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Magnetic clutches and brakes

1. 0 100 200 300 Brake n rpm Electric TB brake characteristics TB units are assembled using various parts described below Main components of the brake are armature and magnet Additional parts are offered to provide for ease of mounting Armature hub Armature Magnet 24V Terminals Prebored B5102 541 001 38 K110 0096 K375 631 012 R TO QOS Wires Indicate bore and keyway Taperlock bushing Armature hub Armature Drive pins Magnet IM 24V Terminals Magnet OM 24V Conduit box Electric 215 mm 180 540 0394 B5301 7720719 B5301 101 001 B5311 631 000 30 R 20 Q 20 C B5311 101 001 B5311 631 000 16 K5200 101 011 B5103 541 001 47 K110 0097 K5365 631 016 R 60 Q 20 C B5103 101 002 259 mm 180 B540 0313 B5302 111 021 B5301 101 001 3x B5312 631 000 36 R 20 Q 20 C B5311 101 001 K5200 101 01 1 B5104 541 001 31 K110 0098 K5367 631 008 R 76 20 C B5103 101 002 D 316 mm 180 540 0015 B5303 111 011 B5301 101 001 4x B5313 631 000 11 R 22 0 20 C B5311 101 001 K5200 101 011 TB825 1225 TB1525 Taperlock bushing Armature hub Armature Drive pins Magnet IM 24V Terminals Magnet OM 24V Conduit box D 395 mm 180 B540 0314 B5304 111 005 04 B5
2. eie NO 0 2 0 4 0 6 0 8 1 1 2 1 4 Thickness mm CU A 0 5 1 1 5 2 25 3 3 5 Diameter mm 51 Data application form To enable us to assist you in selecting the best product type and specification to ensure reliable and accurate tension con trol please submit this APPLICATION FORM Company Contact name Address City 1 1 Country MAX ROLL DIAMETER MIN ROLL DIAMETER LINE SPEED BRAKE RATIO FIRST CASE unwind tension known TENSION FORCE ON TOTAL WEB WIDTH SECOND CASE unwind tension unknown If unknown precise type of material CURRENT VALUES USED ALUMINIUM FOIL CELLOPHANE 0 05 N cm thickness micron ACETATE 0 035 N cm thickness micron MYLAR POLYESTER 0 505 N cm thickness micron POLYETHYLENE 0 017 N cm thickness micron POLYSTIRENE 0 06 N cm thickness micron SARAN 0 008 N cm thickness micron VINYL 0 01 N cm thickness micron VALUE PER CENTIMETER WIDTH NUMBER OF MICRON MATERIAL THICKNESS TENSION FORCE BY CENTIMETER WIDTH ROLL WIDTH TOTAL FORCE ON ROLL WIDTH MAX ROLL SPEED MIN ROLL SPEED THEORIC BRAKE TORQUE SLIDDING TORQUE REQUIRED BRAKE TORQUE TOTAL HEAT DISSIPATION REQUIRED BRAKE SIZE NUMBER OF BRAKE PER ROLL REQUIRED TENSION CONTROL REGULATION 52 00 7 N cm thickness micron Tel e mail Date Business m MASS m m mn i 722 2
3. Tension Control Systems Max Lamb GmbH amp Co KG Am Bauhof 97076 W rzburg Tel 0931 2794 0 Fax 0931 274557 email ant lamb de Electric Tension Control Systems WARNER ELECTRIC offers the most complete product line dedicated to the TENSION CONTROL MARKET The long experience in the market led us to develop high performance controls able to operate in open and closed loop with brakes WARNER ELECTRIC electromagnetic brakes find an optimum use in tension control when associated with the new digital control line ABOUT THIS CATALOGUE This master catalogue groups all the solutions products that WARNER ELECTRIC offers An important part is dedicated to the solution design with particular consideration regarding the machine and the tension control installed This should help you for the right solution choice taking in consideration the results you want to achieve All the product characteristics and dimensions are included for every product Applying the appropriated Tension Control will lead you E To improve quality of the operation E To increase the production E Finally to lower your production cost CONTACT WARNER ELECTRIC FOR ANY ASSISTANCE YOU REQUIRE www warnerelectric eu com Electric Index Pages SYSTEM CONFIGURATIONS 4 System configuration 1 4 System configuration 2 4 System configuration 3 5 Open loop solutions 6 Closed loop solutions 7 TENSION CONT
4. Accurate torque control with instantaneous engagement Warner Electric Precision Tork magnetic particle clutches and brakes are unique because of the wide operating torque range avail able Torque to current is almost lin ear and can be controlled very accu rately The unique features of the magnetic particle clutches and brakes make them ideal for 3 tension control O load simulation O cycling indexing soft starts and stops Specials are our business Special Shaft Configurations Customer specified shaft configu rations for easy machine mounting and retrofitting Wash Down Environment O Stainless steel units available for extreme environments Special Torque O Maximum torque configurations to meet customer specifications Metric units 1 On request regarding quantities 34 Features and Benefits Torque independent of slip speed 1 Torque is transmitted through mag netic particle chains which are formed by an electromagnetic field The torque is independent of slip speed depending only on circuit current and is infinitely variable from disengaged to rated torque Precise engagement O Precision Tork magnetic particle clutches and brakes engage to transmit torque with speed and precision Response of the parti cles to the field is virtually instanta neous providing perfectly con trolled jerk free engagement Customer specified engagement Engagement time may be v
5. Do not oversize the load cell respect to your calculation Max admitted factor 3 recommended 1 5 Respect a minimum wrapping angle on load cell Min 240 So far as it is possible use load cell in compression with web tension effect in same direction as the weight of shaft Warner 95 gt Electric Tension brakes and clutches range Electromagnetic brakes TBM Size 10 Magnetic particle brakes on y Magnetic particle clutches Permanent magnetic brakes Permanent magnetic clutches 26 Monodisc 0 5 300 Nm 24 VDC power supply 28 31 Monodisc 10 Nm 24 VDC power supply Completely packaged 0 04 27 Nm and enclosed unit Shaft output 24 or 90 VDC power supply 34 Completely packaged 0 04 13 2 Nm and enclosed unit Both end shaft output 24 or 90 VDC power supply 34 Completely packaged 0 33 Nm and enclosed unit Shaft output Manual setting 43 Completely packaged and 0 07 Ncm 33 Nm enclosed unit Bore output Manual setting B E B B Electric Tension brake sizing Two important parameters are used in brake selecting O Max torque requirement O Max thermal power to be dissipated These two values are determined by the application see calculation example on pages 52 53 ELECTROMAGNETIC BRAKE TYPE TB SELECTION TB brake selection is based on two values Max torque need Nm on the brake Max brake rotation speed for the max torque rpm A
6. active low Set point change front face switch Main features Gain multiplier active low Three mounting possibilities Output limitation active low Software password protected ABC binary combination active low Scrolling menu program ABC inputs synchronisation active low O Multipurpose application otop integral form active low RS232 communication O Two ouput channels Digital outputs 1 Automatic sensor scaling Sensor level indication Two binary outputs O Programmable output configuration Output sensor information Other outputs 1 External set point change Power supply sensor 15 VDC 100 mA O Automatic or imposed PID correction 5 VDC 100 mA All features requested for tension control Power supply 24 VDC O Plugable memory card Voltage reference 10 VDC 10 mA 71 Service manual MC525 MCS2000 CRD 2 MEMORY CARD All setting data saved It allows a quick loading operation on new machine or on running machine to optimise O Memory for 2 different programs Plugable on line in MCS2000 ECA unit MCS2000 WIN PROGRAMME The program can modify the running setting by this software running with Windows 95 98 XP 2000 fter 23 Electric Load cells The FOOT MOUNTED LOAD CELL is the ideal solution to retrofit machines or for heavy tension measurement The foot mounted model has to be installed with a pillow block type ball bearing supporting the sensing shaft FMO1A and FMO2 are only differenciated by
7. 0 1 2 3 Unit torque settings MC4 MB4 Torque Nm Unit torque settings MC6 MB6 ast ot LEE er wt ET volt EL tt Torque C1 amp 0 Unit ings Warner gt Electric MC2 MB2 15 8 of tt tt Tt N Torque Ncm Unit torque settings MC5 MB5 II I Ir ttt pee e LLL LLL tt yA atzA TEI ty ER Torque Nm Unit torque settings MC9 MB9 Ty Torque Nm H rl 0 1 2 3 4 5 Unit torque settings D MC3 MB3 Torque Nm BE A _ _ EH EE NN HT Unit MC5 5 MB5 5 Torque Nm Unit torque settings 49 Magnetic clutches and brakes Stub shaft adapters Utilized when clutch coupling configuration is desired Comes complete with attachment hardware and drive key Stub shaft adapters should be used in conjunction with a flexible coupling Flat gt us MCA MCA MC5 MC5 5 MC5 MC5 5 MC6 Flat Flat Key 3 16 inch Key 1 4 inch Key 1 8 inch Key 3 16 inch N C iE How to Order On request units in metric size available minimum 15 pcs 1 Torque 3 Model selection 5 Example Determine the maximum torque that your application requires See the application example Energy dis
8. 1 Operator Easy to start up intervention admitted Graphic display for output O Large roll e ratio percentage value O Functions control available remote manually by operator MCS2000 POT OPTION for am Ultrasonic MCS2000 DRYV sensor MCS2000 PS Power supply 24VDC Ultrasonic sensor signal 0 10 VDC yp Amplifier MCS2000 PSDRV 0 24 VDC 0 10 VDC Brake TB 100 260 Y Amplifier MCS2000 DRV 0 24 VDC O 10 VDC Additional control signals Fast Stop Hold Brake OFF 12 Warner Electric Automatic setting by diameter reading Ultrasonic sensors Dimensions see page 7 Model SCUA 130 SCUA 140 Power supply 15 to 30 VDC max 30 mA 15 to 30 VDC max 30 mA Min distance 100 mm 400 mm Max distance 1000 mm 2400 mm Accuracy 1 mm 1 mm Protection class IP67 IP67 SCUA 130 SCUA 140 Accessory 5 m cable 5 m cable Service manual MC487 MC488 Ultrasonic Diameter Sensing MCS2000 POT 1 A simple analogue open loop torque control Power supply 24 VDC Internal consumption 150 mA QUTPUT VALUE Aiii ee 0 Fast o wn amer STOP OF O Adjustable maximum level of the output signal relatively to the ultrasonic input level Graphic display of the output level full screen equal 10 VDC O FAST STOP HOLD and BRAKE OFF can be activated either through the front switches or through the terminal bloc WEB TENS
9. Warner e Electric secondes secondes secondes secondes Nm secondes metres Newtons Newtons Nm secondes metres secondes metres O if MB not defined O if MB not defined O if t3 not defined 53 Zentrale Max Lamb GmbH amp Co KG Am Bauhof 97076 W rzburg Telefon 09 31 27 94 0 Telefax 09 31 27 45 57 eMail ant lamb de Internet www lamb de Niederlassungen ASCHAFFENBURG Schwalbenrainweg 30 a 63741 Aschaffenburg Telefon 0 60 21 34 88 0 Telefax O 60 21 34 88 32 eMail ab lamb de NURNBERG Dieselstra e 18 90765 F rth Telefon 09 11 76 67 09 0 Telefax 09 11 76 67 09 22 eMail no lamb de SCHWEINFURT Carl Zeiss Stra e 20 97424 Schweinfurt Telefon 0 97 21 76 59 0 Telefax 0 97 21 6 99 93 eMail sw lamb de STUTTGART Heerweg 15 A 73770 Denkendorf Telefon 07 11 93 44 83 0 Telefax 07 11 93 44 83 22 eMail st lamb de LA WA AbWiBr 06 04
10. 15 1 377 1 000 1 001 Shallow key 0 250 4 1 4 20 on 5 875 BC 3 3 3 3 4 6 32 on 1 350 BC 8 32 on 2000 BC 6 32 on 1 350 BC 6 32 on 1 350 BC 10 32 on 4 228 BC 10 32 on 4 228 BC 1 4 20 on 4 812 BC 1 4 20 on 4 812 BC m m m m m JT Metric shafts or bores on request 4 NN NO Am mM Rated Resistance Rated Response Response Inertia of Max heat voltage current zero with output shaft dissipation force force W W 1592 058 0 0037 1 1800 0 45 1501 0 06 2 1000 1 36 10 10 A 0 0 0 0 0 0 0 044 0 22 90 E EE 0 044 1 69 90 IUe EHE 0 11 19 90 613 0 147 1000 90 90 120 0 22 13 5 0 22 135 92 80 35 33 0 742 140 1000 5 45 415 0 19 140 1000 5 45 MPB240 0 44 19 0 44 971 246 ow ose m e 0 366 150 200 1000 9 1 Minimum speed 30 RPM Warner 41 gt Electric Current regulator power supply for powder brakes The TCS250 card was designed especially for controling powder brakes and for increasing their yield In fact this per mits complete elimination of residual magnetism in the pow der and therefore it is possible to work in low torque ranges without limits The components used are professional type and this assures absolute reliability over time Its limited size facili tates wall mounting Connection is easy and is done via 10 pole connector fastened to the terminals with screws Specifi
11. 5 78 RPM Heat Mp 0 103 torque slip dissipation 0 103 5 5 78 44 46 watts oelect a brake that exceeds the maximum torque and thermal energy requirements from Quick Selection Chart MPB70 Fullrole Speed x D _ 90 0 23 125 RPM Slip Input speed Full roll 500 125 375 RPM Thermal 0 103 Torque slip 0 103 2 53 375 97 72 watts oelect a clutch that exceeds the maximum torque and thermal energy requirements from the Quick Selection Chart MPC120 To maximize tension control and minimize heat generated select a drive system that will result in an actual input speed as close to but not less than 30 RPM greater than the core RPM In this example 358 30 388 would be ideal but 500 RPM was more readily available 39 Magnetic particle clutches LF 9 K Flat square Precision Tork Model MPC 15 Torque 15 Ib in WARNER ELECTRIC m Dimensions and specifications MPC2 93 09 1905 1902 9703 0 2497 0 2492 MPC15 75 18 2857 2855 122 17 0 4997 0 4992 MPC70 113 79 4127 4125 166 37 0 7497 0 7492 MPC120 13335 41 27 41 25 178 31 0 7497 0 7492 Metric shafts on request Drag Rated Rated Resistance Response Response Inertia of Max heat torque torque voltage current zero with output shaft dissipation force force V Q A ms ms 0 044 0 2
12. 60 13 watts Bobbin Coil winding Constant tension provided by hysteresis unit Film tensioning Constant tensioning supplied by hysteresis unit Select MC5 Model Overload protection Torque limiting Soft start Motor horsepower method p Information required Power motor 0 37 kw Speed motor 1750 RPM Conveyor How to size Cluteh Torque 9550 kw N 9550 0 37 1750 2 Nm Coupling Motor Select an MC5 Model from the Kuren a Material handling specification chart yS nn Be Provides Hysteresis clutch can provide overload overload protection protection and soft start ia Electric Magnetic clutches and brakes Specifications CLUTCHES Torque Watts 0 071 0 71 Nem 0 071 1 58 Nom 0 033 0 68 Nm 0 056 1 24 Nm 0 11 34 Nm 0 11 5 6 Nm 0 22 79 Nm 1 69 33 8 Nm BRAKES Torque Watts O 0 078 Nem 0 071 0 71 Ncm 0 071 1 58 Nom 0 033 0 68 Nm 0 055 1 24 Nm 0 11 3 4 Nm 0 11 5 6 Nm 0 22 79 Nm 1 69 33 8 Nm Typical mounting Vv Brake Typical setup for tensioning wire film and fibers Electric Dissipation Dissipation Clutch Inertia Bending Speed Weight moment Inertia moment kgm Nm RPM kg Clutch Typical setup for material handling soft starts and torque limiting Standard bores Inch 1 4 1 4 3 8 3 8 1 2 5 8 3 8 1 2 5 8 3 4 7 8 1 5 8 3 4 7 8 1 5 8 3 4 7
13. 8 1 5 8 3 4 7 8 1 1 1 8 1 1 4 Metric bores on request Bending Speed Weight Standard Metric shafts on request Minimum speed 2 RPM Stub shaft adapter Flexible coupling Clutch Coupling Typical setup for torque limiting protection used for labeling capping and printing appli cations 45 Magnetic clutches C gt lt IE 92 Both ends 810 31 mm x 7 87 mm deep 2 holes 180 gt lt 2 54 MC5 only C EM E WARNER ELECTRIC Precision Tork Model MC PRECOR G Bore 5 MIN lt TORQUE SETTING MAX 3 1 0 46 99 46 99 69 85 82 04 118 11 134 37 154 94 238 76 Metric bore and key min 50 pcs Without Without Without Without 1 8 3 16 Without 1 8 3 16 3 16 3 16 1 4 Shallow key 3 16 3 16 3 16 1 4 Shallow key 3 16 3 16 3 16 1 4 Shallow key On request Precision Tork Model MC6 WARNER ELECTRIC H centring diameter x deep in mm both side 22 225 22 20 x 2 22 225 22 20 x 2 35 13 35 08 x 3 05 46 99 46 965 x 2 62 61 97 x 2 54 62 61 97 x 2 54 62 61 97 82 55 82 5 apart both ends bore Inch 3 6 32 x 5 16 dp 1 25 B C 3 6 32 x 5 16 dp 1 25 B C 3 10 32 x 7 16 dp 1 875 B C 3 10 32 x 7 16 dp 2 375 B C 3 10 32 x 1 2 dp 3 00 B C 3 10 32 x 1 2 dp 3 00 B C 3 1 4 20 x 5 16 dp 2 875 B C 4 5 16 18 x 1 2 dp 5 8 5 B C Sett
14. any torque control problem Torque is extremely consistent and smooth at low as well as high speeds No external control or power source O Simple to install O Nothing to monitor O Unaffected by power interruption or power fluctuation Safe to use Dependable performance Smallest possible transition from static to dynamic torque O Virtually eliminates the stick slip pheno menon associated with friction devices O Long life The only wearing parts are the ball bearings O Extremely accurate Precision Tork units out perform all other devices at low RPM Versatile mounting Easy to retrofit O Clutches are available with hollow bores for mounting on motor shafts or jack shafts Bolt circles allow for fixed mounting adding a pulley or stub shaft adapters O Brakes are available with solid shaft outputs Electric Rotating centre disc Multiple pole high energy magnets Low drag seals Precision ball bearings There are no other mechanical wear parts or electrical com ponents to fail Dichromate coating for improved corrosion resistance Hollow shaft for direct mounting Easy to read graduations Torque adjustment ring establishes position of permanent magnets to vary the amount of torque Bolt circles on both ends for versatile mounting SPECIAL APPLICATIONS Specials are our business O Special shaft bores and keyways Shaft extensions 1 System retrofits O Metr
15. speed difference in area B C give required tension All tension systems must be according the speed line in close loop IMPORTANT CONSIDERATION ZONE 2 Typical characteristics In every machine the speed point location must be clearly identified In general one of driving nip roll is choose to set the linear speed The machine speed is considered as MASTER function The tension control whatever the selected solution works in SLAVE mode Practically the operator sets the machine 24 2 speed with a simple potentiometer and all tension control system existing on the machine have to follow keeping the required tension at any speed and during all transitory speed phases Tension zone definition B C Speed point in B or C Constant roll rotation speed NOTE Each zone is individually controlled Tension may be different in each zone It is Constant inertia assumed that there is no slipping on the nip roll In general constant tension Y O Brake system applicable Warner 5 Electric System configurations OPEN LOOP CONFIGURATION Working in open loop requires an external reference setting applied to the driver The torque applied to the unwind roll has to vary according to the diameter of the roll We don t control acceleration deceleration and emergency stop as the sensor Is blind regarding the band tension Application needs one sensor only which drives an amplifier without return information for the in
16. unit MCS2000 WIN PROGRAMME The program can modify the running setting by this software running with Windows 95 98 XP 2000 2 Electric IV Double tension control in closed loop The command unit MCS2000 CTLC is a complete solution with power supply and programmer display integrated There are 2 software version available See technical data below MAIN APPLICATIONS ADVANTAGE DISADVANTAGE Setting type Where When Why Advantage Disadvantage Load cell Slitter Sheeter O Direct tension measure O No tension peak Coater 1 Mechanically well absorption 1 For heavy material integrated Accel decel machine O Limited room O No moving part not easy to manage 1 No fast accel decel O Flying splice function O Tension peak accepted not easy One or two load cells Memory card MCS2000 CRD 2 Amplifier MCS2000 PSDRV 11 lu Controller MCS2000 CTLC Brake MPB 100 260 VAC 0 10 VDC Or Amplifier MCS2000 DRV MCS2000 WIN 0 24 VDC are Programme 0 24 VDC 22 Warner Electric Automatic setting by load cell ELECTRICAL AMPLIFIERS MCS2000 PSDRV and MCS2000 DRV see page 9 CONTROLLER MCS 2000 CTLC Specifications Input power supply 110 240 VAC selectable Analogue inputs Two analogue inputs 0 10 VDC Analogue outputs Two controlled channels 10 VDC 0 20 mA Open loop signal 0 10 VDC Digital inputs Set point change active low Set point change
17. 2 90 1502 0 058 8 4 0 0039 10 1800 0 454 0 044 1 65 90 1501 0 06 25 0 043 20 1000 2 12 0 11 19 90 613 0 147 10 7 0 26 100 1000 0 22 13 0 90 475 0 19 90 25 1 1 140 1000 9 98 Optional Mounting Bracket for mounting MPB Brakes and MPC Clutches Hole J C MPB 2B 2 T 40 2 2 2 3 8 240 29 3 Dimensions in mm All brackets are 4 2 67mm steel hm Electric Magnetic particle brakes 305 Both ends T M 4 gt Lr x T m gt lh Ose T Q9 y E _D 4 Dimensions and specifications MPB2 1 53 59 19 05 19 02 56 64 1 FLAT MPB15 1 74 42 28 57 28 55 77 47 1 FLAT MPB15 2 74 42 28 57 28 55 52 07 0 499 0 375 0 376 Bore 0 125 MPB15 3 74 42 28 57 28 55 68 58 0 4997 0 4992 Solid shaft 1 FLAT MPB70 1 113 79 41 27 41 25 66 55 0 749 0 500 0 501 Bore 0 125 MPB70 2 113 79 41 27 41 25 85 6 0 7497 0 7492 Solid shaft Keyway 0 188 120 1 133 35 41 27 41 25 102 11 0 749 0 500 0 501 Bore 0 156 MPB120 2 1133 35 41 27 41 25 102 11 0 7497 0 7492 Solid shaft Keyway 0 188 MPB240 1 157 73 62 61 98 118 36 0 7497 0 7492 Solid shaft Keyway 0 188 4 1 4 20 on 5 875 BC MPB240 2 157 73 62 61 98 89 15 1 377 0 875 0 876 Keyway 0 188 4 1 4 20 on 5 875 BC MPB240 3 157 73 62 61 98 89
18. 2000 DRV see page 9 ROTARY SENSOR MCS605 E see pages 16 et 17 CONTROLLER MCS2000 CTDA Specifications Input power supply 110 240 VAC selectable Analogue inputs Two analogue inputs 0 10 VDC Analogue outputs Two controlled channels 10 VDC 0 20 mA Open loop signal 0 10 VDC Digital inputs Set point change active low Set point change active low Set point change front face switch Main features Gain multiplier active low Three mounting possibilities Output limitation active low 1 Software password protected ABC binary combination active low Scrolling menu program ABC inputs synchronisation active low O Multipurpose application otop integral form active low RS232 communication 1 Two ouput channels Digital outputs Automatic sensor scaling Sensor level indication Two binary outputs O Programmable output configuration Output sensor information Other outputs 1 External set point change Power supply sensor 15 VDC 100 mA 1 Automatic or imposed PID correction 5 VDC 100 mA All features requested for tension control Power supply 24 VDC O Plugable memory card Voltage reference 10 VDC 10 mA O Variable tension value to prevent telescopic effect on unwinding CTDA 22 Service manual MC525 MCS2000 CRD 2 MEMORY CARD All setting data saved It allows a quick loading operation on new machine or on running machine to optimise O Memory for 2 different programs Plugable on line in MCS2000 ECA
