ERS Electrically Released Brakes
P-219
819-0337
Installation Instructions
2
Warner Electric • 800-825-9050 819-0337
Contents
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drive Hub Data . . . . . . . . . . . . . . . . . . . . . . . . 5
Troubleshooting Information . . . . . . . . . . . . . . 5
Warranty . . . . . . . . . . . . . . . . . . . . . Back Cover
The Warner Electric ERS brake you purchased has been designed to provide long and trouble free
service. It’s a rugged, simple unit which is easy to install and requires no adjustment or maintenance.
This service manual includes detailed installation instructions, complete product dimensions,
performance data, and troubleshooting information.
Installation
1. Remove your ERS brake from its shipping
carton and inspect it thoroughly to ensure
that it has arrived in good condition. An
accessory kit included with your brake
contains screws and insulator boots for the
electrical termination. In addition, you may
have ordered the optional splined drive hub,
mounting flange, and/or conduit box.
2. If used, install the Warner Electric conduit
box in accordance with the instructions furnished with the conduit box accessory.
3. The ERS brake is shipped fully assembled
and ready to mount. No adjustments or
brake run-in are necessary. The mating
mounting holes in your mounting surface
must be within 0.014 inch diameter of true
position to the shaft center line and the
mounting surface must be within .005” of
perpendicular to the shaft axis. If you are
mounting your brake with through-bolts (see
Mounting Options below) you will need four
of the following fasteners:
Maximum
Brake Fastener Size Fastener Torque
ERS-26 #6-32 20 in.lbs.
ERS-42 #8-32 35 in.lbs.
ERS-49 #10-32 75 in.lbs.
ERS-57 1/4”-20 120 in.lbs.
ERS-68 3/8”-16 150 in.lbs.
Through-Bolt
Mounting through the brake
magnet provides rigid
support for the unit with a
space equal to the outside
diameter of the brake. May
be mounted on either end.
Your ERS Brake is designed to
self-engage in case of an electrical power
failure. Replace only with an identical unit.
Do not disassemble. Brake parts are under
high spring pressure. Failure to follow these
instructions may result in product damage,
equipment damage, and serious or fatal
injury to personnel.
If the optional Warner Electric mounting flange is
being used, assemble with the supplied screws
into the tapped holes in the back of the brake.
You will need to provide a mounting hole pattern
in the flange that corresponds to your application.
Brake Mounting Options
ERS Brakes can accommodate different mounting
orientations. The following mountings are possible
with the standard ERS brake:
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Warner Electric • 800-825-9050 819-0337
Tapped Holes
Mounting the brake by
drawing it into a housing or
cavity again provides the rigid
support in an area no larger
than the outside diameter of
the brake. It is used where
through-bolt mounting is
impractical.
Flange
Mounting flanges can be
attached to the base design
using the tapped holes
provided.
Since the mating spline (either the Warner
Electric splined hub or your splined shaft) is
smaller than the brake bore, either end of the
brake can be positioned against the mounting
surface when using through bolts. If a Warner
Electric conduit box is being used and the back
of the brake must be against the mounting
surface, a relief in the mounting surface will be
required to accommodate the conduit box
mounting plate. (See page 4 for details).
Hub Mounting Options
If the Warner Electric splined drive hub is to be
used, it can be mounted in either of the
following sequences:
Note: Full spline engagement contact is
required between the splined hub or splined
shaft and the splined brake disc. The disc
must be able to move freely on the hub.
Recessed Hub
Mounting the hub on the
driving member prior to
mounting the brake
allows the splined hub to
be recessed in the brake
bore for maximum space
efficiency.
Extended Hub
Mounting the hub on the
driving member after
mounting the brake allows
the splined hub to extend
beyond the brake where
space allows.
When the splined hub has been located on the
shaft with its appropriate key, tighten the set
screws to the following torque values:
Brake Torque
ERS-26 10 lb. in.
ERS-42 20 lb. in.
ERS-49 35 lb. in.
ERS-57 35 lb. in.
ERS-68 85 lb. in.
Loc-tite
®
242 may be applied on screw threads
to minimize chances of screws backing off
under severe vibration.
4. After the brake and hub are secured in place,
attach the DC power source to the brake
terminals. Feed the wires through the brake
insulator boots before attaching them. After
the terminal screws are tightened (torque to
15 lb. in.), slide the boots over the screws
and terminals to insulate the electrical
connection.
Either terminal can be connected to the + or side of the power source. If a Warner Electric
CBC-100 or other Warner Electric control is
used, follow the wiring instructions supplied
with the control.
5. Your ERS brake is now ready for its static
test. Apply the rated DC voltage to the brake.
It should disengage and the shaft should
rotate freely.
Your ERS Brake is now ready to run.
