Warner Electric CBC-1000 User Manual
CBC-1000 Series Loop Unidirectional
Clutch/Brake Control System
P-275
819-0496
Installation & Operating Instructions
Contents
Introduction
Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Selection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Control Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Diagnostics Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Serial Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Page
Ordering Information
Model Number Part Number
CBC-1000 . . . . . . . . . . . . . . . . . . . . . . . . . 6060-448-001
Encoder Cable (Accessory) . . . . . . . . . . . . 6060-101-001
100 Pulse Per Revolution Encoder
w/10’ Cable. . . . . . . . . . . . . . . . . . . . . . . . 6060-101-010
250 Pulse Per Revolution Encoder
w/10’ Cable. . . . . . . . . . . . . . . . . . . . . . . . 6060-101-025
600 Pulse Per Revolution Encoder
w/10’ Cable. . . . . . . . . . . . . . . . . . . . . . . . 6060-101-060
1200 Pulse Per Revolution encoder
w/10’ Cable. . . . . . . . . . . . . . . . . . . . . . . . 6060-101-120
RS-232 to RS-422/485
Converter (Accessory. . . . . . . . . . . . . . . . . 6060-101-232
Warner Electric’s CBC-1000 is a closed-loop
positioning control with error compensation designed
for industrial clutch/brake applications. The position
loop is closed through encoder
feedback which generates pulses proportional to load
motion. The CBC-1000 uses this feedback to
determine the optimum brake actuation point. The
control can be programmed to operate in one of two
distinct modes: absolute or incremental. The CBC1000 includes eight solid state control outputs, a
batch counter and a serial communications interface.
The CBC-1000 system consists of four key
elements: the CBC-1000, a clutch/brake, a
clutch/brake control, and an encoder. Nearly any
electric clutch/brake size and configuration can be
used. These products are described in Warner
Electric’s Clutch/Brake Catalog, P-1234. The
Clutch/ Brake control, also found in Warner Electric’s
Clutch/Brake Catalog, should have solid-state
compatibility. Simple on-off, soft start/stop, and
overexcitation controls may all be utilized based on
the desired velocity profile. Warner Electric also offers
industrial grade encoders of various resolutions.
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 P-275 • 819-0496
Addendum Sheet
Warner Electric LLC
31 Industrial Park Road
New Hartford, CT 06057
tel 815-389-3771
fax: 815-389-2582
An Altra Industrial
Motion Company
CBC-1000AH
Service and Installation Instructions Additions to P-275
The CBC-1000AH Closed Loop Unidirectional Clutch/Brake Control System has had a feature addition and
the current manual number P-275 does not reflect this addition. The added feature is the auto home
capability (CBC-1000AH) which requires a marker input from the encoder to find its user defined home
position which might be lost during a power loss condition. There are a few simple steps that should be
followed to set up the CBC-1000AH properly.
1. Connect all the necessary components making sure the sig z wire (the marker pulse input) from the
encoder goes to control input 11 (sig z/marker) on the CBC-1000AH. This input was previously labeled
Continuous/Single.
2. After the encoder and the controls are installed and turned on, position the machine at home and reset
the counter.
3. Rotate the machine until the ‘ref’ light to the left/bottom of the display lights up.
4. Record the number displayed on the counter when the ‘ref’ light is lit.
5. Enter the programming mode by pressing the RUN/PGM key on the front panel of the control and
typing 1000. The number that you recorded should be put in programming line 1 (h, the home
reference number). Subsequently, all the programming line numbers in the P-275 manual will be
incremented by 1.
6. Every cycle when the CBC-1000AH sees the marker pulse the home reference number that was
recorded will be loaded into the counter value on the front panel display. It is important that this value is
as close as possible to what it should be. If more than ten cycles have occurred and your error is greater
than +/- 15, you should decrease/increase respectively the home reference number.
7. After cycling approximately ten times observe your actual braking distance number (BRK DIS, key 8 on
the front keypad) enter the programming mode and record this number in line 2 (bd, initial braking
distance). Subtract the home reference number recorded in line 1 from the move preset (MOV PST, key 2
on the front keypad). This number must be greater than the actual braking distance number. If the
braking distance number is larger, then the encoder needs to be rotated without the machine being
rotated to change where the marker pulse occurs. Otherwise, the marker pulse will occur after the brake
has come on and will not be detected.
