Failure to follow these
instructions may result in product damage, equipment damage, and serious or
fatal injury to personnel.
Introduction
Warner Electric’s CBC-300 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-300 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-300 series both outputs are adjustable.
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-300 are provided to
handle a wide range of applications. These
include both enclosed and chassis mount
versions for mounting in an external enclosure
or control panel. The standard version is offered
the same as before, but with the chassis version
added. The CBC-300-1 and CBC-300-C1
versions are being offered where an external
limit adjustment potentiometers are required.
The CBC-300-2 and CBC-300-C2 versions
maintain the limit adjust potentiometers on the
PC board but allow 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 adjusted
output channels. The CBC-300-3 and
CBC-300-C3 allow for both the current limit and
level adjustment potentiometers to be mounted
remotely.
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.
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.
Warner Electric • 800-825-9050P-269-1
2
Specifications
Input Power: 120 VAC, +10%, -15%, 50/60 Hz,
single phase, 215 VA maximum.
Output: Pulse-width modulated full wave rectified
DC. Constant current, switch selectable ranges
designed for 90 volt DC clutches and brakes.
External Switching: Mechanical or Electro-mechanical
Switching: 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.
Ambient Temperature: -32°F to + 113°F (0°C to +
45°C) with plastic cover installed. -32°F to
+150°F (0°C to + 66°C) with plastic cover
removed, or board assembly only.
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 FastActing type fuse recommended.
Control Adjust: CBC-300 and CBC-300-C via front
panel potentiometer for current adjustment.
CBC-300-1 and CBC-300-C1 via external
mounted potentiometer for current adjustment.
CBC-300-2 and CBC-300-C2 current
adjustment via front panel potentiometer and
output level adjust via external potentiometer.
CBC-300-3 and CBC-300C3 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 switches, SW1 for Channel 1 and SW2 for
Channel 2.
Current Ranges:
Switch Setting12 3 4 5
Max Output, ma60175245305533
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.
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.
Any vertical, horizontal, or angled surface is
suitable for mounting the CBC-300, CBC-300-1,
CBC-300-2, CBC-300-3 control.
Follow these procedures to mount your control.
q 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-300-2 was installed.
q 1. Remove the front cover by removing the
top and bottom retaining screws.
q 2. Set the control on the mounting surface
and mark for the three mountings holes in
accordance with “Dimensions.” (See Figure 1)
q 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.
q 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-300-1, CBC-300-2, or the
CBC-300-3 control is used, then the following
additional procedure must be followed.
q 1. For the CBC-300-2 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.
Mounting 2 Plcs
q 2. On the CBC-300-1, CBC-300-2 or
CBC-300-3 remove the four screws that hold
the faceplate bracket and PC board to the
chassis plate.
q 3. Bring the external potentiometers wires
through the conduit entrance hole and wire
the potentiometers to the appropriate
terminals blocks as shown.
Warner Electric • 800-825-9050P-269-1
4
(Figure 1)
Chassis Mount PC Board Assemblies
1
TB3
2
31 2
1
1
FRONT
LED1
LED2
TB2
SW1
VR1
TB1
Q5
Q3
CGND
TB4
31 2
VR2
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)
Any vertical, horizontal, or angled surface is
suitable for mounting the CBC-300-C,
CBC-300-C1, CBC-300-C2, or CBC-300-C3
control.
Follow these procedures to mount your control:
q 1. Determine the mounting location where the
control will be placed.
q 2. Layout the mounting hole dimensions and
drill holes and taps using a 4-40 tap.
Two options exist for mounting. The panel
can be drilled and tapped for mounting or
through holes can be used. (See Figure 2)
q 3. If the CBC-300-C1, CBC-300-C2 or
CBC-300-C3 controls are used, wire the
external potentiometers to the appropriate
terminal blocks as shown.
q 4. Place the faceplate over the PC board
assembly aligning the holes on the faceplate
with the holes on the PC board.
q 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.
q 6. Tighten all four mounting screws securely if
the panel was drilled and tapped. Discard the
nuts supplied with the screws. If the panel
was drilled only, then use the nuts with the
screws to secure the control to the panel.
q 7. If the CBC-300-C or CBC-300-C2 was
used, insert the knob on the internal
potentiometer shaft.
q 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 • 800-825-9050P-269-1
(Figure 2)
5
Electrical Connections
456789231
231
1.5A
FUSE
or
G
H
N
120 VAC
G
H
N
120 VAC
Clutch
Brake
Channel 1Channel 2
+
-
+
-
Note: CBC-300 Channel 1
and Channel 2 current
output is adjustable.
