Warner Electric ATT Tension Brakes User Manual

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ATT Tension Brakes
P-221 819-0338
Installation Instructions
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Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Wear Indication . . . . . . . . . . . . . . . . . . . . . . . . . .5
Brake Repair on the Shaft . . . . . . . . . . . . . . . . . .6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .8
Dimensions and Specifications . . . . . . . . . . . . . .9
Exploded View and Parts Lists . . . . . . . . . . . . .10
Warranty . . . . . . . . . . . . . . . . . . . . . . . .back cover
Failure to follow these instructions may result in product damage, equipment damage, and serious or fatal injury to personnel.
Introduction
The Warner Electric AT Tension (ATT) brake you have purchased has been designed to provide long and trouble free service. It is a rugged and durable unit which is rebuildable with friction face replacement kits discussed in this service manual. The friction face replacement kit renews the friction surfaces.
This service manual includes instructions required for installation, repair on the shaft, and troubleshooting information, specifications, dimensions, an exploded view and parts lists. Please refer to the Table of Contents for section page numbers.
All installation and repair involving ATT 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.
Warner Electric • 800-825-9050 P-221 • 819-0338
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Other Tensioning Products
Warner Electric offers many tension control products in addition to the ATT line. Basic tension brakes and high performance modular tension brakes are available, as well as a complete line of electronic tension controls. These include a basic manual control, a load cell control, a closed loop
dancer control, and splicer controls. For more information on these and other products, please call or write:
Warner Electric 31 Industrial Park Road New Hartford, CT 06057 Phone (815) 389-3771
Modular control systems for tension brakes are either manual adjust or closed loop types.
Simple tension control requires only a tension brake and this manual control.
Splicer control offers dual functions for two roll systems requiring simultaneous tensioning and holding.
Load cell control system automatically adjusts tension from load cell amplifier input.
Modular tension brakes are available in 10", 13", 15", and 20" diameters with single or dual friction discs and two to twelve magnets.
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Brake Installation
1. Remove your ATT brake from its shipping carton and inspect it thoroughly to ensure that is has arrived in good condition.
An accessory kit included with your brake contains a coil wire retainer and mounting hardware.
2. If used, install the Warner Electric conduit box in accordance with its furnished instructions.
3. Mount the magnet to the machine frame using the hardware in the accessory kit so that the magnet face is square with the armature shaft within .006 T.I.R. and the magnet mounting pilot diameter is concentric with the armature shaft within .010 T.I.R.
This is important to assure proper function and unit life.
5. Slide the armature over the input hub.
6. Slide the hub onto the shaft and provide a 1/16" gap between the friction faces.
4. Tighten the mounting screws to the machine frame to the appropriate torque for your size brake.
Size Torque
25 12.5 ft.-lbs. 55 25 ft.-lbs. 115 25 ft.-lbs.
7. 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.
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8. When using a Warner Electric tension control, follow the connection diagram supplied with the control.
If a Warner Electric TCS-210, -220, -310, or 320 control is used, add a 68 ohm resistor across the sense circuit. Although the TCS series controls are recommended, a MCS control can be used with normal hook-up.
Wear Indication
Your ATT 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.
9. Your ATT 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.
10. Run the brake under its operating load.
11. Your ATT 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 ATT brake is now ready to run.
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.
ATT-25 5161-101-008 ATT-55 5162-101-008 ATT-115 5163-101-008
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Complete Brake Repair–On The Shaft
The new ATT design incorporates a rugged, durable design for long life and maximum heat dissipation. Easy-to-replace friction surfaces extend the design life for continued like-new performance. The ATT offers complete repair-on the shaft following ten easy steps. The repair can be completed utilizing the parts in the friction face replacement kit.
1. Move the brake armature away from the magnet for disassembly and reassembly.
2. Remove the hex head cap screws, washers and lockwashers to loosen the armature segments from the cast iron carrier.
6. Insert two new friction material segments.
The recessed holes should be facing away from the magnet body.
3. Lift out the two worn armature segments.
4. Remove the screws which attach the friction material segments to the brake magnet through the appropriate access holes.
5. Lift the worn friction material segments.
7. Attach the new friction material segments to the brake with the screws through the appropriate access holes. Apply one drop of Loctite (grade 290 or equivalent) to each screw.
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Note: Use only the screws included with the repair kit since any other screws may damage the unit. Tighten to 18 to 22 lb. in. torque.
8. Insert the two new armature segments.
9. Attach the new armature segments to the cast iron carrier with hex cap screws, lockwashers and washers. Apply one drop of Loctite (grade 290 or equivalent) to each screw. Tighten to the appropriate torque for your size unit.
Size Torque
ATT 25 29-35 in.-lbs. ATT 55 60-84 in.-lbs. ATT 115 60-84 in.-lbs.
10. Ensure there is a 1/16" gap between the friction faces.
11. Your ATT 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”.
12. Run the brake under its operating load.
13. Your ATT 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 ATT brake is now ready to run.
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ATT Brake Troubleshooting Guide
In performance problems are present after carefully following the instructions in this manual, use the following check list.
Symptom Check
Brake armature 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 3/32" gap around entire periphery, reset.
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.
Low Tension • 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.
• 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 24 20.6 25 90 290 55 24 19.6
55 90 230 115 24 16.5 115 90 182
Chart 1
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Electric Brakes and Clutches
ATT Series – Advanced Technology Brakes and Clutches
D
Customer shall maintain:
1. Squareness of brake mounting face with armature hub shaft within .006 T.I.R.
Shaft Bore and Keyway Dimensions
Model Unit Bore Key
ATTB-25
ATTB-25
ATTB-25 .7525 19.11 ATTB-55 .7505 19.06
ATTB-25 .8775 22.29 ATTB-55 .8755 22.24
( ) denotes millimeters
Model Max. Nom. Max. Dia. Dia. Nom. Max. Nom. Max.
