CBC-500 & 550 Series
Torque Adjustable Clutch/Brake Controls
P-239-24
819-0486
Installation Instructions
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Control Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Switching Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Dimensional Diagrams . . . . . . . . . . . . . . . . . . . . . . . . 6
System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 7
Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . 8
Mounting Templates. . . . . . . . . . . . . . . . . . . . . . . . . 10
Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . back cover
Failure to follow these
instructions may result in product damage,
equipment damage, and serious or fatal
injury to personnel.
Introduction
Warner Electric's CBC-500 and CBC-550 series
clutch/brake controls are compact units
designed for operation with Warner Electric
90VDC and 24VDC clutches and brakes, including failsafe units. Dual channel torque adjustment is provided via on-board potentiometers
for soft starts and stops as well as accurate
release points for failsafe designs. These controls can operate with each channel either in
dual or single mode. Dual or single mode is controlled via an on board jumper for use in a variety of applications. A transformer is provided on
the CBC-550 series controls, extending the
input AC voltage range. Four models are
available:
CBC-500-90 120 VAC input
CBC-500-24 24-30 VAC input
CBC-550-90 120/220/240/380/480 VAC input
CBC-550-24 120/220/240/380/480 VAC input
Three optically isolated inputs provide full flexibility in interfacing customer supplied switching
schemes. Internal circuitry provides suppression
of transients during decay of the magnetic field
to assure rapid cycle rates. Two LED indicators
are provided on the control board for channel 1
and channel 2 indication.
Warner Electric • 800-234-3369 P-239-24
2
Specifications
Input:
CBC-500-90: 120 VAC ± 10%, 50/60 Hz, 1 phase, 250 VA max.
CBC-500-24: 24-30 VAC, 50/60 Hz, 1 phase, 250 VA max.
CBC-550-90: 120/220/240/380/480 VAC ± 10%, 50/60 Hz, 1 phase, 250 VA max.
CBC-550-24: 120/220/240/380/480 VAC ± 10%, 50/60 Hz, 1 phase, 250 VA max.
Output:
CBC-500-90: 0-90 VDC full-wave rectified nominal,
1.0 amp per channel max., 2.0 amps total
CBC-500-24: 0-24 VDC full-wave rectified nominal,
5.0 amps per channel max., 5.0 amps total
CBC-550-90: 0-90 VDC full-wave rectified nominal,
1.0 amp per channel max., 1.2 amps total
CBC-550-24: 0-24 VDC full-wave rectified nominal,
4.0 amps per channel max., 4.0 amps total
Circuit Protection: (fusing)
CBC-500-90: 2.5 amp, 250 V fast-blo, 3AG
CBC-500-24: 6.3 amp, 250 V fast-blo, 5 x 20 mm
CBC-550-90: 1.5 amp, 250 V fast-blo, 3AG
CBC-550-24: 5 amp, 125 V fast-blo, 5 x 20 mm
Switching Inputs: (external to control, supplied by customer)
Three optically isolated, 10-30 VDC:
Channel 1 Input (adjustable voltage applied to channel 1)
Channel 2 Input (adjustable voltage applied to channel 2)
Channel 2 Override Input (full voltage applied to channel 1)
Maximum off-state leakage < 1 mA
Adjustments:
Channel 1 Voltage (via potentiometer)
Channel 2 Voltage (via potentiometer)
Jumper (selects simultaneous or alternate mode)
Frequency Adjustment: 60-400 Hz (via potentiometer)
Ambient Temperature:
-20° to 122°F (-29° to 50°C)
Auxiliary Supply:
12 VDC, 250 mA maximum
Enclosure:
Optional NEMA 13 enclosure available
Warner Electric • 800-234-3369 P-239-24
3
Installation
1
1
2
3
4
5
6
7
1
2
3
4
5
6
7
8
8
1
1
2
2
2
3
3
3
4
4
4
5
5
5
6
6
6
7
7
8
8
POWER/SWITCHING
SWITCHING
CHANNEL 2 INPUT
(10-30 VDC)
CHANNEL 1 INPUT
(10-30 VDC)
CHANNEL 2 OVERRIDE INPUT
(10-30 VDC)
AUXILARY SUPPLY
+12 VDC, 250 mA
+
+
+
+
–
–
–
–
(Channel 2 LED) (Channel 1 LED)
CBC-500
WARNER ELECTRIC
480
VAC
CHANNEL 2
INPUT
(10-30 VDC)
CBC-550
WARNER ELECTRIC
OUTPUT
CHANNEL 2
(CLUTCH OR BRAKE)
CHANNEL 1
(CLUTCH OR BRAKE)
Factory
Connections
DO NOT USE
CHANNEL 2
(CLUTCH OR BRAKE)
CHANNEL 1
(CLUTCH OR BRAKE)
SPARE
SPARE
CBC-500-90: 120 VAC
CBC-550-24: 24 VAC
CBC-550 Series
+
+
+
+
–
–
–
–
+
+
–
–
+
+
–
–
HOT
AC
(Channel 2 Adjust) (Channel 1 Adjust)
Dual
Single
(Jumper)
on Bottom 4 pins - Alternat
on Top 4 pins - Dual Output
(Frequency Adjust)
POWER/OUTPUT
(Channel 2 LED)
(Channel 1 LED)
(Channel 2 Adjust)
(Channel 1 Adjust)
Dual
Single
(Jumper)
on Bottom 4 pins - Alternat
on Top 4 pins - Dual Output
(Frequency Adjust)
0
VAC
380
VAC
240
VAC
220
VAC
120
VAC
- NEUTRAL
CHANNEL 1
INPUT
(10-30 VDC)
CHANNEL 2
OVERRIDE
(10-30 VDC)
AUXILARY
SUPPLY
12VDC
250 mA
The voltages present in this control can cause serious injury (even death). When
installing this 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.