Note: If Solid-state NPN switching
is used, emitter is connected to
terminal 6 or 9 and collector is
connected to terminal 5 or 8.
External switching by
customer, see
specification.
Normal Clutch–Brake Wiring
(Power applied clutch or brakes)
All electrical current must be
off when making electrical connections to
prevent injury or death which can result from
contact with live wires.
AC Input Power Connections
q 1. Connect Earth Ground wire to Terminal 1
and tighten securely.
q 2. Connect the Hot side of the 120 VAC line
to Terminal 2 and tighten securely.
Note: Customer supplied fuse is desirable.
See diagram for connection and sizing.
q 3. Connect the neutral side of the 120 VAC
line to Terminal 3 and tighten securely.
q 4. Determine which clutch/brake arrangement
is to be used and proceed to the appropriate
wiring section.
q 1. Connect either the clutch or brake magnet to
Terminals 4 and 5. Tighten Terminal 4 securely.
q 2. Connect the other magnet, either brake or
clutch to Terminals 7 and 8. Tighten Terminal 7
securely.
q 3. Connect switching for Channel 1 to Terminals
5 and 6. Tighten both terminals securely.
q 4. Connect switching for Channel 2 to Terminals
8 and 9. Tighten both terminals securely.
q 5. Set DIP Switch, SW1 for proper current
setting before applying power to the control.
See Internal Switch Settings Chart for proper
DIP Switch settings
q 6. If external potentiometers are being used,
then proceed to the external potentiometer
wiring section. If external potentiometers are not
used, this completes the wiring of the control.
q 7. Double check all connections before applying
power.
Warner Electric • 800-825-9050P-269-1
6
(Figure 3)
Clutch – Electrically Released Brake Wiring
456789231
231
1.5A
FUSE
or
G
H
N
120 VAC
G
H
N
120 VAC
Clutch
Brake
Channel 1Channel 2
+
-
+
-
ER
External switching by
customer, see
specification.
Note: If Solid-state NPN switching
is used, emitter is connected to
terminal 6 or 9 and collector is
connected to terminal 5 or 8.
Note: Electrically released
brake must be connected to
Channel 1 Output when
CBC-200 is used.
(Power on clutch / power off Brake)
q 1. Connect the Brake to Terminals 4 and 5.
Observe the polarity when making
connections. Tighten Terminal 4 securely.
q 2. Connect the Clutch to Terminals 7 and 8.
Tighten Terminal 7 securely.
q 3. Connect the switching for Channel 1 to
Terminals 5 and 6. Tighten terminals securely.
q 4. Connect the switching for Channel 2 to
Terminals 8 and 9. Tighten terminals securely.
q 5. Set DIP Switch, SW1 for proper current
setting before applying power to the control.
See Internal Switch Settings Chart for proper
DIP Switch settings.
q 6. If external potentiometers are being used,
then proceed to the external potentiometer
wiring section. If they are not used, this
completes the wiring of the control.
q 7. Double check all connections before
applying power.
(Figure 4)
Warner Electric • 800-825-9050P-269-1
7
External Potentiometer wiring for
CBC-300-1, CBC-300-1C
External Current
Limit Adjust
WHT
RED
BLK
CW
10K POT
10 FT MAX
CH1
TB3
3
2
1
TB-3
CBC-300-1, CBC-300-1C
External Current
Limit Adjust
WHT
RED
BLK
CW
10K POT
10 FT MAX
10K, 2W POT
10% TOL, LINEAR OR
6011-101-002
ACCESSORY KIT (1)
CH2
TB4
3
2
1
TB-4
CBC-300 Series Controls
Enclosed Models
CBC-300-1
CBC-300-2
CBC-300-3
Depending on which control is being used,
options for external potentiometer are available
via terminal blocks on the PC board of the unit.
q 1. For CBC-300-2 only, remove the internal
torque adjust knob.
q 2. Remove the four screw that hold the
bracket assembly and PC Board to the
chassis. This step applies to all versions of
the enclosed models.
q 3. Based on which model being used, route
the potentiometer cable(s) through one of the
conduit entrance holes on the bottom of the
unit and wire to the appropriate terminal
block on the PC board. Refer to the wiring
diagrams below for the proper connections.
