ERD Series Electrically Released Brakes

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Scot Hudson
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CALLNOW 00-9-99 The Inside Story Continuous duty coil is epoxy-sealed; windings have Class F insulation. Lead wires have standard Class B insulation rating on sizes 00 0.

1 CALLNOW The Inside Story Continuous duty coil is epoxy-sealed; windings have Class F insulation. Lead wires have standard Class B insulation rating on sizes Sizes have Class F rating. Central Torque Adjustment (VAR 0) allows braking torque ad just ment down to 0% of nominal rating; ideal for controlling stopping dis tanc es. Compression Springs are used to provide balanced armature plate loading. has double friction surfaces for increased torque in small package size. Splined Center Hub is steel for wear resistance and avail able in a variety of bore sizes and keyways. Friction Flange can easily be modified to suit unique bolt pat terns. In special cases, brakes may be mounted directly to the motor without the need for the flange. ERD Series brakes are de signed to safely keep the load in position in the event of a power or motor failure, whether intentional or ac ci den tal. By applying voltage to the ERD, an elec tro mag net ic field is cre at ed which causes the armature plate to pull-in against helical com pres sion springs, thus re leas ing the brake. When power is re moved, the springs force the armature to compress the friction carrier against the mounting flange, thus stopping and holding the load. Fully dynamic friction ma te ri al on the carrier allows for re - peat ed braking cycles from full motor speed with no torque fade. An optional manual release allows the operator to safely move the load even when no power is available. Brakes are available in eight different sizes ranging from. inches to 9.9 inches in diameter with torque capacities from to 0 lb.ft. Features/Benefits Dynamic friction material can stop loads from motor speeds up to 00 RPM. Few moving parts means quiet operation. Lead and asbestos free, dy nam ic friction material is suited for high cycle rates. Variety of voltages available. Simple DC control (or AC with available rectifiers). Low power requirements for energy savings. Air Gap is factory pre-set and easy to adjust during field main te nance. Bi-directional stopping capability. Epoxy encapsulated coil for uniform heat transfer. Corrosion resistant. Low inertia rotating parts. Splined hub for quiet dependable operation. Metric and inch standard bore sizes. P--WE / Warner Electric 00-- CALLNOW

CALLNOW 00-9-99 ERD Series Electrically Released Bakes Applications As a fail-safe, power-off brake, the ERD family is

Positioning Scooters Floor Sweepers/Cleaners Motor Brakes Overhead Doors Hoist/Winch Fork Lift Hoist/Winch The ERD with

the proper torque level on each pro duc tion hoist.

event of power failure. Overhead Door The ERD can be used in con junc tion with a photo eye.

The brake then applies and holds the door in position.

2 CALLNOW ERD Series Electrically Released Bakes Applications As a fail-safe, power-off brake, the ERD family is ideally suited for such load-stopping and holding ap pli ca tions as: Conveyors Machine Tools Robotics Medical X-Y Positioning Scooters Floor Sweepers/Cleaners Motor Brakes Overhead Doors Hoist/Winch Fork Lift Hoist/Winch The ERD with central torque ad just ment can be used to con sis tent ly stop the rated load within a fixed dis tance by di al ing-in the proper torque level on each pro duc tion hoist. The ad - di tion of a man u al re lease al lows the load to be grad u al ly and safe ly low ered to the ground in the event of power failure. Overhead Door The ERD can be used in con junc tion with a photo eye. In this application, whenever the light beam is broken, voltage to the brake is removed. The brake then applies and holds the door in position. Further, the manual release feature allows the operator to open/close the door in the event of a power failure. Fork Lift ERD s are used as safety and/or park ing brakes on electric fork trucks to hold the vehicle on inclines etc. without the need for manual brake linkage or expensive hydraulic brakes. Warner Electric 00-- P--WE / CALLNOW