Connection Diagrams
CBC-500 Series
CBC-550 Series
Control Adjustments
Channel 1 and Channel 2 Torque Adjustment: Provides adjustment of 0 to full rated voltage.
Jumper: Allows operation of alternate or simultaneous mode of operation. In the single mode,
Frequency Provides adjustment of 60 to 400 Hz. This adjustment is simply to reduce the
Adjustment: clutch/brake "hum" associated with machine frequencies.
Warner Electric • 800-234-3369 P-239-24
4
Channel 1 and Channel 2 function in an alternate mode. In the dual mode Channel 1
and Channel 2 function simultaneously. This mode will be employed in applications with
a clutch and a failsafe brake. The control is shipped with the jumper placed for the
single mode of operation. To change to dual mode, carefully remove the jumper and
reinsert it on the dual side of the terminal block.
1
2
3
4
5
6
7
8
12 VDC
CH2 Input
Ch1 Input
Ch2 Override
Out IN
+
+
−
CH2 Input
Ch1 Input
Ch2 Override
1
2
3
4
5
6
7
8
1
2
3
10
Clutch/Brake
Control
Out 1
Out 2
Out 3
GND
PLC
1
2
3
4
5
6
7
8
− +
20VDC
Power
Supply
No Connection
No Connection
CH2 Input
Ch1 Input
Ch2 Override
Clutch/Brake
Control
Clutch/Brake
Control
Switching Options
Option 1: External Power Supply
Option 2: Internal Power Supply
Mode Options
Single Mode
Ch1 Ch2 Ch2 Ch1 output Ch2 output
Ove
000 No change No change
0 01 On at full torque Off
010 Off On at full torque
011 On at full torque Off
100On at adjusted torque Off
101 Full torque Off
110On at adjusted torque Off
111 Full torque Off
Dual Mode
Ch1 Ch2 Ch2 Ch1 output Ch2 output
Ove
000 No change No change
001 Off Off
010On at adjusted torque On at adjusted torque
011 Off Off
100 Off Off
101 Off Off
110 Off Off
111 Off Off
Note 1: In single mode, when power is applied
to the control, Ch1 comes on at adjusted voltage until a logic input changes the output voltages.
Option 3: PLC
Note 1: The minimum "on time" or "close time"
of each switch is 10m seconds.
Note 2: The switches in the above schematics
can be replaced with any kind of dry contact
switches; or any kind of relays. Examples:
mechanical relays, momentary contact switches,
toggle switches, transistors, mosfets, solid state
relays, PLC outputs, etc.
Note 3: The logic inputs of the clutch/brake
control are optically isolated.
Note 2: In single mode the control can not “turn
off” both channels at the same time; or “turn
on” both channels at the same time.
Note 3: When voltage is applied to “Ch2 override”, Ch2 and Ch1 logic inputs are ignored and
the outputs are changed to:
Ch1 = full torque and Ch2 = off.
When power is removed from “Ch2 override”,
the control reads the logic inputs and changes
the voltage output accordingly. If no power is
applied to the logic inputs when power is
removed from Ch2 override, then the output
voltages remain at:
Ch 1 = full torque for Ch 1 and Ch2 = Off.
Example:
5
Ch1 in
Ch2 in
Ch2 override in
Ch1 output at adjusted torque
Ch2 output at adjusted torque
Ch1 out=full torque and Ch2 out=off
Ch1 in
Ch2 in
Ch2 override in
Ch1 output at adjusted force
Ch2 output at adjusted force
Logic Inputs vs. Time Examples
CBC-500
W
ARNER ELECTRIC
1.75"
0.90"
6.00"
0.20"
3.90"
1.15"
1.25"
1.40"
This control may be mounted on its base (two mounting slots) or on its back (four mounting slots).
