Electrically Released Brakes
ER 825 and 1225 Heavy Duty
P-251
819-0121
Installation Instructions
This service manual tells how to install, adjust, and maintain your Warner Electric brake. It also
ontains information for part replacements when needed.
c
Warner Electric Electrically Released Brakes are high performance, high torque units. To obtain the
required performance and life, the brake must be installed exactly in accordance with the instructions
in this service manual.
The Warner Electric warranty does not apply to any unit which is not installed, used, operated and
maintained in accordance with Warner Electric's instructions.
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Controls Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Ohmmeter Procedure to Detect Armature Release . . . . . . . . . . . .8
Coil Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
MCS-805-1, MCS-805-2 Mounting Dimensions . . . . . . . . . . . . . .8
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Dimensions and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .11
Bushing Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BC
ER-825 and ER-1225
Introduction
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
the Electrically Released Brake depends on
permanent magnets rather than electromagnets.
With the power off, the unit produces full
braking torque. The brake is released by
reversing the direction of flux flow in an
electromagnetic coil, thus opposing the field
produced by the permanent magnets.
The opposition to and cancellation of
electromagnetic force which releases the brake
occurs nominally at one value of ampere turns.
This ampere turn value can vary among brakes
because of allowable manufacturing tolerances.
Release voltage varies mainly because of coil
tolerance and autogap spring variations. Properly
adjusting the power supply voltage is important so
the autogap springs will separate the magnet and
armature, causing full release of the brake.
Ceramic permanent magnets, which are the heart
of Electrically Released Brakes, are not subject to
fatigue losses, therefore, Warner Electric
Electrically Released Brakes are self-adjusting.
Warner Electric Electrically Released Brakes are
“burnished” at the factory to assure rated torque
shortly after initial application. Very little additional
wear-in is required.
Warner Electric • 800-825-9050 P-251 • 819-0121
2
Sizes ER-825 and ER-1225 with Spline
Drive Armatures Installation Instructions
Failure to follow these
instructions may result in product damage,
equipment damage, and serious or fatal injury
to personnel.
Note: Failure to set control voltage using the step by
step procedures in this manual may cause
overheating and premature failure.
Section 1
Step 1: Check to insure that the magnet and its
mounting surface are clean and free from burrs.
Basic Mechanical Considerations
Electrically released brakes require special
mounting considerations. Please review the items
listed below prior to starting installation contained in
steps 1-12.
A. If the brake magnet is to be mounted to
a surface of magnetic material, isolate the
brake approximately 1/2 inch from the
surface with a plate or spacer of nonmagnetic material.
B. If a choice of armature shaft material exists, this
should also be nonmagnetic. Materials such as
type 302-304 stainless have been used very
successfully.
C. In order to minimize stray flux, the unit should be
exposed as much as possible or, if enclosed, it
should be placed in a housing of nonmagnetic
material such as stainless steel or aluminum.
D. 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.
Step 2: Bolt the magnet in place with capscrews and
lockwashers.
Note: The magnet pilot diameter must be concentric
to the shaft within .010 inch T.I.R. The magnet
mounting surface must be square with the shaft
within .006 inch T.I.R. measured at the bolt circle.
Step 3: Assemble the splined armature assembly
(armature, splined armature adapter and autogap are
preassembled) to the hub.
New armatures shipped from the
factory are flat to within .005 inch and this
flatness must be retained to maintain full torque.
Any attempt to pry the armature loose from the
magnet will distort the armature. When
adjusting the armature position, apply any
required force only to the hub, not to the outer
edge of the armature. Also, use care when
handling the armature as dropping may also
cause distortion.
E. Foreign Materials: If units are used on
machinery where fine, abrasive dust, chips, oil or
grit are dispelled into the atmosphere, a
protective screen over the unit may be
necessary. Where units are used near gear
boxes or transmissions requiring frequent
lubrication, means should be provided to
protect the friction surfaces from oil and
grease to prevent serious loss of torque
Applications requiring a vertical
shaft mounting must be reviewed and approved
by Warner Electric Applications Engineering.
Warner Electric • 800-825-9050 P-251 • 819-0121
Step 3A: Place the armature-splined adapter assembly
on a flat surface, segments up. Press the splined hub
(retainer ring end first) through the autogap spring and
splined armature adapter.
Figure 1
3
Figure 2
5
1
3
4
2
.062"
Thick
Steel Shims
Friction
Material
lip the armature hub assembly onto the brake
S
haft until armature makes contact with shims.
s
Step 5: Using a hex wrench, tighten the hub
bushing bolts alternately and evenly until tight.
