General Trouble Shooting
P-233
819-0451
Failure to follow these
instructions may result in product damage,
equipment damage, and serious or fatal
injury to personnel.
Contents
Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . 2
Clutch and Brake . . . . . . . . . . . . . . . . . . . . . . . . . 2
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Mechanical Troubleshooting
Autogap Installation . . . . . . . . . . . . . . . . . . . . . . . 4
Safety Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Taper Bushings. . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Brushholder Mounting . . . . . . . . . . . . . . . . . . . . . 5
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Armature Flatness. . . . . . . . . . . . . . . . . . . . . . . . . 5
Environmental Problems
Oil, Grease, Dirt, Chips, Abrasive Grit . . . . . . . . . . 6
Wear Pattern
Burnishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wear Life
Heat Dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . back cover
General Troubleshooting For All Units
The Service Manuals listed below are available
without charge. When ordering, specify form
number of desired publication.
Form Description
Number
P-200 Service Manual: SF-120, 170;
SFC-120, 170; PB-120, 170;
SF-250, 400; SFC-250, 400.
P-201 Service Manual: PB-250, 400.
P-202 Service Manual: SF-500, 650; SFC-
500, 650; SPBC-500, 650.
P-203 Service Manual: PC-500; PCC-500,
PCBC-500.
P-204 Service Manual: PB-500, 650.
Installation Instructions
P-205 Service Manual: PCB-825, 1000,
1225; PCBC-825, 1000, 1225.
P-206 Service Manual: PC-825, 1000, 1225,
1525; PCC-825, 1000, 1225, 1525.
P-207 Service Manual: SFC-825, 1000, 1225,
1525; SFC-1525, Hi-Torque
P-208 Service Manual: PB-825, 1000, 1225,
1525; MB-825, 1000, 1225.
P-209 Service Manual: PB-825, 1000, 1225,
1525.
P-210 Service Manual: EC-375, 475, 650,
825, 1000, 1225.
P-211 Service Manual: EB-375, 475, 650,
825, 1000, 1225.
P-212 Service Manual: EP-170, 250, 400,
500, 825, 1000, 1525.
P-213 Service Manual: EM-50-10, 180-10,
210-10; EM-50-20, 180-20,
210-20; EM-50-30, 180-30, 210-30;
EM-50-40, 180-40, 210-40.
P-214 Service Manual: PCBC-1225/1000,
1525/1225; PCB-1225/1000,
1525/1225.
P-215 Service Manual: SF-825, 1000, 1225,
1525; SF-1525 Hi-Torque
P-220 Service Manual: Controls
P-231 Service Manual: Electro-Disc
P-235 Tension Control System
P-237 Service Manual: Electrically Released
FB-375, 475, 650.
P-238 Installation Manual: Motion Control
P-239 Installation Manual: Power-Supplies
P-248 Technical Manual: W-Line
P-250 Service Manual: ER-825 & 1225 Pin
Drive
P-251 Service Manual: ER-825 & 1225 Spline
Drive
P-252 Service Manual: MCS-129, 129-1
P-256 Service Manual: Modular Tension
Brake
Electrical Troubleshooting
Coil Data
Unit Size SF/PB 120 SF/PB 170 SF/PB 250
Voltage – DC 6 24 90 6 24 90 6 24 90
Resistance @ 20°C – Ohms 6.32 104 1386 6.96 111.2 1506 5 76.4 1079
Current – Amperes .949 .230 .065 .861 .215 .060 1.2 .314 .084
Watts 5.69 5.52 5.85 5.85 5.16 5.37 7.2 7.5 7.51
Coil Build-up – milliseconds 12 12 11 17 17 16 48 48 44
Coil Decay – milliseconds 887 8 7 6 15 15 13
Unit Size SF/PB 400 SF-500 PB & PC 500 SF-650
Voltage – DC 6 24 90 6 24 90 6 24 90 6 24 90
Resistance @ 20°C – Ohms 4.88 73 1087 1.076 14.9 206.1 1.36 23.8 251.1 1.16 17.7 225
Current – Amperes 1.23 .322 .083 5.58 1.61 .44 4.4 1.01 .36 5.19 1.36 .4
Watts 7.39 7.96 7.45 34 39 39 26 24 32 31 33 36
Coil Build-up – milliseconds 154 154 154 82 85 90 84 87 93 110 115 120
Coil Decay – milliseconds 62 60 55 40 40 40 38 35 30 50 50 50
