of the
magnet. (See Figure 2)

Step 4

onnect electric supply cable to the fitting

C
installed on the conduit box. If an external
power supply is furnishing DC current to the
clutch or brake, proceed to Step 5 and skip
Step 6. If a Warner Electric CBC-100 power
supply is being installed in the conduit box, skip
Step 5 and proceed to Step 6.

Step 5 - DC Connection

Slide one terminal cap (8) onto each of the two
supply conductors, small end first. Connect the
two supply conductors (with rubber caps) to the
magnet or field terminals using two No. 8 brass
screws (11) and ring terminals (9-1). The
stripped wires can wrap around the screw
between the terminal ring and the screw head or
other ring type terminals may be used. Electrical
supply connections must confirm to local
electrical codes. Install plug (12) into cover hole.

Figure 2

Step 3

Mount conduit box to bracket. The conduit box
flange must be toward flange side or the magnet
(rear of bracket). Thread terminal spacers into
field/magnet before fastening conduit box to
bracket. Do not over tighten, excessive torque
will pull thread insert out of magnet/field. Secure
conduit box to bracket with two No. 10-32 hex
washer head screws (4). (See Figure 3)

Step 6 - AC Connection

When a CBC-100 power supply is used, refer to
installation sheet P-266 provided with the
CBC-100, following instructions carefully. To
mount the CBC-100 to the conduit box, place
the control into the cover so the curved surfaces
conform, line up the cover hole with the control
mounting hole and fasten with screw provided in
the mounting kit. Connections to the magnet or
field terminals are as outlined in Step 5.

Step 7

A ground wire is recommended for grounding of
the conduit box and brake magnet or clutch
field. Connect this wire with the green ground
screw (8) to the hole in the bottom of the box.
Consult electrical local codes regarding
grounding requirements.

Step 8

Install cover (10) by sliding the slot in the cover
over the tab on one end of the conduit box and
secure the cover on the opposite end with one
No. 10-32 hex washer head screw (11).

Figure 3

Warner Electric • 800-825-9050 P-1391 • 819-0198

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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 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.

Warner Electric LLC

31 Industrial Park Road • New Hartford, CT 06057
815-389-3771 • Fax: [phone]
www.warnerelectric.com

P-1391 819-0198 8/11 Printed in USA

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