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Warner Electric • 800-825-9050 819-0337
Dimensions
*Available only on the ERS-49, 57, and 68 sizes.
AB CDE FGH JK L M N PQ
Model Max. Max. Dia. Dia.
ERS-26 2.460 1.515 1.375 1.125 .860 1.250 – – – – – 2.125 .172/.164 4-40 .375
(63) (39) (35) (28) (22) (32) (54) (4) –
ERS-42 3.520 1.595 2.000 1.600 1.375 1.255 – – – – – 3.125 .200/.190 6-32 .400
(90) (41) (51) (41) (35) (32) (79) (5) –
ERS-49 4.270 1.767 2.600 1.750 1.500 1.332 3.625 4.625 1.000 1.625 3.750 3.750 .228/.218 8-32 .400
(109) (45) (66) (44) (38) (34) (92) (117) (25) (41) (95) (95) (6) –
ERS-57 5.020 1.937 3.240 2.100 1.750 1.503 4.000 5.000 1.170 1.625 3.750 4.500 .288/.278 10-24 .400
(128) (49) (82) (53) (44) (38) (102) (127) (30) (41) (95) (114) (7) –
ERS-68 6.520 2.030 4.504 2.800 2.425 1.565 4.750 5.750 1.265 1.625 3.750 5.875 .413/.404 1/4-20 .500
(166) (52) (114) (71) (62) (40) (121) (146) (32) (41) (95) (149) (10) –
(–) denotes millimeters
Note: Mating holes for mounting brake to be within .014 diameter true position, max. material condition, to the center of shaft.
5
Warner Electric • 800-825-9050 819-0337
Drive Hub Data
A Mating Key B C Set
Model Bore (Not furnished) Nom. Nom. Screws Size Torque
ERS-26 .2525/ .2505 1/16 x 1/16 .600 .135 6-32 10
.3150/ .3130 1/16 x 1/16 x 1/8 lb. in.
.3775/ .3755 3/32 x 3/32
ERS-42 .3775/ .3755 3/32 x 3/32 .700 .150 8-32 20
.5025/ .5005 1/8 x 1/8 x 3/16 lb. in.
.6275/ .6255 3/16 x 3/16
.7525/ .7505 3/16 x 3/16
ERS-49 .3775/ .3755 3/32 x 3/32 .800 .160 10-32 36
.5025/ .5005 1/8 x 1/8 x 3/16 lb. in.
.6275/ .6255 3/16 x 3/16
.7525/ .7505 3/16 x 3/16
.8775/ .8755 3/16 x 3/16
ERS-57 .5025/ .5005 1/8 x 1/8 .800 .160 10-32 36
.6275/ .6255 3/16 x 3/16 x 3/16 lb. in.
.7525/ .7505 3/16 x 3/16
.8775/ .8755 3/16 x 3/16
1.0025/1.0005 1/4 x 1/4
ERS-68 1.0025/1.0005 1/4 x 1/4 .900 .190 1/4-20 87
1.1275/1.1255 1/4 x 1/4 x 1/4 lb. in.
1.2525/1.2505 1/4 x 1/4
1.3775/1.3755 5/16 x 5/16
1.5025/1.5005 3/8 x 3/8
Note: Hub may be located in any position on shaft as long as the external
and internal splines are 100% engaged.
ABCD
Model Nom. Nom. Holes Nom.
ERS-26 4.000 .935 #4 .100
(101.6) (23.7) (2.6)
ERS-42 5.000 1.450 #6 .144
(127.0) (36.8) (3.7)
ERS-49 6.250 1.575 #8 .193
(158.8) (40.0) (4.9)
ERS-57 7.500 1.825 #10 .193
(190.5) (46.4) (4.9)
ERS-68 9.500 2.500 1/4 .224
(241.3) (63.5) (5.7)
(—) denotes millimeters
Note: Holes for attaching flange to mounting
surface to be provided by customer.
Troubleshooting
Symptom Check
Brake will not release a. Proper voltage at the brake terminal(s).
b. Correct unit voltage matched to power supply.
c. Coil continuity if proper voltage is at the brake leads.
d. Spline for binding. Friction disk must be able to move freely on mating spline.
If the above checks do not determine the cause of the failure, the brake is non-operational and must be replaced.
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
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
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.
Electric LLC’s prior consent.
defective under the terms of this warranty, repair or replacement will be made,
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. W
eights 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 t New Hartford, CT 06057
815-389-3771 t Fax: 815-389-2582
www.warnerelectric.com
An Altra Industrial Motion Company
P-211 819-0043 9/11 Printed in USA
P-219 819-0337 9/11 Printed in USA
Warner Electric LLC
31 Industrial Park Road t New Hartford, CT 06057
815-389-3771 t Fax: 815-389-2582
www.warnerelectric.com
An Altra Industrial Motion Company
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