Warner Electric CBC-300C User Manual

CBC-300 Series & CBC-300C Series Dual

Channel Adjust Clutch/Brake Controls

P-269-1
819-0408

Installation & Operating Instructions

Installation Instructions

Contents

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

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.

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 • 800-825-9050 P-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 Setting 12 3 4 5
Max Output, ma 60 175 245 305 533

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.

Part Numbers:

Enclosed Versions

CBC-300 6021-448-001
CBC-300-1 6021-448-002
CBC-300-2 6021-448-003
CBC-300-3 6021-448-004
Chassis Versions
CBC-300-C 6021-448-005
CBC-300-C1 6021-448-006
CBC-300-C2 6021-448-007
CBC-300-C3 6021-448-008

Warner Electric • 800-825-9050 P-269-1

3

Mounting

SHORTPOWER

WARNER ELECTRIC

CLUTCH-BRAKE

CURRENT CONTROL

CBC-300-1

SHORTPOWER

WARNER ELECTRIC

CLUTCH-BRAKE

CURRENT CONTROL

CHANNEL 1

TORQUE ADJUSTMENT

CBC-300

1

2

3

4

5

6

7

8

9

10

0

CBC-300-1
CBC-300-3

CBC-300

CBC-300-2

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.

CHANNEL 2

1

2

3

4

5

6

7

8

9

10

0

Enclosed Units

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 • 800-825-9050 P-269-1

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(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 • 800-825-9050 P-269-1

(Figure 2)

5