Warner Electric ER-375, ER-475, ER-650 User Manual

Electrically Released Brake ER-375,

ER-475, ER-650 with Pin Drive Armatures

P-253
819-0315

Installation Instructions

Contents

Basic Mechanical Considerations

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

Installation Instructions . . . . . . . . . . . . . . . . . . . .3

Power Supplies/Brake Release Adjustment . . . . .4

Autogap Adjustment . . . . . . . . . . . . . . . . . . . . . .5

Operating Instructions . . . . . . . . . . . . . . . . . . . . .6

Dimensions and Specifications . . . . . . . . . . . . . .8

Bushing Part Numbers . . . . . . . . . . . . . . . . . . . .9

Exploded View . . . . . . . . . . . . . . . . . . . . . . . . .10

Component Parts/How to Order . . . . . . . . . . . .11

Warranty . . . . . . . . . . . . . . . . . . . . . . .Back Page

Failure to follow these
instructions may result in product damage,
equipment damage, and serious or fatal
injury to personnel.

Introduction

Electrically released brakes require special
mounting considerations. Please review the items
listed below prior to starting installation per Step 1.

a) If the magnet mounting surface is a magnetic

material, the magnet must be insulated
approximately 1/2 inch from that surface with a
plate or spacers of non-magnetic material.

b) Caution must be exercised when the armature

is moved close to the magnet assembly since
the permanent magnets create a very strong
attractive force. Injury may result if fingers are in
between the armature and magnet when the
gap is 1/2" or less.

This service manual tells how to install, adjust,
and maintain your Warner Electric brake. It also
contains information for part replacements
when needed.

Warner Electric Electrically Released Brakes are
high performance, high torque units. After carefully
reading these instructions, no assembly or
installation difficulties should be encountered.
Warner Electric Electrically Released brakes
function on the same principle of "response to
magnetic attraction" that operates other Warner
Electric brakes and clutches. Braking torque in
these brakes depends on ceramic permanent
magnets which have a high resistance to
demagnetization. With the power off, the unit
produces full braking torque. The brake is released
by generating an electromagnetic field which
opposes the field produced by the permanent
magnets.

Warner Electric • 800-825-9050 P-253 • 819-0315

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Installation Instructions

Magnet

Pilot Diameter

Mounting Surface

A. Customer Shall Maintain:

1. Squareness of brake mounting face with

armature hub shaft within .006 T.l.R.

2. Concentricity of brake mounting pilot

diameter with armature hub shaft within
.010 T.l.R.

Figure 2

B. Mounting the Magnet

The brake magnet is mounted to a stationary
machine member by a flange. Extreme care must
be taken in selecting the location for the mounting
of the magnet. Proper positioning is very important
for the unit to function correctly.

1. A pilot diameter on the mounting surface is

essential to hold the magnet within the required
tolerances. (See Figure 1)

4. Use a dial indicator to check the unit for
concentricity and squareness to the shaft. The
unit should be concentric within .010 T.l.R. and
square within .006 T.l.R. (See Figure 3)

Figure 3

C. Armature To Shaft Assembly

2. A machined pilot diameter is provided on the

3. Once the mounting surface has been

Warner Electric • 800-825-9050 P-253 • 819-0315

Figure 1

magnet mounting flange (See Figures 1, 2, & 3)
to aid in the proper positioning of the
magnet.

prepared the magnet is bolted in place with
capscrews and lockwashers. (See Figure 2)

Check to insure that all parts are clean and free
from burrs or chips. Insert the key into the shaft
keyway. Place the bushing into the hub and match
half holes to make complete holes. Each hole will
be threaded on one side only. Place the screws
loosely into the holes which are threaded on the
hub side. Slip the assembly onto the shaft and
position it so the armature is in contact with
the magnet.

Keep fingers clear of area
between the magnet and the armature as the
armature will be puIled sharply toward the
magnet after the gap is closed to
approximately 1/8 inch.

3

Tighten the screws alternately and evenly until all
are pulled up very tightly. Tap against the large
end of the bushing with a plastic hammer to
avoid damaging the bushing. The screws can
then be tightened again, using the following
torque specifications:

ER-475 55 in. Ib.
ER-650 175 in. Ib.

Repeat this alternate tapping and retightening
until the specified wrench torque no longer turns
the screws.

brake surfaces is created by permanent
magnets. The brake is electrically released by
applying DC power to the electro-magnetic coil in
the brake that opposes the permanent magnets.
Electrically released brakes are polarity sensitive:
the positive lead of the power supply must be
connected to the positive lead of the brake, and
the negative lead of the power supply must be
connected to the negative lead of the brake. The
power supply applied to the brake must be
adjustable so that the optimum release voltage for
each individual brake can be determined and set.

To disassemble, remove both screws and
reinsert one screw in the vacant hole (threads
on bushing). Tighten this screw until the bushing
is loosened in the hub. If the bushing does not
loosen, tap on the hub.

D. Power Supplies

The ER style electrically released brakes are
designed to operate with an adjustable voltage
power supply because the voltage at which the
individual brakes will release can vary slightly from
brake to brake. The output voltage needs to be
adjusted to obtain the optimum release point.
Warner Electric offers two different model power
supplies, either of which can be used to operate
the ER style brakes. They are the MCS-103-1
or the CBC-200. Refer to the control operation
manual for instructions on how to wire the
control.

E. Brake Release Adjustment

The following procedure describes how to set the
adjustable power supply to the optimum release
point of the brake. A volt-meter is required to
perform the procedure.

No power is applied to motor
during this procedure. Power normally supplied
by motor to brake control should be supplied
by alternate method.

After control is adjusted per steps below, brake
control may need to be fine tuned (adjusted)
with motor running to compensate for any
changes in supply voltage used.

1. With power off, connect the positive lead of

the power supply to the positive lead of the
brake and the negative lead of the power
supply to the negative lead of the brake.

2. Connect a volt-meter to measure the voltage

applied across the brake.

Instructions for setting the optimum release
voltage of permanent magnet applied
electrically released brakes.

The following procedure will
result in the brake releasing and allowing the
load to be free to move. Be sure the load is in
a safe condition before proceeding with this

3. Adjust the power supply to its lowest possible
output, then energize the power supply only,
to apply power to the brake.

4. Starting from the low point, slowly increase
the applied voltage until the brake armature
disengages from the magnet. Note and record
the applied voltage at this point.

process.

In a permanent magnet applied/electrically
released brake, the attractive force between the

Warner Electric • 800-825-9050 P-253 • 819-0315

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