8. Before exiting the program mode you will need to turn Count Retention off (CrEt, programming line 8). If
count retention is left on and a power failure occurs while the system is in its braking mode when power
is reapplied, it will take three cycles to find home.
The auto home feature will be very helpful when a power failure occurs and the encoder/control are unable to
track position. When power is reapplied a remote start can be applied and the machine will rotate until the
marker pulse is detected then the home reference number that was loaded in will be downloaded to the counter and CBC-1000AH will know its position and perform an accurate stop. The machine may miss its first home
position if the power up position is past where the marker pulse occurs.
The CBC-1000AH is programmed to not allow any outputs to fire until a home reference number is entered.
Also, depending on the speed of your system a lower resolution encoder may be needed to increase the length
of the marker pulse so it can be properly detected. The encoder that has been sent is a 600ppr
encoder. Therefore, your MOVE PRESET (key 2 on the front panel) needs to be changed to 600 if you are only
moving one revolution per cycle.
Selection Procedures
Select the Proper Clutch/Brake
Determine torque and inertia requirements.
Calculate heat dissipation for required cycle rate.
For best accuracy, mount clutch/brake directly on
nip or drive shaft. Avoid backlash.
Select Encoder (Quadrature)
Select encoder PPR for desired system resolution
(i.e., inches/pulse, degrees/pulse. Determine input
frequency; do not exceed 20 KHz (20,000 pulses/
sec). Mount encoder directly to nip or drive shaft for
best accuracy. Refer to Encoder Selection, page 7.
Select Clutch/Brake Power Supply
Use CBC-700 overexcitation control for best accuracy. Use CBC-500/550 for soft starting and/or
stopping. Note: Brake autogap may have to be
removed for best accuracy. Refer to clutch/brake
control, page 7.
Plan System Logic (Switching Requirements)
Use absolute mode for indexing applications such
as conveyors and turntables or cutoff applications
where close registration is required. Use
incremental mode for cutoff applications where
close registration is required. Use incremental mode
for cutoff applications. Refer to mode of operation,
page 8. Determine switching and relays required for
machine operation. Refer to pages 14-19 for
specific wiring options. Examples of incremental and
absolute wiring schematics are shown on pages 18
and 19.
Calculate Scaling Factor
Reference display scaling, page 8, to scale the
display to read inches, meters, degrees, rotations,
etc.
Determine Program Steps
Select absolute or incremental mode, output delays
and other options. Refer to Programming Section,
page 12.
Serial Communications
For data collection or remote operation, refer to
Serial Interface on pages 20-23.
Warner Electric • 800-825-9050 P-275 • 819-0496
3
Specifications
RESET
CLEAR
Press
to clear error code
Make panel cutout. Affix adhesive gasket (if required) to panel. Remove
panel straps and slide unit thru cutout. Slide panel straps into enclosure
guides. Thread 5/8” long hex washer head screws into guides using a
3/16” hex driver and tighten securely.
5.43 ± 040
(138 + 1, -0 mm)
allow 0.32” (8mm) each
side between cutouts
2.68 ± .030
(68 + 1, -0 mm)
5.68
(144 mm)
Part No. 6060-448-001
Input Power 100 to 130 VAC, 50/60 Hz, 20VA
(200 to 260 VAC selectable)
Auxiliary Supply 12 VDC @ 175 mA
Used for powering encoder, etc.
Main Counter
Range 6 Decade
Reset Input 2 Individual with 6 decade range
Operation Quadrature
Reset Input External and front panel
Count Rate (20 kHz external input frequency)
Batch Counter
Range 6 Decade
Presets 1 with 6 Decade range
Operation Count UP by detecting Zero Speed
Reset Through front panel only
Output Latched, fixed to output terminal 21
Signal A and B Inputs
Input Frequency DC, 20 kHz quadrature max.
Input Type Single ended, Current Source
Input Logic Times 2
Input High Level 3.25 VDC min.
Input Low Level 1.75 VDC max.
Input Impedance 1.0Ω to common
Input current 3.25 mA steady state
Input Response 10 µs. min high and low time
Control Inputs
Input Frequency DC to 20 Hz max. each input
Input Type Single ended, current sinking
Input Logic Both Edge and Level sensitive
as defined by input use
Input High Level 10 VDC min. to 20 VDC max.