Note: All dimensions nominal.
4.60"
2.85"
3.50"
4.72"
4.08"
3.90
Example: (Single Mode)
Example: (Dual Mode)
Dimensional Diagrams
CBC-500
CBC-550
Warner Electric • 800-234-3369 P-239-24
6
System Troubleshooting
The chart below will be helpful when attempting to isolate problems which may occur in the control
system. It will also prove helpful when encountering problems during initial system start-up.
Symptom A: No output on either channel upon power-up.
Probable Cause Solution
Improper wiring Check wiring and correct if necessary.
No power available Check that AC power is available to control.
Blown fuse See Fuse keeps blowing, Symptom C.
Symptom B: Channel 2 activates upon power-up.
Probable Cause Solution
Improper wiring Check wiring and correct if necessary.
Faulty input switching circuit Check that input switching network is providing proper signal.
Symptom C: Fuse keeps blowing.
Probable Cause Solution
Improper wiring Check wiring and replace fuse.
Shorted brake/clutch coil Check coil resistance and replace if necessary.
Fuse too small Replace with proper fuse.
Improper AC line voltage Check line voltage and correct if necessary.
Improper magnet voltage Check magnet voltage rating and replace with correct magnet if necessary.
Symptom D: Magnets do not appear to have enough torque.
Probable Cause Solution
Magnets incorrectly sized Verify sizing by repeating the selection process.
Symptom E: Outputs don't switch; Inputs don't switch.
Probable Cause Solution
Incorrectly wired inputs Check wiring and correct if necessary.
Faulty switching device Check for proper operation and replace if defective.
Faulty control Replace control.
Reorder Information
Model Part No.
CBC-500-90 6024-448-003
CBC-500-24 6024-448-002
CBC-550-90 6024-448-006
CBC-550-24 6024-448-005
CBC-500 Series Enclosure 6042-101-004
CBC-550 Series Enclosure 6006-101-007
7
DECLARATION OF CONFORMITY
WE: WARNER ELECTRIC
449 Gardner Street
South Beloit, IL 61080
declare under our sole responsibility that the products of the family
CBC 500-90 &CBC 500-24
CBC 550-90 & CBC 550-24
are exclusively designed for incorporation in another machine. The operation of
the product is submitted to the conformity of the complete equipment, following the provisions of the directive 89/392/EEC.
The conformity of the above specified products with the provisions of the
Directive 72/23/EEC is supported by the full respect of the standards EN
61010-1.
If the mounting and connecting instructions of the installation’s manual have
been respected, this product will be conform to the standards EN50081-1 and
EN50082-1 relating to the EMC directive 89/336/EEC.
South Beloit, IL 61080
VP and General Manager: S. O.
To avoid injury, always make certain all
power is off before attempting to install
or repair this control.
DO NOT TOUCH THE BOARD IF POWER IS APPLIED.
Mounting and Connecting Instructions
related to the EMC-directive 89/336/EEC
For Clutch and Brake Control
1. The control must be mounted in a closed metal cabinet.
2. The power connection between control and clutch/brake must be MADE
using shield cable.
3. The control connection must utilize shielded cables.
4. The shield of the cables must be grounded at both ends.
5. Power connections and control connection must be placed in separate
canals.
DECLARACION DE CONFORMIDAD
Nosotros: WARNER ELECTRIC
declaramos bajo nuestra propia responsabilidad que los productos de la familia
son diseñados exclusivamente para incorporarse en otra maquina. El funcionamiento de este producto esta sujeto al cumplimiento de todo el equipo
usado en la maquina, con los lineamientos de la norma 89/392/EEC.
El cumplimiento de los lineamientos de la norma 72/23/EEC con los productos
mencionados anteriormente, se basa y respeta los estandares EN 61010-1.
Si las instrucciones de montaje e instalación electrica del instructivo son
respetadas, este producto cumplirá con los estandares EN50081-1 y
EN50082-1 que se relacionan con la norma 89/336/EEC.
South Beloit, IL 61080
VP and General Manager: S. O.
instalar o reparar este control, siempre asegurese que
todas las fuentes de poder esten apagadas.
NO TOQUE EL CIRCUITO ELECTRICO SI LA FUENTE DE PODER
ESTA ENCEDIDA.
en relación a la norma de EMC 89/336/EEC
PARA CONTROLES DE CLUTCHES Y FRENOS
1. El control debe de instalarse adentro de una caja metalica.
2. Las conexiones electricas entre el control y el cluch/freno DEBEN hacerse
con cable blindado.
