Warner Electric PCC-825, PCC-1000, PCC-1225, PCC-1525 User Manual

Primary Clutch, Pin Drive

Armature, Spline Drive Armature

PC-825, PC-1000, PC-1225, PC-1525

Primary Clutch Coupling, Spline Drive Armature

PCC-825, PCC-1000, PCC-1225, PCC-1525

P-206 819-0519

Installation Instructions

Contents

Installation Instructions PC-825, PC-1000, PC-1225, PC-1525

Pin Drive Armature . . . . . . . . . . . . . . . . . . . . . 3

PC-825, PC-1000, PC-1225, PC-1525

Spline Drive Armature . . . . . . . . . . . . . . . . . . . 7

PCC-825, PCC-1000, PCC-1225, PCC-1525

Spline Drive Armature . . . . . . . . . . . . . . . . . . . 9

Coil Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Burnishing and Maintenance . . . . . . . . . . . . . . 12

Illustration Drawings

PC-825, PC-1000 (Pin Drive) . . . . . . . . . . . . . 14

PC-1225, PC-1525 (Pin Drive) . . . . . . . . . . . . 18

PC-825, PC-1000 (Spline Drive) . . . . . . . . . . . 22

PC-1225, PC-1525 (Spline Drive . . . . . . . . . . . 26

PCC-825, PCC-1000 . . . . . . . . . . . . . . . . . . . . 30

PCC-1225, PCC-1525 . . . . . . . . . . . . . . . . . . . 34

Bushing Part Numbers . . . . . . . . . . . . . . . . . . . 38

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.

PC-825

Pin Drive

Warner Electric • 800-825-9050 P-206 • 819-0519

PC-825

Spline Drive

PCC-825

Spline Drive

PC-825, PC-1000, PC-1225, PC-1525

Short

Wire

Collector

Ring

Terminal

Cap

Long

Wire

Clutch Pin Drive Armature

Installation Instructions

The illustration drawings, parts lists, and exploded views for these units can be found beginning on page 14.

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. 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. (See Figure 1)

2. Mount the magnet to the magnet hub using capscrews and lockwashers. (See Figure 2)

Figure 2

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. (See Figure 10.)

Figure 1

3. Secure the lead wires to the magnet terminals with screws and lockwashers.

4. Pull the rubber caps over the terminals.

Warner Electric • 800-825-9050 P-206 • 819-0519

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.

Machining Instructions for Gear, Sprocket, or Pulley

A



B



1-9/32"

5/16"

2-1/4"

1/2"–13 UNC–3A Threads

+.0005"

.6185"

Dia.

–.0010"

Unit Size AB CD

825 3.085 ± .001 3.563 ± .001 1000 4.548 ± .002 5.252 ± .002 1225 4.155 ± .002 5.877 ± .002 1525 6.010 ± .002 8.500 ± .002

Figure 3

C. Assembling the 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 (See Figures 3 & 4) 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

sufficient depth, and tap for 1/2-13 NC3 one-inch minimum full threads. Pin holes must be square with plane of mounting surface and magnet mounting.

c. Ream .500/.501 to a 3/8-inch depth

and to be concentric with tapped holes.

2. Once the pulley, gear, etc. has been adapted to the armature according to the above directions, it may be mounted to the armature using the autogap accessory.

Armature

Straight

Spring (White)

Boss

(Figure 4)

Detent Spring

Retainer

Armature

Detent Spring

Retainer Ring

Drive

Heavy Spring

(Red)

Figure 5

Warner Electric • 800-825-9050 P-206 • 819-0519

3. 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-inch, while the straight spring automatically follows up for wear. This combination maintains maximum performance efficiency throughout the life of the unit. (See Figure 5)

The assembly procedure for the autogap accessory is as follows:

Note The 1225 and 1525 units are 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 the straight (white) springs over

the armature bosses on the back (unsegmented) side of the armature. (See Figure 6)

Step 3 Insert the assembled drive pins

through the armature (entering from the segmented side), through the straight (white) springs, and into the armature hub or customer-supplied pulley, sprocket or hub.

Note Apply Grade "AA" Loctite

Sealant on the pin threads (SeeFigure 8).

Figure 8

Figure 6

Step 2 Compress the heavy (red) spring

against the retainer ring by sliding the detent spring towards the head of the pin. (See Figure 7)

Step 4 Tighten the pins until the shoulders of

the pins are against the face of the hub or customer-supplied part.

The straight springs must

not get caught under the

shoulders of the drive pins.

Step 5 Check to see that the armature is

completely compressed against the face of the hub or customer-supplied part.

Step 6 To get the autogap, slide the detent

spring retainers against the armature face.

Note This portion must not be

disturbed during completion of the assembly. (See Figure 9)

Figure 7

Warner Electric • 800-825-9050 P-206 • 819-0519

Figure 9

D. Mounting the Armature Assembly

1/32-inch

Armature

Magnet

E. Mounting the Brushholder

1. Slide the armature assembly and customer supplied pulley, sprocket or hub onto the shaft.

If the magnet and magnet hub assembly has been secured to the shaft first, then adjust the magnet's position to allow approximately 1/32-inch between the two faces.

Once this 1/32" gap has been set, it will be automatically maintained throughout the life of the unit. (See Figure 10)

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.

Figure 10

2. Secure the armature assembly and customer supplied pulley, sprocket and hub in this 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.