Unit Size PB-650 SF-825 SF-825 Brg PB & PC 825 SF-1000 PB & PC 1000
Voltage – DC 6 24 90 6 24 90 6 24 90 6 24 90 6 24 90 6 24 90
Resistance @ 20°C – Ohms 1.24 18.3 257.2 1.23 20.9 267.0 1.098 14.6 221 1.27 20.4 223.3 1.07 14.4 214.4 1.23 19.7 248.7
Current – Amperes 4.84 1.31 .35 4.9 1.15 .34 5.464 1.65 .407 4.74 1.18 .4 5.61 1.67 .42 4.87 1.22 .36
Watts 29 31 32 29 28 30 33 40 37 28 28 36 34 40 38 29 29 33
Coil Build-up – milliseconds 100 105 110 222 200 245 180 200 225 170 170 170 256 275 283 205 220 235
Coil Decay – milliseconds 50 50 50 105 120 100 115 120 130 70 75 80 123 105 90 70 75 80
Unit Size SF-1225 PB & PC 1225 SF-1525 PB & PC 1525 SF-1525 H.T.
Voltage – DC 6 24 90 6 24 90 6 24 90 6 24 90 6 90
Resistance @ 20°C – Ohms 1.21 19.5 268.3 1.33 22.3 261.7 1.11 15.5 239.1 1.45 19.8 258.4 55 113.4
Current – Amperes 4.97 1.23 .34 4.5 1.08 .34 5.41 1.55 .38 4.13 1.21 .35 10.83 .794
Voltage Check
The initial electrical check should be the input
voltage to the magnet, as follows:
For 90 volt units connect a DC voltmeter with a
range of 0-100, or more, directly across the
magnet terminals. With the power on the
potentiometer turned up, a normal reading is 90
volts, although 85 to 105 is satisfactory. The
reading should drop smoothly as the
potentiometer is turned counterclockwise.
For 6 volt magnets use a DC range on the
voltmeter of approximately 0-15 volts. A normal
reading is from 5.5 to 6.5 volts, depending on
the power supply.
Current Check
A low range ammeter, when connected in series
with one magnet lead, will normally indicate
approximately .35 amperes for the 90 volt IHP
units and 4.0 amperes for the 6 volt series. These
readings are with power on and the potentiometer
control in the maximum position.
Resistance Check
Ohmmeter checks should be made with the
power off and the circuit open (to be certain,
disconnect one magnet lead). Average resistance
for the IHP 90 volt series is 250 ohms; for the 6
volt series, 1.5 ohms. A very high or infinite
resistance reading would indicate an open coil.
Summary
If the above checks indicate that the proper
voltage and current is being supplied to the
magnet, mechanical parts should be checked to
assure that they are in good operating condition
and properly installed.
Warner Electric • 800-825-9050 P-233 • 819-0451
2
Note: The following steps apply to the basic
standard controls.
General
1. Make a visual check from the control input to
the clutch or brake units, looking for frayed
wires, broken wires, or loose connections.
Examine the lead wires or terminals at the
clutch or brake. Look for dirt, grease, or metal
chips that would interfere with a good electrical
circuit. Make a special check at the
brushholder when a PC clutch is involved.
Problems may result from a loose brushholder,
worn-out brushes, or a loose terminal
connection caused by steady machine
vibration or simply a broken wire.
A current check is usually not necessary
although one can be made by placing an
ammeter in series with the clutch or brake
coil. Correct readings are listed in the coil
data chart on page 4.
Voltage Control
4. Check the potentiometer or rheostat settings.
Frequently an operator will change the original
settings thinking that this will improve the
performance of the machine. The
potentiometer or rheostat should be set at a
voltage level no lower than necessary to
achieve satisfactory operation. Since
conditions vary from one application to
another the setting must be determined
through trial and error.
