Global Series Clutches User Manual
Contents
1. This step is made easier by supporting the clutch on the opposite end of the rotor shaft 25 Manually rotate the rotor shaft to insure smooth operation of the rotating parts 26 Place the clutch on a clean piece of paper Support the clutch at 45 so that the cross drilled holes are facing up Fill the clutch with all of the Magnetic Powder supplied in the repair kit While filling slowly rotate the rotor to evenly distribute the Magnetic Powder NOTE Collect any Magnetic Powder spilled on the clean paper and pour it into the clutch 27 Install the Powder Fill Screw and washer for GCA GCAM GCB amp GCBM only into the Right Stator 28 Install the collar and set screws on the rotor shaft 29 Hold the complete clutch assembly at a 45 angle and rotate the rotor to distribute the Magnetic Powder my aD cB GUIDING INSPECTION TENSION CONTROL SLITTING WINDING MAXCESS INTERNATIONAL COMPANIES2. 1 10 on a bench with the cross drilled holes facing up Wrap a 6 x 6 152mm x 152mm piece of stiff paper thin plastic or shim stock around the rotor shaft forming a sleeve This will allow the Powder Seal to slide over the end of the rotor shaft and the External Snap Ring groove 12 Slide the Right Stator and Powder Seal over the thin sleeve until it bottoms on the Left Stator Assembly Pull the sleeve off the end of the rotor shaft NOTE The Powder Seal lip must face the rotor when installing the Right Stator Assembly For Models GCB GCBM GCC GCCM GCD GCDM for Model Numbers GCA GCAM proceed to step 14 13 Install the three stator screws loosely 14 Press the other Bearing onto the end of the rotor shaft until it seats against the Internal Snap Ring of the Right Stator NOTE The seal side of the Bearing must face the inside of the clutch For Models GCB GCBM GCC GCCM GCD GCDM for GCA GCAM proceed to step 16 15 Tighten the stator screws evenly until the Left and Right Stators are clamped together 16 Apply 2 or 3 drops of Wicking Loctite to the inner and outer race of both Bearings Wait ten seconds and wipe off the excess Loctite For Models GCB GCBM GCC GCCM GCD GCDM for GCA GCAM proceed to step 18 17 Install the other External Snap Ring on the rotor shaft against the Bearing This step is made easier by supporting the clutch on the opposite end of the rotor shaft NOTE Insure that the right bearing
3. a 222 W Memorial Road Oklahoma City OK 73126 0508 che 1 A XB international Phone 1 800 624 7697 Fax 405 755 8425 Compan ee www magpowr com E mail magpowr magpowr com INSTRUCTION MANUAL GLOBAL SERIES CLUTCH Model GCA GCAM GCB GCBM GCC GCCM GCD GCDM CAUTION This product contains rotating parts which could cause injury at time of installation Appropriate protective guards should be installed by the user according to his use of this product All of the information herein is the exclusive proprietary property of Maxcess International and is disclosed with the understanding that it will be retained in confidence and will neither be duplicated nor copied in whole or in part nor be used for any purpose other than for which disclosed Copyright 2004 all rights reserved Periodically there will be updates to this manual The latest version is available at www magpowr com or by calling 1 800 MAGPOWR 624 7697 THEORY OF OPERATION The clutch construction consists of two stators a rotor a coil assembly a slip ring magnetic powder and two bearings The bearings support and align the rotor within the stators and allow the rotor to rotate within the clutch assembly The stator is also allowed to rotate via the slip rings The magnetic powder occupies the space between the stator and the rotor and represents a key element in the operation of the clutch The right stator is connected to the driving input member The rot
4. he end of the rotor shaft NOTE The seal lip must face the rotor when installing the stator 5 Press one bearing onto the end of the rotor shaft until it seats against the internal snap ring of the Left Stator NOTE The seal side of the Bearing must face the inside of the clutch 6 Install the Eternal Snap Ring on the rotor shaft 7 Turn this assembly over 8 Install the left side Coil Gasket For Models GCA GCAM GCB and GCBM Install the Coil gasket into the slot in the Left Stator Insure that the Coil Gasket is evenly seated all the way around the stator slot For Models GCC GCCM GCD and GCDM Install the Coil Gasket into the slot in the coil bobbin Insure that the Coil Gasket is evenly seated all the way around the bobbin slot 9 Bend the coil lead wires perpendicular to the coil surface Feed the lead wires through the holes in the Left Stator frame until the Coil seats against the left stator Bend the lead wires against the Left Stator to hold the Coil in place for further assembly 10 Install the Right Side Coil Gasket For Models GCA GCAM GCB and GCBM Install the Coil Gasket into the slot in the Right Stator Insure that the Coil Gasket is evenly seated all the way around the stator slot For Models GCC GCCM GCD and GCDM Install the Coil Gasket into the slot in the coil bobbin Insure that the Coil Gasket is evenly seated all the way around the bobbin slot 11 Support the Left Stator assembly Steps
5. is seated against the Internal Snap Ring before attempting to install the External Snap Ring 18 Insure that the Left Stator frame side of the clutch is facing up and the cross drilled shaft side is down Rotate the assembly such that the coil lead wires are at three and nine o clock One of the tapped holes should be facing twelve o clock 19 Bend a loop in the stripped end of the lead wires to fit under the slip ring screws 20 Hold the molded Slip Ring so that the back side is facing the lead wires Attach the lead wire at nine o clockto the inner tapped hole aligned with the through hole and counterbore with the screw Attach the other lead wire to the outer tapped hole with the other screw NOTE The wires must be attached so that when the Slip Ring is rotated 90 counterclockwise the lead wires point in the direction of rotation This will prevent bulging and kinking when the slip ring is attached to the stator housing 21 Place the three bushings in the matching counterbores of the Left Stator frame 22 Rotate the Slip Ring 90 counterclockwise and align with the three bushings Place the Slip Ring over the bushings and make sure that the lead wires are not pinched 23 Insert the three screws through the Slip Ring and evenly tighten to 20 Ib in NOTE On Model GCA these screws also hold the stator frames together NOTE For Models GCA GCAM only 24 Install the other External Snap Ring on the rotor shaft against the Bearing
6. ng on the rotor shaft with a soft mallet from the Left Stator side 9 Remove the Powder Seals from the stators by prying around the inner lip with a screwdriver 10 Remove the Internal Snap Rings from both stators 11 Press the Bearing out of each stator 12 Remove the Powder Fill Screw and washer fir GCA GCAM GCB and GCBM only from the Right Stator NOTE Discard all bearings powder seals gaskets and magnetic powder These parts must be replaced and are included in the repair kit REASSEMBLY IMPORTANT Reassembly of the clutch must be performed in a clean dry area The clutch components must be cleaned with solvent and must be dry and totally free of grease and oil Grease or oil on the clutch parts will cause failure when the unit is rebuilt CAUTION Do not immerse the Coil in solvent 1 Install the Internal Snap Rings in the stators 2 Press the new Powder Seals into the Left and Right Stators The Powder Seals will bottom on the Internal Snap Rings NOTE The seal lip must face toward the inside of the clutch 3 Support the rotor on a bench with the cross drilled holes facing down Wrap a 6 x 6 152mm x 152mm piece of stiff paper thin plastic or shim stock around the rotor shaft forming a sleeve This will allow the Powder Seal to slide over the end of the rotor shaft and the External Snap Ring groove 4 Slide the Left Stator and Powder Seal over the thin sleeve until it bottoms on the rotor Pull the sleeve off t
