How it Works
Warner Electric
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PCBC-1000
User Manual
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Warner Electric PCBC-825, PCBC-1000, PCBC-1225 User Manual

Primary Clutch/Brake Pin Drive, Spline Drive
PCB-825, PCB-1000, PCB-1225
Primary Clutch/Brake Coupling
PCBC-825, PCBC-1000, PCBC-1225
P-205 819-0474
Installation Instructions
Contents
Installation Instructions
PCB-825, PCB-1000, PCB-1225 . . . . . . . . . . . . . . .3
Pin Drive Armature
PCB-825, PCB-1000, PCB-1225 . . . . . . . . . . . . . . .8
Spline Drive Armatures
PCBC-825, PCBC-1000, PCBC-1225 . . . . . . . . . . . .9
Coil Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Burnishing and Maintenance . . . . . . . . . . . . . . . .14-15
Illustration Drawings
PCB-825, PCB-1000, PCB-1225 . . . . . . . . . . . . . .16
Pin Drive
PCB-825, PCB-1000, PCB-1225 . . . . . . . . . . . . . .22
Spline Drive
PCBC-825, PCBC-1000, PCBC-1225 . . . . . . . . . . .28
Bushing Part Numbers . . . . . . . . . . . . . . . . . . . . . . .34
Warranty . . . . . . . . . . . . . . . . . . . . . . .Back Page
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.
PCB-825 PCBC-825 Pin Drive Spline Drive
2
Clutch-Brake Pin Drive Armatures
Field
Pilot diameter
Mounting Surface
PCB-825 PCB-1000 PCB-1225
The illustration drawings, parts lists, and exploded views for these units can be found starting on page 16.
The brake half of the clutch/brake unit is usually installed first; however, in some cases it may be necessary to start with the clutch portion of the unit to assure a proper assembly when complete.
A. Installing the Conduit Box
Install the conduit box on the brake magnet. Instructions for this procedure can be found with Conduit Box.
B. Mounting the Brake 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.
2. A machined pilot diameter is provided on the
magnet mounting flange (refer to illustration drawings) 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 lock-washers. (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)
1. A pilot diameter on the mounting surface is essential to hold the magnet within the required tolerances. (Figure 1)
Figure 3
Figure 1
Warner Electric • 800-234-3369 P-205-01 • 819-0474
3
C. Assembling the Clutch Magnet and
Short
Wire
Collector
Ring
Terminal
Cap
Long
Wire
Armature Boss
Straight Spring
(White)
Detent Spring
Retainer
Retainer
Ring
Detent
Spring
Drive Pin
Heavy Spring
(Red)
Armature
Magnet Hub
D. Assembling the Brake Armature and Magnet Hub
1. Insert the lead wires through the rubber termi­nal caps and into the collector ring. The shorter wire goes into the hole in the front of the ring (the side that will be mounted to the magnet). The longer wire goes through the ring and into the hole in the back.
Press the bullet-type connectors firmly into place. (Figure 4)
Figure 4
2. Mount the magnet to the magnet hub using capscrews and lockwashers. (Figure 5)
Assemble the armature to the magnet hub with the autogap mounting accessory.
The autogap accessory 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 magnet face, leaving a 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.
The assembly procedure for the autogap accessory is as follows. (Figure 6)
4
Figure 6
Note: The 1225 unit is mounted with four drive pins instead of three as shown in the pictures; however, the assembly procedure is the same for either case.
Figure 5
Step 1
Place straight springs (white) over armature bosses
3. Secure the lead wires to the magnet terminals
on back side of armature. (Figure 7)
with screws and lockwashers.
4. Pull the rubber caps over the terminals.
Figure 7
Step 2
Armature
Brake
1/32-inch Gap
Compress the heavy (red) spring on each drive pin by sliding detent spring towards head of pin. (Figure 8)
Figure 8
Step 6
To set the autogap, slide the detent spring retainers against the armature face. (Figure 10)
Step 3
Insert assembled drive pins through armature (entering from segmented side), through straight (white) springs, and into magnet hub. (Figure 9)
Figure 9
Note: Apply Grade "AA" Loctite® Sealant on pin threads.
Figure 10
Note: This position must not be disturbed during completion of assembly.
E. Mounting the Magnet-Hub-Armature Assembly
This assembly is 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 loosely into the bushing, and slide the assembly onto the shaft.
Step 4
Tighten pins until shoulders of pins are against face of hub. Since threads are class No. 3 fit, pins may seem to bind.
Straight springs must not get
caught under shoulders of drive pins.
Step 5
Check to see that the armature is completely compressed against the face of the hub.
Warner Electric • 800-234-3369 P-205-01 • 819-0474
Figure 11
5
3. Position the assembly to allow a gap of about
A
C
D
B
1-9/32"
5/16"
2-1/4"
1/2"–13 UNC–3A Threads
+.0005"
.6185"
Dia.
–.0010"
1/32-inch between the brake magnet and armature faces. (Figure 11)
Once this gap is set, it will be automatically maintained for the life of the unit.
4. Secure the assembly in this position on the shaft by alternately tightening each setscrew. During the tightening process, the bushing should be tapped lightly to make certain it seats-in properly.
Note: For pin drive armatures (normal duty), continue to F. For spline drive armatures (heavy duty), proceed to F. on page 8.
F. Assembling the Clutch Armature
1. A customer may wish to use the autogap accessory to mount a clutch armature to his own pulley, hub, gear, etc. Follow the illustrated dimensions (Figures 12 & 13) to properly adapt these parts to the armature.
a. Chordal dimensions "A" and "C" must be
held for all chords between pin holes.
b. Drill 27/64-inch diameter holes to a suffi-
cient depth and tap for 1/2-13 NC-3 1-1/8-inch minimum full threads. Pin holes must be square with plane of mounting sur­face and magnet mounting.
c. Ream .501/.500 to a 3/8-inch depth and to
be concentric with tapped holes.
Machining Instructions for Gear, Sprocket, or Pulley
Unit Size AB C D
825 3.085 ± .001 3.563 ± .001 1000 4.548 ± .002 5.252 ± .002 1225 4.155 ± .002 5.877 ± .002
Figure 12
Figure 13
6
2. Once the pulley, gear, etc., has been adapted
Armature
Clutch
Magnet
1/32-inch G
1/32-inch Gap
to the armature according to the above directions, it may be mounted to the armature using the autogap accessory.
The procedure is the same as described for the brake armature on page 3.
Figure 14
H. Mounting the Brushholder
1. The brushholder is mounted on a bracket which must be furnished by the customer. The bracket must be firmly secured to prevent vibration which could cause improper contact between the brushes and collector ring.
2. The distance from the centerline of the shaft to the top of the brushholder should be 5-3/4". Maintaining this distance will assure proper spring tension on the brushes and maximum wear follow-up. A detailed dimensional drawing is included with each brushholder.
G. Mounting the Clutch Armature
1. Slide the armature and customer supplied pulley sprocket or hub assembly onto the shaft.
2. Adjust the armature's position to allow a 1/32" gap between the magnet and armature faces. (Figure 14)
Once this gap is set, it will be automatically maintained for the life of the unit.
3. The armature and customer supplied pulley, sprocket or hub assembly can be held in position on the shaft by (a) retainer rings, (b) set collars, (c) a shoulder on the shaft, or (d) any combination of these. The best method will depend on the characteristics of each application.
Warner Electric • 800-234-3369 P-205-01 • 819-0474
7
Armature
1/32-inch Gap
Clutch
Magnet
PCB-825 PCB-1000 PCB-1225 Clutch-Brake Spline Drive Armature
The illustration drawings, parts lists, and exploded views for these units can be found beginning on page 22.
Refer to the installation instructions for pin drive armature units, page 3, for steps A-E.
F. Assembling the Spline Drive Armature
2. A customer may mount the clutch armature to his own pulley, hub, gear, etc. Refer to the illustration drawings, "Armature View," for the dimensional information needed to drill and tap holes in the customer part.
The splined hub pilot diameter must be concentric with the splined armature center of rotation within .010 T.I.R.
3. Mount the armature to the customer's part using the capscrew accessory provided.
1. These clutch-brake 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.
The spline drive armature assembly is shipped with the armature, splined armature adapter, and autogap already assembled. The splined hub and capscrew accessories are shipped as separate parts.
Follow these instructions to assemble the splined armature assembly and hub:
a. Place the armature-adapter assembly on a
flat surface with the segmented side up.
b. Push the splined hub, with the pilot diameter
down (refer to illustration drawings) through the autogap spring and splined armature adapter. (Figure 12)
Maintain a 1/16-inch clearance between the armature adapter and the customer part after the parts have been assembled.
G. Mounting the Clutch Armature Assembly
1. Slide the complete armature and customer supplied pulley, sprocket or hub assembly on to the shaft.
2. Adjust the armature's position to allow a 1/16­inch gap between the magnet and armature faces. (Figure 13)
8
Figure 12
Figure 13
3. Secure the armature assembly in position by a) retainer rings, b) set collars, c) shoulder on the shaft, or d) any combination of these. The best method will depend on the characteristics of each application.
4. When the armature is secure on the shaft, push the armature against the magnet face. When the armature is released, it will spring back about 1/32-inch. This gap will be automatically maintained for the life of the unit.
H. Mounting the Brushholder
Field
Pilot diameter
Mounting Surface
1. The brushholder is mounted on a bracket which must be furnished by the customer. The bracket must be firmly secured to prevent vibration which could cause improper contact between the brushes and collector ring.
Clutch-Brake Coupling PCBC-825 PCBC-1000 PCBC-1225
The illustration drawings, parts lists, and exploded views for these units can be found beginning on page 28.
The brake half of the clutch/brake unit is usually installed first; however, in some cases it may be necessary to start with the clutch portion of the unit to assure a proper assembly when complete.
A. Installing the Conduit Box
Install the conduit box on the brake magnet. Instructions for this procedure can be found with Conduit Box.
2. The distance from the centerline of the shaft to the top of the brushholder should be 5-3/4". Maintaining this distance will assure proper spring tension on the brushes and maximum wear follow-up. A detailed dimensional drawing is included with each brushholder.
Figure 1
2. A machined pilot diameter is provided on the magnet mounting flange (refer to illustration drawings) to aid in the proper positioning of the magnet.
B. Mounting the Brake 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)
Warner Electric • 800-234-3369 P-205-01 • 819-0474
3. Once the mounting surface has been prepared, the magnet is bolted in place with capscrews and lockwashers. (Figure 2)
Figure 2
9
4. Use a dial indicator to check the unit for con-
Short
Wire
Collector
Ring
Terminal
Cap
Long
Wire
Armature Boss
Straight Spring
(White)
Detent Spring
Retainer
Retainer
Ring
Detent
Spring
Drive Pin
Heavy Spring
(Red)
Armature
centricity 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 5
3. Secure the lead wires to the magnet terminals with screws and lockwashers.
Figure 3
C. Assembling the Clutch Magnet and Magnet Hub
1. Insert the lead wires through the rubber terminal caps and onto the collector ring. The shorter wire goes into the hole in the front of the ring (the side that will be mounted to the magnet). The longer wire goes through the ring and into the hole in the back.
Press the bullet-type connectors firmly into place. (Figure 4)
4. Pull the rubber caps over the terminals.
D. Assembling the Brake Armature and Magnet Hub
Assemble the armature to the magnet hub with the autogap mounting accessory.
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 magnet face, leaving a gap of about 1/32 inch, while the straight spring automatically follows up for wear. This combination maintains maximum efficiency throughout the life of the unit.
The assembly procedure for the autogap accessory is as follows (Figure 6):
10
2. Mount the magnet to the magnet hub using capscrews and lockwashers. (Figure 5)
Figure 4
(Figure 6)
Note: The 1225 unit is mounted with four drive pins instead of three as shown in the pictures; however, the assembly procedure is the same for either case.
Step 1
Place straight springs (white) over armature bosses on back side of armature. (Figure 7)
Figure 9
Step 4
Tighten pins until shoulders of pins are against face of hub. Since threads are class No. 3 fit, pins may seem to bind.
Figure 7
Step 2
Compress the heavy (red) spring on each drive pin by sliding detent spring towards head of pin. (Figure 8)
Figure 8
Step 3
Insert assembled drive pins through armature (entering from segmented side), through straight (white) springs, and into magnet hub.
Straight springs must not get
caught under shoulders of drive pins.
Step 5
Check to see that the armature is completely compressed against the face of the hub.
Step 6
To set the autogap, slide the detent spring retainers against the armature face.
Note: This position must not be disturbed during completion of assembly. (Figure 10)
Note: Apply Grade "AA" Loctite® Sealant on pin threads. (Figure 9)
Figure 10
Warner Electric • 800-234-3369 P-205-01 • 819-0474
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