Using a drift and small hammer, tap lightly at
several points around the circumference of the
taper lock bushing. Repeat this alternate tapping
and re-tightening until the specified torque is
reached and wrench no longer turns the screw after
tapping. Tighten bolts to the following:
Unit Torque Bushing Type
ER-825 87 in. lb. Browning Series H
ER-1225 290 in. lb. Browning Series Q
Step 3B: Turn the assembly over and insert the
retainer ring in the groove. Take care not to bend or
distort retainer ring.
Step 3C: Turn the assembly over and slide the
armature against the retainer ring.
During steps 4 through 7, handle
the armature/hub assembly by the hub (Figure
3, item 2) only, making sure the armature
(Figure 3, item 3) is as close to the retainer ring
(Figure 3, item 4) as possible. Any movement of
the armature on the splined hub will reduce
available armature travel and may cause
improper setting of the running air gap.
1/16 inch thick steel shims are
recommended for shim stock selection. Do not
use shims thicker than 1/8 inch or you will
shorten brake life by reducing available
armature travel.
free of any contamination (oil, grease). Keep
Shim stock must be clean and
fingers clear of the area between the magnet
and the armature as the armature will be pulled
sharply toward the magnet after the gap is
closed to approximately 1/2 inch.
Step 4: Place three steel shims 120 degrees apart
on the magnet as shown in Figure 3. Insert the
taper-lock bushing (Figure 3, item 5) into the hub
(Figure 3, item 2).
Do not attempt to pull the
bushing flange flush with the hub end as
there should be 1/8” to 1/4” clearance
when tightened.
The airgap between armature and magnet must be
.062 to .125 inch. If the airgap is outside of that
range, reposition the armature hub assembly by
repeating steps 1 and 2 of the disassembly
procedure and steps 4 and 5 of the assembly
procedure.
1 – Magnet
2 – Splined Hub
3 – Armature
4 – Spiral
Retainer Ring
5 – Bushing
Warner Electric • 800-825-9050 P-251 • 819-0121
Figure 3
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tep 6: Electrical Connections. Several different
115 VAC
Brake
Release
Brake
(-)
(+)
230 VAC
Brake
Release
Brake
Coil
(-)
(+)
MCS 805-1
MCS 805-2
S
ypes of controls can be used on the ER-825.
t
However, only one control can be used on the
ER-1225 electrically released brakes. If you are
installing an ER-825 brake, follow the
procedures in Section I below. When completed
with Section I, proceed to Step 7. If you are
installing an ER-1225, follow the procedures in
Section II below. When completed with Section II,
proceed to Step 7.
Section I For ER-825 Brakes
ER-825 brakes require a variable voltage or
variable current control to release the brake by
offsetting the magnetic force generated by
permanent magnets. Warner Electric controls,
such as the CBC-200 (single channel) or
CBC-300 (dual channel), offer variable output and
are suitable for use with ER-825 brakes.
Connection should be made in accordance with
instructions provided with the chosen control.
. 115 VAC supply to terminals 1 and 4. Jumpers
A
o connect terminal 1 with terminal 2 and
t
terminal 3 with terminal 4. Recommended fuse
is 3/4A slow blow.
or:
230 VAC supply to terminals 1 and 4.
Jumper to connect terminal 2 with terminal 3.
Recommended fuse is 3/4A slow blow.
B. A chassis ground should be provided as a
non-current conducting ground wire (color
coded green).
C. Switching. Follow instructions per control
models listed.
MCS-805-1 Standard Control Operation
1. For switching DC side: Switch connected to
terminals 7 and 8. Switch open will allow
brake to be engaged. Switch closed will
enable the release of the brake.
Section II For ER-1225 Brakes
Connect the MCS-805-1 or MCS-805-2 Power
Supply per the following diagram and
instructions:
ER brakes are polarity
sensitive. Connect the “+” terminal of the
brake to the “+” terminal of the control and
the “-” terminal of the brake to the “-”
terminal of the control. Plus to plus and
minus to minus connections are imperative.
Put machine in safe condition
so that when voltage is applied to the control
and switch closures are made the brake
does not rotate and machine does not run.
2. For switching AC side: Line power off will
allow brake to be engaged. Line power on
will release brake. A jumper connection
must be made between 7 and 8.
3. Slower brake actuation will result when
switching the AC side.
MCS-805-2 Two Step Control Operation
1. With switch connected to terminals 7 and 8
and switch is open with AC power applied,
brake will be partially engaged.
2. With switch connected to terminals 7 and 8
and switch is closed with AC power
applied, brake will be fully released.
3. With switch connected to terminals 7 and 8
and switch closed with AC power removed,
brake will be fully engaged.
Warner Electric • 800-825-9050 P-251 • 819-0121
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