Electrically Released
Brakes FB-375, 475, 650
P-237
819-0289
Installation Instructions
Contents
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installing the Brake . . . . . . . . . . . . . . . . . . . . . . . 4
Power Supplies and Electrical Connections. . . . . 6
Autogap Adjustment . . . . . . . . . . . . . . . . . . . . . . 6
Operating Instructions . . . . . . . . . . . . . . . . . . . . . 7
Illustration Drawings . . . . . . . . . . . . . . . . . . . . . 10
Motor Adapter Dimensions . . . . . . . . . . . . . . . . 11
Bushing Part Numbers . . . . . . . . . . . . . . . . . . . 13
Warranty . . . . . . . . . . . . . . . . . . . . . . . Back Page
Failure to follow these
instructions may result in product
damage, equipment damage, and
serious or fatal injury to personnel.
This service manual tells how to install, adjust,
and maintain your Warner Electric brake. It also
contains information for part replacements when
needed.
Warner 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 of this service manual. Failure to do so
can result in unit breakdown or destruction and
possible injury or damage to persons and property.
After carefully reading these instructions, no
assembly or installation difficulties should be
encountered.
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.
Warner Electric • 800-825-9050 P-237 • 819-0289
2
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 these brakes
depends on ceramic permanent magnets which
have a high resistance to demagnetization. With the
Autogap
Automatic wear adjust
®
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. An adjustable voltage or
current control should be used to achieve best
release.
Long Life – High Cycle Rates
Segmented armature provides high
heat dissipation and long service life.
Capable of rapid cycling.
High Torque
Powerful permanent magnets.
Electrically Released
Brake automatically
engages when power is
turned off– releases
when power is applied.
Mounting Flexibility
The FB torque arm feature permits
mounting on any shaft. Wide
range of shaft sizes.
Warner Electric • 800-825-9050 P-237 • 819-0289
3
Installation Instructions
Motor Shaft
Brake Key
Set
Screws (2)
Shaft
FB-375
Sheave Key Motor Shaft
Key
Motor
Shaft
Set
Screws (2)
Set
Screws (2)
FB-375
Adapter
Electrically
Released
Brake Key
Sizes FB-375 Through FB-650
Installing the Brake
Note: Failure to set autogap using the
procedures in this manual may cause
overheating and premature failure.
Step1:
The first installation step applies only to the
optional motor adapter (See Figure 1). For
installation on a double shaft extension motor or
through shaft, proceed to Step 2A for the FB-375
or Step 2B for the FB-475 or FB-650.
tapered bushing or straight bore. Install the belts or
chain. To assemble the brake on the motor adapter
proceed to Step 2A for the FB-375 or Step 2B for
the FB-475 or FB-650.
Step 2A:
Check to insure that all parts are clean and
free from burrs and chips. Insert the key in
the shaft extension keyway. Slide the brake
assembly into position on the shaft extension
(See Figure 1 or 2). Tighten the set screws.
Go to Step 3.
Step 2B:
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
locate it in the desired position (See Figure 3).
All parts must be clean and free from burrs or
chips before assembly. Insert the motor shaft key
in the motor shaft. Tighten the motor adapter set
screws. Insert the sheave or sprocket key into
the motor adapter keyway. Install the sheave or
sprocket on the motor adapter either with a
Figure 2
FB-375 without Motor Adapter
Tighten the screws alternately and evenly until all are
pulled up very lightly. 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:
FB-475 55 in. lb.
FB-650 175 in. lb.
Repeat this alternate tapping and retightening until
Figure 1
FB-375 with Motor Adapter
Warner Electric • 800-825-9050 P-237 • 819-0289
4
the specified wrench torque no longer turns the
screws.
To disassemble, remove both screws and
FB-475 or FB-650
Bushing
Bushing
Screws
Bushing Key
Shaft
Counterclockwise Rotation
Clockwise Rotation
Rotation
Torque Arm May Be Mounted
in Any Direction
If Direction of
Belt Pull
Then Locate
Torque Arm Tab
Rotation
If Direction of
Belt Pull
Then Locate
Torque Arm Tab
If Direction of
Belt Pull
Then Locate
Torque Arm Tab
If Direction of
Belt Pull
Then Locate
Torque Arm Tab
Electrically Released Brake
Viewed From Armature Side
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. Go to Step 3.
