WARNER ELECTRIC

WARNER ELECTRIC

Tension
Control
Systems
Tension Control Systems
WARNER ELECTRIC offers the most ABOUT THIS CATALOGUE
complete product line dedicated to This master catalogue groups all
the TENSION CONTROL MARKET. The the solutions / products that
long experience in the market led us to WARNER ELECTRIC offers. An
important part is dedicated to the
develop high performance controls able to solution design with particular
operate in open and closed loop with consideration regarding the
brakes. WARNER ELECTRIC machine and the tension control
installed. This should help you for
electromagnetic brakes find an optimum the right solution choice taking in
use in tension control when associated with consideration the results you want
the new digital control line. to achieve. All the product
characteristics and dimensions are
included for every product.

Applying the appropriated

Tension Control will lead you

■ To improve quality of the

operation

■ To increase the production

■ Finally to lower your production

cost

CONTACT WARNER ELECTRIC

FOR ANY ASSISTANCE YOU
REQUIRE

www.warnerelectric-eu.com

2
 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 CONTROL IN OPEN LOOP 8

I.a - Manual setting by pot. 8-9
I.b - Manual setting by following arm 8-9
II - Automatic setting by diameter reading 10-11
III - Automatic setting by diameter reading with additional functions 12-15

TENSION CONTROL IN CLOSED LOOP 16

I - Single roll tension control, automatic setting by dancer arm 16 - 21
II - Double roll tension control, automatic setting by dancer arm (modular) 22 - 23
III - Double roll or splicer tension control, automatic setting by dancer arm (compact) 24 - 25
IV - Double roll or splicer tension control, automatic setting by load cells 26 - 29

BRAKES AND CLUTCHES RANGE 30

Brakes and clutches models 30

ELECTROMAGNETIC BRAKE TYPE TB 32

Tension brake sizing 31
TB brake characteristics 32 - 35
Tension brake for strapping machine 36 -37

MAGNETIC PARTICLE CLUTCHES AND BRAKES 38

MPB, MPC Series 38 - 45
BB, BC Series 46 - 68

MAGNETIC CLUTCHES AND BRAKES 69

MB, MC Series 69 - 75
Applications 76

DATA APPLICATION FORM 77

Tension selection 77
Data application form 78 - 79

3
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 in 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

Zone 1 (unwind)
A B

❐ Tension zone definition: A-B

❐ Speed point in B
❐ Variable roll rotation speed
❐ Variable inertia
❐ In general constant tension X
X ❐ 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
different 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)
Zone 1 Zone 3
A B C

❐ Tension zone definition B-C

❐ Speed point in B
❐ Variable roll rotation speed
❐ Variable inertia
❐ Constant or Taper tension Z
X Y ❐ Particle brake system
applicable

4
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 speed difference in area B/C give required tension.

All tension systems must be according the speed line in close loop.

B C
Zone 1 Zone 2 Zone 3
A D

X Y Z

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
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
❐ Brake system applicable

5
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 influence of
correction.

Sensor Amplifier Brake

OPEN LOOP SOLUTION

Manual setting by pot.

Amplifier Brake 8 9
Pot.

Manual setting by following arm

8 9
Amplifier Brake

Pot.

Automatic setting by diameter reading

Amplifier Brake 10 11

Ultrasonic
sensor
Additional
functions

Automatic setting by diameter reading

with additional functions 12 15
Amplifier Brake

Ultrasonic
sensor
Additional
functions

6
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 Brake

Position regulation by dancer arm

16 25
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

26 27
This is an electromechanical system and the quality of load cells mounting
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 systems 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 HMCS2000. These controls include loop control
with PID, a lot of options and are able
to be programmed by PC (via RS232
26 27
line) or by external programmer poc-
ket (visual function).
A

The PID function is optimised for one inertia value. The HMCS2000 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 Each parameter P, I and D can be set individually for the smallest
100%
(core) and biggest diameter. As soon as the correct parameters are
found for the extreme diameter value, they are stored. The diameter
P information provided will fix the PID values for the present diameter
50% value. This will allow the system to keep an excellent stability during
I the whole diameter evolution. In the case where the diameter infor-
D mation is not available we can provide this signal by installing a
sonic sensor or by working with internal correction. The external
Diam. Info
diameter information supplied to the controller will ensure a better
Core precision compensation compared to an internal correction.
Typical PID values for TB brakes

7
I - 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

Setting type Where, When, Why ? Advantage

By Pot. Diameter ❐ Cable machine ❐ Low cost solution

reading ❐ No fast accel/deccel ❐ Easy to start-up
❐ Low roll diameter ratio ❐ Automatic regulation by diameter
❐ Operator intervention admitted following arm
❐ Manual correction feasible

Power supply
BTCS252/255

90 - 264 VAC

24 VDC
and Pot.
BTCS254-06/10

0 - 24 VDC 0 - 10 VDC

Brake TB

32 35

Brake MPB, BB Amplifier

HMCS2000-DRV2
38 45 or
0 - 1,8 A

0 - 10 VDC

Numeric control
BTCS251

8
Manual setting by Pot.

Potentiometer BTCS254
With strong housing and axis with bearing, the potentiometer BTCS254 is suitable for open or closed loop
applications.

BTCS254-06 6 mm axis Dimensions (mm)

BTCS254-10 10 mm axis
Potentiometer 10 k Ohm ø30

15
Shaft material Stainless steel
AISI3003

11
Cover material Plastic reinforced
with glass fibre

48
45°

37
Body material Alu UNI 9002/5
Protection Standard IP54 4x M3x90°
Operating temperature 0°C / +60°C ø42 ø30
Cable length 1,5 m øD g6
Weight 150 g
Service manual MC554

45°

4x M3x90°

BTCS 252/255 - Single phase power supply / 24 VDC Dimensions (mm)

55
The Warner Electric switching power supply units of the BTCS252 series
are designed and developed for industrial uses where safety, ease of use
and reliability are essential. These units comply with the parameters set out
by the Low Voltage Directive.

115
The low working temperature at full power operating temperature combined
with the use of first quality components ensure high reliability and duration.

