Warner Electric PB-650 User Manual

PB-500 Pin Drive, PB-500 Spline Drive

PB-650 Pin Drive

P-204
819-0485

Installation Instructions

Contents

Installation Instructions

PB-500 Pin Drive . . . . . . . . . . . . . . . . . . . . . . .3

PB-500 Spline Drive . . . . . . . . . . . . . . . . . . . .6

PB-650 Pin Drive . . . . . . . . . . . . . . . . . . . . . . .8

Coil Data/Electrical Specifications . . . . . . . . . .11

Conduit Box Installation Instructions . . . . . . . .12

Burnishing and Maintenance . . . . . . . . . . . . . .14

Illustration Drawings

PB-500 Pin Drive . . . . . . . . . . . . . . . . . . . . . .16

PB-500 Spline Drive . . . . . . . . . . . . . . . . . . .18

PB-650 Pin Drive . . . . . . . . . . . . . . . . . . . . . .20

Bushing Part Numbers . . . . . . . . . . . . . . . . . . .22

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-500 PB-500 PB-650

Pin Drive Spline Drive Pin Drive

Warner Electric • 800-825-9050 819-0485

2

PB-500 Primary Brake Normal

Mounting Surface

Pilot diameter

Magnet

Duty Pin Drive Armature

Installation Instructions

A. Installing the Conduit Box

Please follow instructions supplied with conduit
box.

B. Mounting the Magnet

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. (Figure 1)

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. (Figure 3)

Figure 3

C. Assembling the Armature Hub

Assemble the armature to the armature hub with
the autogap mounting accessory. Refer to Figure

4. The hub is reversible. The side on which the

armature is mounted will depend on the direction
in which the taperlock bushing must enter.

2. A machined pilot diameter is provided on the

3. Once the mounting surface has been

Warner Electric • 800-825-9050 819-0485

magnet mounting flange (refer to illustrations)
to aid in the proper positioning of the magnet.

prepared, the magnet is bolted in place with
capscrews and lock-washers. (Figure 2)

The autogap assembly is a double spring device
which allows for automatic armature clearance
and adjustment for wear. The smaller or conical
spring pushes the armature from the rotor face,
leaving the gap of about 1/32 inch, while the
straight spring automatically follows up for wear.
This combination maintains maximum
performance efficiency throughout the life of
the unit.

3

Armature

Armature

Boss

Straight

Spring

Armature

Hub

Detent
Spring

Retainer

Conical

Spring

Drive Pin

The assembly procedure for the autogap
accessory is as follows:

Step 1

Place straight springs over armature bosses on
back side of armature. (Figure 5)

Figure 4

Figure 6

Step 3

Compress conical spring against retainer ring by
sliding detent spring towards head of pin. (All 3
pins) (Figure 7)

Figure 5

Step 2

Place armature hub over straight springs.

Straight springs must fit into

gr

4

ooves in armature hub. (Figure 6)

Warner Electric • 800-825-9050 819-0485

Figure 7

Step 4

1/32-inch

Armature

Magnet

Insert assembled drive pins through armature
hub and straight springs and into the threaded
armature bosses. Apply grade "AA" Loctite
Sealant on drive pin threads. (Figure 8)

Figure 8

Step 5

Tighten drive pins until shoulders of pins are
against face of armature bosses. Since threads
are class No. 3 fit, pins may seem to bind.

D. Mounting the Armature Assembly

The armature and armature hub are mounted on
the shaft with a taperlock bushing. All parts
must be clean and free from burrs and chips
before assembling.

1. 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.

2. Insert the locking setscrews into the bushing
and slide the assembly onto the shaft.

3. Place the face of the armature approximately
1/32" from the face of the magnet. Once this
gap is set, it will be automatically maintained
throughout the life of the unit. (Figure 10)

Step 6

Compress the retainers against the armature
hub and check to see that the armature hub is
held tightly to the armature bosses.
Note: This position must not be disturbed
during completion of assembly. (Figure 9)

Figure 9

Figure 10

4. Securely fasten the armature assembly to the
shaft by alternately tightening each setscrew.
During the tightening process, the bushing
should be tapped lightly to make certain it
seats-in properly.

Warner Electric • 800-825-9050 819-0485

5

PB-500 Primary Brake Heavy

Mounting Surface

Pilot diameter

Magnet

Duty Spline Drive Armature

Installation Instructions

A. Installing the Conduit Box

Please follow instructions supplied with conduit
box.

B. Mounting the Magnet

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. (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. (Figure 3)

2. A machined pilot diameter is provided on the
magnet mounting flange (refer to illustrations)
to aid in the proper positioning of the magnet.

3. Once the mounting surface has been
prepared, the magnet is bolted in place
with capscrews and lockwashers. (Figure 2)

Warner Electric • 800-825-9050 819-0485

6

Figure 3

Figure 1

C. Assembling the Armature and Hub

1/32-inch

Armature

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" between the armature and magnet faces
for the life of the unit.

Follow these instructions to assemble the
armature and splined hub.

Step 1

Place the splined hub on a flat surface. The
extended portion of the hub, where the set
screw holes are located, should be down.

Step 2

Check the detent ring in the armature assembly
to make sure it is centered evenly around the
spline. This ring moves freely, but it should be
centered for easier assembly of the hub.

Step 4

Push the assembly against the retainer ring.

D. Mounting the Armature-Hub Assembly

1. Slide the armature-hub assembly onto the
shaft until the armature face touches the
magnet face.

2. Move the assembly back to allow a gap of
about 1/16" between the two faces.

3. Secure the armature-hub assembly in this
position by tightening the two setscrews in
the hub.

4. Check the assembly by pressing the
armature into contact with the magnet face
and then releasing it. The armature should
spring back about 1/32". This gap will be
automatically maintained throughout the life
of the unit. (Figure 5)

Step 3

Holding the armature with the segmented side
up, press the armature onto the splined hub.
This is most easily done by applying firm
back-and-forth pressure. (Figure 4)

Figure 5

Figure 4

Warner Electric • 800-825-9050 819-0485

7

PB-650 Primary Brake

Mounting Surface

Pilot diameter

Magnet

Installation Instructions

A. Installing the Conduit Box

Please follow instructions supplied with conduit
box.

B. Mounting the Magnet

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. (Figure 1)

2. A machined pilot diameter is provided on the
magnet mounting flange (refer to illustrations)
to aid in the proper positioning of the magnet.

3. Once the mounting surface has been
prepared, the magnet is bolted in place with
capscrews and lockwashers. (Figure 2)

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. (Figure 3)

Figure 3

C. Assembling the Armature and Hub

Figure 1

Assemble the armature to the armature hub with
the autogap mounting accessory. Refer to
Figure 4. The hub is reversible. The side on
which the armature is mounted will depend on
the direction in which the taperlock bushing
must enter.

The autogap assembly is a double spring device
which allows for automatic armature clearance
and adjustment for wear. The smaller or conical
spring pushes the armature from the rotor face,
leaving a gap of about 1/32", while the straight
spring automatically follows up for wear. This
combination maintains maximum performance
efficiency throughout the life of the unit.

8

Warner Electric • 800-825-9050 819-0485