19. 301 101 001 4 x B5314 631 000 08 R 20 50 20 B5311 101 001 K5200 101 011 E18 050000900 K5300 541 004 B110 0047 K5300 101 003 3x B5300 631 040 B5311 101 001 B5300 631 000 46 K5200 101 010 29 TB brake characteristics All TB brakes are rated at 24 VDC nominal When selection is correct the voltage on the brake should be approxi mately 12 VDC for your maximum parameters used in calculation All TB brakes are able to work for short periods of time less than 10 seconds in the 12 24 VDC range for example in machine deceleration or in emergency stop Technical data and dimensions TB170 TB260 TB425 TB500 IM TB825 IM TB1000 IM TB1225 IM 99 52 0 025 TB500 OM TB825 OM TB1000 OM TB1225 OM 0 8 4 35 75 300 450 Mg 150 Mg min 0 08 1 5000 2400 pru 0 40 1 224 P Continu 0 030 0 360 P Alternativ 0 045 0 650 R 20 C 60 19 6 th 0 040 0 152 Inertia 116 10 0 041 Mass 0 650 12 48 5 105 12 30 5 56 5 69 259 32 36 5 Alternativ duty based on 30 minutes ON and 30 minutes OFF 30 Warner Electric TB brake characteristics TB1525 IM TB825 1525 01 27 0025 1 2 13 UNC 3B Steel 0 290 C 661 0005 Non magnetic F mm 28 5 eG mm 19 5 0 05 35 62 49 55 98 114 180 H mm 15 9 30 1 31 8 118 159 175 152 5 K mm 10 3 17
20. 5 22 2 38 38 44 5 76 76 L max mm 10 20 22 32 42 60 75 75 98 42 90 49 133 4 149 3 215 9 3x120 120 120 4 90 4 90 N 0 05 mm 52 40 88 93 136 55 161 95 228 60 60 3 108 155 6 184 1 8 x M4 6 x M8 6 x M8 6 x M8 20 005 165 10 24762 149 2 255 5 4 x M10 4 x M8 T mm 49 U mm 110 170 M 0 025 mm P for screw mm eS for screw mm Reverse mounting of taperlock bushing is possible Warner 31 Electric Tension brake for strapping machine Specially designed for strapping machine the electromagnetic brake TBM10 adjustable for the different kind of plastic film Mounted on the intermediate roller it will tighten the plastic film and will permit a perfect strapping TBM BRAKE PLASTIC FILM ROLLER TBM SIZE 10 Heat dissipation torque Brake torque IERI 1 EHEN 30 50 80 150 300 500 n rpm 2 Electric Tension brake for strapping machine TBM SIZE 10 D min 8 mm with standard keyway D min 13 mm with standard keyway 3 pins on o 57 96 U max 24 VDC P 20 C 10 8 Watts Inductor 24VDC B6650 631 000 39 Armature VARO3 B110 0000 1358 Hub prebored 97 5 B540 0000 2519 Keway according to ISO R773 BS 4235 Hub 212 H8 Keyway 4 P9 B540 0000 2517 NFE 22175 tolerance P9 Armature VARO4 B6650 111 000 08 Warner 33 gt Electric Magnetic particle clutches and brakes
21. 71 Brake on roll axis i 1 N max N min PAPER PAPER 10 gr m 0 5 N cm 130 gr m 3 1 N cm 25 gr m 0 7 N cm 150 gr m 3 8 N cm 40 gr m 1 N cm 200 gr m 5 5 N cm 60 gr m 1 5 N cm 250 gr m 7 7 N cm 80 gr m 2 N cm 330 gr m 11 5 N cm 100 gr m 2 5 N cm 400 gr m 14 8 N cm N cm micron Paper note 1 N max N min cm max cm min N N min RPM RPM Nm max Nm min Nm Nm max Nm min kW rner Electric Data application form START STOP t1 MACHINE STARTING TIME t2 ROLL ACCELERATING TIME t3 MACHINE DECCELARATING TIME t4 BRAKE ACCELARATING TIME MB see catalogue or TB or stopping brake applied ACCELERATION TIME t2 120 force must accelerate the roll Storage length v 120 t2 t1 if machine is accelerating faster t1 t2 If the dancer load is a mass the tension force will increase F F v 118 t1 or the dancer load is a mass the tension force will increase 118 2 DECCELERATION 1 Maintaining the web force warning exact values if MB or t3 defined Braking torque m D v 240 t4 D 2 1 i Time t4 v 240 i F 0 2 Si t4 gt t3 necessary lenght v t4 t3 120 2 Uncontrolled emergency stop Emergency stopping time t D 240 1 Material length spillage v t 120 Subject to alteration without prior notice
22. 9 4 51 5 64 6 77 7 9 Torque Nm Warner gt Electric MPB15 MPC15 1000 800 Heat dissipation 20 watts max 600 Slip RPM 400 200 0 0 0 2 0 45 0 67 0 9 1 1 1 35 1 58 Torque Nm MPB120 MPC120 1000 Heat dissipation 140 watts max 800 600 Slip RPM 400 200 1000 800 600 Slip RPM 400 200 2 2 4 51 6 77 9 Torque Nm MPB240 Heat dissipation 200 watts max 4 4 9 13 5 18 22 5 Torque Nm 11 3 13 55 27 37 Magnetic particle clutches and brakes Applications Warner Electric Precision Tork magnetic particle clutches and brakes are the ideal solution for controlling and maintaining torque If the application is tensioning load simulation torque limiting or soft starts and stops the magnetic particle unit is the preferred torque controlling device Typical Applications Unwind stand under load cell control Wire Processing winding hooking cut ting O Paper Foil Film Processing O Labelling Applications O Textile Processing O Load profile simulation on Exercise Equipment Flight Simulators Healthcare Equipment Life testing on Motors Gears Pulleys Rewind stand under dancer control Belts Chains Many other Rotating Dev
23. ADVANTAGE Setting type Where When Why Advantage Disadvantage Dancer arm O Printing machines O Absorb tension peak O Need more space Intermittent function Can act as store O Moving parts O Flying splice need O Easy flying splice Accel decel machine phase well absorbed O Flexibility Sensor MCS605 E 110 230 VAC Analogue Control Brake TB MCS202 E 0 0 24 VDC LIE Additional functions TLEC Taye O Brake open O Emergency stop I Drift stop stop integral term of PID O Gain change 14 Electric Automatic setting by dancer arm ROTARY SENSOR MCS605 E see pages 16 and 17 ANALOGUE CONTROL MCS202 E 71 MCS202 E1 Standard execution O MCS202 E54 Standard IP54 protected MCS202 EC1 Open frame execution Technical characteristics valid for 3 executions Range Values Comments Power supply 110 220 VAC selectable Open front face to access Output current capability Max 2 5 Amps short circuit protected Able to power 2 TB in parallel User settings Loop gain Front face potentiometer Offset torque Front face potentiometer Output voltage brakes 0 24 VDC Compatible all elec Warner Electric Housing Metal rugged housing Only MCS202 E1 and E54 Loop gain 2 adjustable range selection Can be change during operation Accessories MCS KIT1 2 3 5 and 6 See details on page 17 Sensor compatible Dancer arm with MCS605 E See details on pages 16 a
24. CATIONS ADVANTAGE DISADVANTAGE Setting type Where When Why Advantage Disadvantage Dancer arm O Printing machines O Absorb tension peak O Need more space Intermittent function Can act as store O Moving parts O Flying splice need O Easy flying splice Accel decel machine phase well absorbed 3 Flexibility Sensor MCS605 E Brake TB Ck Memory card zae MCS2000 CRD 2 gt Amplifier Brake MPB MCS2000 PSDRV ap E Controller MCS2000 ECA MESON 100 260 VAC A 0 10 VDC BEES 3 Hand Programmer MCS2000 PRG Amplifier MCS2000 WIN MCS2000 DRV programme rner 1 8 Warner Automatic setting by dancer arm ELECTRICAL AMPLIFIERS MCS2000 PSDRV and MCS2000 DRV see page 9 ROTARY SENSOR MCS605 E see pages 16 et 17 CONTROLLER MCS2000 ECA O Digital controller 2 channels Main Characteristics 24 VDC power supply unit unn Automatic adaptation for PID parameters splicing logic included I Opto isolation for input and output gt Compatible PLC Automatic sensor scaling and output sensor information Programming easy by pocket keyboard or PC Windows Available in open loop as calculator 2 analogic input 2 output channels Plugable memory card Three language available Most dedicated for unwinding and rewinding with electromagnetic brakes and clutches Service manual MC514 3222200060000 MCS2000 PRG HAND PROGRAMMER 4
25. ION ADJUST 1 FAST STOP and HOLD levels are adjustable via potentiometer 71 FAST STOP a ratio of 1 to 10 times to OPERATING LEVEL OPERATING LEVEL maximum 10 VDC divided by the FAST STOP ratio Mounting and dimensions mm HOLD output level adjustable between and 10 VDC Overall dimensions maximum Height 160 mm To be used ONLY with scalable ultrasonic sensors type SCUA 130 Width 95 mm 1 m or SCUA 140 2 5 m Depth 75 mm Weight 0 350 kg 9 Service manual MC520 ELECTRICAL AMPLIFIER MCS2000 MCS2000 PSDRV MCS2000 DRV MCS2000 DRV8 O 1 alternative continue current supply card 711 logic card with 8 individual 1 1 logic card with 8 individual 1 1 logic card with 2 individual channels output channels output channels 1 fixed 1 with calibration ps msg sme Dimensions mm input signal current current n MCS2000 DRV8 0 10 VDC 24 VDC 3 A 0 24 VDC 0 3 A per channel Wiring Shielded cable Setting Anti residual Mounting position Vibrations free vertically Service manual MC517 149 fter Electric Simple tension control in closed loop If your machine requires a very accurate web tension control then you need to work in closed loop An important unit in the loop is the sensor Several possibilities are offered The choice now depends on the kind of machine you are building the mechanical construction and the max tension value you desire to control MAIN APPLICATIONS ADVANTAGE DIS
26. ROL IN OPEN LOOP 8 la Manual setting by pot 8 9 l b Manual setting by following arm 8 9 l Automatic setting by diameter reading 10 11 I Automatic setting by diameter reading with additional functions 12 13 TENSION CONTROL IN CLOSED LOOP 14 Single roll tension control automatic setting by dancer arm 14 17 I Double roll tension control automatic setting by dancer arm modular 18 19 I Double roll or splicer tension control automatic setting by dancer arm compact 20 21 IV Double roll or splicer tension control automatic setting by load cells 22 25 BRAKES AND CLUTCHES RANGE 26 Brakes and clutches models 26 ELECTROMAGNETIC BRAKE TYPE TB 28 Tension brake sizing 27 TB brake characteristics 28 31 Tension brake for strapping machine 32 33 MAGNETIC PARTICLE CLUTCHES AND BRAKES 34 Design and operation 34 35 Selection 36 37 Applications 38 39 Dimensions and specifications 40 41 Current regulator power supply for powder brakes 42 MAGNETIC CLUTCHES AND BRAKES 43 Design and operation 43 Applications 44 Dimensions and specifications 45 50 DATA APPLICATION FORM 91 Material tension data 51 Calculation dates form 52 53 Warner 3 Electric System configurations Analysing and preparing a project in tension control requires good analysis support The general block diagrams below are a good representation of any machine generally supporting tension control We recommend using these diagrams or a part of it i
27. S2000 PSDRV Dimensions mm O 1 alternative continue current supply card 1 1 logic card with 2 individual channels 1 fixed 1 with calibration Model Electrical Power supply Output voltage ent Wiring Shielded cable Setting Anti residual Mounting position Vibrations free vertically Service manual MC517 75 183 149 ELECTRICAL AMPLIFIER MCS2000 Dimensions mm MCS2000 DRV 1 1 logic card with 2 individual channels 1 fixed 1 with calibration MCS2000 DRV8 1 logic card with 8 individual output channels Model Electrical Power supply Output voltage pes aigu MCS2000 DRV8 0 24 VDC 0 3 A per channel 183 149 Wiring Shielded cable Setting Anti residual Mounting position Vibrations free vertically Service manual MC517 Warner Electric Tension control in open loop MAIN APPLICATIONS ADVANTAGE DISADVANTAGE Setting type Where When Why Advantage Disadvantage Diameter reading O The most commonly used Physical reading O Poor reading solution in open loop no reset accuracy on core O No operator Easy to start up intervention admitted O Large roll e ratio Amplifier MCS2000 PSDRV Ultrasonic my 0 10VDC E O 24 VDC 100 260 VAC Brake MPB 0 10 VDC sa il O 24 VDC ns 11 1 611 Amplifier MCS2000 DRV 10 warner Electric Automatic setting by diameter readi
28. Tension control in open loop Working in open loop requires that a torque setting is defined The choice depends on the machine complexity and the automation required One important factor that remains is the tension precision For unwind and rewind systems the diam eter ratio will play an important role Working in open loop also requires special considerations regarding system inertia a Manual setting by pot b Manual setting by following arm MAIN APPLICATIONS ADVANTAGE DISADVANTAGE Setting type Where When Why Advantage Disadvantage Diameter O Cable machine 1 Low cost solution O Tension precision reading O No fast accel deccel O Easy to start up depends 1 Low roll diameter ratio 1 Automatic regula on operation 1 Operator intervention tion by diameter For diameter admitted following arm following arm O Manual correction accuracy according feasible the roll geometry Amplifier MCS2000 PSDRV 0 24 VDC 0 10 VDC 100 260 VAC Brake TB a Brake MPB 0 24 VDC 0 10 VDC AM 1 all n Amplifier MCS2000 DRV 8 warner Electric Manual setting by Pot Pot Dimensions mm Resistance value 10kQ Type Linear 20 4 Power rating at 40 C 0 4 W Tolerance 20 Electric rotation 280 20 Mechanic rotation 300 5 Operating temperature 25 C to 70 C Shaft 26 mm Panel mounting hole 10 mm Part number B90 26325C 1 1x0 45 ELECTRICAL AMPLIFIER MC
29. cations Power supply TCS250 C 24 VAC or 24 VDC Power supply TCS250 T 110 230VAC 50 60 Hz Input 0 10VDC from Pot 10K Output 0 2A modulated PWM Absorbed power 30 W max Sensibility 10 mV Repeatability 1 Current limiter Polarization from 50 to 50 from O to 100 Operating temperature 50 max Size 171 x 120 x 95 mm Weight 1 500 kg TCS250 T Card with transformer TCS250 C Only card B90 26325C Potentiometer Service manual MC544 o Brake TB 42 Brake current regulated Brake MPB Clutch MPC 60 Pot amp Roll dancer amp External reference 0 10 VDC TCS250 Electric Magnetic clutches and brakes Precision Tork units provide constant torque independent of slip speed They offer excellent overload and Jam protec tion for all drive train components and also provide soft starts with zero slip when a preset torque is reached Precision Tork permanent magnet clutches and brakes do not require maintenance and provide extremely long life Features and Benefits Fast precise torque adjustment 3 Torque is set with a large knurled adjust ment ring O Infinite adjustability between minimum and maximum settings This allows units to be fine tuned to your unique require ment Torque is constant with respect to speed 1 By using the Precision Tork unit you can solve almost
30. co co c Option PRTEETETETSTETETRTETE Mounting Bracket g Lis M5 293 11 635 381 762 Note Mount bracket to fixed end cap MB4 MC4 MC5 ae 1238 293 11 1524 413 889 1588 MC5 5 M j pa 9 ao ck Dimensions in mm Hole for P B d 6 35 mm screw ES Fixed end cap a Bs ge Pu 8 x b 2 I lew z m amp 2 a lt 9 zo C 5 2 E 2 i m 4 H 6 3 7 Ca All brackets are A7 mm steel Warn ner 47 wu Electric Magnetic clutches and brakes Heat Dissipation Charts EXE intermittent operation 5O amp duty cycle re Continuous operation MB1 MC1 5 MB1 5 MC2 MB2 035 05 06 Torque Ncm Torque Ncm Torque Ncm MC3 MB3 MC4 MB4 MC5 MB5 Oh a EET 0 22 0 33 O 01 02 03 04 05 06 07 09 1 1 1 Torque Nm Torque Nm Torque Nm MC5 5 MB5 5 MC6 MB6 MC9 MB9 0 0 O5 11 16 22 28 34 39 45 5 24 Torque Nm Torque Nm Torque Nm 48 Warner Electric Magnetic clutches and brakes Torque Setting Charts MB1 Torque Ncm o o o o o c n2 A O1 l 49 N N
31. command keys only 2 x 16 characters display O Menu in languages 1 Connectable and disconnectable during operation Supply by control MCS 2000 EC MCS2000 CRD 2 MEMORY CARD All setting data saved It allows a quick loading operation on new machine or on running machine to optimise O Memory for 2 different programs Plugable on line in MCS2000 ECA unit MCS2000 WIN PROGRAMME The program can modify the running setting by this software running with Windows 95 98 XP 2000 Electric MCS2000 _ PID parameters setting on line 19 III Double tension control in closed loop compact The command unit MCS2000 CTDA is a complete solution with power supply and programmer display integrated There are 2 software version available See technical data below MAIN APPLICATIONS ADVANTAGE DISADVANTAGE Setting type Where When Why Advantage Disadvantage Dancer arm O Printing machines O Absorb tension peak O Need more space Intermittent function Can act as store O Moving parts O Flying splice need O Easy flying splice Accel decel machine phase well absorbed O Flexibility Sensor MCS605 E Memory card MCS2000 CRD 2 Amplifier 8 MCS2000 PSDRV Controller MCS2000 CTDA 100 260 VAC 0 10 VDC Amplifier MCS2000 WIN MCS2000 DRV programme rner 2 0 Warner Automatic setting by dancer arm ELECTRICAL AMPLIFIERS MCS2000 PSDRV and MCS
32. eat is generated Heat is described in terms of energy rate and is a function of speed inertia and cycle rate For continuous slip applications such as tension control in an unwind or rewind application slip watts are calculated using the following formula Slip Watts 0 103 torque Nm speed RPM 2 For cycling applications heat is generated intermittently and is calculated using the following formula speed RPM cycle 10000 min Slip Watts 0 00077 J kgm The average heat input must be below the clutch or brake s heat dissipation rating If the application generates intermittent heat dissipation use the average speed for the thermal energy slip watts calculations Torque 1 Tension applications calculate torque as a function of roll radius and tension T N D 2 Soft controlled stopping applications calculate torque as a function of inertia speed and desired time to stop the load J kgm N RPM C Nm 9 55 Time s rner 3 6 Warner Magnetic particle clutches and brakes Quick Selection Charts MPB2 MPC2 1800 Heat dissipation 1500 10 watts max S 1200 A x 900 un 600 300 0 04 0 09 0 13 0 18 0 22 0 02 0 07 0 11 0 15 0 2 Torque Nm MPB70 MPC70 1000 Heat dissipation 800 100 watts max 2 22 600 Y 400 200 1 13 226 3 3
33. ems are used with double roll unwinders with splicer The 2 brakes are always controlled when one is in regulation the other has holding function through numeric control range MCS2000 These controls include loop control with PID a lot of options and are able to be programmed by PC via RS232 line or by external programmer poc ket visual function os 2s The PID function is optimised for one inertia value The MCS2000 line is inclusive of an important feature namely the PID correction Based on the available diameter information you can apply a continuous PID correction When no information is available an internal PID change can be programmed PID relative values 100 Diam Info 2 Core Typical PID values for TB brakes Warner Electric Each parameter P and D can be set individually for the smallest core and biggest diameter As soon as the correct parameters are found for the extreme diameter value they are stored The diameter information provided will fix the PID values for the present diameter value This will allow the system to keep an excellent stability during the whole diameter evolution In the case where the diameter infor mation is not available we can provide this signal by installing a sonic sensor or by working with internal correction The external diameter information supplied to the controller will ensure a better precision compensation compared to an internal correction 1
34. ery gradual or extremely fast The fre quency and torque of the engage ment disengagement sequence is limited only by the capabilities of the control circuitry No wearing parts O There are no friction surfaces to grab or wear and the units are not affected by changes in atmospher ic or other environmental condi tions Efficient Compact design High torque to size ratio and low consumption of electric power Versatile mounting Convenient bolt circle for easy mounting O Mounting brackets available for all SIZes O Brakes are available with solid shafts and through bore Can be mounted horizontally or vertically to solve virtually any motion control requirement Modular Customised products Interchangeable with industry stan dard sizes Electric Design and operation Stainless steel hardware Zinc dichromate plating on all steel surfaces Stainless steel input shaft Convenient pilot and mounting bolt pattern Operating Principles The magnetic particle unit consists of four main components 1 Housing 2 Shaft disc 3 Coil 4 Magnetic powder Torque current curve Percent of rated torque 40 60 80 Percent of rated current Electric 100 120 Completely packaged and enclosed unit Easy to install Low current coil gen erates magnetic field Extremely long life spherical magnetic particles Magnetic powder cavity F em Hr NI N New and unique dua
35. fluence of correction OPEN LOOP SOLUTION Manual setting by pot B Manual setting by following arm E Automatic setting by diameter reading RR Amplifier Ultrasonic sensor gt Automatic setting by diameter reading with additional functions 4 Ultrasonic sensor 2 13 Additional functions 6 Warner Electric System configurations CLOSED LOOP CONFIGURATION Working in close loop needs one sensor This one will measure directly or indirectly the band tension Tension variations detected by sensor are sent to the brake through the control This action corrects the variation and the new corrected sen sor value is sent to the brake and so on Give a accurate tension regulation during acceleration deceleration emergency stop Sensor Amplifier Position regulation by dancer arm This is an electromechanical system and the building quality for the dancer arm must be verified The band tension is created by the roll weight and or by pneumatic actuator which have sensible air exhaust Regulation by load cell This is an electromechanical system and the quality of load cells mounting J must be checked The band influences directly the load cells or loads cells The load cells choice and the mounting are very important regarding over load during starting or emergency stop Splicer system regulation Our control syst
36. ic bores and keyways 3 Stainless steel construction 1 Fixed torque units Stainless steel MC4D Long shaft extension 43 Applications Unwind tension Information required Check tension range control Full roll amp m 0 15 Max tension core m 0 1 Torque 2 coree Brake mounted on shaft of unwinds Average tension N 18 1 08 2 0 1221 6N spool or bobbin Velocity m mn 30 Min tension Torque 2 full roll How to size 1 08 2 0 152 14 4 N Average radius Full roll e core Slip watts watt 0 4 0 15 0 1 4 0 06 tension velocity 60 21 6 30 60 10 8 watts Film unwind Tension provided Average tension Nm by hysteresis units Average tension Average radius Select MC4 Model 18 0 06 1 08 Nm Bottle Information required Select an MC4 Model from the capping Slip 500 tr mn specification chart Constant torque Clutch Torque 0 90 Nm provided by a hysteresis clutch slip time of total cycle time 25 Consult factory if peak slip watts are extremely high or if duration of slip period is in excess of 1 minute How to size Torque slip _ 095 900 09 595 Watts 9 55 9 55 11 8 watts Information required Pulley or nip roll diameter 0 1 m Tension 26 N Velocity 30 m mn Brake How to size Torque Tension 2 2 26 0 1 2 1 3 Nm Slip watts max tension velocity 60 26 30
37. ices Conveyors Bottle Capping Wyner Electric Magnetic particle clutches and brakes Tensioning Magnetic Particle clutches and brakes offer smooth controlled torque for tensioning in both the unwind zone and rewind zone Torque produced from the magnetic particle clutches and brakes is independent of slip speed offering a distinct advantage over competing technologies Since torque can be varied infinitely by varying the input current the magnetic particle clutches and brakes are ideal in an open loop system To close the loop in the tensioning system combine the magnetic particle clutch or brake with a Warner Electric sensor and control resulting in more precise control of tension Particle clutches and the MCS2000 CIDA control provide accurate closed loop tension control for rewind applica tions Application example Information Full roll 0 5 m required Tension 22 Velocity 122 m min tension full roll e Max torque 2 22 0 5 EM 5 5 Nm Particle clutches and the MCS202 E1 control provide accu rate closed loop tension control for rewind applications Application example Information Core o 0 08 m required Full roll e 0 23 m Tension 22N Velocity 90 m mn Input speed 500 RPM Max torque Tension roll o _ 22 0 23 2 2 53 _ _Speed _ 90 0 08 358 gt Electric Velocity T D Slip 122 mT 0
38. ing locking Pin 3 32 Pin 3 32 Set Screws Set screws Set screws Set screws Set screws Set screws Set screws Set screws Set screws Set screws Set screws Set screws Set screws Set screws Set screws Set screws Set screws Set screws Set screws Set screws Set screws Set screws Set screws Set screws Warner hm Electric Magnetic brakes C l E F Both ends 810 31 mm x 7 87 mm deep 2 holes 180 apart both ends 2 54 only MB5 C WARNER ELECTRIC Model MB WARNER ELECTRIC Precision Tork Precision Tork a gt Set screw adjustment Drawing C Spanner wrench adjustment Drawing D H Centring diameter x I Bores deep in mm both side Inch 25 4 35 3 0 170 Plat 7645 768 x 2 54 3 4 40 x 1 4 dp 0 610 B C 46 99 59 69 On request 0 230 Plat 22 225 22 20 x 2 3 6 32 x 5 16 dp 1 250 B C 46 99 59 69 min 15 pcs 0 230 Plat 22 225 22 20 x 2 3 6 32 x 5 16 dp 1 250 B C 69 85 76 71 0 350 Plat 35 13 35 08 x 3 05 3 10 32 x 7 16 dp 1 875 B C 82 04 75 44 i 0 518 0 503 46 99 46 965 x 2 3 10 32 x 7 16 dp 2 375 B C 118 11 111 76 0 859 0 844 62 61 97 x 2 54 3 10 32 x 1 2 dp 3 000 B C 134 37 115 06 0 859 0 844 62 61 97 x 2 54 3 10 32 x 1 2 dp 3 000 B C 154 94 114 3 0 859 0 844 62 61 97 3 1 4 20 x 5 16 dp 2 875 B C 238 6 137 41 0 859 0 844 82 55 82 5 3 5 16 18 x 1 2 dp 5 875 B C CD
39. l seal design Power input DC Stationary field The coil is assembled inside the housing The shaft disc fits inside the housing coil assembly with an air gap between the two the air gap is filled with fine magnetic powder Magnetic flux path Magnetic particles Rotor Cylinder Engagement When DC current is applied to the magnetic particle unit a magnetic flux chain is formed linking the shaft disc to the housing As the cur j rent is increased the magnetic flux nemen becomes stronger increasing the torque The magnetic flux creates extremely smooth torque and virtually no stick slip Output shaft Disengagement When DC current is removed the magnetic powder is free to move within the cavity allowing the input shaft to rotate freely Magnetic particle clutches and brakes Selection Sizing To properly size magnetic particle clutches or brakes the thermal energy slip watts and torque transmitted must be consi dered If thermal energy and torque are known for the application select the unit from the charts to the right Speed Velocity m min V RPM T coil m In rewind applications the motor RPM should be higher 10 than the fastest spool RPM In applications with the web running over a pulley or in a nip roll application use the pulley diameter as the roll diameter kk Thermal Energy slip watts 1 When a brake or clutch is slipping h
40. n any discussion and correspondence in order to be clear and to avoid possible misunderstandings The tension area in an unwinding system is defined by places where we want to control this tension SYSTEM CONFIGURATION 1 In single roll unwinding we have one area tension between A and B One brake can be easy installed in A The brake control system selected will be according to the accuracy required open loop or close loop ZONE 1 Typical characteristics unwind O Tension zone definition Speed point in B O Variable roll rotation speed O Variable inertia 1 In general constant tension X O Brake system applicable SYSTEM CONFIGURATION 2 Most usual configuration with driving roll a rewinder and an unwinder 2 separate tension area with tension could be diffe rent in X and in Y Regarding accuracy required we will choice open loop or close loop In A unwinding brake in B motor for the speed and in C clutch or moto reducer for rewinding Zone 3 Typical characteristics rewind 79 Tension zone definition B C Speed point in B O Variable roll rotation speed 71 Variable inertia Constant or Taper tension Z O Particle brake system applicable Electric System configurations SYSTEM CONFIGURATION 3 More complicated machine with intermediary tension area between winder and unwinder The intermediary area give the line speed A master slave system with
41. nd 17 Service manual MC403 Technical information MCS202 control is based on classical and fixed PID terms The loop gain can be set on front face potentiometer Due to the fixed PID terms its use is limited in terms of roll diameter ratio One input is provided to change the loop gain and has to be used when diameter ratio exceeds 8 To ensure proper operation it is important to wire the function Drift Stop This function releases the Integral term as soon as the machine runs Dimensions mm e LOOP GAIN O BRAKE Qro TORQUE OFFSET WARNER ELECTRIC Electric Automatic setting by dancer arm ROTARY SENSOR MCS605 E A position sensor Is used in 2 possible ways To detect dancer moving in the closed loop installation working on dancer principle O To sense the diameter of the roll to operate open loop control or make PID compensation in closed loop installation MCS605 E Power supply 10 to 30 VDC 30 mA or 5 to 15 VDC Max detection angle 200 100 Sensitivity 25mV V 7 Service manual MC483 ELECTRICAL CONNECTIONS CONNECTOR Supply White Green Brown Shield Supply Signal View from outside Working in closed loop with the arm dancer principle is very popular especially in the printing market where a good flexi bility of the system is required to absorb the eventual ten sion peaks The rotary sensor is necessary to read the dan cing roll movement MCS605 E i
42. ng ULTRASONIC SENSORS Model 2 5 0 130 SCUa Power supply 15 to 30 VDC max 30 mA 15 to 30 VDC max 30 mA Min distance 100 mm 400 mm Max distance 1000 mm 2400 mm Accuracy 1 mm 1 mm Protection class IP67 IP67 SCUA 130 SCUA 140 Accessory 5 m cable 5 m cable Service manual MC487 MC488 Dimmensions mm 18 5 31 30 1 5 SCUA 130 SCUA 140 ELECTRICAL AMPLIFIER MCS2000 PSDRV Dimensions mm O 1 alternative continue current supply card 1 1 logic card with 2 individual channels 1 fixed 1 with calibration Model Electrical Power supply Output voltage Wiring Shielded cable Setting Anti residual Mounting position Vibrations free vertically Service manual MC517 75 183 149 ELECTRICAL AMPLIFIER MCS2000 Dimensions mm MCS2000 DRV 1 1 logic card with 2 individual channels 1 fixed 1 with calibration 75 183 MCS2000 DRV8 1 logic card with 8 individual output channels Model Electrical Power supply Output voltage 0 24 1003 A per channel 149 Wiring Shielded cable Setting Anti residual Mounting position Vibrations free vertically Service manual MC517 P Warner gt Electric Tension control in open loop MAIN APPLICATIONS ADVANTAGE DISADVANTAGE Setting type Where When Why Advantage Disadvantage Diameter reading O The most commonly used Physical reading O Poor reading solution in open loop no reset accuracy on core
43. referenced on the load cell body normally an arrow indicates the sensitive direction ES LOAD CELL FEATURES 01 400 and ES02 52C Power supply 10 to 15 VDC 40 mA 5 VDC in Warner Electric control Sensitivity 2 mV V supply at nominal load 1 mV V supply for 50 and 150 N models Rating 50 150 250 500 1000 2000 N Connections 5 m shielded cable supplied Mechanical overload Max 150 in any direction Dimensions See mounting instructions ref MC481 and MC482 Mounting See recommendations below Service manual MC481 and MC482 AVAILABLE MODELS CAPACITY 50 40C 150 40C 250 40C 500 40C 1000 40C 2000 40C 250 52C 500 52C 1000 52C 2000 52C LOAD CELLS SIZING MOUNTING RECOMMENDATIONS Wrapping Angle Please keep this principle in mind the load cell installed is destined to measure the WEB TENSION and not other constraints applied to it Oo Take the following points into consideration before selecting sizing and installing material components O Load cells location should be vibration free Vibrations will decrease quality measurement O The sensing shaft fitted on or in has to be very well balanced Unbalanced shaft will create measurement oscillation causing variations in control quality Adapted ball bearing have to be used to avoid original stress on load cell self aligning ball bearing O Respect a reasonable sensing shaft weight web tension measure ratio Less than 1
44. s ideal for easy mounting It is encapsulated in rugged metal housing preventing mechanical shocks Furthermore it is provided with built in switch in order to change the signal output polarity TB brake rner 1 6 Warner Automatic setting by dancer arm MCS605 E ACCESSORIES The MCS202 Exx is designed to work with dancer arm principle Usually the sensor is a rotary type Warner Electric sensor MCS605 E are delivered with complete mounting kit Mounting kit comprises of CABLE COUPLING BRAKETS and all necessary SCREWS Various KITS have various lengths of cable and cable with or without connector at control end side MCS2000 line requires free leads MCS2000 control line is provided with terminal block MCS202 Exx requires a connector MCS202 Exx is provided with the connector Cable length One Two connectors Compatible MCS KIT1 MCS202 Exx MCS KIT2 MCS2000 MCS KIT3 MCS202 Exx MCS KIT4 MCS2000 MCS KIT7 MCS202 Exx MCS KIT8 MCS2000 Dimensions mm Mounting min 47 max 70 fter 17 Electric II Double tension control in closed loop modular MCS2000 ECA is a digital controller that can be used in both open or closed loop Operation in open and closed loop is also possible It is mainly destined for OEM application The programming tool is detachable Sensor sensor mounting kit display are available as options The unit has to be powered with 24 VDC MAIN APPLI
45. s the curve given for TB selection takes the power dissipation into account this value is used Tmax torque needed at the brake for the max tension in material and the max roll diameter taking any gear ratios into account Selection point Nmax brake rotation speed for the max linear speed and the max roll diameter taking any gear ratios into account Note the constant tension in the web gives a constant power on the brake However we make the selection for the max torque then at full roll diameter because it s the moment where the brake has the least natural cooling Electric TB brake selection The table pictured below left illustrates the selection of the correct TB brake The table on the right determines the maxi mum torque provided by the brake when nominal voltage is applied After selection you can consult the complete brake characteristics and dimensions on pages 30 to 31 28 Dynamic braking torque TB170 TB1525 Torque Mq Nm 400 300 30 Brake n rpm 40 50 80 60 100 200 150 400 300 500 Maximum braking torque emergency stop TB170 TB1525 Brake torque Mg Nm 500 400 3007 200 150 100 80 60 50 40 30 O Co i 0 6
46. sipation Determine the amount of energy or heat that will be generated dur ing operation Each clutch or brake is rated for a specific amount of energy given in units of watts that it can safely dissipate o0 Select the clutch or brake based on torque and energy require ments See the specifications under Heat Dissipation and Torque Setting Charts Select Bore Size Select the proper bore size for the application On request units in metric size available minimum 15 pcs Torque Requirement 1 Nm Energy Requirement 35 watts Bore Requirement 5 8 inch Select Model MC5 58 Electric Tension selection The WARNER ELECTRIC experience enables us to offer a tension guide as shown below For any special material not included in the chart below please consult WARNER ELECTRIC 7hese values are usual values for information only please check exact tension you need in your application PAPER WEIGHT F fxwidth cm FOIL fx width cm WIRE Usual values for information only MATERIAL DENSITY Paper Paper board Alu foil Alu wire Copper PVC Warner hm Electric Tension f N gt O 920 1420 2720 2750 8550 400 1050 O O Tension f N cm Tension f N cm 20 40 60 80 100 120 140 Weight PW g m2
47. the physical dimensions FOOT MOUNTED TYPE FMO1A and FMO2 Foot mounted load cells are available in two versions With incorporated amplifier FM AC Without amplifier FM C AC amplifier and connector on the load cell body C connector on load cell body Specifications all FM series i FM AC Sensitivity 0 5 VDC nominal load 10 mV nominal load Rating 100 250 500 1000 2500 5000 10000 N Connections Cable supplied Permitted overload Compression 150 Extension 120 Radial permitted force 50 Dimensions See mounting instructions ref MC480 Mounting See recommendations on page 25 Service manual MC480 AVAILABLE MODELS CAPACITY 1000 AC 2500 AC 5000 AC 1000 C 2500 C 5000 C 5000 AC 10000 AC 5000 C 10000 C 24 Electric Load cells END SHAFT LOAD CELLS are normally used in new machines designed with the possibility to place the load cell directly on the sensing roll The end shaft version offers the advantage of being able to easily place the load cell in any tension resultant direction The ES model exists in two versions differenciated with the diameter of ball bearing which has to be placed in All end shaft load cells are based on the Wheatstone bridge principle They have no built in amplifier They are delivering a signal which is proportionnal to the voltage supply and tension applied It is important to respect the measurement direction

Magnetic clutches and brakes

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