Input Low Level 0 VDC min. to 2 VDC max.
Input Impedance 4.7Ω pullup to +12 VDC
Input Current 2.5 mA steady state
Input Response 25 ms. make and break time
Display
Decade 7 Decade, 0.6" red LED
Decimal Point User programmable
Range: xxx.xxx to xxxxxx
Keyboard Sealed tactile feel, 18 positions
Program Security Program LOCK of lines 1 - 34
Control Outputs
Type 8 Solid State, 100 mA sink max.,
24 VDC max.
Serial Interface
Type RS-422A/485 compatible
Baud Rate Selectable: 300, 600, 1200, 2400
Parity Selectable: None, Odd, Even
Data ASCII
Format Start bit, 7 bit ASCII data, Parity bit,
Stop bit
I.D. Number Programmable 0 to 98: Allows
multidrop systems
Diagnostics
Test 0 Keyboard Test
Test 1 Non-Volatile RAM Test
Test 2 Input Test
Test 3 Output Test
Test 4 Display Test
Test 5 Program Memory Test
Test 6 Date Code Test
Test 7 Serial I/O Test
Test 8 Return to Factory Programming
Mechanical
Enclosure Aluminum extrusion with molded
VALOX bezel. 2.91” high x 5.67” wide x
6.03” deep overall
Weight 2.5 lbs.
Cutout 5.43” ± 0.04” x 2.68” ± 0.03”
Panel Thickness 1/16” to 1/4”
Panel Depth 5.68” minimum
Environmental
Operating Temp. 0° to +50°C (32° to 122°F)
Storage Temp. -18° to 85°C (0° to 186°F)
Ambient Humidity 90% and noncondensing
Controller Error Codes
Error 2: Low AC Line Voltage
Error 3: Input Frequency too fast
Error 4: Processor time fully utilized
Dimensions For Panel Mounting
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Warner Electric • 800-825-9050 P-275 • 819-0496
144.0001
CBC-1000WARNER ELECTRIC
E.W. PGM
CNT EDIT
BRK BCH
MOV PST
1
COUNT
2
MOV PST
3
E.W.
4
5
9
0
6
BATCH
7
BCH PST8BRK DIS
EDIT
RUN
PGM
RESET
CLEAR
START
STOP
Metal Enclosure
• Improves Noise Immunity
• Eliminates RFI Emissions
• High Strength for Industrial Environment
Auxiliary Supply
Encoder Inputs
Control Inputs
Control Outputs
Display and Mode Annunciators
Display Function Keys
Numeric Keys 0-9
Start Key
Stop Key
CURSORS
RUN/PGM
RESET/CLEAR
EDIT
Neoprene Gasket Seal
AC Power Input
Serial Data I/O
Large LED Display
Sealed Front Panel
• NEMA 4 Rated
• 7 Decades
• High Intensity, High Contrast
• RS-422A/485
• Up to 32 units may be bussed together
• 115/230 VAC Selectable
• Built-in Line Filter
• Non-volatile Memory
• Used to enter the EDIT mode
to alter presets. Press again to
exit the EDIT mode
• Enabled by Programming Line
6 in the “off” position
• Resets the controller during operation
if Programming Line 5 is “on”
• Resets the Batch Counter if it
is being displayed
• Acts to clear the display in the
EDIT and PGM modes
• Used to switch between the RUN and
PGM modes
• UP: moves display toward top of program list in PGM mode
• RIGHT: moves display on same line in PGM mode
• DOWN: moves display thru programming steps in PGM
mode
• Used to initiate brake
• Used to initiate clutch
• Used to enter numeric
data in the EDIT and PGM modes
• COUNT: displays encoder input in engineering units
• MOV PST: displays desired length
• E.W.: displays desired duration of Early Warning
• BATCH: displays current batch count
• BCH PST: displays batch preset
• BRK DIS: displays stopping distance
• Displays the operation of the controller
(CNT, PGM, EDIT)
• Indicates what is being shown on the display
(MOV PST, E.W., BCH, BCH PST, BRK DIS)
• Start
• Early Warning
• Brake On (Stop)
• Zero Speed
• Zero Speed + Delay Time 1
• Zero Speed + Delay Time 2
• Auxiliary Start
• Batch Complete
• Start
• Stop
• Continuous/Single
• Reset
• Quadrature
• 12 VDC @ 175mA
Control Overview
Warner Electric • 800-825-9050 P-275 • 819-0496
5
Operation
Velocity
(Speed)
Inputs:
(Active Low)
Outputs:
(Momentary)
(Edge Triggered)
Start
Start
Stop
Early Warning
Brake On
Zero Speed
Zero Speed & Delay Time 1
Zero Speed & Delay Time 2
Auxiliary Start
Batch Complete
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
Delay Time 1
Delay Time 2
Time
(count)
Braking
Distance
Brake On
Point
Early Warning
Point
Start
Point
Successful operation will require knowledge of the following definitions and their relationships to the
timing diagram.