To determine if a potentiometer or rheostat is
working properly, measure the resistance with
the power off. A smooth variation in
resistance should be noted from a minimum
of 0 to approximately 1000 ohms.
If the voltage settings are correct and the
control still does not function, check the input
to the control.
Fuse
2. Check the fuse. The fuse is a glass cartridge
type and can be checked visually. Make certain
that the fuse is of the proper value.
Output
3. With a DC voltmeter, check the output of the
control at the clutch and brake (potentiometer
or rheostats should be at maximum). With the
coil connected, a normal reading is 85-105
volts DC. If the output is normal and the unit
still does not function, check the clutch and
brake coils against the nominal readings in the
coil data chart on page 4.
When checking resistance, make sure the
power is off. Disconnect one lead to be certain.
A shorted coil will indicate a zero resistance,
while an open coil will read infinity.
Input
5. Place an AC voltmeter across the AC input
connections to the control (connections are
shown on each drawing). The AC supply
voltage should be within ±5% of the nominal
rating. Example: for a 115 volt AC input the
acceptable range is from approximately 110
to 120 volts.
When using a control with a transformer, the
AC voltage must be checked both at the
input (transformer primary) and the output
(transformer secondary). The output should
be approximately 115 volts AC regardless of
whether the input is 230, 460, or 575
volts AC.
If the readings are normal, the switching
should be checked next.
Warner Electric • 800-825-9050 P-233 • 819-0451
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Switching
A
B
C
D
Armature Boss
Straight Spring
(White)
Detent Spring
Retainer
Retainer
Ring
Detent
Spring
Drive Pin
Heavy
Spring
(Red)
Armature
6. With normal input and no output, a problem
may lie in the switching. The switch
connections are shown on each drawing.
A voltage or resistance check at these points
will show whether or not the circuit is being
closed as the switch is actuated.
Mechanical Troubleshooting
Proper Assembly
Check the unit for proper assembly. See the
specific service manual that covers your unit.
Is the armature free to slide in and out axially?
Check the autogap installation.
Autogap Installation Instructions For
Automatic Adjustment of Armature
Clearance
If the switching is done with an external relay,
the relay should be checked to make sure it is
actuating and making contact.
If the switching is done electronically inside the
control, it is recommended that the complete
control be replaced.
Drive Pins
Are the drive pins screwed in tightly?
If the armature hangs up on the drive pins, the
pins may have worked loose or the hub was
incorrectly machined.
Machine Instructions For Gear, Sprocket or Pulley
Warner Electric • 800-825-9050 P-233 • 819-0451
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All drive pins should have Loctite or an equivalent
thread sealant applied to the threads prior to
installation.
Unit Size ABCD
825 3.563 ± .001 3.085 ± .001
1000 5.252 ± .002 4.548 ± .002
1225 4.155 ± .002 5.877 ± .002
1525 6.010 ± .002 8.500 ± .002
Taper Bushings
0.56
(14.22)
0.75
(19.05)
1.41
(35.81)
1.56
(39.69)
0.78
(19.84)
1.72
(42.69)
1.34
(34.03)
By
Customer
By
Customer
1.88
(47.8)
1.31
(33.34)
0.75
(19.05)
0.38
(9.53)
0.75
(19.05)
0.38
(9.53)
0.188
(4.78)
4 holes tapped for #8-32 screws
(by customer) to enter brushholder
case 0.31 (7.87) max.
Rotation
1/2 standard
straight pipe
tap 0.391 (9.93)
deep
Dim.
“A”
1.03
(26.16)
0.28
(7.11)
Alternate Mounting
0.188 (4.76) dia. 2 holes thru
screws and nuts by customer
Are the taper bushings tight on the shaft? Proper
bushing installation is important. Proceed as
follows: All parts must be clean before assembly.
Place the bushing into the hub and insert the key.
The key is a side to side fit and should not contact
the top of the keyway. Lubricate the locking set
screws, insert them into the bushing and slide the
assembly on to the shaft. Position the hub so that
a 1/16" running clearance will be provided
between the magnet and armature faces. Tighten
the bushing on the shaft by drawing up on each
screw alternately. During the tightening process
the busing should be wrapped sharply from time
to time, to make certain that it seats-in properly.
