Warner Electric CBPC-3590 User Manual
CBPC-3590
Clutch-Brake Positioning Controller
P-291-1
819-0526
Service & Installation Instructions
Warner Electric • 800-825-9050 P-291-1 • 819-0526 1
Contents
compensation is maintained in the stop position
from cycle to cycle.
Introduction ............................2
Theory of Operation ......................2
Specications...........................3
Mechanical Installation....................4
Dimensional Information ..................5
Electrical Wiring .........................7
Start Up ...............................9
Programming Information ................11
RS-485 Programming ...................12
Troubleshooting ........................18
Warranty ............................. BC
instructions may result in product damage,
equipment damage, and serious or fatal injury
to personnel.
Only Authorized Personnel to set
up and maintain this unit.
Failure to follow these
Introduction
The CBPC-3590 Clutch Brake Positioning Control
is a dedicated control incorporating a counter
system, control logic, and clutch brake power
supply for closed loop control operation. The
controller uses an incremental encoder input with
marker pulse to register position for single
revolution operation.
The one board design eliminates interconnec-
tion between numerous boards and controls and
improves reliability by removing unnecessary
interconnecting cables. With everything located
on one board, replacement of the control board is
simplied.
An external start input signal is used to provide
the start input to the controller which applies
power to the clutch. The encoder registers the
position to the controller and when the preset
count is reached turns power on to the brake. An
internal averaging circuit takes the actual stop
position from the required stop position and
compensates so the controller provides the stop
at the precise position. In this method,
The control has front panel indicators to tell when
the clutch is on, brake is on, a fault has occurred
and a home pulse indicator. In addition, a front
panel run-jog switch allows the user to operate the control in normal running mode or in jog
mode for set up and troubleshooting purposes.
When in the jog mode, the jog push-button allows
the clutch to be activated at a preset level below
the maximum set output level. The clutch will be
engaged as long as the push-button is held in and
brake is actuated as soon as it is released.
This control will directly replace the older style
CBC1500-AHFC controller. Connectors are
provided on the housing of the control for
hook-up to existing cables where the
CBC1500-AHFC is used. If existing cables are
non-existent, optional cable accessories are
available.
Set up has been simplied to minimize the
number of steps necessary to commission the
unit. All functions are accessed internally in the
controller via the keypad and display. Once the
unit is set up and closed, the operator does not
have access to any of the functions without going
into the controller. Remote indicators on the
faceplate show the status of the controller.
Theory of Operation
The CBPC-3590 operation is simple and straight
forward. The unit is typically setting with the brake
output engaged. A “start input” signal is received
by the control from the external signal source. The
controller disengages the brake and applies
power to the clutch. The output level to the clutch
is adjustable via the programming mode to obtain
the proper engagement of the clutch. With the
clutch engaged, the drive mechanism starts to
rotate generating a signal to the controller from
the encoder. The controller counts the encoder
pulses and the display (internal) counts in an up
direction. If the count is in the reverse direction,
then the encoder signals “A” and “B” are
improperly connected and need to be reversed for
2 Warner Electric • 800-825-9050 P-921-1 • 819-0526
correct operation. Additionally a marker pulse is
generated by the encoder to the controller which
looks at this pulse and internally in the processor matches the system count with the encoder
count. When the system count is equal to the
preset count (600 minus the braking distance) a
brake output signal is generated and the
controller applies the brake. Brake torque is
adjustable to obtain optimum stop conditions.
Specications
Input Power: 120 VAC, +/- 10%, 50-60 Hz, Single
Phase, 300 VA maximum
Fusing: 1.6 Amp, 250 V fast acting (5x20mm)
Output: Adjustable 0 – 90 VDC pulse width
modulated full wave rectied DC via keypad.
1 Amp per channel maximum
The controller internally compares the actual stop
point with the desired stop point based on the
preset distance, the braking distance, and any
over or undershoot that might occur. This brak-
ing distance is averaged on a continuous basis
to provide a stopping point as close to the preset
point as possible.
The controller also can handle multiple start signal
inputs so that the controller can make numerous moves and yet still return to the correct stop
point. This is accomplished through the integrated
control logic of the processor on the board.
A batch counter is also incorporated into the
controller to keep track of the number of
operation cycles the unit operates. This can be
useful in both troubleshooting as well as
scheduling preventative maintenance on the
machine.
Output Frequency: Adjustable from 60 to 400 Hz
via keypad
Start Input: 120 VAC, 50-60Hz signal. Minimum
on time of 0.02 seconds (20 milliseconds),
maximum on time 0.100 seconds
(100 milliseconds)
Front Panel Switches
Power: On-Off power switch with internal
indicator
Run-Jog: Allows for operation of the control in
normal run or in jog mode for set-up and
troubleshooting
Jog Push-button: Allows for jogging when switch
is depressed. When released, brake is
re-engaged. Active only when Run-Jog switch is
in Jog mode.