Specifications
Input 90-264 VAC / 110 VDC, 50/60 Hz
Output 24 VDC, 3 A (BTCS252) and 5 A (BTCS255)
Service manual MC550

ELECTRICAL AMPLIFIER HMCS2000 Dimensions (mm)

HMCS2000-DRV2
❐ 1 logic card with 2 individual channels 75 183

Model Electrical Power supply / Output voltage /

149
165
174

input signal current current

HMCS2000-DRV2 0 – 10 VDC 24/48 VDC 0-24/48 VDC/4,5 A
Wiring Shielded cable
Setting Anti-residual 60
Mounting position Vibrations free, vertically
Service manual MC517

NUMERIC CONTROL BTCS251 (see page 17)

Service manual, mounting with Pot. : SM563

9
II - Tension control in open loop

MAIN APPLICATIONS - ADVANTAGE

Setting type Where, When, Why ? Advantage

Diameter reading ❐ The most commonly used ❐ Physical reading, no reset

solution in open loop ❐ Easy to start-up
❐ No operator intervention admitted
❐ Large roll ø ratio

Power supply
BTCS252/255

Ultrasonic
sensor

90 - 264 VAC

24 VDC
and

Brake TB 0 - 24 VDC 0 - 10 VDC

32 35

Brake MPB, BB
Amplifier
HMCS2000-DRV2
38 45 or
0 - 1,8 A

0 - 10 VDC

Numeric control
BTCS251

10
Automatic setting by diameter reading

ULTRASONIC SENSORS
Model HSCUA-130 HSCUA-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 900 mm 2400 mm
Accuracy ±1 mm ±1 mm
Protection class IP67 IP67
HSCUA-130 HSCUA-140 Accessory 5 m cable 5 m cable
Service manual MC487 MC488

Dimmensions (mm) ø44,5

14,2
23
30
65

5 20

10

95
60
70
4,3
4,6

11,2
M12x1
18,5 M12x1
15 15
31 M30x1,5
30

HSCUA-130 HSCUA-140

BTCS 252/255 - Single phase power supply / 24 VDC Dimensions (mm)

55
The Warner Electric switching power supply units of the BTCS252 series
are designed and developed for industrial uses where safety, ease of use
and reliability are essential. These units comply with the parameters set out
by the Low Voltage Directive.

115
The low working temperature at full power operating temperature combined
with the use of first quality components ensure high reliability and duration.

Specifications

Input 90-264 VAC / 110 VDC, 50/60 Hz

Output 24 VDC, 3 A (BTCS252) and 5 A (BTCS255)
Service manual MC550

ELECTRICAL AMPLIFIER HMCS2000 Dimensions (mm)

HMCS2000-DRV2
❐ 1 logic card with 2 individual channels 75 183

Model Electrical Power supply / Output voltage /

149
165
174

input signal current current

HMCS2000-DRV2 0 – 10 VDC 24/48 VDC 0-24/48 VDC/4,5 A
Wiring Shielded cable
Setting Anti-residual 60
Mounting position Vibrations free, vertically
Service manual MC517

NUMERIC CONTROL BTCS251 (see page 17)

Service manual, mounting with ultrasonic sensor : SM564

11
III - Tension control in open loop

MAIN APPLICATIONS - ADVANTAGE

Setting type Where, When, Why ? Advantage

Diameter reading ❐ The most commonly used ❐ Physical reading, no reset

solution in open loop ❐ Easy to start-up
❐ Operator intervention admitted ❐ Graphic display for output percentage
❐ Large roll ø ratio value
❐ Functions control available remote/
manually by operator

Ultrasonic sensor signal

0 - 10 VDC

Power supply
BTCS252/255

HMCS2000-POT-00
Ultrasonic
sensor

90 - 264 VAC

24 VDC
and

Brake TB 0 - 24 VDC 0 - 10 VDC

32 35

Brake MPB, BB OPTION for

Amplifier HMCS2000-DRV2 :
HMCS2000-DRV2 BTCS252
38 45 or Power supply
+24VDC

0 - 1,8 A

0 - 10 VDC

Numeric control
BTCS251

12
Automatic setting by diameter reading

Ultrasonic sensors - Dimensions, see page 11

Model HSCUA-130 HSCUA-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 900 mm 2400 mm
Accuracy ±1 mm ±1 mm
Protection class IP67 IP67
HSCUA-130 HSCUA-140 Accessory 5 m cable 5 m cable
Service manual MC487 MC488

Ultrasonic Diameter Sensing – HMCS2000-POT-00

❐ A simple, analogue, open loop torque control.

❐ Power supply 24 VDC / Internal consumption 150 mA.

❐ Adjustable maximum level of the output signal relatively to the

ultrasonic input level.

❐ Graphic display of the output level – full screen equal 10 VDC.

❐ FAST STOP, HOLD and BRAKE OFF can be activated either

through the front switches or through the terminal bloc.

❐ FAST STOP and HOLD levels are adjustable via potentiometer.

❐ 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 0 and 10 VDC Overall dimensions maximum:
Height 160 mm
To be used ONLY with scalable ultrasonic sensors type HSCUA-130 Width 95 mm
(0,9 m) or HSCUA-140 (2,5 m) Depth 75 mm
Weight 0,350 kg
❐ Service manual : MC520

ELECTRICAL AMPLIFIER HMCS2000 Dimensions (mm)

75 183
HMCS2000-DRV2
❐ 1 logic card with 2 individual output channels

Model Electrical Power supply / Output voltage /

149
165
174

input signal current current

HMCS2000DRV2 0 – 10 VDC 24/48 VDC 0-24/48 VDC/4,5 A
Wiring Shielded cable
Setting Anti-residual
60
Mounting position Vibrations free, vertically
Service manual MC517

POWER SUPPLY BTCS252/255 (see page 15)

NUMERIC CONTROL BTCS251 (see page 17)

Service manual, mounting with 0-10 V signal : SM571

13
III - Tension control in open loop

MAIN APPLICATIONS - ADVANTAGE

Setting type Where, When, Why ? Advantage

Diameter reading ❐ The most commonly used ❐ Physical reading, no reset

solution in open loop ❐ Easy to start-up
❐ Operator intervention admitted ❐ Particle brake current controled
❐ Large roll ø ratio ❐ Cheaper solution

Ultrasonic
sensor Ultrasonic sensor signal
0 - 10 VDC

or
Pot. 10 K Ohm
0 10 V signal

0-2A

Power Supply
BTCS252/255
Regulator
BTCS250-C
Brake MPB / BB 38 61
24 VDC
Brake TB 32 35

90 / 264 VAC

Ultrasonic
sensor Ultrasonic sensor signal
0 - 10 VDC

or
Pot. 10 K Ohm
0-10 V signal

0-2A
115 / 230 VAC

Brake MPB / BB 38 61 Regulator

BTCS250-T
Brake TB 32 35

14
Automatic setting by diameter reading

Ultrasonic sensors - Dimensions, see page 11

Model HSCUA-130 HSCUA-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 900 mm 2400 mm
Accuracy ±1 mm ±1 mm
Protection class IP67 IP67
HSCUA-130 HSCUA-140 Accessory 5 m cable 5 m cable
Service manual MC487 MC488

BTCS 250 - Current regulator power supply for particle brakes

The BTCS250 card was designed especially for controling

particle brakes and for increasing their yield. In fact, this
permits complete elimination of residual magnetism in the
powder 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
facilitates wall mounting.

Connection is easy and is done via 10-pole connector

fastened to the terminals with screws.

Specifications Dimensions (mm)

Power supply BTCS250-C 28 VAC or 24 VDC 171
Power supply BTCS250-T 110/230 VAC 50/60 Hz 120
Input 0-10 VCC from Pot. 10K
Output 0-2 A modulated PWM
120

BTCS250-C Only card

108

BTCS250-T Card with transformer

BTCS250-C BTCS250-T
Service manual MC544

BTCS 252/255 - Single phase power supply / 24 VDC

The Warner Electric switching power supply units of the

BTCS252 series are designed and developed for industrial
uses where safety, ease of use and reliability are essential. 55
These units comply with the parameters set out by the Low
Voltage Directive.

The low working temperature at full power operating tem-

115

perature combined with the use of first quality components

ensure high reliability and duration.

Warner Electric switching power supply units comply with

EMI standards. The BTCS252 series with 90 – 264 VAC
input has no ignition problems at full load even with low
mains voltage and therefore suitable for critical supply Specifications
mains. This series very compact and has an IP 20 degree of
protection against incidental contacts according to IEC Input 90-264 VAC / 110 VDC, 50/60 Hz
529. All the functions are located on the front panel and Output 24 VDC, 3 A (BTCS252) and 5 A (BTCS255)
marked with IEC symbols. Service manual MC550

15
I - Tension control in closed loop

BTCS251 is a digital controller that can be used in both open or closed loop. The brake driver is included and supply cur-
rent regulation especially for powder brakes. One 3 digit display permit to follow signal variations.

MAIN APPLICATIONS - ADVANTAGE

Setting type Where, When, Why ? Advantage

Dancer arm ❐ Unwinders ❐ Output PWM included

❐ Printing machines ❐ Digital inputs
❐ Intermittent or continuous function ❐ Numeric with micro-processor
❐ Adapted to powder brakes ❐ Accel / decel machine with separated
PID
❐ Can drive motor or pneumatic brake

Sensor
BTCS254

Dancer
arm

Numeric control
BTCS251

Brake MPB / BB

38 61 0-2A

Brake TB
Power supply
32 35 BTCS252/255

24 VDC

90 / 264 VAC

16
Automatic setting by dancer arm

BTCS251 - Numeric control

This device integrates a microprocessor control function and the power output to control the electromag-
netic powder brakes.

Equipped with only 3 push buttons for calibration and programming and one display with a 3 digit read-
ing, it has been designed to be mounted on a DIN rail inside customers electrical control panel.

The compact size, simple installation and easy to use make the
instrument extremely flexible.
Spécifications
The 24 VDC digital inputs can be easily interfaced with the instru-
mentation running the machine logic (PLC). The type of input and
output electrical signals can be chosen via a keyboard by the sys- Supply 24 VDC / 18 VCA
tem designer and the P.I.D. control logic results in high perfor- Power with particle brake: 50 W max.
mance precision control. Power with pneumatic brake
6 W max.
or motor:
The unit has been designed specifically for machines utilising a Regulated analog output 0-10V/-5+5V/4-20 mA
dancer roll and magnetic particle brake however it can also be selectable via keyboard
used with pneumatic brakes or motors, on unwind or rewind Analog output 0-10V
applications and with amplified load cells. PWM output 24VDC, 1,8 A max
Analog input keyboard selection 0-5V/0-10V/0-20 mA
Digital input 24 VDC
Working temp. 0-50 °C
Weight 180 g
Standard approval CE/UL
Mounting Rail DIN
Service manual MC553
Applications
Dimensions
Torque control
control with
withDANCER
DANCERROLL
ROLL--Mode
Mode00
01
73
26,5 21,5 25

14
71

8,5
90

8,5

68
14

Speed control with DANCER ROLL - Mode 02 Torque control wit LOAD CELLS - Mode 00

17
I - 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

Setting type Where, When, Why ? Advantage

Dancer arm ❐ Printing machines ❐ Absorb tension peak

❐ Intermittent function ❐ Can act as store
❐ Flying splice need ❐ Easy flying splice
❐ Accel / decel machine phase well
absorbed
❐ Flexibility

Sensor
HMCS605-E2

110/230 VAC
Dancer
arm Analogue
Control
Brake TB HMCS202-E1

32 35

Brake MPB

38 44

0 - 24 VDC

Additional functions
❐ Brake open
❐ Emergency stop
❐ Drift stop(stop integral term of PID)
❐ Gain change

18
Automatic setting by dancer arm

ROTARY SENSOR HMCS605-E2 (see pages 20 and 21)

ANALOGUE CONTROL HMCS202-E1

❐ HMCS202-E1 Standard execution

❐ HMCS202-E54 Standard IP54 protected

❐ HMCS202-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 HMCS202-E1 and –E54
Loop gain 2 adjustable range selection Can be change during operation
Accessories HMCS-KIT1, 2, 3, 5 and 6 See details on page 21
Sensor compatible Dancer arm with HMCS605-E2 See details on pages 20 and 21
Service manual MC403

Technical information
HMCS202 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)
37
29
99

51,5 73 60
282 87
265

MCS 202-E
POWER

LOOP GAIN
120
57

BRAKE 14,3
TORQUE OFFSET
ø65

19
Automatic setting by dancer arm

ROTARY SENSOR HMCS605-E2

A position sensor is used in 2 possible ways:

❒ To detect dancer moving in the closed loop installation working on dancer principle.

❒ To sense the diameter of the roll to operate open loop control or make PID compensation in closed loop installation.

HMCS605-E2 is 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.
Sensor

HMCS605-E2
Power supply 10 to 30 VDC / 30 mA
(or ± 5 to 15 VDC)
Max. detection angle 200° or ± 100°
Sensitivity 2,5 mV / V / °
TB brake
Service manual MC483

Dimensions (mm) – Mounting

130 min 47 / max 70

50,8 65 18

ø6,35
57

Coupling

ø38,1
31,6
57

20
3x1

3 x ø45 45
21,9 14,2
ø6,5

38,1

20
Automatic setting by dancer arm

HMCS605-E2 - MOUNTING KIT

The HMCS202-Exx is designed to work with dancer arm principle. Usually the sensor is a rotary type.

Warner Electric sensor HMCS605-E2 are delivered without mounting kit.

Mounting kit comprises of CABLE WITH CONNECTOR(S), COUPLING, MOUNTING BRACKETS and all necessary
SCREWS. Various KITS have various lengths of cable and cable with or without connector at control end side.

HMCS2000 line requires free leads (HMCS2000 control line is provided with terminal block).

HMCS202-Exx requires a connector (HMCS202-Exx is provided with the connector).

Old kit 3 wires New kit 4 wires Cable length 1 or 2 Compatibility Wiring
connectors

HMCS-KIT1 HMCS-KIT1A 3m 2 HMCS202-E1 A

HMCS-KIT2 HMCS-KIT2A 3m 1 HMCS2000-ECA/CTDA B
HMCS-KIT3 HMCS-KIT3A 4,5 m 2 HMCS202-E1 A
HMCS-KIT4 HMCS-KIT4A 4,5 m 1 HMCS2000-ECA/CTDA B
HMCS-KIT7 HMCS-KIT7A 6m 2 HMCS202-E1 A
HMCS-KIT8 HMCS-KIT8A 8m 1 HMCS2000-ECA/CTDA B

ELECTRICAL CONNECTIONS

A (New kit)
Shield
BROWN

SIGNAL /1 YELLOW
0V /2 3 2 2 3
-15VDC (0V) /3 4 1 1 4
+15VDC /4 GREEN
WHITE
MALE CONNECTOR FEMALE CONNECTOR
Front view Front view

B (New kit)
Shield
-15VDC (0V) /3
BROWN
0V /2
YELLOW
2 3
1 4
SIGNAL /1
GREEN
+15VDC /4
WHITE
MALE CONNECTOR FEMALE CONNECTOR
Front view Front view

21
II - Double tension control in closed loop (modular)

HMCS2000-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 APPLICATIONS - ADVANTAGE

Setting type Where, When, Why ? Advantage

Dancer arm ❐ Printing machines ❐ Absorb tension peak

❐ Intermittent function ❐ Can act as store
❐ Flying splice need ❐ Easy flying splice
❐ Accel / decel machine phase well
absorbed
❐ Flexibility

Sensor
HMCS605-E2 20 21

Dancer
arm

Brake TB Memory card

HMCS2000-CRD2
24 VDC Amplifier
32 35 HMCS2000-DRV2 9

Brake MPB
Controller
38 44 HMCS2000-ECA

0 - 10 VDC

Hand
Programmer
HMCS2000-PRG
HMCS2000-WIN01
programme

22
Automatic setting by dancer arm

POWER SUPPLY BTCS252/255 and HMCS2000-DRV2 (see page 9)

ROTARY SENSOR HMCS605-E2 (see pages 20 and 21)

CONTROLLER HMCS2000-ECA
❐ Digital controller - 2 channels

Main Characteristics

❐ 24 VDC power supply unit

❐ PID parameters setting on line
❐ Automatic adaptation for PID parameters, splicing logic included
❐ Opto isolation for input and output
❐ 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

BTCS232FM - RS232 SERIAL CABLE

The BTCS232FM cable is specially adapted to connect MCS2000 range
controls to PC.

❐ Service manual : SM374

HMCS2000-PRG - HAND PROGRAMMER

❐ 4 command keys only

❐ 2 x 16 characters display
❐ Menu in 3 languages
❐ Connectable and disconnectable during operation
❐ Supply by control HMCS 2000-EC

HMCS2000-CRD2 - MEMORY CARD

All setting data saved. It allows a quick loading operation on new machine
or on running machine to optimise.

❐ Memory for 2 different programs

❐ Plugable on line in HMCS2000-ECA unit

HMCS2000-WIN01 – PROGRAMME

The program can modify the running setting by this software running with:
Windows 95/98/XP/2000.

23
III - Double tension control in closed loop (compact)

The command unit HMCS2000-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

Setting type Where, When, Why ? Advantage

Dancer arm ❐ Printing machines ❐ Absorb tension peak

❐ Intermittent function ❐ Can act as store
❐ Flying splice need ❐ Easy flying splice
❐ Accel / decel machine phase well
absorbed
❐ Flexibility

Sensor
HMCS605-E2 20 21

Dancer
arm Memory card
HMCS2000-CRD2
Brake TB

32 35 24 VDC Amplifier
HMCS2000-DRV2 9

Brake MPB
Controller
38 44 HMCS2000-CTDA-20

0 - 10 VDC

HMCS2000-WIN01
programme

24
Automatic setting by dancer arm

POWER SUPPLY BTCS252/255 and HMCS2000-DRV2 (see page 9)

ROTARY SENSOR HMCS605-E2 (see pages 20 and 21)

BTCS232FM - RS232 SERIAL CABLE (see page 23)

CONTROLLER HMCS2000-CTDA20
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
❐ Software password protected ABC binary combination active low
❐ Scrolling menu program ABC inputs synchronisation active low
❐ Multipurpose application Stop integral form active low
❐ RS232 communication
❐ Two ouput channels Digital outputs
❐ Automatic sensor scaling Sensor level indication Two binary outputs
❐ Programmable output configuration
❐ Output sensor information Other outputs
❐ External set point change Power supply sensor ± 15 VDC / 100 mA
❐ Automatic or imposed PID correction ± 5 VDC / 100 mA
❐ All features requested for tension control Power supply 24 VDC
❐ Plugable memory card Voltage reference + 10 VDC / 10 mA
❐ Variable tension value to prevent telescopic effect on
unwinding – CTDA-22
❐ Service manual : MC525

HMCS2000-CRD2 - MEMORY CARD

All setting data saved. It allows a quick loading operation on new machine
or on running machine to optimise.