Installing The Torque Arm
Step 3:
The maximum length threaded rod is furnished
for normal mounting. (Consult the factory for
recommendations on a longer arm.) The
threaded rod can be cut to any desired length.
One rod end must be secured to the tab on the
Electrically Released Brake and the other end
must be secured to a solid base. Although the
torque arm may be mounted in either direction,
the position of the tab and arm is important.
Recommended position relative to shaft rotation
is shown in Figure 4. On reversing applications
where the rod is in compression every other
cycle, the rod must be relatively short, or a
special heavier rod may be necessary.
Figure 3
Do not connect rigid conduit
directly to the conduit box. A minimum of 12”
of flexible liquid tight conduit or other suitable
flexible wiring with appropriate fittings is
required. Flexible wiring is required to prevent
side loading of bearing on bearing mounted
clutches and possible deformation or breakage
of the conduit box or clutch/brake components
during assembly.
Warner Electric • 800-825-9050 P-237 • 819-0289
Figure 4
5
Power Supplies for Electrically Released
Brakes. Electrical Connections and
Adjustments.
Step 4:
Connect the brake to an adjustable
voltage/current control following the
instructions for that control. Warner Electric’s
controls are suitable for these brakes.
Note: FB brakes are polarity sensitive.
The positive terminal of the brake must be
connected to the positive terminal of the
control and vice versa.
Note: For failsafe or Electrically released
brake units (FBB, MBFB, FBC, ER or FB)
see instruction on proper electrical setup
procedure.
Instructions for setting the optimum
release voltage of permanent magnet
applied/electrically released brakes
2. Connect a volt-meter to measure the voltage
applied across the brake.
3. Adjust the power supply to its lowest
possible output, then energize the supply 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.
5. Continue to slowly increase the applied
voltage until the armature re-engages the
magnet. If the maximum voltage available
from the supply does not cause the armature
to re-engage, the armature should be
manually assisted into engagement.
6. With the armature re-engaged, slowly
reduce the applied voltage until the armature
disengages from the magnet. Note and record
the applied voltage at this point.
In a permanent magnet applied/electrically
released brake, the attractive force between the
brake surface 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 also be adjustable so
that the optimum release voltage for each
individual brake can be determined and set.
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.
1. With the 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.
7. The optimum release point for the brake is
half-way between the two recorded voltage
readings. Adjust the supply to this optimum
release voltage.
Autogap Adjustment
Step 5:
Turn the power on to electrically release the
brake. The armature should spring back
approximately 1/32-inch as shown. If the
armature fails to disengage, turn the control
knob on the brake control CCW to 0 and then
CW until the armature releases. You’ve now
reached the minimum release voltage. The
knob can be turned further CW to find the
most favorable release point. If the armature
does not spring back, follow the autogap
adjustment procedure as follows (refer to
Figure 6):
Warner Electric • 800-825-9050 P-237 • 819-0289
6
Detent Spring
Retainer
Carrier
Armature
Armature Spring
Back 1/32-Inch
Magnet
Detent Spring
Drive Pin
Figure 6
Operating Instructions
A worn out Electrically Released Brake can
lose its ability to produce torque. Consequently, it
is imperative that the brake be inspected
frequently for wear and to insure that it engages
and disengages properly. The frequency of
inspections is dictated by usage; a brake used
in a high cycle rate and/or heavy load application
must be inspected more often than one used less
severely. Experience will determine proper
inspection intervals.
Keep fingers clear of area
between the magnet and the armature
because the armature will be pulled sharply
toward the magnet if the release voltage is
altered for any reason.
1. With the brake power on, pull gently on the
O.D. of the armature to separate it from the
magnet by a 1/32-inch or greater airgap.
Do not pry. This could damage the
components.
2. Slide the detent spring retainer on each drive
pin until it bottoms against the carrier.
If armature cannot be moved, check voltage
and polarity. (See Operating Instructions “Fails
to Release” on page 8.)
3. Push against the drive pins to push the
armature into contact with the magnet.
The end of normal service will occur when the
armature wears through the friction material and
into the coil, causing an open circuit and failure to
release when voltage is applied. Brake wear is
determined by two checks. The first determines
whether the brake is about to lose torque; the
second ensures that the armature has not worn
through the friction material, endangering the coil.
If either of these checks indicates excessive wear,
the unit should be replaced.
Check No. 1
Examine the three autogap release springs to
assure that none of them are approaching total
compression. If any one of them is approaching
total compression or if the distance from the
underside of the drive pin head to the top of the
detent cup washer is less than .062 inch, the
brake should be replaced.
Warner Electric • 800-825-9050 P-237 • 819-0289
4. Release the drive pins and the armature will
spring back approximately 1/32-inch. The
armature gap will now be provided by the
autogap mechanism.
Must be greater than
.062 inch
Step indicating
friction material
thickness
Check No. 1
7
Check No. 2
A step is machined on the O.D. of the brake
magnet where the armature and magnet meet.
This step is equal to the friction material
thickness. When this step is completely covered
by the armature with the brake engaged, the brake
is worn out and should be replaced.
OK
New
After completing an inspection with the
machine turned off, cycle it several times. If
the Electrically Released Brake stopping time has
more than doubled since the original set-up, this
also indicates the brake is worn out and should
be replaced.
Magnet worn to step
Worn out
Check No. 2
The drive pins should be kept free of foreign
materials to ensure proper function of the brake.
Fails to Release: If the Electrically Released
Brake does not release completely, make the
following checks:
1. Check that the electrical connections
(polarity) between the brake coil and the power
supply are correct for the power supply being
used (refer to Step 4, page 6).
2. Connect a DC voltmeter across the brake
terminals. (Do not disconnect the leads to the
terminals.) The voltmeter should indicate a
voltage in the range of 75 to 110 volts.
3. The above checks are normally sufficient.
Further checks may be made by checking the
brake coil resistance.
a. Turn off the power to the brake.
b. Disconnect one lead from the coil to make
sure the circuit is open.
Foreign Materials: If units are used on
machinery where fine, abrasive dust, chips
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’s, means should be provided to
protect the friction surfaces from oil and
great to prevent serious loss of torque by
reducing the coefficient of friction and
swelling the friction material. Oil and grease
accidentally reaching the friction surfaces may be
removed by wiping with a rag dampened with a
suitable cleaner, which leaves no residue. In
performing this operation, do not drench the
friction material. If the friction material has been
saturated with oil or grease, no amount of
cleaning will be completely effective. Once such
a unit has been placed back in service, heat will
cause the oil to be boiled to the surface
resulting in further torque loss.
c. Connect an ohmmeter across the brake
terminals. The resistance should be as
shown:
24V Coil Resistance 90V Coil Resistance
Brake Size at 20°C (±10%) at 20°C (±10%)
FB-375 29 447
FB-475 22 310
FB-650 16 235
A very high or infinite resistance reading would
indicate an open coil. A very low resistance would
indicate a shorted coil. In either case, the unit
should be replaced.
Wear Pattern: Wear grooves appear on the
friction surfaces. This is a normal wear condition,
and does not impair functioning of the unit. Never
machine the friction surfaces to remove grooves or
score marks resulting from normal wear.
Warner Electric • 800-825-9050 P-237 • 819-0289
8
There are two main wear parts, magnet and
armature. When either is worn out, the complete
brake must be replaced.
Heat: Excessive heat and high operating
temperatures are causes of rapid wear. Air should
be allowed to circulate around the unit as efficiently
as possible, especially if the application requires
fast, repetitive cycle operation.
If the above checks indicate that the proper
voltage and current is being supplied to the coil,
mechanical parts should be checked to assure
that they are in good operating condition and
properly installed.