During normal operation if any one of a number
of faults would occur; the controller will provide a
visual indication via the front panel “LED” marked
fault as well as tripping an internal relay which can
be wired to external alarms or sensors for
detection purposes. Additionally, the display will
provide a reference as to which fault possibly
occurred.
Front Panel Indicators
Power on: Integral to Power On-Off Switch
Clutch on: Green LED
Brake on: Red LED
Home Marker: Yellow LED
Fault: Red LED
Enclosure Connectors
5 Pin Brad Harrison for encoder connections:
Mating connector for wiring to encoder cable:
Brad Harrison # 1A5000-34 screw terminal
connections
Warner Electric • 800-825-9050 P-291-1 • 819-0526 3
9 Pin Brad Harrison for clutch, brake, power and
switching.
Mating connector for wiring to power, load, and
switching circuits:
Brad Harrison
# 309002A01F030 with 3 foot pigtails
# 309002A01F060 with 6 foot pigtails
# 309002A01F120 with 12 foot pigtails
Certications
®
IND. CON. EQ.
763R
Internal Connections and Functions
Internal Wiring Connections: via plug on Molex
type terminal blocks
Internal Switches: SW1: Set-up/Normal switch
used for initial set up and calibration of control
Keypad functions: 0 through 9 numeral inputs
when in programming mode
Start and Stop functions:
Clutch-Brake Output Level: Programmable via
display and keypad
Output Frequency: Programmable via display and
keypad
Communications: RS-485 communications port
via terminal strip
Optional OEX function card: An optional OEX
function card can be added for special
applications that require reduced build-up times
of the clutch or brake magnets.
Input/Outputs: Additional programmable inputs
and outputs available but not active for other
specic functions and typically are not used when
this controller is used for replacing the
CBC1500-AHFC or being used in pusher type
applications. Consult factory for further
information.
Control Part Number: 6051-448-002 CBPC-3590
Control
Encoder Part Number: 6060-101-061 Encoder,
600 PPR with marker pulse and cable
Note: Start key also functions as the home set
Installation
up key in set-up mode.
Replacing CBC1500-AHFC Control with
Up, Down and right arrow keys for scrolling and
CBPC-3590 Control
selecting data
q 1. Insure that power is turned off and
Edit Key: Run/PGM Key for entering set up
disconnected to the CBC1500-AHFC control.
modes
q 2. Disconnect both the encoder cable
Reset/Clear Key: For resetting variables or
clearing data in programming mode
connector and the main power/clutch-brake
wire connector from the plugs on the control-
ler.
Fault Relay: In the event of a fault, relay contacts
via terminal strip for external customer
connections.
q 3. Remove the 4 bolts or nuts fastening the
controller to the isolation mounts on the
machine frame.
Contacts: Rated at 1 Amp, 120 VAC resistive load
q 4. Remove the controller and set aside.
Fault Conditions: Low voltage, feedback too fast,
process time fully utilized
q 5. Install the CBPC-3590 controller on the
isolation mounts and reattach with either the
bolts or nuts depending on what was originally
used. Make sure bolts or nuts are securely
4 Warner Electric • 800-825-9050 P-921-1 • 819-0526
tightened.
q 6. Reconnect the power/clutch-brake wiring
connector to the large plug on the CBPC-3590
control and tighten snugly.
q 7. Reconnect the encoder cable connector to
the small plug on the CBPC-3590 control and
tighten snugly.
q 8. Insure everything is connected properly and
the control is secured properly to the machine
frame.
q 4. Mount and attach the CBPC-3590
controller to the other side of the vibration
isolator mount. Insure that control and mounts
are fastened securely at both the control and the
machine frame.
q 5. With the control mounted, route the wiring cables
such that they can be easily attached to the
external connectors on the control. Insure sufcient
length so that undue stress is not placed on either
the connectors or the cables to the control.
q 9. This completes the replacement of the
control. Proceed to the Start-Up Section on
page 9 for set up and programming.
First Time New Installation of CBPC-3590
Control
Refer to the dimensional diagram, Figure 1 for
actual mounting dimensions.
q 1. Select the location where the control will be
mounted. Insure that mounting will not
interfere with anything else and that wiring
access will not be impeded.
q 2. Using the dimensional information from the
diagram below, drill 4 mounting holes to
accept ¼-20 studs from the vibration
mounts for attaching the controller to
the machine frame.
q 3. Depending on the type of vibration
isolator mounts used, male to male or
male to female, attach one end of the
mount to the machine frame at all 4
10.500
points.