❐ Memory for 2 different programs

❐ Plugable on line in HMCS2000-ECA unit

HMCS2000-WIN01 – PROGRAMME

The program can modify the running setting by this software running with:
Windows 95/98/XP/2000.

25
IV - Double tension control in closed loop

The command unit HMCS2000-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

Setting type Where, When, Why ? Advantage

Load cell ❐ Slitter, Sheeter and Coater ❐ Direct tension measure

❐ For heavy material ❐ Mechanically well integrated
❐ Limited room ❐ No moving part
❐ No fast accel/decel
❐ Tension peak accepted

One or two load cells Memory card

HMCS2000-CRD2

Brake TB

32 35 Controller
HMCS2000-CTLC-20
Brake MPB

38 44

0 - 10 VDC

24 VDC Amplifier
HMCS2000-DRV2
HMCS2000-WIN01
0 - 24 VDC Programme
9
0 - 24 VDC

26
Automatic setting by load cell

POWER SUPPLY BTCS252/255 and HMCS2000-DRV2 (see page 9)

BTCS232FM - RS232 SERIAL CABLE (see page 23)

CONTROLLER HMCS-2000-CTLC-20
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
❐ Software password protected ABC binary combination active low
❐ Scrolling menu program ABC inputs synchronisation active low
❐ Multipurpose application Stop integral form active low
❐ RS232 communication
❐ Two ouput channels Digital outputs
❐ Automatic sensor scaling Sensor level indication Two binary outputs
❐ Programmable output configuration
❐ Output sensor information Other outputs
❐ External set point change Power supply sensor ± 15 VDC / 100 mA
❐ Automatic or imposed PID correction ± 5 VDC / 100 mA
❐ All features requested for tension control Power supply 24 VDC
❐ Plugable memory card Voltage reference + 10 VDC / 10 mA
❐ Variable tension value to prevent telescopic effect on
unwinding – CTLC-22
❐ Service manual : MC516

HMCS2000-CRD2 - MEMORY CARD

All setting data saved. It allows a quick loading operation on new machine
or on running machine to optimise.

❐ Memory for 2 different programs

❐ Plugable on line in HMCS2000-ECA unit

HMCS2000-WIN01 – PROGRAMME
The program can modify the running setting by this software running with:
Windows 95/98/XP/2000.

27
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. HFM01A... and
HFM02-... are only differenciated by the physical dimensions.

FOOT MOUNTED TYPE FM01A… and FM02-…

Foot mounted load cells are available in two versions:

With incorporated amplifier : HFM……..-AC Without amplifier : HFM……..-C

AC = amplifier and connector on the load cell body C = connector on load cell body

Specifications (all HFM series)

HFM……..-AC HFM……..-C
Power supply ±12 to ±15 VDC ± 5 VCC or +10 VDC
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 29
Service manual MC480

AVAILABLE MODELS / CAPACITY

Nom. load 100 N 250 N 500 N 1000 N 2500 N 5000 N 10000 N

HFM01A- -100-AC -250-AC -500-AC -1000-AC -2500-AC -5000-AC
HFM01A- -100-C -250-C -500-C -1000-C -2500-C -5000-C
HFM02..- -5000-AC -10000-AC
HFM02..- -5000-C -10000-C

HMCS2000-IS - Load Cell Interface

The interface sensor will sum and amplify the input signals from two load cells, and can
be used with a number of different load cells. The interface should be positioned close
to the load cells to ensure that no noise is injected into the low voltage signal before it
is amplified.

Specifications
Input power / Output power
Input supply: +24 VDC, ±10%, 300 mA Analog outputs (short circuit protected)
Analog inputs Calibrated load cell/
2 load cell input: any voltage between 20 mV and ultrasonic-sensor output: 0-10 VDC, 10 mA max.
10 VDC 5 K Ω input impedance Power for ultrasonic sensor: +24 VDC
Ultrasonic input: 0-10 VDC, delta mon. of 1 V Voltage reference: 10 VDC, 10 mA
10 K Ω input impedance Service manual MC521
max. gain: 1000
3 inputs for line speed: 0-10 VDC, 10 K Ω impedance

28
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 HES 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 referenced on the load cell body (normally an arrow indicates the sensitive direction).

HES..-... LOAD CELL FEATURES

HES01-40C and HES02-52C
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

Nominal load 150 N 250 N 500 N 1000 N 2000 N

HES01-... -150-40C -250-40C -500-40C -1000-40C -2000-40C
HES02-... - -250-52C -500-52C -1000-52C -2000-52C

LOAD CELLS SIZING - MOUNTING RECOMMENDATIONS Wrapping

Angle
240 min.
Please keep this principle in mind: the load cell installed is destined to measure the
WEB TENSION and not other constraints applied to it.

Take the following points into consideration before selecting, sizing and installing material components.

❐ Load cells location should be vibration free. Vibrations will decrease quality measurement.

❐ 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).

❐ Respect a reasonable sensing shaft weight/web tension measure ratio. Less than 1.

❐ 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 = 180°.

❐ So far as it is possible, use load cell in compression, with web tension effect in same direction as the weight of shaft.

