Warner Electric CBC-200C User Manual
CBC-200 Series & CBC-200C Series Single
Channel Adjust Clutch/Brake Controls
P-269
819-0407
Installation & Operating Instructions
Contents
ntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
I
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 3
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrical Connections . . . . . . . . . . . . . . . . . . . 6
Internal Adjustments . . . . . . . . . . . . . . . . . . . 11
Troubleshooting Checklist . . . . . . . . . . . . . . . 12
Warranty . . . . . . . . . . . . . . . . . . . . . . Back Page
Failure to follow these
instructions may result in product damage, equipment damage, and serious or
fatal injury to personnel.
r control panel. The standard version is offered
o
the same as before, but with the chassis version
added. The CBC-200-1 and CBC-200-C1
version is being offered where an external limit
adjustment potentiometer is required. The
CBC-200-2 and CBC-200-C2 version maintains
the limit adjust potentiometer on the PC board
but allows for an external potentiometer for level
adjustment of the output. This allows the output
to be controlled from zero to maximum level on
both the current adjust channel and steady state
output channel. The CBC-200-3 and
CBC-200-C3 allow for both the current limit and
level adjustment potentiometers to be mounted
remotely.
Introduction
Warner Electric’s CBC-200 series Constant
Current Clutch Brake Controls are solid-state
electronic power supplies designed to operate
any of the Warner Electric 90 Volt clutches and
brakes, including fail safe designs. They can
operate a single clutch or brake, two clutches,
two brakes, a combination clutch and brake, or
a combination clutch and fail safe brake,
depending on the switching arrangement used
and the application requirements.
The CBC-200 series controls operate from 120
VAC single-phase input power. They provide
constant current output as set by the torque
adjustment potentiometers on the front panel or
remote potentiometer. Additionally, on some
versions a level adjust can be used to set the
operating level with the torque adjustment
setting the maximum current level. On the
CBC-200 series Channel 2 is a fixed output level
and an adjustable output on Channel 1. Output
current ranges are selectable for the adjustable
output channels in one of five ranges by the DIP
switches located on the control’s printed circuit
board.
Several versions of the CBC-200 are provided to
handle a wide range of applications. These
include both enclosed and chassis mount
versions for mounting in an external enclosure
Operations of all units are identical except for
the method of the control potentiometer
mounting. All units that have external
potentiometer options have terminal blocks
mounted on the PC boards for connection of the
potentiometers.
The potentiometers used can be supplied either
as optional accessory items or be obtained from
a local electronic supply house.
A short circuit protection scheme is integral
which trips on occurrence of line to line shorts
on the output. No protection is provided for line
to ground shorts because the unit is not
isolated.
Two LED indicators are provided on the front
panel of the control for “POWER” and “SHORT”
indications. The green indicator marked
“POWER” is illuminated whenever the AC input
power is applied to the control. A red indicator
marked “SHORT” is illuminated whenever a
short circuit condition occurs in either of the
outputs. To reset, power must be removed, the
shorted condition cleared, and the AC input
power reapplied to the control.
The enclosed version may be used with or
without the cover. Removal of the plastic cover
when the control is used in an enclosure will
increase the operating temperature range of the
control.
The chassis mount version does not have a
cover and must be mounted in an enclosure or
control panel.
2
Warner Electric • 800-825-9050 P-269 • 819-0407
Specifications
nput Power: 120 VAC, +10%, -15%, 50/60 Hz,
I
single phase, 215 VA maximum.
Output: Pulse-width modulated full wave rectified
DC. Constant current, switch selectable
ranges, for one channel and fixed 90VDC
second channel, designed for 90 volt DC
clutches and brakes.
Ambient Temperature: -32˚ F to + 113˚F (0˚C to + 45˚)
with plastic cover installed. -32˚F to +150˚F
(0˚C to +66˚C) with plastic cover removed, or
board assembly only.
External Switching: Mechanical or electromechanical
lectromechanical
E
Customer supplied; 1 amp, 125 V minimum
rating.
Solid-state NPN isolated transistor
Customer supplied; 2 amp, 250V minimum rating. Maximum off state leakage current < 1 ma.
External Pots:
Remote current adjust pot
customer supplied; 10,000 ohm, 2 watt, linear,
maximum distance from control to potentiometer not to exceed 10 feet.
Circuit Protection: Internal short circuit protection
on outputs, but no circuit protection for AC
ground faults. Optional customer supplied
fusing on AC line, 1.5 amps, 250 VAC
Fast-Acting type fuse recommended.
Control Adjust: CBC-200 and CBC-200-C via front
panel potentiometer for current adjustment.
CBC-200-1 and CBC-200-C1 via external
mounted potentiometer for current adjustment.
CBC-200-2 and CBC-200-C2 current
adjustment via front panel potentiometer and
output level adjust via external potentiometer.
CBC-200-3 and CBC-200-C3 both current
adjust and limit adjustment are via external
potentiometers.
Status Indicators: “POWER” – green LED indicating
AC power is applied to the control.
“SHORT” – red LED indicating that a short
circuit condition exists on one or both of
the outputs.
Internal Adjustments: Current Range Selection via
DIP switch, SW1
Current Ranges:
Switch Setting 12 3 4 5
Max Output, ma 60 175 245 305 533
Optional Accessory Pot Kit;
part number, 6011-101-002
Remote Level adjust pot
Customer supplied; 5,000 ohm, 2 watt, linear,
maximum distance from control to potentiometer not to exceed 10 feet.
Optional Accessory Pot Kit;
part number, 6011-101-001.