Note: For new installations where no wiring previously
exists, see the connector wiring diagram, Figure 4 for
pin/function descriptions.
5 Pin Socket
8.250
11.500
(Encoder)
Optional Hole
(Aux. Wiring)
9 Pin Socket
(CI-Bk/Power)
0.700
1.850
1.400
4.125
7.000
4.275
Figure 1
Dimensional Diagram
Warner Electric • 800-825-9050 P-291-1 • 819-0526 5
Encoder Mounting & Installation
Normally, if the CBPC-3590 is replacing an existing
CBC1500-AHFC control, the encoder has already
been installed and set-up correctly.
new installations follow the procedure below
For
referring to gures 2 and 3 for correct encoder
mounting and positioning.
q 1. Taking the encoder, position the at on the
shaft to the position shown in Figure 2 below.
Marker Pulse
reference “X”
with at of the
X
shaft
q 2. Position the paddles on the pusher parallel to
the length of the pusher. This will be the position
the paddles are in when the pusher is static or not
rotating.
q 3. Determine if the pusher operates in a clockwise
(CW) or counter-clockwise (CCW) direction when
operating.
q 4. Mount the encoder with the bracket into the
pusher shaft keeping the shaft aligned in the
position as shown or as close as possible using
gures 3A or 3B for positioning the marker pulse
within the desired range.
q 5. Double check mounting and insure encoder is
fastened properly.
q 6. Connect encoder cable and tighten connector
securely.
q 7. This completes encoder mounting for new
application.
Figure 2
Encoder Marker Pulse Position Reference
Front
CW
Front
Ø
180
Note: Properly mounting the encoder in this method
insures the marker pulse will occur in the 50 to 450
pulse count range consistently. This is mandatory for
proper control operation.
90
270
180
Encoder
Marker Pulse Locating
Position 30° to 270°
Long Axis
Figure 3a
90
Ø
Long Axis
270
CCW
Marker Pulse Locating
Position 30° to 270°
Encoder
Figure 3b
6 Warner Electric • 800-825-9050 P-921-1 • 819-0526
System Wiring
Figure 4 - Connector Pinouts and
Designations
Encoder Connector (5 Pin) Inside Wire Colors
Wiring the Warner Electric encoder
(6060-101-061) and cable to the connector
q 1. Route the encoder cable to avoid strains,
kinking and interference with mechanical
components.
Pin 1 – Encoder Signal “A” White
Pin 2 – Encoder +12 VDC Power Red
Pin 3 – Encoder Signal “Z” - Ref Green
Pin 4 – Encoder Signal “B” Orange
Pin 5 – Encoder DC Common Black
1
2
5
4
3
Power/Clutch-Brake Connector (9 Pin) Inside Wire Colors
Pin 1 – AC Start Signal (Hot 120 VAC) Orange/Black
Pin 2 – Channel 1 output (-) Brake Blue
Pin 3 – Channel 2 output (-) Clutch Red/Black
Pin 4 – Channel 2 output (+) Clutch Green/Black
Pin 5 – AC Power 120 VAC neutral line White
Pin 6 – AC Power 120 VAC hot line Red
Pin 7 – AC Earth Ground Green/Yellow
Pin 8 – Channel 1 output (+) Brake White/Black
Pin 9 – AC Start Signal (Neutral 120 VAC) Green/Black
q 2. Once cable has been routed and excess
length remains, cut the excess length off but
allow sufcient length for connection to
control. Strip the outer jacket to the
appropriate length for insertion of the wires
into the connector assembly.
q 3. Open the connector by removing the strain
relief nut and removing the rubber bushing
inside the housing. Snap the two halves of the
housing apart and separate from the header
connector.
q 4. Thread the encoder cable through the
strain relief nut and the rubber bushing pulling
enough cable through to strip and work on the
header and cable.
q a. Strip the cable jacket approximately ¾”
from the end of the wires.
q b. Strip the red lead (+12 VDC)
approximately ¼” and fasten to terminal 2 of
the connector and fasten securely.
Mating connector accessory are called out in the
specication section, Pages 3 and 4.
q c. Strip the black lead (DC Com)
approximately ¼” and fasten to terminal 5 of
7
1
6
the connector and fasten securely.
q d. Strip the orange lead (Signal A)
approximately ¼” and fasten to terminal 1 of
the connector and fasten securely.
2
5
q e. Strip the brown lead (Signal B)
approximately ¼” and fasten to terminal 4 of
8
3
9
4
the connector and fasten securely.
q f. Strip the green lead (Signal Z ref)
approximately ¼” and fasten to terminal 3 of
the connector and fasten securely.
Warner Electric • 800-825-9050 P-291-1 • 819-0526 7
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