ATTB-25
ATTB-55
ATTB-115
.5025 12.76 .5005 12.71
.6275 15.94 .6255 15.89
( ) ( ) ( ) ( )
DE F G H J L M P
1.347 4.748 3.767 5.250 5.625/5.623 1.544 .225 3.586 2.080
(34.21) (120.60) (95.68) (133.35) (142.87/142.82) (39.22) (5.71) (91.08) (52.83)
1.770 5.37 3.767 6.875 7.373/7.375 1.544 .491 4.208 3.105
(44.96) (136.40) (95.68) (174.62) (187.27/187.33) (39.22) (12.47) (106.88) (78.87)
2.152 6.278 3.767 8.500 9.000/8.998 1.544 .463 5.116 3.105
(54.66) (159.46) (95.68) (215.90) (228.60/228.55) (39.22) (11.76) (129.95) (78.87)
1/8 Sq.
3/16 Sq.
3/16 Sq.
3/16 Sq.
Model Unit Bore Key
ATTB-55 1.0025 25.46 1/4 Sq.
1.0005 25.41
ATTB-55 1.1275 28.64 1/4 Sq.
ATTB-115 1.1255 28.59
ATTB-115 1.2525 31.81 1/4 Sq.
1.2505 31.76
ATTB-115 1.7775 34.99 5/16 Sq.
1.3755 34.94
ATTB-115 1.5025 38.16 3/8 Sq.
1.5005 38.11
2. Concentricity of brake mounting pilot diameter with armature hub shaft within .010 T.I.R.
ABC
Max. Min.
Model Dia. Max. Dia.
ATTB-25
ATTB-55
ATTB-115
Pilot
4.822 2.730 .264
(122.48) (69.34) (6.70)
6.271 3.010 .330
(159.28) (77.97) (8.38)
7.906 3.625 .330
(200.81) (12.07) (8.38)
For replacement parts list and exploded view drawing, see page 10.
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Brake Assemblies and Part Numbers
ATT Series – Advanced Technology Brakes
ATTB-25, ATTB-55, ATTB-115
Brake Assemblies
Unit Size Voltage Part No.
ATTB-25-1/2 24 5191-6 ATTB-25-1/2 90 5191-10 ATTB-25-5/8 24 5191-7 ATTB-25-5/8 90 5191-11 ATTB-25-3/4 24 5191-8 ATTB-25-3/4 90 5191-12 ATTB-25-7/8 24 5191-9 ATTB-25-7/8 90 5191-13 ATTB-55-3/4 24 5192-6 ATTB-55-3/4 90 5192-10 ATTB-55-7/8 24 5192-7
ATTB-55-7/8 90 5192-11
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Unit Size Voltage Part No.
ATTB-55-1 24 5192-8 ATTB-55-1 90 5192-12 ATTB-55-1-1/8 24 5192-9 ATTB-55-1-1/8 90 5192-13 ATTB-115-1-1/8 24 5193-6 ATTB-115-1-1/8 90 5193-10 ATTB-115-1-1/4 24 5193-7 ATTB-115-1-1/4 90 5193-11 ATTB-115-1-3/8 24 5193-8 ATTB-115-1-3/8 90 5193-12 ATTB-115-1-1/2 24 5193-9 ATTB-115-1-1/2 90 5193-13
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Part Numbers
Item ATTB-25 ATTB-55 ATTB-115 No. Description Qty. Part No. Qty. Part No. Qty. Part No.
1 Armature Hub 1 540-0908 1 540-0851 1 540-0864 2-1 Armature 1 110-0220 1 110-0218 1 110-0223 2-2 Facing Assem. 1 5191-445-003 1 5192-445-003 1 5193-445-003 2-3 Screw 6 797-1389 8 797-1389 8 797-1389 2-4 Screw 4 797-1020 6 797-1387 6 797-1174 2-5 Lockwasher –– 6 950-0355 6 950-0355 2-6 Flatwasher –– 2 950-0023 2 950-0023 3 Magnet Assem. 1– 1 – 1–
24 Volts D.C. 5191-631-007 5192-631-007 5193-631-014 90 Volts D.C. 5191-631-008 5192-631-008 5193-631-015
4 Splined Hub 1– 1 – 1 –
1/2" Bore 5191-541-002 –– –– 5/8" Bore 5191-541-003 –– –– 3/4" Bore 5191-541-004 5192-541-002 ––
7/8" Bore 5191-541-005 5192-541-003 –– 1" Bore –– – 5192-541-004 –– 1-1/8" Bore –– – 5192-541-005 5193-541-002 1-1/4" Bore –– – – –5193-541-003 1-3/8" Bore –– –5193-541-004 1-1/2" Bore –– – – –5193-541-005
5 Mtg. Acc’y. 1 5191-101-007 1 5192-101-007 1 5192-101-007
Optional Accessory Items
6 Conduit Box 1 5162-101-002 1 5162-101-002 1 5162-101-002
Kit Items
7 Friction Face
Replacement Kit 1 5161-101-008 1 5162-101-008 1 5163-101-008
(includes items 2-1, 2-2, 2-3, 2-4, 2-5, 2-6)
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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
31 Industrial Park Road • New Hartford, CT 06057
815-389-3771 Fax: 815-389-2582 www.warnerelectric.com
P-221 819-0338 8/11 Printed in USA
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