Warner Electric CBC-1550AHFC User Manual

CBC-1500AHFC & 1550AHFC Closed Loop

Unidirectional Clutch/Brake Control System

P-291
819-9050

Installation Instructions

To prevent personal injury, ensure all personnel are clear of
conveyor line and the pusher before performing any adjustments on the
control.

Contents

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

Ordering Information . . . . . . . . . . . . . . . . . . . . . 3

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Connection Diagram CBC-1500 . . . . . . . . . . . . 4

Control Adjustments. . . . . . . . . . . . . . . . . . . . . . 4

Connection Diagram CBC-1550 . . . . . . . . . . . . 5

CBC-1000AH Operation. . . . . . . . . . . . . . . . . . . 6

Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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

Introduction

Warner Electric's CBC-1500AHFC and CBC­1550AHFC are closed-loop positioning controls
designed with error compensation and auto­home capabilities for industrial clutch/brake
applications. The position loop is closed through
encoder feedback which generates pulses pro­portional to load motion. The CBC-1500AHFC
and CBC-1550AHFC use this feedback to deter­mine the optimum brake actuation point. The
autohome feature requires a marker input from
the encoder to find its user defined home posi­tion upon power up. The CBC-1500AHFC and
CBC-1550AHFC are a combination of a CBC-

Additional Features. . . . . . . . . . . . . . . . . . . . . . 13

CBC-1000AH Diagnostic Tests . . . . . . . . . . . . 14

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 15

Electrical Diagram . . . . . . . . . . . . . . . . . . . . . . 16

Dimensional Diagram . . . . . . . . . . . . . . . . . 17-18

Programming Adjustments . . . . . . . . . . . . . 19-20

Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Torque Adjustments . . . . . . . . . . . . . . . . . . . . . 21

Warranty . . . . . . . . . . . . . . . . . . . . . . Back Cover

1000AH and a CBC-500 or CBC-550, respec­tively, joined together in one package for a total
control solution (for more information on either
control refer to the Warner Electric Master
Catalog, P-1000). Dual channel torque adjust­ment is provided via on-board potentiometers
for accomplishing soft starts and stops. Each
unit operates in absolute mode where it main­tains its position in an absolute sense and com­pensates for any slight errors made on the prior
move. The two outputs can be energized alter­nately or simultaneously and internal circuitry
provides suppression of transients during decay
of the magnetic field to assure rapid cycle rates.

Installation

The voltage present in this
control can cause serious injury (even death).
When installing the control or any electrical
equipment, make certain that the input
power is off. Do not apply power to this con­trol until it is securely mounted and com­pletely wired in accordance with local codes
and all installation work, including cleanup,
has been completed.

Warner Electric • 800-825-9050 819-9050

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Ordering Information

Model Number Part Number

CBC-1550AHFC Control 6050-448-008
CBC-1500AHFC Control 6050-448-006
Encoder Cable (Accessory) 6060-101-003
600 Pulse Per Revolution Encoder with Marker Pulse & 10' Cable 6060-101-061
RS-232 to RS-422/485 Converter (Accessory) 6060-101-232

Specifications

Input:

CBC-1500AHFC-90: 120 VAC ±10%, 50/60 Hz, 1 Phase, 300 VA max.
CBC-1000AH: Switch selectable AC power input to be 120 VAC only.
CBC-1550AHFC-24: 220 VAC ±10%, 50/60 Hz, 1 Phase, 300 VA max.
CBC-1000AH: Switch selectable AC power input to be 220 VAC only.

Programming Options (described on pages 6 through 8.)

Start input:

CBC-1500AHFC: 120 VAC
CBC-1550AHFC: 24 VAC

Output:

CBC-500-90: 0-90 VDC full-wave rectified nominal, 1.0 amp per channel max., 2.0 amps total.
CBC-550-24: 0-24 VDC full-wave rectified nominal, 4.0 amps per channel max, 4.0 amps total.
CBC-1000AH: Open collector active low outputs, 100mA sink max., 24 VDC max.

Circuit Protection: (fusing)

CBC-1500AHFC-90: 1.6 amps, 250 V fast blo
CBC-1550AHFC-24: 3 amps, 250 V fast blo
CBC-500-90: 2.5 amps, 250 V fast blo, 3AG
CBC-550-24: 5 amps, 250 V fast blo, 3AG

Encoder:

600 ppr with marker pulse.

Adjustments:

CBC-500-90 and CBC-500-24:
Channel 1 Voltage (via potentiometer)
Channel 2 Voltage (via potentiometer)
Jumper (selects simultaneous or alternate mode)
Frequency Adjustment: 60-400 Hz (via potentiometer)
CBC-1500AHFC and CBC-1550AHFC:
Run/Jog Switch
Clutch Jog push button

Ambient Temperature:

-20° to 122°F (-29° to 50°C)

Auxiliary Supply:

CBC-500-90 and CBC-500-24
12 VDC, 250 mA maximum

Warner Electric • 800-825-9050 819-9050

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Connection Diagram CBC-1500AHFC

1 2345 6789101112131415161718192021222324

RED (+12v)

BRN (SIG A)

ORN (SIG B)

BLK (COM)

GRN (SIG Z)

120 VAC
Start Input

TB2

TB1

120 VAC Input Power
EARTH GROUND
NEUTRAL
HOT

+
_

1.6A, 250v

FUSE

ENCODER

INPUTS

RXD -

RXD +

TXD -

TXD +

+12v

SIG A

SIG B

COM

START

STOP

MARKER/SIG Z

RESET

COM

START

EARLY WARNING

BRAKE ON

ZERO SPEED

ZERO SPEED + DELAY 1

ZERO SPEED + DELAY 2

AUX START

BATCH COMPLETE

HOT

NEUTRAL

BLD. GND.

SERIAL

DATA

SIGNAL
INPUTS

CBC-1000AH

VAC

120

Back side of cover

CONTROL OUTPUTS

CONTROL

INPUTS

1

2

3

4

5

6

7

8

8

7

6

5

4

3

2

1

CHANNEL 1
(Brake)

CHANNEL 2
(Clutch)

CBC-500-90

FAC TORY

CONNECTIONS

See Page 17

DO NOT

USE

Auxilary
Supply
+12VDC, 250mA

+
_

+
_

+
_

(CHANNEL 2

LED)

(CHANNEL1

LED)

(CHANNEL 2

ADJUST)

(CHANNEL 1

ADJUST)

(FREQUENCY

ADJUST)

DUAL
SINGLE

(JUMPER)

FAC TORY

CONNECTIONS

See Page 17

FAC TORY

CONNECTIONS

DO NOT

USE

DO NOT

USE



















Control Adjustments

CBC-500-90 and CBC-550-24:
Channel 1 and Channel 2 Torque
Adjustments:

Provides adjustment from 0 to full rated voltage.
Jumper: Allows operation of alternate or simul­taneous mode. In the single mode, Channel 1
and Channel 2 function alternately. In the dual
mode, Channel 1 and Channel 2 function simul­taneously. This mode will be employed in appli­cations with a clutch and failsafe brake.
Frequency Adjustment: Provides adjustment of
60 to 400 HZ to reduce the clutch/brake "hum"
associated with machine frequencies.

CBC-1000AH:
Switch Selectable AC Input: Allows for choice

of inputting 120 VAC or 240 VAC to unit.
Programming Options: Described on the fol­lowing pages.

CBC-1500AHFC and CBC-1550AHFC:
Run/Jog Switch: Allows operation in run or jog

mode. In run mode the unit will use the motion
profile programmed and cycle continuously until
interrupted. In jog mode the clutch can be
jogged using the clutch jog push button
described below.
Clutch Jog Push Button: Causes clutch to
rotate when push button is pressed.

Warner Electric • 800-825-9050 819-9050

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Connection Diagram CBC-1550

1 2345 6789101112131415161718192021222324

RED (+12v)

BRN (SIG A)

ORN (SIG B)

BLK (COM)

GRN (SIG Z)

24 VDC
Start Input

TB2

TB1

240 VAC Input Power
EARTH GROUND
NEUTRAL
HOT

+
_

3A, 250v

FUSE

ENCODER

INPUTS

RXD -

RXD +

TXD -

TXD +

+12v

SIG A

SIG B

COM

START 

STOP

MARKER/SIG Z

RESET

COM

START

EARLY WARNING

BRAKE ON

ZERO SPEED

ZERO SPEED + DELAY 1

ZERO SPEED + DELAY 2

AUX START

BATCH COMPLETE

HOT

NEUTRAL

BLD. GND.

SERIAL

DATA

SIGNAL
INPUTS

CBC-1000AH 

VAC

230

Back side of cover

CONTROL OUTPUTS

CONTROL

INPUTS

1

2

3

4

5

6

7

8

8

7

6

5

4

3

2

1

CHANNEL 1
(Brake) 

CHANNEL 2
(Clutch)

CBC-550-24

FACTORY 

CONNECTIONS

See Page 17

DO NOT

USE

Auxilary
Supply
+12VDC, 250mA

+
_

+
_

+
_

(CHANNEL 2

LED)

(CHANNEL 1

LED)

(CHANNEL 2

ADJUST)

(CHANNEL 1

ADJUST)

(FREQUENCY

ADJUST)

DUAL
SINGLE

(JUMPER)

FACTORY

CONNECTIONS

See Page 17

DO NOT

USE

FAC TORY

CONNECTIONS

DO NOT

USE









5

CBC-1000AH Control Operation

1

COUNT

2

MOV PST

3

E.W.

6

BATCH

7

BCH PST

8

BRK DIS

Successful operation will require knowledge of the following definitions and their relationships to the
Timing Diagram below.

Function Key Definitions

Count The actual move distance, in pulses or scaled into engineering units

(inches, feet, rotations, degrees, etc.), displayed dynamically.

Move Preset The desired move distance in pulses or scaled into engineering units.

This is the value the operator enters to select a new move distance. It
can also be locked during the RUN mode by simply programming line
6 to "off".

Early Warning A distance prior to Move Preset at which the early warning output is

activated. Expressed as pulses or engineering 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 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 by the batch (key 6).

Braking Distance The actual distance required to stop. This value is dynamically updat-

ed to determine the brake actuation point. 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 particular
brake being utilized. The amount of cycles needed for tuning depends
on how far the true braking distance value is from the default of 25.

* The batch counter is not factory enabled. To utilize, see "Additional Features" section.

Warner Electric • 800-825-9050 819-9050

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Programming

1

COUNT

2

MOV PST

3

E.W.6BATCH

7

BCH PST

8

BRK DIS

2

MOV PST

EDIT

RESET

CLEAR

EDIT

2

MOV PST

EDIT

EDIT

7

BCH PST

EDIT

RESET

CLEAR

EDIT

6

BATCH

RESET

CLEAR

1

COUNT

RESET

CLEAR

View Presets and Values

The six function keys may all be viewed during the RUN mode. To view their values, press the desired
function key and the value is displayed with the corresponding display annunciator. The controller
process continues without interruption.

Press to display the current length or position (up to six digits).

Press to display the move preset (up to six digits).

Press to display the early warning preset (up to four digits).

Press to display the batch counter (up to six digits).

Press to display the batch counter preset (up to six digits).

Press to display the average braking distance (up to four digits).

Entering Presets

The three presets (MOV PST, E.W., and BCH PST) may also be changed during the RUN mode provid­ed that programming line 7 (panel lock) is programmed "off". To edit, press the desired preset function
key, next press the EDIT key followed by the CLEAR key. Enter the new value using the numeric keys,
then press the EDIT key to exit the edit mode and to replace the existing value in memory. The CBC­1000 will use the new number entered after the edit mode is exited.

Move
Preset Press , then press , and press , now enter a new value using the numeric keys,

then press

or Press , then press , and press or to change the value incrementally, Then press

Batch
Preset Press ,then press , and press , now enter a new value using the numeric keys,

then press

Batch
Counter To manually reset the batch counter: Press , then press
Reset

System
Home To home the system: Press , then press

7