Warner Electric • 800-825-9050 P-206 • 819-0519

PC-825, PC-1000, PC-1225, PC-1525

Short

Wire

Collector

Ring

Terminal

Cap

Long

Wire

Clutch Spline Drive Armature

Installation Instructions

The illustration drawings, parts lists, and exploded views for these units can be found beginning on page 22.

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

Figure 2

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. (See Figure 1)

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 assembly has been secured to the shaft first, then adjust the magnet's position to allow approximately 1/32-inch between the two faces when the outer side of the splined adapter is flush with the pilot end of the hub.

Once this 1/32-inch gap has been set, it will be automatically maintained throughout the life of the unit. (See Figure 3)

Figure 1

2. Mount the magnet to the magnet hub using capscrews and lockwashers. (See Figure 2)

3. Secure the lead wires to the magnet terminals with screws and lockwashers.

4. Pull the rubber caps over the terminals.

Warner Electric • 800-825-9050 P-206 • 819-0519

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.

1/32-inch

Armature

Magnet

Figure 3

2. A customer may mount the clutch armature hub 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 .020 T.I.R.

3. Mount the armature hub to the customer supplied pulley, sprocket or hub, using the capscrew accessory provided. Maintain a 1/32-inch clearance between the armature adapter and the customer part after the parts have been assembled.

C. Assembling the Armature

1. The spline drive armature unit is shipped with the armature, splined armature adapter, and autogap already assembled. The splined hub and capscrew accessory are shipped as separate parts.

Follow these instructions to assemble the splined armature assembly and hub:

a. Place the armature-splined 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. (See Figure 4)

D. Mounting the Armature Assembly

1. Slide the armature assembly on to the shaft.

2. If the magnet and magnet hub assembly have been secured to the shaft first, then adjust the armature's position to allow approximately 1/32-inch between the two faces.

Once this 1/32-inch gap has been set, it will automatically be maintained throughout the life of the unit. (See Figure 3)

E. Mounting the Brushholder

Figure 4

Warner Electric • 800-825-9050 P-206 • 819-0519

PCC-825, PCC-1000, PCC-1225,

Short

Wire

Collector

Ring

Terminal

Cap

Long

Wire

Armature

Magnet

1/32-inch

PCC-1525 Clutch-Coupling Spline Drive Armature

Installation Instructions

The illustration drawings, parts lists, and exploded views for these units can be found beginning on page 30.

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

Figure 2

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. (See Figure 1)

2. Mount the magnet to the magnet hub using capscrews and lockwashers. (See Figure 2)

B. Mounting the Magnet and Magnet Hub

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. (See Figure 3)

Figure 1

3. Secure the lead wires to the magnet

Warner Electric • 800-825-9050 P-206 • 819-0519

terminals with screws and lockwashers.

4. Pull the rubber caps over the terminals.

Figure 3

4. Secure the magnet's position on the shaft by alternately tightening each setscrew with a torque wrench to 175 in. lbs. maximum 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 clutch-coupling 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.

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.

Follow these instructions to assemble the splined armature assembly and 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 4 Slide the armature-adapter

assembly up against the retainer ring.

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

Figure 4

Step 3 Turn the armature-adapter assembly

over, and insert the retainer ring in the groove. (See Figure 5)

D. Mounting the Armature and Hub

Assembly

1. Slide the complete armature and hub assembly onto the shaft until the armature face touches the magnet face. (See Figure 7)

Figure 7

Figure 5

Warner Electric • 800-825-9050 P-206 • 819-0519

2. Tighten the bushing capscrews, taking a few 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)

Figure 8

3. When the bushing is secure on the shaft, push the armature against the magnet face (See Figure 9). 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. (See Figure 3)

E. Mounting the Brushholder

Figure 9

Warner Electric • 800-825-9050 P-206 • 819-0519

Coil Data

Unit Size 825 1000 1225 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

Notes: Build-up time equals current to approximately* 90% of steady state value and flux to 90%. Decay time equals current to approximately* 10% of steady state value and flux to 10%. * Approximately because current leads or lags flux by a small amount.

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.

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

armature 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 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.

Warner Electric • 800-825-9050 P-206 • 819-0519

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 potentiometer turned up, a normal reading is 90 volts, although 85 to 95 is satisfactory. The reading should drop as the potentiometer control is adjusted counterclockwise.

24-Volt Series: Use a DC voltmeter with a range of 0-30 volts or more. A normal reading is approximately 22-26 volts.

6-Volt Series: Use a DC voltmeter of approximately 0-15 volt range. A normal reading is from 5.5 to 6.5 volts.

The above checks normally are sufficient. Further checks may be made as follows: a low range ammeter, when connected in series with one magnet lead, will normally indicate approximately .40 amperes for the 90 volt units, 1.0 ampere for the 24 volt, and 3.5 amperes for the 6 volt series. These readings are with the power on and the potentiometer control in the maximum position.

Ohmmeter checks should be made with the power off and the circuit open (to be certain, disconnect one lead to the magnet). Average resistance for the 90 volt series is 220 ohms; for the 24 volt, 20 ohms; and for the 6 volt series,

1.5 ohms. A very high or infinite resistance reading would indicate an open coil.

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-206 • 819-0519

+ 29 hidden pages

Warner Electric PCC-825, PCC-1000, PCC-1225, PCC-1525 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual