CBC-802 Plug-In Clu tch/Brake Control
with Solid State Switching
P-239-35
819-0409
Service & Installation Instructions
Brake (Red) and clutch
(Green) indicator lights
Potentiometer for
anti-overlap adjustment
Introduction
When used with the Warner Octal Sockets, the
control meets the appropriate UL and CuL
certifications.
Failure to follow these
instructions may result in product damage,
equipment damage, and serious or fatal injury to
personnel.
The CBC-802 is a solid-state clutch/brake control
designed for operation of all Warner Electric 90 volt
DC clutches and brakes with the exception of the
high torque series. It should not be used to directly
power Warner Electric permanent magnet electrically
released brakes as the units require an adjustable
current or voltage supply to provide optimum
release.
The CBC-802 clutch/brake control is a direct plug-in
replacement for the previous MCS-802-2 control.
The difference between the two versions is that the
CBC-802 has a potentiometer for adjustment of the
anti overlap between clutch and brake where the
MCS-802-2 was switch selectable for preset times
only. Additionally, the fuse changed for a 3AG type
for the MCS-802-2 to a 5mm type fuse on the
CBC-802. Also included in the CBC-802 are LED
indicators indicating when the brake or clutch is
energized.
The CBC-802 clutch/brake control is designed to
switch between a clutch/brake combination, two
clutches or two brakes, one unit on at a time.
Control design is such that on power up, the brake
channel energizes initially, with normal switching
inputs. The time delay feature is designed to
minimize clutch/brake interaction by reducing
clutch/brake torque overlap. Indicator LED’s on the
control show when the brake channel (RED) or
clutch channel (GREEN) is energized. An internal
fuse provides protection from overload conditions.
Additionally the control is protected against output
short circuit conditions. The control does not protect
from AC ground loops or faults on the DC output
side.
Specifications
Power Input 120VAC ±10% 50/60 HZ
Output 90 VDC full wave rectified.
0.50 amps maximum.
Fusing 1/2 amp, 250V, 5 x 20mm
internal. Replacement
458-8001-086
Switching Momentary contact, maintained
contact, or solid state open
collector logic.
Minimum contact rating 20VDC
resistive, 0.01 amps.
Minimum input pulse –
1 millisecond.
Time Delay Adjustable potentiometer for 0 to
130ms - both channels
Dimensions Approx. 4'' high x 3-1/2'' wide x
1-1/2'' deep.
Ambient
Temperature -20° to +122°F (-29° to +50°C)
Cycle Rate Consult the Application
Engineering section of Warner
Electric’s Master Catalog,
P-1234, for capabilities in your
application.
Model Part No.
CBC-802 6002-448-001
Octal Socket, Foot Mounted 6001-101-001
Din Rail Mount Octal Socket 6001-101-002
The control mounts in one of the two optional octal
sockets which are purchased separately. Wiring is
made at the socket terminals.
Warner Electric • 800-825-9050 P-239-35 • 819-0409
2
To avoid injury (or even death),
3.60" MAX
3.80"
MAX
.07" MAX
Std. Octal Keyed Plug
1.45"
MAX
Anti-Overlap
Potentiometer
Anti-Overlap ADJ
Clutch
Brake
1.57"
(39.9)
2.39"
(60.7)
.70"
(17.8)
2.40"
(61)
.71"
(18)
1.57"
(39.9)
6
2
4
1
5
H
120 VAC,
± 10%
N
CBC 802
50/60 Hz
90 V
90 V
Clutch
Brake
always make certain all power is off before
attempting to install this control or any
electrical equipment. Do not touch the board
if power is applied.
Installation
Mounting
1. Select a suitable location in the panel or
cabinet where the CBC-802 will be
located. Insure sufficient space is
available for socket & wiring and control
when plugged into the socket.
2. Mount the socket (foot mount) to the
panel or attach the DIN Rail Mount to its
track where it will be located. Make sure
socket is properly secured.
3. Once socket is mounted and secured,
proceed to the control wiring section.
Dimensions
Wiring Hook-up
The CBC-802 clutch/brake control is
interchangeable with its predecessor, the
MCS-802-2, but is not directly interchangeable
with other Warner Electric plug-in controls. Before
actual installation of the CBC-802 into its socket,
insure all external wiring conforms to the following
hook-ups:
Power and Load Wiring
1. Connect the hot side of the 120 VAC power
to terminal 1 of the socket and secure
tightly.
2. Connect the neutral side of the 120 VAC
power to terminal 5 of the socket and
secure tightly.
Note: The “hot line” must be connected to
terminal 1. This line measures 120 VAC to conduit
ground. The “neutral” line (color coded white or
natural-gray) is grounded at the 120 VAC
transformer and must be connected to terminal 5.
This line measures zero VAC to conduit ground. A
chassis ground should be provided as non-current
conducting ground wire (color coded green).
3. Connect the two (2) wires from the clutch to
terminal 2 and terminal 6 of the socket.
Octal Socket
P/N 6001-101-001 Purchased Separately
4. Connect the two (2) wires from the brake to
Secure terminal 2 tightly.
terminal 4 and terminal 6 of the socket.
Securely tighten both terminals.
This is a floating type power
supply and is not referenced to AC ground.
