Warner Electric AT Brakes User Manual

AT Brakes

P-218
819-0334

Installation Instructions

2

Warner Electric • 800-825-9050 819-0334

The Warner Electric AT brake you have pur-

chased has been designed to provide long and
trouble-free service. It is a rugged and durable
unit which is rebuildable with both friction face
replacement and complete brake rebuild kits
offered in this service manual. The friction face
replacement kit renews the friction surfaces,
while the complete brake rebuild kit includes
new bearings, Autogap™ components and
hardware in addition to the friction faces.

For friction material replacement refer to manual
819-0341.

For complete rebuild refer to manual 819-0325.

This service manual includes instructions
required for installation, troubleshooting informa­tion.

All installation and repair involving AT brakes
must be carried out in accordance with the pro­cedures specified in the service manual. All stat­ed or implied manufacturer warranties are void­ed if this product is not installed and serviced in
accordance with these instructions.

Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Brake Installation . . . . . . . . . . . . . . . . . . . . . . . 3

AT Brake Troubleshooting Guide . . . . . . . . . . . 5

Warranty . . . . . . . . . . . . . . . . . . . . . . Back Page

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

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Warner Electric • 800-825-9050 819-0334

Brake Installation

1. Remove your AT brake from its shipping car­ton and inspect it thoroughly to ensure that it
has arrived in good condition.

An accessory kit included with your brake
contains a coil wire retainer. In addition, you
may have ordered the optional brake torque
arm.

2. If used, install the Warner Electric conduit
box or conduit box/CBC-100 control combi­nation in accordance with instructions fur­nished with the conduit box.

3. The Warner Electric patented Autogap auto­matically adjusts the proper operating gap
between the armature and friction face for
the life of these components.The proper gap
is approximately .050". If the armature and
friction face have moved during shipment, re­set the Autogap by pushing the armature
against the friction material face. Release.
The armature will spring back about .050"
and the proper gap is set.

4. Slide the brake onto its shaft over its key.

If the brake is to be operated in a vertical
position, it must be mounted with the
armature fins up.

5. Install the optional Warner Electric torque arm
or the customer furnished pin. The arm must
be strong enough to withstand the brake’s
full torque capacity, and should be affixed to
the machine frame, and to the brake tangent
to its circumference in the notched attach­ment point on the back plate. It must also be
flexible enough to compensate normal shaft
and bearing runout without causing binding
or side loading to the brake.

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Warner Electric • 800-825-9050 819-0334

10. Your AT brake may not achieve its full

torque until after a short “break-in” period.
To break in the brake, cycle it on and off
under full load at operating speed a mini­mum of ten times in quick succession.

Your AT brake is now ready to run.

Note: Depending on application break in peri­od may be longer due to load and RPM, and
require more cycles.

Wear Indication

Your AT brake should be visually inspected on a
periodic basis to determine if the wearing sur­faces warrant replacement. The friction face and
armature should be replaced when the armature
reaches the wear indicator on the magnet shell.
If replacement is not made at this time, further
use will wear into the screw heads, making
removal and replacement of the friction facing
difficult. The drawing below illustrates the area
to be inspected.

When the friction surfaces are worn to this
point, replace with the appropriate friction face
replacement kit. All of the components needed
to refurbish the wearing surfaces of your brake
are provided in the replacement kit.

6. Tighten the set screws located in the hub to
the appropriate torque for your size unit:

Size Torque

25 80 in.-lbs.
55 160 in.-lbs.
115 275 in.-lbs.

7. Attach the wires to the DC power source,
using wire nuts or other approved connecting
devices. Either wire can be connected to the
+ or - of the voltage source. If a Warner
Electric CBC-100 or other Warner Electric
control is used as the power source, follow
the connection diagram supplied with the
control. Assure that the voltage rating of the
brake is the same as the output rating of the
power source.

8. Your AT brake is now ready for its static test.
Apply DC voltage to the coil through the
brake control. The armature should pull
against the friction material face with an audi­ble click.

9. Run the brake under its operating load.

Friction Face

Wear Indicator

Armature

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Warner Electric • 800-825-9050 819-0334

AT Brake Troubleshooting Guide

If performance problems are present after carefully following the instructions in this manual, use the
following check list.

Symptom Check

Problem Possible Causes

Clutch Rotor will not move or • Coil Resistance
engage when power is applied Coil may be open. See Chart 1.
to the coil • Power Supply

Assure proper DC voltage is being delivered to the brake

• Airgap
If greater than .050" around entire periphery, reset Autogap.

• Autogap
Assure that brake armature is free to move on hub spline and releases approxi-

mately .050" when pressure is removed.

Vibration • Runout

Assure that shaft on which the clutch is mounted doesn't have excessive runout.

• Shaft Engagement
Assure adequate shaft length and diameter engagement in the hub.

Excessive Start or Stop Times • Power Supply

Assure proper DC voltage is being delivered to the brake.

• Adequate Burnishing
Unit must be run and cycled a few times to achieve full rated torque.

• Friction Surfaces
Replacement may be required.

• Friction Surfaces
Installation of replacement friction material or armature segments may be

incorrect and not allow full contact.

Clutch/Brake Coil Approx. Coil

Size Voltage Resistance (Ohms)

25 6 1.4

25 24 20.6

25 90 290

55 6 1.2

55 24 19.6

55 90 230

115 6 1.0

115 24 16.5

115 90 182

Chart 1

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 notied 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 specic legal
rights and you may also have other rights which vary from state to state.

Changes in Dimensions and Specifications

All dimensions and specications shown in Warner Electric catalogs are subject to change without
notice. Weights do not include weight of boxing for shipment. Certied 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-218 819-0334 6/05 Printed in USA