Wiring Entrance: Two 7/8” diameter entrance holes
located on the bottom of the control chassis on
enclosed units. No conduit entrances are on
chassis mount versions.
Enclosure: Rated NEMA 1 only – Control must be
kept clear of foreign materials, dust, grease and
oil which might affect its operation.
Part Numbers:
Enclosed Versions
CBC-200 6011-448-001
CBC-200-1 6011-448-002
CBC-200-2 6011-448-003
CBC-200-3 6011-448-004
Chassis Versions
CBC-200-C 6011-448-005
CBC-200-C1 6011-448-006
CBC-200-C2 6011-448-007
CBC-200-C3 6011-448-008
Warner Electric • 800-825-9050 P-269 • 819-0407
3
Mounting
SHORTPOWER
WARNER ELECTRIC
C
LUTCH-BRAKE
CURRENT CONTROL
CBC-200-1
SHORTPOWER
WARNER ELECTRIC
C
LUTCH-BRAKE
CURRENT CONTROL
VOLTAGE
FIXED
CHANNEL 2
C
HANNEL 1
TORQUE ADJUSTMENT
CBC-200
1
2
3
4
5
6
7
8
9
10
0
CBC-200-1
CBC-200-3
CBC-200
CBC-200-2
4.460
(113.3)
Max.
6.500
(165.1)
Max.
2.250
(57.2)
1.095
(27.81)
0.620
(15.75)
5.185
(131.7)
2.220
(56.39)
Ø0.180
(4.57)
Mounting
Ø0.375
(9.53)
(2 Plcs)
Ø0.180
(4.57)
Slot
Mounting (2 Plcs)
2.500
(63.5)
Max.
1.812
(46.02)
Max.
2.062
(52.4)
Max.
Enclosed Units
Any vertical, horizontal, or angled surface is suitable for mounting the CBC-200, CBC-200-1,
CBC-200-2, CBC-200-3 control.
Follow these procedures to mount your control.
❑ 4. After wiring the external potentiometers,
mount the PC board assembly and faceplate
assembly to the chassis with the four screws
previously removed. Replace the knob if the
CBC-200-2 was installed.
❑ 1. Remove the front cover by removing the
top and bottom retaining screws.
❑ 2. Set the control on the mounting surface
and mark for the three mounting holes in
accordance with “Dimensions.” (See Figure 1)
❑ 3. Install the top two mounting bolts or
screws until they are nearly flush, set the
control over the larger top mounting holes
and pull down to position the control.
❑ 4. Tighten the top bolts or screws and install
the bottom bolt or screw and tighten.
This completes the mounting of the control. The
control is now ready for final wiring. Refer to the
wiring section for final wiring.
If the CBC-200-1, CBC-200-2, or the
CBC-200-3 control is used, the following
additional procedure must be followed.
❑ 1. For the CBC-200-2 remove the knob from
the control.
This completes the preliminary wiring of the
remote potentiometers. The control is now ready
for final wiring. Refer to the wiring section for
final wiring.
Note: Be careful not to pinch or crimp the pot
wiring to prevent shorting to the housing or
components.
❑ 2. On the CBC-200-1, CBC-200-2 or
CBC-200-3 remove the four screws that hold
the faceplate bracket and PC board to the
chassis plate.
❑ 3. Bring the external potentiometer wires
through the conduit entrance hole and wire
the potentiometers to the appropriate
terminals blocks as shown in (Figure 5)
CBC-200-2, (Figure 6) CBC-200-1, or
(Figure 7) CBC-200-3.
4
Warner Electric • 800-825-9050 P-269 • 819-0407
Figure 1
Chassis Mount PC Board Assemblies
1
TB3
2
31 2
1
1
FRONT
LED1
L
ED2
TB2
S
W1
VR1
TB1
Q5
Q3
CGND
4-40 Screw
(4) Places
Customer
Mounting
Surface
1.300
(33.02)
Max
4.0790
(103.61)
Max
4.860
(123.44)
Max
0.375
(9.53)
0.350 ± 0.015
(8.89 ± 0.381)
1.025 ± 0.015
(26.04 ± 0.381)
3.375 ± 0.015
(85.73 ± 0.381)
3.375 ± 0.015
(85.73 ± 0.381)
ny vertical, horizontal, or angled surface is
A
suitable for mounting the CBC-200-C,
CBC-200-C1, CBC-200-C2, or CBC-200-C3
control.
Follow these procedures to mount your control:
❑ 5. Using the 4-40 screws supplied, mount the
PC board and faceplate assembly to the
panel. Insure that the faceplate aligns
correctly and does not contact any of the
components on the PC board.
❑ 1. Determine the mounting location where the
control will be placed.
❑ 2. Layout the mounting hole dimensions and
drill holes and taps using a 4-40 tap. (Figure 2)
❑ 3. If the CBC-200-C1, CBC-200-C2 or
CBC-200-C3 controls are used, wire the
external potentiometers to the appropriate
terminal blocks. (See Figure 2)
❑ 4. Place the faceplate over the PC board
assembly aligning the holes on the faceplate
with the holes on the PC board.
❑ 6. Tighten all four mounting screws securely.
❑ 7. If the CBC-200-C or CBC-200-C2 was
used, insert the knob on the internal
potentiometer shaft.
❑ 8. Attach the switch setting label next to the
control as a reference for switch set up.
Note: Be careful not to pinch or crimp the
potentiometer wiring to prevent shorting to the
chassis or control components.
This completes the mounting of the control. The
unit is now ready for final wiring. Refer to the
wiring section for final wiring.
Warner Electric • 800-825-9050 P-269 • 819-0407
Figure 2
5
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