DIN Rail Mount Socket
P/N 6001-101-002 Purchased Separately
Warner Electric • 800-825-9050 P-239-35 • 819-0409
Under no cirmcumstances should any of the
output wire leads be connected to earth or
chassis ground as the unit will be destroyed.
3
There are switching options that can be used with
7
8
3
START
STOP
CBC-802
7
8
3
CBC-802
7
8
3
CBC-802
8
3
7
CBC-802
the CBC-802 clutch/brake control. Determine
which switching option you will be using and wire
the switching inputs for that option.
Option 1 – Momentary Push Button Switches
Switches
Normally open
pushbutton.
Momentarily
contact closure
1. Connect the normally open start switch
contacts to terminals 7 and 8 of the socket.
Tighten terminal 8 securely.
2. Connect the normally open stop switch
contacts to terminals 7 and 3 of the socket.
Tighten both terminals securely.
3. This completes the wiring of the CBC-802.
Double check all terminal wiring at this time
Proceed to the start-up section of this
manual.
Option 2 - 2-wire Maintained Switching
or
3. This completes the wiring of the CBC-802.
Double check all terminal wiring at this time.
Proceed to the start-up section of this
manual.
Option 3 - Solid State Switching – NPN Open
Collector Logic
Solid
StateSwitches
NPN type open
collector outputs,
or NPN type
transistor with
both collector
and emitter
unterminated
When using solid state switching,
the emitter or output common of the switching
device cannot be grounded. If the outputs are
grounded, then either different switching
devices must be used or an input isolation
transformer on the AC input to the CBC-802
must be used, or the CBC-802 will be
destroyed.
1. Connect the collector of the NPN output
transistor or switching device to terminal 3
of the socket for stop input. Tighten terminal
3 securely.
2. Connect the collector of the NPN output
transistor or switching device to terminal 8
of the socket for start input. Tighten terminal
8 securely.
3. Connect the emitter of the NPN output
When using option 2 for switching input, the
switch wiring must be such that in normal state the
contacts are closed at power-up to insure brake
output is energized. Switching can be either
through a maintained type switch or relay contacts
as shown above.
4. This completes the wiring of the CBC-802.
transistors or switching device common for
both stop and start to terminal 7 of the
socket. Tighten terminal 7 securely.
Double check all terminal wiring at this time.
Proceed to the start-up section of this
1. Connect a jumper wire from terminal 7 to
manual.
terminal 8 of the socket. Tighten terminal 8
securely.
2. Connect the normally closed switch or
4
normally closed relay contacts to terminal 7
and terminal 3 of the socket. Tighten both
terminals securely.
Warner Electric • 800-825-9050 P-239-35 • 819-0409
Start-Up
6
5
4
3
7
8
1
2
ACV
Term 1-2 0V
Term 1-3 0V
Term 1-4 0V
Term 1-5 (line
voltage 120V)
Term 1-6 0V
Term 1-7 0V
Term 1-8 0V
The following procedure may be used to check out
the socket and wiring installation prior to plugging
in and powering the CBC-802. This procedure will
check for any grounding problem and prevent the
control from being blown. To carry out this test, a
digital voltmeter set to measure AC voltage with a
range of 250 VAC is needed.
5. With control installed in socket, apply power
to the CBC-802. On power up, the brake
output LED (Red) should be on, and the
brake should be energized.
6. Cycle the control between clutch/brake
channels and observe that the channel
output lights switch between brake and
clutch (Red LED to Green LED) and insure
brake and clutch are energizing properly.
1. With the CBC-802 control still unplugged
from the socket, apply the 120 VAC to the
control socket.
2. Place one test lead of the meter to terminal
1 (hot side of 120 VAC input power) and with
the other test lead of the meter measure to
the other terminals of the socket.
A zero volt reading should be observed
between terminal 1 and all other terminals
except terminal 5 which should measure
the AC line voltage to the socket.
A reading of other than (0) zero volts to any
of the terminals (except 1 to 5) indicates
some type of leakage or grounding
condition and MUST be removed or the
control will potentially be destroyed on
power up.
3. Once test is complete, turn off AC power.
7. Start the machine and allow unit to cycle.
Make any adjustment on anti-overlap
potentiometer while machine is running.
Adjust only enough to eliminate any
interaction from one unit turning off and
other unit turning on.
Note: If time delay is set too high, a delay between
one unit turning off and other unit turning on will
be noticed. This could cause loss of control in
machine function momentarily.
8. This completes the installation of the
CBC-802.
Note: Voltages other than zero indicates problems.
4. After completion of ground fault checks is
done and power off to the control socket,
insert the CBC-802 into the octal socket.
Note: The socket is keyed, so control will only go
in one way.
Warner Electric • 800-825-9050 P-239-35 • 819-0409
5
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 cons
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. I
f 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 maintena
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 aut
or to assume any other obligation or liability on its behalf.
ent.
nce.
horizes any other person to give any other warranty
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
OT
HERWISE, 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 s
ubject 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
31 Industrial Park Road • New Hartford, CT 06057
815-389-3771 • Fax: 815-389-2582
www.warnerelectric.com
P-239-35 • 819-0409 3/08 Printed in USA
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