(Figure 6)
CBC-300-1
External Current Limit Adjustment
q 1. Wire the external current limit
potentiometer to Terminal Block TB-3 for
Channel 1 and TB-4 for Channel 2 as shown
in the diagram. (See Figures 6 & 7)
q 2. If the accessory potentiometer kit is used,
wire the potentiometers per the colors as
shown in the diagram.
q 3. Make sure all terminals are securely
fastened and the wiring cable is secured so
that it can’t pull loose from the terminals.
Warner Electric • 800-825-9050P-269-1
8
(Figure 7)
CBC-300-2
CBC-300-2, CBC-300-2C
External Level Adjust w/Internal
Current Limit Adjust
RED
BLK
CW
5K POT
10 FT MAX
LEVEL
1
TB2
2
TB-2
External Level Adjustment with Internal
Current Limit Adjust
q 1. Wire the external level adjustment
potentiometer on Terminal Block TB-2 as
shown in the diagram. (See Figure 5)
q 2. If the optional accessory potentiometer kit
is used, wire the potentiometer per the colors
as shown in the diagram.
q 3. Make sure all terminals are securely
fastened and the wiring cable is secured so
that it can’t pull loose from the terminals.
Note: The level adjustment controls both the
Channel 1 and Channel 2 outputs from 0
maximum as set by the current limit adjust
potentiometers.
CBC-300-3
External Current Limit and Level Adjust
q 1. Wire the external current limit adjust
potentiometer to Terminal Block TB-3 for
Channel 1 and Terminal Block TB-4 for
Channel 2 as shown in the diagram. (See
Figures 6 & 7)
q 2. If the optional accessory potentiometer kits
are used, wire per the color codes as shown
in the diagram.
q 3. Make sure all terminals are securely
fastened and the wiring cables are secured
so that it can’t pull loose from the terminals.
q 4. Wire the external level adjust potentiometer
to Terminal Block TB-2 as shown in the
diagram. (See Figure 5)
q 4. After the pot(s) have been wired to the
appropriate terminal block(s), mount the PCB
and bracket assembly and reattach to the
chassis with the four screws removed in step
2 above.
q 5. For the CBC-300-2 reattach the internal
potentiometer knobs.
q 6. Double check all wiring connections for the
potentiometer(s) and the main terminal block
to insure proper connections.
q 5. If the accessory potentiometer kit is used,
wire per the color codes as shown in the
diagram.
q 6. Make sure all terminals are securely
fastened and the wiring cable is secured so
that it can’t pull loose from the terminals.
Note: The level adjustment controls both
Channel 1 and Channel 2 outputs from 0
maximum level as set by the current limit adjustment potentiometers.
Warner Electric • 800-825-9050P-269-1
(Figure 5)
9
Chassis Mount Models
CBC-300-C1
CBC-300-C2
CBC-300-C2
q 1. The CBC-300-C series chassis mount
version controls are shipped with the face
plate bracket assembly loose.
q 2. Wire the control per the appropriate wiring
configuration for the type of external
potentiometers being used.
q 3. Based on which model is being used, route
the pot cable accordingly. Make sure to keep
the cable away from components which may
get hot during operation or points where the
cable may become pinched. Refer to the
wiring diagrams for the proper connection.
CBC-300-C2
External Level Adjust with Internal Current
Limit Adjust
q 1. Wire the external level adjust potentiometer
on Terminal Block TB-2 as shown in the
diagram. (See Figure 5)
q 2. If the optional accessory pot kit is used, then
wire according to the colors as shown in the
diagram
q 3. Make sure all terminals are securely fastened
and the wiring cable is secured so that it can’t
pull loose from the terminals.
CBC-300-C3
External Current Limit and Level Adjust
q 4. After the pot(s) have been wired to the
appropriate terminal blocks, mount the PCB
and bracket assembly and attach to the
mounting surface with the mounting
hardware provided.