29
Tension brakes and clutches range

Brake and clutch

Series Main characteristics Torque range Pages
types

Electromagnetic brakes TB Monodisc 0,5 - 300 Nm

24 VDC power supply
28 35

Electromagnetic brakes TBM Monodisc 10 Nm

24 VDC power supply
36 37

Magnetic particle brakes MPB Completely packaged 0,04 - 500 Nm

BB and enclosed unit
Shaft output or bore
38 68
24 or 90 VDC power supply

Magnetic particle clutches MPC Completely packaged 0,04 - 500 Nm

BC and enclosed unit
Both end shaft output
38 68
or bore
24 or 90 VDC power supply

Permanent magnetic MB Completely packaged 0 - 33 Nm

brakes and enclosed unit
Shaft output
69 75
Manual setting

Permanent magnetic MC Completely packaged and 0,07 Ncm - 33 Nm

clutches enclosed unit
Bore output
69 75
Manual setting

30
Tension brake sizing

Two important parameters are used in brake selecting:

❐ Max. torque requirement
❐ Max. thermal power to be dissipated

These two values are determined by the application (see calculation example on pages 78-79).

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)

* As 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 -
Tmax
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.
N max

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.

Gear box

Speed

Brake

Torque

31
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 34 to 35.

Dynamic braking torque Maximum braking torque (emergency stop)

TB170 - TB1525 TB170 - TB1525
400 500
300 400 TB 15
25
300
200 TB 122
5
TB

150 200
TB
15

12
25

100 150
25 TB 10
TB 1000 00
80
Brake torque MB [Nm]

60 100
TB 825 80
Torque Md [Nm]

TB 825
40
60
30 50
40
20 TB 500 TB 500
30
15

10 20
TB 425
8 15
6 TB 425
10
4 8
3 6
5
2 TB 260
TB 260 4
1,5
3
1
0,8 2
0,6

0,4
TB 170 1
0,3 TB 170
0,8

0,2 0,6
10 20 40 60 100 200 400 0 100 200 300 400 500
15 30 50 80 150 300 500
Brake n (rpm) Brake n (rpm)

32
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.

Part TB170 TB260 TB425 Part TB500

D = 46 mm D = 69 mm D = 111 mm D = 130 mm
1 Armature hub* B5102-541-001-38 B5103-541-001-47 B5104-541-001-31 1 Taperlock bushing** B180-xxxx-xxxx
2 Armature K110-0096 B110-0097 B110-0098 2 Armature hub K5300-541-004
K5375-631-012 K5365-631-016 K5367-631-008 3 Armature B110-0047
3 Magnet 24V
R = 110 Ω, 20°C R = 60 Ω, 20°C R = 76 Ω, 20°C K5300-101-003
4 Drive pins
4 Terminals Wires B5103-101-002 B5103-101-002 3x
5 Magnet IM 24V B5300-631-040
* Prebored 5-1 Terminals B5311-101-001
** Indicate bore and keyway 6 Magnet OM 24V B5300-631-000-46
7 Conduit box K5200-101-010

Part TB825 TB1000 TB1225 TB1525

D = 215 mm D = 259 mm D = 316 mm D = 395 mm

1 Taperlock bushing** B180-xxxx-xxxx B180-xxxx-xxxx B180-xxxx-xxxx B180-xxxx-xxxx
2 Armature hub B540-0394 B540-0313 B540-0015 B540-0314
3 Armature B5301-111-019 B5302-111-021 B5303-111-011 B5304-111-005-04
B5301-101-001 B5301-101-001 B5301-101-001 B5301-101-001
4 Drive pins
3x 3x 4x 4x
B5311-631-000-30 B5312-631-000-36 B5313-631-000-11 B5314-631-000-08
4 Magnet IM 24V
R = 20 Ω, 20°C R = 20 Ω, 20°C R = 22 Ω, 20°C R = 20 Ω, 20°C
5-1 Terminals B5311-101-001 B5311-101-001 B5311-101-001 B5311-101-001
6 Magnet OM 24V B5311-631-000-16 - - -
7 Conduit box K5200-101-011 K5200-101-011 K5200-101-011 K5200-101-011

33
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

A B
C
B 1,6 E
øG

øQ
øS

3,2
K

øN
2,4

øP
øH
øD

øM
øL

øD

øM
øH
øD
øL

øL
K øN K
øG

øP

øG
3,2
øQ
øS

øQ
øS
3,0
ø9,52 0,025

0,4 E F E
A 1,2 T C
B A

TB500 OM TB825 OM, TB1000 OM, TB1225 OM

Size TB170 TB260 TB425 TB500 TB825 TB1000 TB1225 TB1525

Md [Nm] 0,8 4 16,5 35 75 150 300 450
Md min [Nm] 0 0,08 0,16 0,2 0,5 1,1 2 3
n max [rpm] 5000 5000 5000 5000 3000 2400 2000 1600
I 24V = [A] 0,22 0,40 0,32 1,010 1,177 1,224 1,076 1,212
P Continu [kW] 0,015 0,030 0,060 0,100 0,200 0,360 0,520 0,810
P* Alternativ [kW] 0,022 0,045 0,100 0,180 0,360 0,650 0,950 1,580
R 20° C [Ω] 110 60 76 23,8 20,4 19,6 22,3 19,8
tb [s] 0,020 0,040 0,080 0,052 0,112 0,152 0,290 0,310
Inertia [kgm2] 12 • 10-6 116 • 10-6 1,4 • 10-3 1,9 • 10-3 0,022 0,041 0,095 0,213
Mass [kg] 0,180 0,650 1,800 2,3 8,2 12 21 27,5
A [mm] 30,5 48,5 52 79 94 105 138 116
B [mm] 7 12 14 77 30,5 30,5 30,5 30,5
C [mm] - - - 51 54 56,5 62 65
øD [mm] 46 69 111 130 215 259 316 395
E [mm] 20,6 32 30,5 30,5 33,5 36,5 41,5 44,5

* Alternativ duty based on 30 minutes ON and 30 minutes OFF.