7. or is connected to a rotating machine shaft The magnetic powder functions as the adjustable bond or link between the stators and the rotor and is the medium for the transmission of torque An electric current in the coil creates a magnetic flux field which passes through the stator magnetic powder and the rotor The flux aligns the powder particles forming a bond or link between the stators and the rotor The strength of the bonding action torque is proportional to the amount of current in the coil 4 2 5 12 PARTS LIST 13 WY i 1 Rotor Assembly 7 Powder Seals _ fanny P 2 Coil 8 Internal Snap Rings J 4 Pate 11 3 Collar 9 External Snap Rings Ne ry 4 Left Stator 10 Magnetic Powder Wy WY LLL i 5 Right Stator 11 Powder Fill Screw and 1 haze h 3 6 Bearings washer for GCA GCAM FO A POS GCB amp GCBM only 9 7 9 12 Coil Gaskets 13 Slip Ring Assembly MECHANICAL INSTALLATION 1 The rotor shaft centerline must be mounted within 30 of the horizontal plane 2 Prior to installation manually check the rotation of the rotor and observe that it is smooth and free of binding or scraping 3 Mount the clutch on the shaft and tighten the two set screws Attach a drive mechanism to the right stator via the mounting rabbet and bolt pattern 5 Position the brush block assembly so that the brushes are centered on the slip rings There should be a 06 in 1 5 mm to 125 in 3 2 mm gap between the slip ring s
8. r charge and the appropriate bearings seals and snap rings which are generally needed to rebuild the unit NOTE When ordering parts not contained in the kit provide the model number serial number and parts list item number TROUBLESHOOTING PROBLEM POSSIBLE CAUSE ACTION Power supply voltage output low Replace or repair control Magnetic powder has been worn excessively Overhaul clutch using repair kit Insufficient Torque Load operates in an intermittent manner with proper voltage Coil is intermittently open Replace coil Clutch is noisy and has vibration DISASSEMBLY Refer to Figure 1 1 Remove the set screws and Collar from the rotor shaft 2 Remove the External Snap Rings from both sides of the rotor shaft 3 Remove the three screws which hold the Slip Ring to the Left Stator 4 Remove the two screws which hold the lead wires to the back of the Slip Ring Straighten the ends of the lead wires 5 Remove the three screws which hold the Left and Right Stators together For model numbers GCA and GCAM these three screws were removed in step 3 6 Separate the stator frames by tapping on the end of the rotor with a soft mallet Tap on the Right Stator side first The rotor will remain attached to the Left Stator CAUTION Do not attempt to pry the left and right stators apart with a screwdriver or wedge 7 Remove the Coil and the Coil Gaskets from the stators 8 Remove the rotor from the Left Stator by tappi
9. urface and the brush block housing R 850A187 1 10 04 Rev C ELECTRICAL INSTALLATION Connect the control output wires to the brush block assembly per the Brush Block Instruction Manual Note The clutch coil system has been changed from Class A to Class F Refer to the nameplate on your unit to determine which insulation class you have If you have Class F insulation the nameplate will denote Class F If you have Class A there will be no notation on the nameplate MAXIMUM CURRENT ADC Supply Voltage vdc 0 24 0 90 Model Class A Class F Class A Class F GCA GCAM 0 94 1 28 0 25 0 28 GCB GCBM 1 06 1 70 0 28 0 37 GCC GCCM 1 56 2 06 0 42 0 55 GCD GCDM 2 03 2 68 0 54 0 69 ENVIRONMENTAL SPECIFICATIONS Temperature Range Operating Storage Relative Humidity Pollution Degree Altitude 0 C to 40 C 30 C to 80 C 5 to 80 2 IEC664 1 0 2000 meters MAINTENANCE Due to its small number of moving components and its basic design maintenance of the brake is generally necessary only after extended service When a problem appears in the system ensure that all couplings belts etc and the control device are functioning properly Use the Troubleshooting guide below to determine the cause of the problem The clutches can be rebuilt with a repair kit which puts it into as new condition A repair kit includes a new powde
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