CBC-300-C1 External Current Limit
Adjustment
q 1. Wire the external current limit
potentiometer to Terminal Blocks TB-3 for
Channel 1 and TB 4 for Channel 2 as shown
in the diagram. (See Figures 6 & 7)
q 2. If the accessory pot kit is used, then wire
per the colors as shown in the diagram.
q 3. Make sure all terminals are securely
fastened and the wiring cable is secured so
that it can’t pull loose from the terminals.
q 1. Wire the external current limit adjust
potentiometer to Terminal Block TB-3 for
Channel 1 and TB-4 for Channel 2 as shown in
the diagram. (See Figures 6 & 7)
q 2. If the optional accessory pot kit is used, wire
per the color codes as shown.
q 3. Make sure all terminals are securely fastened
and the wiring cable is secured so that it can’t
pull loose from the terminals.
q 4. Wire the external level adjust potentiometer
to Terminal Block TB-2 as shown in the
diagram. (See Figure 5)
q 5. If the optional accessory pot kit is used, wire
per the color codes as shown in the diagram.
q 6. Make sure all terminals are securely fastened
and the wiring cable is secured so can’t pull
loose.
Note: The level adjustment controls the output for
both Channel 1 and Channel 2 from 0 to maximum output as set by the current limit pots.
Note: The level adjustment controls the output for
both Channel 1 and Channel 2.
Warner Electric • 800-825-9050P-269-1
10
Internal Adjustments
The internal DIP Switch on the control circuit board adjusts the control for the proper current range to
the clutch and/or brake coil being used. The Chart below indicates the proper setting based on coil
resistance and Warner Electric product. To adjust for products not listed, obtain coil resistance
information and set switches per coil resistance.
Switch DIP No.12 3 4 5
Coil Resistance 1000-1550350-999250-349205-249100-204
at 20° C (W)
Current Range0 - 60 ma0 - 175 ma0 - 245 ma0 - 305 ma0 - 533 ma
Warner ElectricSF-120EC-375ATC-25SF-500ATC-115
Clutch ModelsSF-170EC-475PC-500SF-650SF-1525
Note: Only one switch number is to be set to the “on” position at any time.
Warner Electric • 800-825-9050P-269-1
11
System Troubleshooting
A. Symptom:
Green LED indicator marked “Power” does not come on when power is applied to the CBC-200 Controller.
Probable CauseSolution
No Power is applied to the Control• Check that AC power is applied to the control.
• Incorrect wiring on AC power to the control.
• Check for 120 VAC at Terminals 2 and 3 with an AC Voltmeter.
Optional line fuse is blown• Check for blown fuse – replace.
Indicator LED is defective• Check for 120 VAC at Terminals 2 and 3 of the control.
• Check for output voltage at output terminals for Channel 1 and
Channel 2. If voltage is not present, replace control or board.
B. Symptom: Red LED marked “short” illuminates
Probable CauseSolution
Shorted magnet coil• Check resistance of magnet coil used and replace if necessary.
Wiring between control and magnet shorting• Check for shorted conditions in wiring between the magnets and
the control, and wiring to chassis ground.
Improper magnet coil voltage• Check magnet for proper coil voltage rating.
Transient noise• Check for source of transient noise and suppress. Wire control
using shielded cables. Segregate wiring runs.
C. Symptom: Magnets do not engage when power is applied.
Probable CauseSolution
External switching improperly wired• Check wiring and switch connections and rewire if necessary.
Torque adjust set to zero (0)• Set torque adjustment potentiometer to maximum level.
Current range switch improperly set• Check DIP Switch settings per chart and reset if required.
No power applied to the control• Refer to Symptom A above.
System incorrectly wired• Check wiring per the wiring diagram and rewire if necessary.
Fail safe brake used in place • Check to insure that a fail safe brake is not being used in place of
of power applied brakea power applied brake. Replace brake with correct brake.
D. Symptom: Magnets do not disengage when power is removed
Probable CauseSolution
External switches incorrectly wired• Check wiring of switching circuits and rewire if necessary.
Fail safe brake magnet being used• Check to see if fail safe brake is being used in place of power
applied brake.
Faulty control• Replace control and see if problem is resolved.
E. Symptom: Magnets do not appear to have enough torque
Probable Cause Solution
DIP Switch improperly set• Check DIP switch setting per chart and reset if necessary.
Magnets incorrectly wired• Check wiring between control and magnets and rewire if required.
Torque adjust potentiometer set too low• Check setting of torque adjust potentiometer and set to maximum
if required.
Magnets are incorrectly sized• Verify sizing is correct by repeating selection process.
Warner Electric • 800-825-9050P-269-1
12
Warner Electric • 800-825-9050P-269-1
13
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 LLC
449 Gardner Street • South Beloit, IL 61080
815-389-3771 • Fax: 815-389-2582
www.warnerelectric.com
P-269-1 819-0408 8/11Printed in USA
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