34
TB brake characteristics

TB1525 IM TB825 - 1525

1/2 -13 UNC-3B

B

ø12,7 +0.025
0
10
øG
øN
øP

2,4 9,5
øM
øH
øD

øL

K Steel
30 M
< 0,2 % C

øU
3,5

661-0005
+0.01

E
-0
ø12,7

C Non magnetic
A
15

Size TB170 TB260 TB425 TB500 TB825 TB1000 TB1225 TB1525

F [mm] - - - 28,5 - - - -
øG [mm] 19,5+0,05 35 62 49 55 98 114 180
øH [mm] 15,9 30,1 31,8 - 118 159 175 152,5
K* [mm] 10,3 17,5 22,2 38 38 44,5 76 76
øL max [mm] 10 20 22 32 42 60 75 75
- - - 98,42 90,49 133,4 149,3 215,9
øM±0,025 [mm]
3 x 120° 3 x 120° 3 x 120° 4 x 90° 4 x 90°
øN±0,05 [mm] - - - 52,40 88,93 136,55 161,95 228,60
- - - 60,3 108 155,6 184,1 247,60
øP (for screw) [mm]
- - - 8 x M4 6 x M8 6 x M8 6 x M8 12 x M8
øQ-0,05 [mm] 61,9 88,9 142,47 165,10 247,62 - - -
54 79,4 127 149,2 225,5 - - -
øS (for screw) [mm]
4 x M4 4 x M4 4 x M6 4 x M10 4 x M8 - - -
T [mm] - - - 49 - - - -
øU [mm] - - - 110 170 220 260 340

* Reverse mounting of taperlock bushing is possible

35
Tension brake for strapping machine

Specially designed for strapping machine, the electromagnetic brake TBM10 is 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

PALLET

PLASTIC FILM ROLLER

TBM SIZE 10
Heat dissipation torque Brake torque

20
M d (Nm)

8
M d (Nm)

6 15

4 10
3 8
6
2
5
1.5 4
1 3
10 20 40 60 100 200 400 0 100 200 300 400 500
15 30 50 80 150 300 500
n (rpm) n (rpm)

36
Tension brake for strapping machine

TBM SIZE 10

VAR 03
T ➀
➁

500
45

➂
ø 100 h9

P9
ø 42
ø 90
ø 81
D H8

ø 5.5

4.5
26
D min = 8 mm with standard keyway
D min = 13 mm with standard keyway

VAR 04
7.9 H8

3 pins on
➃
T
ø 57.96 8.3
➀
ø 0,10
ø 41

U max : 24 VDC - P 20°C = 10,8 Watts

Part TBM SIZE 10

26
1 Inductor 24VDC B6650-631-000-39
2 Armature VAR03 B110-0000-1358
Hub prebored ø7,5 B540-0000-2519
3
Keyway according to : ISO R773 / BS 4235 / Hub ø12 H8 + Keyway 4 P9 B540-0000-2517
NFE 22175 / tolerance P9 4 Armature VAR04 B6650-111-000-08

37
Magnetic particle clutches and brakes

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 Features and Benefits
particle clutches and brakes make
them ideal for : Torque independent of slip speed No wearing parts
❐ Torque is transmitted through mag- ❐ There are no friction surfaces to
❐ tension control netic particle chains which are grab or wear, and the units are not
❐ load simulation formed by an electromagnetic field. affected by changes in atmospher-
❐ cycling/indexing The torque is independent of slip ic or other environmental condi-
❐ soft starts and stops speed, depending only on circuit tions.
current, and is infinitely variable
from 0 (disengaged) to rated Efficient/Compact design
Specials are our business torque. ❐ High torque to size ratio and low
consumption of electric power.
Special Shaft Configurations Precise engagement
❐ Customer specified shaft configu- ❐ Precision Tork magnetic particle Versatile mounting
rations for easy machine mounting clutches and brakes engage to ❐ Convenient bolt circle for easy
and retrofitting. transmit torque with speed and mounting.
precision. Response of the parti- ❐ Mounting brackets available for all
Wash Down Environment cles to the field is virtually instanta- sizes.
❐ Stainless steel units available for neous, providing perfectly con- ❐ Brakes are available with solid
extreme environments. trolled, jerk-free engagement. shafts and through bore.
❐ Can be mounted horizontally or
Special Torque Customer specified engagement vertically to solve virtually any
❐ Maximum torque configurations to ❐ Engagement time may be very motion control requirement.
meet customer specifications. gradual or extremely fast. The fre-
quency and torque of the engage- Modular
ment/disengagement sequence is ❐ Customised products
limited only by the capabilities of ❐ Interchangeable with industry stan-
the control circuitry. dard sizes
Design and operation

Completely packaged and enclosed unit.

Easy to install

Stainless steel Low current coil gen-

hardware erates magnetic field

Zinc dichromate Extremely long

plating on all steel life spherical
surfaces magnetic particles

Magnetic
powder cavity

Stainless steel
input shaft

Convenient pilot
and mounting bolt New and unique
pattern dual seal design

Operating Principles
Power input (DC)
The magnetic particle unit consists of The coil is assembled inside the Stationary field
four main components: housing. The shaft/disc fits inside the Magnetic-flux path
housing/coil assembly with an air gap
Magnetic particles
1) Housing between the two; the air gap is filled
Rotor
2) Shaft/disc with fine magnetic powder. Cylinder
3) Coil Seal
4) Magnetic powder Engagement

When DC current is applied to the

Output shaft Input shaft
magnetic particle unit, a magnetic flux
Torque current curve (chain) is formed, linking the
120
shaft/disc to the housing. As the cur- Field coil
rent is increased the magnetic flux
Percent of rated torque

100
becomes stronger, increasing the
80 torque. The magnetic flux creates
extremely smooth torque and virtually
60 no “stick-slip”.

40
Disengagement
20
When DC current is removed the
0 magnetic powder is free to move
0 20 40 60 80 100 120
Percent of rated current 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)* =
π · ø 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.

Thermal Energy (slip watts)

1- When a brake or clutch is slipping, heat 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)2 cycle

Slip Watts = 0,00077 · J (kgm2) · · f
10000 min
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
C (Nm) =
2

2- Soft/controlled stopping applications calculate torque as a function of inertia, speed and desired time to stop the load.