3. Las conexiones de bajo voltaje en el control deben utilizar cables blindados.
4. El blindaje de los cables debe de aterrizarse en ambos lados.
5. Las conexiones entre la fuente de poder, y las conexiones de bajo voltaje
deben de hacerse en diferentes cables.
449 Gardner Street
South Beloit, IL 61080
CBC 500-90 &CBC 500-24
CBC 550-90 & CBC 550-24
ADVERTENCIA:
Para evitar cualquier daño
personal, antes de intentar
INSTRUCCIONES DE MONTAJE Y
CONEXIONES ELECTRICAS
KONFORMITÄTSERKLÄRUNG
Wir: WARNER ELECTRIC
erkälren in alleiniger Verantwortung, daß die Prdukte der Familie
ausschließlich zum Einbau in eine andere Maschine bestimmt sind. Die
Inbetriebnahme ist solange untersagt, bis die Konformität des Endproduktes
mit der Richtlinie 89/392/EWG gegeben ist.
Die Übereinstimmung des bezeichneten Produktes mit den Vorschriften der
Richtlinie 72/23/EWG wird nachgewiesen durch die Einhaltung der Normen EN
61010-1.
Sofern die Montage-Anweisungen der Bedienungsanleitung eingehalten wurden, ist dieses Podukt knoform zu EN50081-1 und EN50082-1 und die EMV
somit gewährleistet - Richtlinie 89/3366/EWG.
South Beloit, IL 61080
VP and General Manager: S. O.
KARTE BEI EINGESCHALTETER STROMVERSORGUNG NICHT
BERÜHREN.
bezogen zu den EMW Richtlinic 89/336/EWG
FÜR STEURGERÃTE KUPPLUNGEN UND BREMSEN
1. Das Gerãt muß in einem gesclossenen metallschrank eingebaut werden.
2. Leistungsverbindungen Steuergerãte/Kupplungen - Bremsen mit
3. Steuerdeitungen, Ein-und Ausgãnge mittels abgeschimten Kabeln durch-
4. Abschirmung an beiden Enden des Kabels erden.
5. Leistungs-und Steuerverbindungen in separate Kabelkanãle durchziehen.
449 Gardner Street
South Beloit, IL 61080
CBC 500-90 &CBC 500-24
CBC 550-90 & CBC 550-24
WARUNG:
Vor Einbau oder Wartung des
Gerätes unbedingt die
Stromversorgung unterbrechen um Verletzungen zu vermeiden.
MONTAGE UND KABELVERBINDUNGEN
ANWEISUNGEN
abgeschim Kabel durchfubren.
führen.
DÉCLARATION DE CONFORMITÉ
Nous: WARNER ELECTRIC
déclarons sous notre seule responsabilité que les produits de la famille
sont uniquement destinés à l’intégration dans une machine. La mise en service de ces produits est subséquente à l’homologation de l’ensemble de
l’équipmement, conformément à la directive 89/392/CEE.
La conformité des produits spécifiés ci-dessus avec les exigences de la directive 72/23/CEE est supportée par le respect des normes EN 61010-1.
Si les instructions de montage et de câblage du manuel sont respectées, ce
produit est conforme aux normes EN50081-1 et EN50082-1 directive
89/336/CEE relative à la CEM.
South Beloit, IL 61080
VP and General Manager: S. O.
soit coupée avant installation ou intervention sur ces
équipements.
NE PAS TOUCHER LE CIRCUIT ÉLECTRONIQUE, SI LA PUISSANCE
EST APPLIQUÉE.
relatives à la CEM, directive 89/336/CEE
DES CONTROLES POUR EMBRAYAGES ET FREINS
1. L’ appareil doit être monté dans une armoire métallique close.
2. Liasion de puissance entre contrôle et embrayage/frein par cãble blindé.
3. Raccordements de consigne, entrées et sorties par cãbles blindés.
4. Les blindages sont reliés à la terre aux deux extrémités du cãble.
5. Les cãbles de commande et les cãbles de puissance ne seront pas placés
dans le mëme caniveau.
449 Gardner Street
South Beloit, IL 61080
CBC 500-90 &CBC 500-24
CBC 550-90 & CBC 550-24
ADVERTISSEMENT:
Afin d’éviter des blessures,
s’assurer que toute puissance
INSTRUCTIONS D’INSTALLATION
ET DE CABLAGE
Mounting Template for CBC-500
Mounting Template for CBC-550
Warner Electric • 800-234-3369 P-239-24
9
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
31 Industrial Road
815-389-3771
www.warnerelectric.com
• New Hartford, CT 06057
• Fax: 815-389-2582
P-239-24 819-0486 2/12 Printed in USA
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