Brushholder
Is the brushholder properly installed? The
mounting bracket must be solid. The brushes are
springloaded and should be in good contact with
the collector ring. The brushes may be simply
worn out and should be replaced.
Alignment
Are the friction surfaces correctly aligned? If the
unit is a clutch coupling, the two shafts should be
concentric within .006 T.I.R. The unit does not
compensate for angular misalignment between
shafts. For a brake the magnet face must be
square with the armature shaft within .006 T.I.R.
The magnet mounting pilot diameter must be
concentric with the armature shaft within .010 T.I.R.
Armature Flatness
Is the armature face flat? If it has been dropped or
damaged, it may be out of flat and the torque will
drop off considerably. New armature segments are
held flat and in plane within .002 T.I.R.
Brushholder Assembly And Mounting Dimensions
Dimension “A” for collector ring: Size 500 units is 4" to centerline of shaft. Size 825 and above is 5-3/4"
to centerline of shaft. Brushholder may be mounted at one end opposite conduit or from either side. It is
recommended that brushes be assembled so that arrow on brushes points in the direction of rotation of
collector ring, however brushholder may be used with reversing clutch.
Warner Electric • 800-825-9050 P-233 • 819-0451
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Environmental Problems
New
Burnished
Worn
If units are used on machinery where fine, abrasive
dust, chips or grit are dispelled into the atmosphere,
shielding the clutch may be necessary if maximum
life is to be obtained. Where units are used near
gear boxes or transmissions requiring frequent
lubrication, means should be provided to protect
friction surfaces from oil and grease to prevent
serious loss of torque.
Oil and grease accidentally reaching the friction
surfaces may be removed by wiping with a rag
dampened with a degreasing solvent. In
performing this operation, do not drench the
friction material. If the friction materials have 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 boil to the surface, resulting in
further torque loss.
Wear Pattern
Wear grooves appear on the armature and
magnet surfaces. This is a normal wear condition
and does not impair functioning of the unit.
Burnishing
Intimate metal to metal contact is essential
between the armature and the metal rings
(called poles) of the magnet. Warner Electric
clutches and brakes leave the factor with the
friction material slightly undercut to assure a
good initial contact. Normally, the desired
wearing-in process occurs naturally as the
surfaces slip upon engagement. The time for
wear-in, which is necessary to obtain the
ultimate torque of the unit, will vary depending
on speed, load or cycle duty. If maximum torque
is required immediately after installation, the unit
should be burnished by forcing the friction
surfaces to slip at reduced voltage. It is
recommended that the burnishing be done right
on the installation, if at all possible. Burnishing at
high speed will result in a smoother wear-in
pattern and reduce the time for burnishing.
The voltage should be set at approximately 30
or 40% of the rated value. The unit should be
cycled on and off to allow sufficient time
between slip cycles to prevent overheating.
Remachining Faces
Remachining the face of a worn armature is not
recommended. If a replacement armature is to be
used with a used magnet, it is necessary to
remachine the worn magnet face. In refacing a
magnet: (1) machine only enough material to clean
Heat Dissipation
Excessive heat and high operating temperatures
are causes of rapid wear. Units, therefore,
should be ventilated as efficiently as possible,
especially if the application requires fast,
repetitive cycle operation.
up the complete face of the magnet; (2) hold the
face within .005" of parallel with the mounting
plate; and (3) undercut the molded facing material
.002" - .004" below the metal poles. Normally the
The wear grooves in the armature face result
from a normal wearing-in process.
magnet and armature, as a mating pair, will wear
at the same rate. It is the usual recommendation
that both components be replaced at the same
time.
Warner Electric • 800-825-9050 P-233 • 819-0451
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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 LLC
31 Industrial Park Road
815-389-3771
www.warnerelectric.com
An Altra Industrial Motion Company
P-233 819-01451 8/11 Printed in USA
• Fax: 815-389-2582
• New Hartford, CT 06057
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