Function Key Definitions
Count The actual move distance, in pulses or scaled into engineering units (inches, feet, rotations, degrees, etc.) displayed
Move Preset The desired move distance in pulses or scaled into engineering units. This is the value the operator enters to select a
Early Warning A distance prior to Move Preset at which the early warning output is activated. Expressed as pulses or engineering
1
COUNT
2
MOV
PST
3
E.W.
dynamically.
new move distance.It can also be locked during the RUN mode by simply programming line 6 to “off”.
units, this output can be used to accomplish a soft brake (slow down), energize valves, etc.
Batch A cumulative batch counter that can be dynamically displayed to show the number of operations, cycles, etc. When
6
BATCH
this counter reaches the value programmed by the Batch Preset (key 7) the Batch Complete Output (pin 21 on
CBC-1000) is activated. The batch counter can be manually or automatically reset.
Batch Preset A programmable batch counter activates the batch complete output when the value programmed has been reached
Braking Distance The actual distance required to stop. This value is dynamically updated to determine the brake actuation point.
7
BCH
PST
8
BRK DIS
by the batch (key 6).
Factory default is 25 pulses or engineering units which is only used for the first cycle after power-up. After the first
cycle the CBC-1000 will tune to the braking distance required.
Timing Diagram
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Warner Electric • 800-825-9050 P-275 • 819-0496
Operation
Speed Speed
Speed
On - Off
CBC-400
Time
Soft Start/Stop
Time
CBC-500
Note: Remove the brake autogap for
best
accuracy when soft stopping.
Overexcitation
Time
CBC-700
CBC-750
The CBC-1000 system cycle to cycle accuracy will
usually be plus or minus several encoder counts.
Various factors can affect positional
accuracy, the most significant of which are
discussed below:
d. System Resolution - Can also be increased
by mechanical means. For example,
decreasing the diameter of a nip roll
connected to the encoder will increase
system resolution.
The maximum encoder resolution at any operation
speed is:
Encoder Selection
a. Type - Only quadrature type encoders may be
used.
b. Location - The encoder should be mounted
as close as possible to the location where
accuracy is desired, minimizing the effects of
backlash and slippage. Direct mounting is
preferred to indirect mounting.
c. Resolution - Encoder resolution should be
maximized so the inherent plus or minus
several count tolerance equates to the
minimum linear or rotational inaccuracy. The
product of encoder counts and rotational
speed must be less than the input speed of
20,000 pulses per second (20kHz). The
adjacent table simplifies selection:
Clutch/Brake Control
1
x 20,000 x 60 = Max. PPR
RPM
Encoder Speed Encoder Resolution
(RPM) (pulses/rev.)
12,000 - 4,801 100
4,800 - 2,001 250
2,000 - 1,001 600
1,000 - 0 1200
480 - 0 2500
240 - 0 5000
Various velocity profiles may be achieved by properly selecting the clutch/brake control. These can
generally be classified as overexcitation, on-off, and soft start/stop as depicted by the profiles below.
These are shown in order of decreasing system accuracy. Accompanying each diagram are the
recommended clutch/brake controls per given classification. The control should have solid-state
switching. This will reduce unnecessary time delays inherent in electromechanical or mechanical
switching devices. In addition, the system will not require external components such as relays, etc.
Warner Electric • 800-825-9050 P-275 • 819-0496
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