Wear Pattern
New
Burnished
Worn
Warner Electric • 800-825-9050 P-237 • 819-0289
9
R
U
V
T
HH
FF
DD
CC
EEGG
BB
AA
L
K
W
J
H
G
A B C D
E
F
Q
O
P
N
M
S
FB-375, FB-475, FB-650
Bore Data (Key furnished)
Size Bore Dia. Keyway
FB-375 .626/.625 3/16 x 3/32
FB-475 .500 – .562 1/8 x 1/16
Dodge #1008 .625 – .875 3/16 x 3/32
FB-650 .500 – .562 1/8 x 1/16
Dodge #1310 .625 – .875 3/16 x 3/32
Note: FB-375 has a straight bore. Bushing not required.
Bushings also available in metric bores.
All dimensions are nominal, unless otherwise noted
Size Max. Dia Min. Dia. Min. F Dia. HJ KLMax. NOP
375 4.078 3.125 .7505 — .031 1.906 1.375 3.359 .187 1.281 1.546 2.750 .860 .281 .531
475 5.171 4.000 1.663 1.593 — 1.875 1.781 3.875 — 1.218 1.546 3.330 1.093 .312 .531
650 6.578 5.125 2.343 2.281 — 2.250 2.562 4.800 — 1.550 1.546 3.718 1.065 .343 .640
Size Max. R Dia. TUVWMax. BB CC DD EE FF GG HH
375 — 2.000 1.500 .270 .250 .781 .359 4.468 3.750 1.000 8.000 .666 .781 2.582 1.500
475 .281 2.000 1.500 .270 .250 .781 .390 4.984 3.750 1.000 10.000 .696 .687 3.093 1.500
650 .359 2.000 1.500 .270 .250 .781 .437 5.843 3.750 1.125 11.000 .843 .843 4.062 1.500
Warner Electric • 800-825-9050 P-237 • 819-0289
10
.501/.500 1/8 x 1/16
.937 – 1.000 1/4 x 1/8
.937 – 1.250 1/4 x 1/8
1.312 – 1.375 5/16 x 5/32
ABCDE G M
QS AA
.260
.260
.260
FB-375, FB-475, FB-650
B
Motor
Adapter
A
D
E
B
C
G
A
I
F
H
(Threaded
Removal Hole)
Electrically
Released Static Max. Total
Brake Size Torque Speed Weight
FB-375 10.5 lb. ft. 5000 4.5 lbs.
FB-475 21 lb. ft. 4500 6.3 lbs.
FB-650 56 lb. ft. 3600 13.2 lbs.
Motor Adapter Bore Sizes
Model Shaft Usable B order the following
Size Size Length Dia. Adapter Dodge Bushing
375 .625 2.000 .875 5380-101-005 *None
475 1.125 2.750 1.625 5381-101-003 #1008 1”
650 1.375 3.000 2.000 5382-101-003 #1310 1.375”
*Order FB-375 with 5/8” bore.
Motor A When using an adapter
.875 2.250 1.250 5380-101-004 *None
1.625 3.625 2.250 5382-101-002 #1310 1.375”
FB Shaft Adapter
Shown below are dimensions and specifications for
the optional shaft adapter available for mounting FB
Series brakes on a motor. A standard sheave, pulley,
or sprocket, with either a tapered bushing or straight
bore, can be installed on the shaft adapter. The
brake is mounted on the end of the shaft adapter
and the complete assembly fits onto the motor shaft,
secured with setscrews. Fitting the belts or chain
and torque arm completes the installation.