3 CALLNOW Selection Procedure Proper fail-safe brake se lec tion involves determining, in order:. Static Holding Torque The ERD brake nominal holding torque should exceed the torque from the load by a minimum safety factor of.0.. Dynamic Torque This is determined from the equation: Dynamic Torque Torque in lb.ft ERD-0 ERD-00 0 P K T = N where: T = Dynamic Torque, ft.lb. N = Motor Speed, RPM P = Motor Horsepower K = Momentary Peak Torque Factor (Typically.) Once the dynamic torque has been cal cu lat ed, check the dynamic torque curves (to the right) at the required operating speed to determine the suitable brake.. Energy Capacity (Heat Dissipation) Sizing of the ERD by energy capacity is a function of the cycling frequency (cycles per hour) and the single cycle energy put into the brake as de ter mined from the equation: ( ) N E =. WR 00 where: E = Single Cycle Energy, ft.lb. WR = Load Inertia, lb.ft N=Speed, RPM Applying the energy per cycle with the cycle rate to the energy curve, the brake selection is verified. Torque in lb.ft. Energy Capacity (Heat Dissipation) Joules/Cycle ERD RPM RPM 00,000 0,000,000 ERD-00 ERD- ERD-0 ERD-0 ERD ,000 ERD SIZE Cycles/Hr Note: To convert Joules/min. to ft.lbs./min, multiply times. P--WE / Warner Electric 00-- CALLNOW

4 CALLNOW ERD Series Electrically Released Bakes Specifications Units ERD ERD 0 ERD 0 ERD ERD 0 ERD 00 ERD 0 ERD 00 Holding Torque in.lb ft.lb. Maximum Speed RPM Rotating Inertia S lb.in M lb.in Current Draw Amps VDC VDC* VDC* Resistance at Ambient Temperature VDC Ohms VDC* VDC* 0 Weight lbs 0 * The controls designed on pages 0 and provide output voltages to operate these brakes. Ordering Procedure Specify:. Size: upon sizing criteria, select a size., 0, 0,, 0, 00, 0, or 00. Variation: 0 No torque adjustment With central torque adjusting ring. : Metallic carrier is standard. Thermoplastic carrier is available on sizes & 0. High torque carrier available on sizes 00 through 00.. : Manual Release. Voltage: DC is standard. 9, 0. (90)* & 0/* DC are modifications.. Bore Size: Pilot bored hubs available in all sizes. See table for US-English and Metric bore sizes available by ERD size. Special bores available on request.. Detection Kit Micro Switch For Service Manual, request catalog P-9. This option not retrofittable. Requires a piece minimum order for sizes 00 thru 0. Typical Completely Assembled Brake with options installed. Friction Flange & Mounting Screws: Thick Flange is standard Requires Short Screws. Intermediate Flange available up to Size Requires Long Screws. No Mounting Flange is an option Requires Long Screws. Caution: These units are designed for dry operation. The brake must be free from oil and grease. Exceeding the maximum rotation speed listed in the catalog will invalidate the guarantee. * Coil voltages can vary slightly depending on unit size. Warner Electric 00-- P--WE / CALLNOW

5 CALLNOW Product Configuration Friction Flange (Thick or Intermediate plate) and Screw Kit Rotor/ (M-Metallic or S-Thermoplastic) Hub (See table for Bore Sizes) Magnet/Body Assembly (VAR 00 or VAR 0) (Optional) ** (Optional) E R D Size: 00, 00, 00, 0, 00, 00, 0, 00 Variation: 0 VAR 00 No torque adjustment VAR 0 With central torque adjusting ring : M Metallic carrier is standard S Thermoplastic carrier is available on sizes & 0 H High torque carrier available on sizes 00 through 00 : 0 None ** and Cable Std. Bore Size: See Bore Size Table Voltage: DC is standard 9, 0. (90)* & 0/* DC are modifications Detection kit: 0 None With Friction Flange and Screw Kits: 0 No Friction Flange Intermediate Friction Flange Thick Friction Flange No Friction Flange Intermediate Friction Flange Thick Friction Flange 0 * Coil voltages can vary slightly depending on unit size. ** Manual release available on variation 0 only. P--WE / Warner Electric 00-- CALLNOW

