Warner Electric PCBC-500 User Manual
PC-500 Clutch,
PCC-500 Clutch Coupling,
PCBC-500 Clutch/Brake Coupling
P-203
819-0484
Installation Instructions
Contents
Installation Instructions
PC-500 Pin Drive . . . . . . . . . . . . . . . . . . . . . . . . . . .3
PCC-500 Spline Drive . . . . . . . . . . . . . . . . . . . . . . .7
PCC-500 Pin Drive . . . . . . . . . . . . . . . . . . . . . . . . .9
PCBC-500 Spline Drive . . . . . . . . . . . . . . . . . . . . .12
PCBC-500 Pin Drive . . . . . . . . . . . . . . . . . . . . . . .16
Conduit Box Installation . . . . . . . . . . . . . . . . . . . . . .20
Coil Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Burnishing and Maintenance . . . . . . . . . . . . . . . . . . .23
Illustration Drawings
PC-500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
PCC-500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
PCBC-500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Bushing Part Numbers . . . . . . . . . . . . . . . . . . . . . . .34
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover
Failure to follow these
instructions may result in product damage,
equipment damage, and serious or fatal injury
to personnel.
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.
PC-500
Pin Drive
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PCC-500
Spline Drive
PCBC-500
Pin Drive
PC-500 Clutch Pin Drive Armature
The illustration drawings, parts lists, and exploded views
for these units can be found on pages 24 and 25.
Either the magnet half of the clutch unit or the armature
half of the unit may be mounted on the shaft first,
depending on the characteristics of each application.
A. Assembling the Magnet and Magnet
Hub
1. Determine which side of the magnet hub will be
mounted to the magnet. The hub is reversible.
The side to be used will depend on which side
the taperlock bushing is to enter.
Figure 2
2. Insert the lead wires through the rubber
terminal caps and into the collector ring. The
wires should be inserted from the same side
of the ring that the magnet will be mounted on.
(Figure 1)
Figure 1
3. Mount the magnet to the magnet hub using
capscrews and lockwashers. (Figure 2)
7. Tighten down the screw in the collector ring.
The sharp cone point on the screw should
pierce the lead wire insulation to make a good
electrical contact. The head of the screw should
be below the surface of the collector ring.
(Figure 3)
8. Cut off the excess wire.
Figure 3
4. Secure the lead wires to the magnet terminals
with screws and lockwashers.
5. Pull the rubber terminal caps over the
terminals.
6. Pull the excess lead wire length from the
backside of the collector ring (away from the
magnet) until the wire is snug.
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3.356 .001
Chordal
.3665 .0005 DIA.
3.875 .001
Bolt Circle
1/16
63/64
1-11/32
5/16 - 24 UNF - 3A
Threads
Mounting Instructions for Gear, Sprocket, or Pulley
Drive Pin
Conical
Spring
Retainer
Detent
Spring
Straight
Spring
Armature
Armature
Hub
Armature
Boss
Figure 4
Customer supplied
sheave or sprocket.
Figure 5 - PC Clutch
.062 When
.453
.968
New
.625
1.187
3.187
Figure 6
1.375
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Figure 7
B. Mounting the Magnet and Magnet Hub
C. Assembling the Armature
The magnet and magnet 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 loosely into the
bushing and slide the assembly onto the shaft.
3. If the armature has been secured to the shaft
first, then adjust the magnet's position to allow
approximately 1/32-inch between the two
faces. (Figure 12)
4. Secure the magnet's position on the shaft by
alternately tightening each setscrew with a
torque wrench to 175 in.lbs. torque. During the
tightening process the bushing should be
tapped lightly to make certain it seats-in
properly.
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 4, 8 and 9) to
properly adapt these parts to the armature.
a. The chordal dimension must be held for all
chords between pin holes.
b. Sleeve bearings (Oilite Bronze)
with an I.D. of .376 ±.001 must be
provided in the holes of pulley or hub at the
chordal and bolt circle dimensions shown in
Figure 4 and 6.
c. The drive pins must be square with plane of
mounting surface and magnet within .006
T.I.R.
2. Once the pulley, gear, etc., has been adapted
to the armature according to the above
directions, the ar ma ture may be mounted to
it using the autogap accessory.
3. The autogap assembly is a double spring
device which allows for automatic armature
clearance and ad just ment 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 7)
Note: Autogap accessory is shipped
pre-assembled.
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Step 1 Place straight springs over armature
1/32-inch
Armature
Magnet
Magnet Hub
bosses on back side of armature (Figure 8).
Figure 11
Note: This position must not be disturbed during
completion of as sem bly. (Figure 11)
Figure 8
Step 2 Compress conical spring against retainer ring
by sliding detent spring towards head of pin.
(All 3 pins.) (Figure 9)
Figure 9
Step 3 Insert assembled drive pins through
(customer-supplied part (Figure 5) through the
straight springs, and into the threaded armature bosses. Apply grade "AA" Loctite Sealant
on drive pin threads. (Figure 10)
D. Mounting the Armature Assembly
1. Slide the armature assembly onto the shaft.
Keep adjustment in Step 5 (Figure 11) from
moving.
2. If the magnet and magnet hub assembly
Figure 12
has been secured to the shaft first, then adjust
the armature's position to allow approximately
1/32" between the two faces. (Figure 12)
Once this 1/32" gap has been set, it will be
automatically maintained throughout the life of
the unit.
3. Secure the assembly in this position on the
shaft.
E. Mounting the Brushholder
Figure 10
Step 4 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.
Step 5 Compress the retainer rings against the arma-
ture hub (or customer-supplied part), and
check to see that the part is held
tightly to the armature bosses.