Model A Kwy. B Kwy. Part No. C Kwy. Part No. Size DEFGHI
FB-375 5/8 3/16 x 7/8 3/16 x 590-0016 5/8 3/16 x 590-0043 None 4.391 2 .391 2 1/4-20 1.125
3/32 3/32 3/32 4.359 .359 UNC
FB-375 7/8 3/16 x 1-1/4 1/4 x 590-0022 5/8 3/16 x 590-0043 None 4.578 2-1/4 .516 2-1/4 1/4-20 1.500
3/32 1/8 3/32 4.742 .484 UNC
FB-475 1-1/8 1/4 x 1-5/8 3/8 x 590-0041 1 1/4 x — #1008 4.516 2-3/4 .641 2-3/4 1/2-13 1.750
FB-650 1-3/8 5/16 x 2 1/2 x 590-0042 1-3/8 5/16 x 590-0044 #1310 5.547 3-3/8 .641 3-3/8 1/2-13 2.125
FB-650 1-5/8 3/8 x 2-1/4 1/2 x 590-0042 1-3/8 5/16 x 590-0044 #1310 6.172 4 .641 4 1/2-13 2.375
All dimensions are nominal unless otherwise noted.
Warner Electric • 800-825-9050 P-237 • 819-0289
1/8 3/16 1/8 1" 4.484 .609 UNC
5/32 1/4 5/32 1-3/8" 5.515 .609 UNC
3/16 1/4 5/32 1-3/8" 6.140 .609 UNC
Key Key Bushing
Dodge
11
6
1
2
3
4
5
7
8
9
FB-375, FB-475, FB-650
How to order
1. For thru-shaft mounting, specify bore size. For
FB-475 and FB-650 order bushing separately.
FB-375 does not require a bushing.
2. For motor mounting order adapter separately–
Item 10. Specify the following bore size for the
Electrically Released Brake. This is the bore size
required for mounting the Electrically Released
Brake on the end of the motor adapter.
FB-375 5/8” bore
FB-475 1-1/8” bore
FB-650 1-3/8” bore
Item Description Part Number Qty Part Number Qty Part Number Qty
Optional Parts
1 *Bushing N/A 180-0410 1/2" bore 180-0421 1/2" bore
2 Adapter (optional) 11 1
Service Parts
3 Retainer ring 748-0101 1 748-0102 1 748-0104 1
4 Ball bearing 166-0150 1 166-0110 1 166-0104 1
5 Retainer ring 748-0018 1 748-0002 1 748-0004 1
6 Torque arm mount assembly 5380-101-007 1 5381-101-006 1 5382-101-007 1
7 Torque arm rod assembly 5380-112-001 1 5381-112-001 1 5382-112-001 1
8 Terminal accessory 5311-101-001 1 5311-101-001 1 5311-101-001 1
9 Conduit Box 5200-101-010 1 5200-101-010 1 5200-101-010 1
*See page 13 for specific part numbers.
These units, when used with the correct Warner Electric conduit box, meet the standards of UL508 and are listed under guide card #NMTR2, file
#59164. Magnet and armature are not field replaceable.
Warner Electric • 800-825-9050 P-237 • 819-0289
12
5/8" motor shaft 5380-101-005
7/8" motor shaft 5380-101-004
1-1/8" motor shaft 5381-101-003
1-3/8" motor shaft 5382-101-003
1-5/8" motor shaft 5382-101-002
FB-375 FB-475 FB-650
to 180-0418 1" bore 1 to 180-0435 1-3/8" bore 1
Bushing Part Numbers
Shaft Size Part No.
Dodge 1008 1/2 180-0410
9/16 180-0411
5/8 180-0412
11/16 180-0413
3/4 180-0414
13/16 180-0415
7/8 180-0416
15/16 180-0417
1 180-0418
Dodge 1310 1/2 180-0421
9/16 180-0422
5/8 180-0423
11/16 180-0424
3/4 180-0425
13/16 180-0426
7/8 180-0427
15/16 180-0428
1 180-0429
1-1/16 180-0430
1-1/8 180-0431
1-3/16 180-0432
1-1/4 180-0433
1-5/16 180-0434
1-3/8 180-0435
Warner Electric • 800-825-9050 P-237 • 819-0289
13
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 consent.
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 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 maintenance.
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 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. Weights do not include weight of boxing for shipment. Certified prints will be furnished
without charge on request to Warner Electric.
Warner Electric
31 Industrial Park Road • New Hartford, CT 06057
815-389-3771 • Fax: 815-389-2582
www.warnerelectric.com
P-237 • 819-0289 8/11 Printed in USA
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