6 CALLNOW ERD Series Electrically Released Bakes Mounting (by customer) Magnet Assembly Variations No Friction Flange Requires long screw kit Intermediate Friction Flange Requires long screw kit Available on sizes 00 thru 0 only. Thick Friction Flange (Standard) Requires short screw kit VAR 0 Torque re duc tion up to 0% by loosening one nut. Available in all sizes. Central nut has several Detents per turn allowing accurate torque adjustment. The brake is factory set at the minimum torque (0% of max. torque). VAR 00 No torque ad just ment possible Available in all sizes. No hand release option available. Rotor/ Manual Release (Optional) Available in two styles M Metallic (Standard) S Thermoplastic (Low inertia) Sizes 00 & 00 only Large thermoplastic bore hubs (Available in sizes 00 and 00 only) Large bore metallic disc (Available in sizes 00 thru 0) High torque metallic discs (Available in sizes 00 thru 00. Requires lower speed of rotation.) Hub Automatically returns to neutral position when released, thereby restoring holding torque to the brake. Designed to be retrofitted, except to VAR 00. See Table for hub, bore and keyway size availability by ERD size. (Optional) Available in all sizes. Warner Electric 00-- P--WE / CALLNOW

7 CALLNOW Brakes VAR 0 Dimensions All dimensions are nominal, unless otherwise noted. ERD D L M Size A Max. E K Max / () () () () (0) () (0) () (90) () (.) (0) () () () (.) (.) (0) () () () (.) () () () () () () (.) (0) () () (0) () (.) (0) () (0) (9) () (9) () () () (0) (9) () (0) VAR 00 ERD U Size N S +/-0.00 W () (9) (0.) (.) () () (0.) (.) () () (0.) (0.) () (0) (0.) (.) () () (0.) (.) () () (0.) (.) (.) (0) (0.) (.) () () (0.) (.). Concentricity of field mounting pilot diameter with rotor mounting shaft within.00 T.I.R.. Squareness of field mounting face with rotor mounting shaft within.00 T.I.R. measured at field mounting bolt circle.. Rotor mounting shaft concentric with armature center of rotation within.00 T.I.R.. Armature hub pilot diameter to be concentric with armature center of rotation within.00 T.I.R.. If customer does not use a friction flange, the mating surface must be square to their mounting shaft within.00" and flat within.00". P--WE / Warner Electric 00-- CALLNOW

8 CALLNOW ERD Series Electrically Released Bakes Friction Plates Thick friction plate Intermediate friction plate Dimensions All dimensions are nominal, unless otherwise noted. f k e Bolt Bolt ERD Bolt Clearance Clearance Size B C E Pattern Holes F G H h Holes J P O. 0.. xm x0.... x0. x () (0) () (.) () () (0) (.) () () (.) xm x0.... x0. x (00) (0) (90) (.) () (0) () (.) (0) () (.) xm x x0.0 x () (0) () (.) (0) (.) () (.) () () (.) xm x x0.0 x () () () (.) (0) (.) () (.) () () (.) xm x0..9 x0. x (0) () () (.) () (.) () () () xm x0..0 x0. x () () (0) (.) () (.) () () () xm x0..9 x0. x () () (9) (.) (00) (.) () () () xm0 x0.. x0.0 x (0) (90) (0) (0.) (0) (0.) () () () The thick mounting flange provides the proper material and mounting tolerances for the brake. The intermediate mounting flange provides the proper material in applications where flatness, squareness and concentricity requirements are met on the machine already. Manual Release AA BB EE DD CC Release Angle ERD Size AA BB CC DD EE Release Angle (9) () () () () (0) () () (0) (0) (9) () () () () (9) () () () () (9 ) (0) (0) () () (0) (0) () (9) () (0) (0) () (9) () () () () () (.) Warner Electric 00-- P--WE / CALLNOW

