Warner Electric PB-1525 User Manual
Primary Brake Spline Drive Armature
PB-825, PB-1000, PB-1225, PB-1525
P-209
819-0517
Installation Instructions
Contents
Installation Instructions
PB-825 PB-1000 PB-1225 PB-1525 . . . .3
Coil Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Conduit Box Installation . . . . . . . . . . . . . . . . . . . .6
Burnishing and Maintenance . . . . . . . . . . . . . . . .9
Illustration Drawings
PB-825 PB-1000 . . . . . . . . . . . . . . . . . . . .10
PB-1225 PB-1525 . . . . . . . . . . . . . . . . . . .14
Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Warranty . . . . . . . . . . . . . . . . . . . . . . .Back Cover
Follow the installation
instructions in this manual carefully to ensure
safe, reliable operation. All stated or implied
manufacturer warranties are voided if this
product is not installed in accordance with
these instructions.
Failure to follow these
instructions may result in product
damage, equipment damage, and
serious or fatal injury to personnel.
PB-825
Warner Electric • 800-825-9050 P-209 • 819-0517
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PB-1225
Primary Brake Heavy Duty
Mounting Surface
Pilot diameter
Magnet
Spline Drive Armature
PB-825 PB-1000 PB-1225 PB-1525
The illustration drawings, parts lists, and
exploded views for these units can be found beginning on page 10.
A. Installing the Conduit Box
Install the conduit box on the magnet. Instructions
for this procedure can be found on page 6.
B. Mounting the Magnet
3. Once the mounting surface has been
prepared, the magnet is bolted in place with
capscrews and lockwashers. (See Figure 2.)
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.)
Figure 2
4. Use a dial indicator to check the unit for concentricity and squareness to the shaft. The unit
should be concentric within .010 T.I.R. and
square within .006 T.I.R. (See Figure 3.)
Figure 3
C. Assembling the Armature and Hub
2. A machined pilot diameter is provided on the
Warner Electric • 800-825-9050 P-209 • 819-0517
Figure 1
magnet mounting flange (refer to illustration
drawings page 11) to aid in the proper
positioning of the magnet.
The heavy duty units contain spline drive
armatures and hubs. The armatures are shipped
with a built-in autogap spring accessory. This
device automatically maintains a gap of about
1/32-inch between the armature and magnet
faces for the life of the unit.
3
These units are shipped with the armature, splined
armature adapter, and autogap already assembled.
The splined hub, retainer ring, and bushing are
shipped as separate parts.
Step 4
Slide the armature-adapter assembly up against
the retainer ring.
Follow these instructions to assemble the armature
and splined hub:
Step 1
Place the armature-splined adapter assembly on a
flat surface with the segmented side up.
Step 2
Push the splined hub, with the retainer ring groove
down, through the autogap spring and splined
armature adapter. (See Figure 4.)
Step 5
Insert the bushing into the retainer ring side of the
splined hub. The clearance holes in the bushing
flange should line up with the tapped holes in the
splined hub. (See Figure 6.)
Figure 6
D. Mounting the Armature and Hub
Assembly
Figure 4
Step 3
Turn the armature-adapter assembly over, and
insert the retainer ring in the groove. (See
Figure 5.)
Figure 5
1. Slide the complete armature and hub
assembly onto the shaft until the armature face
touches the magnet face. (See Figure 7.)
Figure 3
Warner Electric • 800-825-9050 P-209 • 819-0517
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2. Tighten the bushing capscrews, taking a few
1/32-inch
Armature
Magnet
turns at a time on each capscrew. As the capscrews are tightened, the armature will back
away slightly from the magnet. There should be
a clearance of 1/16" between the armature and
magnet when the capscrews are completely
tight. (See Figure 8.)
3. When the bushing is secure on the shaft, push
the armature against the magnet face. When
the armature is released, it will spring back
about 1/32". The gap will be automatically
maintained for the life of the unit. (See Figures 9
& 10.)
Figure 8
Figure 9
Figure 10
Coil Data
Unit Size PB-825 PB-1000 PB-1225 PB-1525
Voltage — DC 6 24 90 6 24 90 6 24 90 6 24 90
Resistance @ 20°C — Ohms 1.27 20.4 223.3 1.23 19.7 248.7 1.33 22.3 261.7 1.45 19.8 258.4
Current — Amperes 4.74 1.18 .4 4.87 1.22 .36 4.5 1.08 .34 4.13 1.21 .35
Watts 28 28 36 29 29 33 27 26 31 25 29 31
Coil Build-up — Milliseconds 170 170 170 205 220 235 300 320 350 470 490 512
Coil Decay — Milliseconds 70 75 80 70 75 80 190 190 190 200 170 140
Warner Electric • 800-825-9050 P-209 • 819-0517
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Burnishing and Maintenance
Burnishing
Intimate metal to metal contact is essential
between the armature and the metal rings (poles)
of the magnet or rotor. Warner Electric clutches
and brakes leave the factory with the friction material slightly undercut to assure 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 slipping the friction surfaces together at reduced voltage. It is recommended that the burnishings be
done right on the application, 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.
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
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.
Heat: 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.
Foreign Materials: If units are used on
machinery where fine, abrasive dust, chips
or grit are dispelled into the atmosphere,
shielding of the brake 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 the friction surfaces
from oil and grease to prevent serious loss of
torque.
The unit should be cycled on and off to allow sufficient time between slip cycles to prevent overheating.
When a Warner Electric brake or clutch is
properly assembled and installed, no further servicing, lubrication, or maintenance should be required
throughout the life of the unit.
Maintenance
Wear Pattern: Wear grooves appear on the arma-
ture and magnet surfaces. This is a normal wear
condition, and does not impair functioning of the
unit. Normally, the 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.
Remachining the face of a worn armature is not
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 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.
Torque Loss: If a brake or clutch slips or loses
torque completely, the initial check should be the
input voltage to the magnet as follows:
90-Volt Series: Connect a DC voltmeter with a
range of 0-100 or more directly across the
magnet terminals. With the power on and the
Warner Electric • 800-825-9050 P-209 • 819-0517
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