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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
im proper contact between the brushes and collector ring.
2. The distance from the centerline of the shaft to
the top of the brushholder should be 4".
Maintaining this dis tance will assure proper
spring tension on the brushes and maximum
wear follow-up. A detailed dimensional
drawing is included with each brushholder.
PCC-500 Clutch-Coupling
Heavy Duty Spline Drive Armature
The illustration drawings, parts list, and exploded view
for this unit can be found on pages 28 and 29.
Either the magnet half of the clutch unit or the
armature half of the unit may be mounted on the shaft
first, depending on the characteristics of each
application. (Figure 4)
A. Assembling the Magnet and Magnet
Hub
1. Determine which side of the magnet hub will be
mounted to the magnet. The hub is reversible.
The side to be used will depend on which side
the taperlock bushing is to enter.
2. Insert the lead wires through the rubber
terminal caps and into the collector ring. The
wires should be inserted from the same side
of the ring that the magnet will be mounted on.
(Figure 1)
4. Secure the lead wires to the magnet
terminals with screws and lockwashers.
5. Pull the rubber terminal caps over the
terminals.
6. Pull the excess lead wire length from the backside of the collector ring (away from the magnet) until the wire is snug.
7. Tighten down the screw in the collector ring.
The sharp cone point on the screw should
pierce the lead wire insulation to make a good
electrical contact. The head of the screw should
be below the surface of the collector ring.
(Figure 3)
Figure 1
3. Mount the magnet to the magnet hub using
capscrews and lockwashers. (Figure 2)
Figure 3
8. Cut off the excess wire.
Figure 4 - PCC Clutch Coupling
Figure 2
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B. Mounting the Magnet and Magnet Hub
1/32-inch
Armature
Magnet
Magnet Hub
The magnet and magnet 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 loosely into the
bushing and slide the assembly onto the shaft.
3. If the armature has been secured to the shaft
first, then adjust the magnets's position to allow
approximately 1/32-inch between the two faces.
(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
rocking back-and-forth pressure (Figure 5).
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-inch 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-inch. This gap will be
automatically maintained the life of the unit.
(Figure 6)
Figure 5
4. Secure the magnet's position on the shaft by
alternately tightening each setscrew with a
torque wrench to 175 in.lbs. torque. During
the tightening process the bushing should be
tapped lightly to make certain it seats-in
properly.
C. Assembling the Armature and Hub
The heavy duty units contain spline drive armatures and
hub. 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.
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
setscrew 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.
Figure 6
E. 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 im proper contact between
the brushes and collector ring.
2. The distance from the centerline of the shaft to
the top of the brushholder should be 4".
Maintaining this dis tance will assure proper
spring tension on the brushes and maximum
wear follow-up. A detailed dimensional
drawing is included with each brushholder.
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PCC-500 Clutch Coupling
Normal Duty Pin Drive Armature
4. Secure the lead wires to the magnet
terminals with screws and lockwashers.
The illustration drawing, parts list, and exploded view for
this unit can be found on pages 26 and 27.
Either the magnet half of the clutch unit or the
armature half of the unit may be mounted on the
shaft first, depending on the characteristics of each
application.
A. Assembling the Magnet and Magnet
Hub
1. Determine which side of the magnet hub will be
mounted to the magnet. The hub is
reversible. The side to be used will depend on
which side the taperlock bushing is to enter.
2. Insert the lead wires through the rubber
terminal caps and into the collector ring. The
wires should be inserted from the same side
of the ring that the magnet will be mounted on.
(Figure 1)
5. Pull the rubber terminal caps over the
terminals.
6. Pull the excess lead wire length from the backside of the collector ring (away from the magnet) until the wire is snug.
7. Tighten down the screw in the collector ring.
The shaft cone point on the screw should
pierce the lead wire insulation to make a good
electrical contact. The head of the screw should
be below the surface of the collector ring.
(Figure 3)
8. Cut off the excess wire.
Figure 1
3. Mount the magnet to the magnet hub using
capscrews and lockwashers. (Figure 2)
Figure 2
Figure 3
B. Mounting the Magnet and Magnet Hub
The magnet and magnet 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 loosely into the
bushing and slide the assembly onto the shaft.
3. If the armature has been secured to the shaft
first, then adjust the magnet's position to allow
approximately 1/32-inch between the two
faces. (Figure 10)
4. Secure the magnet's position on the shaft by
alternately tightening each setscrew with a
torque wrench to 175 in. lbs. torque. During the
tightening process the bushing should be
tapped lightly to make certain it seats-in
properly.
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Drive Pin
Conical
Spring
Retainer
Detent
Spring
Straight
Spring
Armature
Armature
Hub
Armature
Boss
Figure 4
C. Assembling the Armature and Hub
Assemble the armature to the armature hub with the
autogap mounting accessory. 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 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 4)
Note: Autogap accessory is shipped pre-assembled.
Step 1 Place straight springs over armature
bosses on backside of armature. (Figure 5)
Step 2 Place armature hub over straight springs.
Straight springs must fit into
grooves in ar ma ture hub. (Figure 6)
Figure 6
Step 3 Compress conical spring against retainer ring
by sliding detent spring towards head of pin.
(All 3 pins) (Figure 7)
10
Figure 5
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Figure 7
Step 4 Insert assembled drive pins through
1/32-inch
Magnet
Armature
Magnet Hub
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 these (3) drive pins until shoulders of
pins are against face of armature bosses.
Since threads are class No. 3 fit, pins may
seem to bind.
Note: Alternately tighten each drive pin a
few turns at a time.
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
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