9 CALLNOW How To Order Hub Bore and Keyway Sizes U.S. English Bore Keyway Available Bores in. Width Depth / / / Std. / / / * Std. Std. / / / *(Max.) * Std. Std. Std. Std. / / / *(Max.) Std. Std. / / / Std.(Max.) Std. Std. / / *(Max.) Std. Std. Std. Std. -/ / / *(- / Max.) Std. Std. Std. -/ / / Std. Std. Metric Bore Keyway Available Bores (mm) Width Depth P.B. 0 Std. P.B. P.B. Std. Std. Std.. * Std. Std. P.B. P.B.. * Std. Std. P.B. * Std. Std. 0 * (0Max.) Std. Std. P.B. Std. Std. * Std.. Std. Std. Std. P.B.. * (Max.) * 0. * (Max.) Std. Std. 0 (Max.) Std. Std. Std. 0 Max. Std. Std.. Std. Std. 0. Max. ( Max.) P.B. = Pilot Bore, * = Large Bore Hub, which requires use of a large bore friction disc. Design Considerations/Limitations. Check the airgap periodically and reset as required per instructions found on page of the service manual P-9. Inspection interval(s) depend on the frequency of brake application.. Check friction material thickness periodically per dimension N (see page ) and replace when below the minimum shown below. Inches (mm) millimeters ERD Size Min Thickness (0.) (0.) (0.) (0.) (0.) (0.) (0.) (0.) P--WE / Warner Electric CALLNOW

10 CALLNOW ERD Control Units Dimensions."."." Ø."." CBC 0- CBC 0-.0" AC DC Specifications CBC-- CBC-- ACG0AP ACG0AP Frequency (Hz) 0/0 0/0 Input Voltage 0 VAC 0 0 Output Voltage 0. VDC 0. 0 Max. Current (A) CBC--: Supply unit with single wave rectification for low current. CBC--: Supply unit with dual wave rectification for low current. Dimensions.9" ±.0" SQ. OCTAL SOCKET P/N: " (.)." ±.0"." ±.0"." (9.9).9" (0.) DIN RAIL MOUNT SOCKET P/N: Specifications STD. OCTAL KEYED PLUG CBC-0-." (9.9).0" () CBC-0- Part No Input Voltage 0 VAC, 0/0 Hz 0/0 VAC, 0/0 Hz Output Voltage 90 VDC,. A max. 90 VDC,. A max. Circuit Protection Fused. Amp, 0 V fast-blo Fused. Amp, 0 V fast-blo Ambient Temperature - to F (- to C) Max. Cycle Rate Limited by the clutch or brake, variable with application Switching Single pole, double throw Minimum contact rating: 0 Amp, VDC resistive or 0 Amp, 0 VAC inductive Status Indicator Red LED indicates brake is energized, Green LED indicates clutch is energized Mounting Two versions of octal socket are available: foot mount DIN rail mount All dimensions nominal unless otherwise specified.." () 0 Warner Electric 00-- P--WE / CALLNOW

11 CALLNOW ERD Control Units Dimensions.0".90".0".0".".".0" Specifications CBC-0-90 CBC-0- Part No Input Voltage 0/0/0/0/0 VAC 0/0/0/0/0 VAC Output Voltage 90 VDC VDC Output Current Amp/Channel Amps/Channel. Amps Total Amps Total Auxiliary Supply VDC 0 ma VDC 0 ma Circuit Protection Fused. Amp Fused Amp Ambient Temperature + to F (0 to 0 C) + to F (0 to 0 C) Status Indicators Red LED indicates channel is energized. Red LED indicates channel is energized. Adjustments Jumper for single or dual operation. Jumper for single or dual operation. Inputs Optically isolated, 0-0 VDC, -9 ma for Optically isolated, 0-0 VDC, -9 ma Channel, Channel and Channel for Channel, Channel and Channel override (E-stop). override (E-stop). P--WE / Warner Electric 00-- CALLNOW

12 CALLNOW ERD00 Variation 00 VDC Variation VDC Variation 00 0 VDC Variation 0 VDC Variation 0 0. VDC Variation 0 0 VDC Standard Synthetic Disc Large Bore Synthetic Disc Standard Metallic Disc Large Bore Metallic Disc Intermediate Flange Thick Flange Short Screw Long Screw Hub Bore size Hub Pilot Bore MM Hub Bored W/Keyway MM Hub Bored W/Keyway 0MM Hub Bored W/O Keyway 0MM Hub Bored W/Keyway /" Large Bore Hub W/Keyway /" Large Bore Hub W/Keyway - / Detection Kit ERD00 Variation-00 VDC Variation VDC Variation-00 0 VDC Variation 0 VDC Variation 0 0. VDC Variation 0 0 VDC Standard Synthetic Disc Large Bore Synthetic Disc Standard Metallic Disc Large Bore Metallic Disc Intermediate Flange Thick Flange Short Screw Long Screw Hub Bore size Pilot Bore 0MM Hub Bored W/Keyway /" Large Bore Hub W/Keyway /" Large Bore Hub W/Keyway - / Detection Kit GUE00A0P GUE00A0P GUE00A0P GUE00AP GUE00AP GUE00AP AUE00BP AUE00BP AUE00B9P AUE00BP AUE00KP AUE00CP AUE00C09P AUE00C0P AUE00KP AUE00KP AUE00C00P AUE00C00P AUE00C00P AUE00C00P AUE00C00P9 AUE00C0P AUE00C0P VNST GUE00A0P GUE00A0P GUE00A0P GUE00AP GUE00AP GUE00AP AUE00BP AUE00BP AUE00B9P AUE00BP AUE00KP AUE00CP AUE00CP AUE00C0P AUE00KP AUE00KP AUE00C00P AUE00C00P consult factory consult factory VNST ERD00 Variation 00 VDC Variation VDC Variation 00 0 VDC Variation 0 VDC Variation 0 0. VDC Variation 0 0 VDC Standard Synthetic Disc Large Bore Synthetic Disc Standard Metallic Disc Large Bore Metallic Disc Intermediate Flange Thick Flange Short Screw Long Screw Hub Bore size Pilot Bore 0MM Hub Bored W/Keyway MM Hub Bored W/Keyway 0MM Hub Bored W/Keyway MM Hub Bored W/Keyway MM Hub Bored W/Keyway /" Hub Bored W/Keyway /" Hub Bored W/Keyway /" Hub Bored W/Keyway /" Large Bore Hub W/Keyway - Detection Kit GUE00A0P GUE00A0P GUE00A0P GUE00AP GUE00AP GUE00AP N/A N/A AUE00B9P AUE00BP AUE00KP AUE00CP AUE00C0P AUE00C0P AUE00KP AUE00KP AUE00C00P AUE00C00P AUE00C00P AUE00C00P AUE00C00P AUE00C00P AUE00C00P AUE00C00P AUE00C00P consult factory VNST ERD0 Variation-00 VDC GUE0A0P Variation VDC GUE0A0P Variation-00 0 VDC GUE0A0P Variation 0 VDC GUE0AP Variation 0 0. VDC GUE0AP Variation 0 0 VDC GUE0AP Standard Synthetic Disc N/A Large Bore Synthetic Disc N/A Standard Metallic Disc AUE0BP Large Bore Metallic Disc AUE0BP-NM AUE0KP -00 Intermediate Flange AUE0CP Thick Flange AUE0C0P Short Screw AUE0KP Long Screw AUE0KP Hub Bore size Pilot Bore Hub MM AUE0C00P Hub Bored W/Keyway 0MM AUE0C00P Warner Electric 00-- P--WE / CALLNOW

13 CALLNOW Hub Bored W/Keyway MM AUE0C00P Hub Bored W/Keyway MM AUE0C00P Hub Bored W/Keyway /" AUE0C0P Hub Bored W/Keyway /" AUE0C0P Hub Bored W/Keyway /" AUE0C0P Hub Bored W/Keyway " AUE0C0P Large Bore Hub W/Keyway - -/ consult factory Detection Kit VNST Rectifiers Half Wave MCS-- ACG0AP Full Wave MCS-- ACG0AP ERD00 Variation 00 VDC Variation VDC Variation 00 0 VDC Variation 0 VDC Variation 0 0. VDC Variation 0 0 VDC Standard Metallic (M) Metallic (HT) Thick Friction Plate Short Screw (for Thick Friction Plate) Long Screw (for No Friction Plate) Hub Bore Size Pilot Bore Hub MM Hub Bored W/Keyway MM Hub Bored W/Keyway 0MM Hub Bored W/Keyway /" Hub Bored W/Keyway " Detection Kit ERD00 Variation 00 VDC Variation VDC Variation 00 0 VDC Variation 0 VDC Variation 0 0. VDC Variation 0 0 VDC Standard Metallic (M) Metallic (HT) Thick Friction Plate Short Screw (for Thick Friction Plate) Long Screw (for No Friction Plate) Hub Bore Size Pilot Bore Hub MM Hub Bored W/Keyway MM Hub Bored W/Keyway 0MM BT090 BT09 BT09 BT09 BT09 BT09 BT09 BT09 BT09 BT099 BT09 BT090 BT09 BT09 BT09 BT09 BT09 BT09 BT0909 BT09 BT099 BT090 BT09 BT09 BT09 BT099 BT09 BT09 BT090 BT09 BT09 BT09 BT09 BT099 BT090 Hub Bored W/Keyway MM Hub Bored W/Keyway /" Hub Bored W/Keyway " Hub Bored W/Keyway -/" Detection Kit ERD0 Variation 00 VDC Variation VDC Variation 00 0 VDC Variation 0 VDC Variation 0 0. VDC Variation 0 0 VDC Standard Metallic (M) Metallic (HT) Thick Friction Plate Short Screw (for Thick Friction Plate) Long Screw (for No Friction Plate) Hub Bore Size Pilot Bore Hub 0MM Hub Bored W/Keyway MM Hub Bored W/Keyway 0MM Hub Bored W/Keyway MM Hub Bored W/Keyway /" Hub Bored W/Keyway -/" Hub Bored W/Keyway -/" Detection Kit ERD00 Variation 00 VDC Variation VDC Variation 00 0 VDC Variation 0 VDC Variation 0 0. VDC Variation 0 0 VDC Standard Metallic (M) Metallic (HT) Thick Friction Plate Short Screw (for Thick Friction Plate) Long Screw (for No Friction Plate) Hub Bore Size Pilot Bore Hub MM Hub Bored W/Keyway MM Hub Bored W/Keyway 0MM Hub Bored W/Keyway MM Hub Bored W/Keyway " Hub Bored W/Keyway -/" Hub Bored W/Keyway -/" Detection Kit BT09 BT09 BT09 BT000 BT0909 BT09 BT099 BT090 BT09 BT09 BT09 BT09 BT099 BT0 BT09 BT0 BT090 BT09 BT00 BT0 BT0 BT0 BT00 BT00 BT00 BT0909 BT09 BT09 BT09 BT09 BT09 BT09 BT099 BT09 BT09 BT09 BT0 BT09 BT09 BT0 BT0 BT0 BT0 BT00 BT00 BT00 BT0909 P--WE / Warner Electric 00-- CALLNOW

ERD Electrically Released Brakes

ERD Electrically Released Brakes P-229 819-0453 Installation Instructions Warner Electric s ERD series spring set, electrically released brakes are designed to hold a load when the power to the brake is