J (kgm2) · N (RPM)
C (Nm) =
9,55 · Time (s)
Magnetic particle clutches and brakes

Quick Selection Charts

MPB2 / MPC2 MPB15 / MPC15

1800 Heat 1000 Heat
dissipation : dissipation :
1500 10 watts max. 20 watts max.
800
Slip (RPM)

Slip (RPM)
1200
600
900
400
600

300 200

0
0 0,04 0.09 0,13 0,18 0,22 0 0,2 0,45 0,67 0,9 1,1 1,35 1,58
0,02 0,07 0,11 0,15 0,2
Torque (Nm)
Torque (Nm)

MPB70 / MPC70 MPB120 / MPC120

1000 1000
Heat Heat
dissipation : dissipation :
800 100 watts max. 800 140 watts max.
Slip (RPM)
Slip (RPM)

600 600

400 400

200 200

0 0
0 1,13 2,26 3,39 4,51 5,64 6,77 7,9 0 2,2 4,51 6,77 9 11,3 13,55
Torque (Nm) Torque (Nm)

MPB240

1000
Heat
dissipation :
800 200 watts max.
Slip (RPM)

600

400

200

0
0 4,4 9 13,5 18 22,5 27
Torque (Nm)
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)

❐ Paper/Foil/Film Processing

❐ Labelling Applications

❐ Textile Processing

❐ 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 Devices

❐ Conveyors

❐ Bottle Capping
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-CTDA control provide Velocity

accurate closed loop tension control for rewind applica- Slip =
π·D
tions.
122
Application example: =
π · 0.5

Information Full roll ø : 0,5 m = 78 RPM

required: Tension : 22 N
Velocity : 122 m/min Heat = 0,103 · torque · slip
dissipation
tension · full roll ø = 0,103 · 5,5 · 78
Max. torque =
2
= 44,46 watts
22 · 0,5
= Select a brake that exceeds the maximum torque and
2
thermal energy requirements from Quick Selection
= 5,5 Nm Chart – MPB70.

Particle clutches and the MCS202-E1 control provide accu- Full roll ø Speed
=
rate closed loop tension control for rewind applications. (π · D)
90
=
(π · 0,23)
Application example:
= 125 RPM
Information Core ø : 0,08 m
required: Full roll ø : 0,23 m Slip = Input speed – Full roll ø
Tension : 22 N
Velocity : 90 m/mn = 500 – 125
Input speed : 500 RPM* = 375 RPM

Max. torque. = Tension · full roll ø Thermal

= 0,103 · Torque · slip
2 Energy
22 · 0.23 = 0,103 · 2,53 · 375
= = 97,72 watts
2

= 2,53 Nm Select a clutch that exceeds the maximum torque and

thermal energy requirements from the Quick Selection
= Speed Chart – MPC120.
(π · d)
90 * To maximize tension control and minimize heat generated, select
= a drive system that will result in an actual input speed as close
(π · 0,08) 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
= 358 RPM more readily available.
Magnetic particle brakes - MPB

305 mm
F K Both ends

G
Flat
or
keyway
R
WARNER ELECTRIC
Model: MPB15M

A B Both ends

E I
D
C

Specifications

Models Max. Drag Rated Resistance Rated Response Response Inertia of Max. heat Max. Weight
torque torque voltage current zero with output shaft dissipation speed
force force
(Nm) (Nm) (VDC) (Ω) (A) (ms) (ms) (kgcm2) (W) (RPM) (kg)

MPB2M-6-24 0,2 0,044 24 92 0,261 8 4 0,0037 10 1800 0,45

MPB15M-12-24 1,7 0,044 24 80 0,302 25 9 0,04 20 1000 1,36
MPB70M-19-24 7,9 0,11 24 35 0,677 70 17 0,23 100 1000 3,2
MPB120M-19-24 13,6 0,22 24 33 0,742 90 25 1,09 140 1000 5,45
MPB240M-24-24 27,1 0,44 24 19 1,286 150 45 3,92 200 1000 9,1
MPB240-007 26,4 0,44 24 19 1,286 150 45 3,92 200 1000 9,1

Dimensions (mm)
Models Shaft ø Keyway - DIN 6885 Mounting Holes
I (h7) (Width x length) K depth
MPB2M-6-24 6 5,5 flat on 16 3 x M4 on ø 34 equidistant 7
MPB15M-12-24 12 4 x 20 3 x M5 on ø 51 equidistant 7,5
MPB70M-19-24 19 6 x 25,4 4 x M5 on ø 107 equidistant 16
MPB120M-19-24 19 6 x 25,4 4 x M6 on ø 122 equidistant 19
MPB240M-24-24 24 8 x 25,4 4 x M6 on ø 149 equidistant 16,5
MPB240-007 29 27 flat on 31,8 4 x M6 on ø 150 equidistant 8

Models A Pilot ø B C D E F G
MPB2M-6-24 53,59 19,05 - 19,03 56,64 29,21 1,52 18 22,1
MPB15M-12-24 74,39 28,59 - 28,56 77,47 37,08 1,78 21,84 34,29
MPB70M-19-24 116,23 41,29 - 41,26 85,6 44,7 2,54 24,89 31,75
MPB120M-19-24 133,35 41,29 - 41,26 102,11 55,12 2,54 29,97 38,1
MPB240M-24-24 158,57 62,01 - 61,99 118,36 67,31 2,54 37,08 41,91
MPB240-007 158,57 62,01 - 61,99 118,36 67,31 2,54 37,08 41,91
Magnetic particle clutches - MPC

305 mm
F
K Both ends

H G
Flat
or
keyway
R
WARNER ELECTRIC
INPUT

Model: MPC15M

A B Both ends

E I
D
C

Specifications
Models Max. Drag Rated Resistance Rated Response Response Inertia of Max. heat Max. Weight
torque torque voltage current zero with output shaft dissipation speed
force force
(Nm) (Nm) (VDC) (Ω) (A) (ms) (ms) (kgcm2) (W) (RPM) (kg)

MPC2M-6-24 0,2 0,044 24 92 0,261 8 4 0,0039 10 1800 0,454

MPC15M-12-24 1,7 0,044 24 80 0,302 25 9 0,043 20 1000 2,72
MPC70M-19-24 7,9 0,11 24 35 0,677 70 17 0,26 100 1000 7,71
MPC120M-19-24 13,6 0,22 24 33 0,742 90 25 1,1 140 1000 9,98

Dimensions (mm)
Models Shaft ø Keyway - DIN 6885 Mounting Holes
I (h7) (Width x length) K depth
MPC2M-6-24 6 5,5 flat on 16 3 x M4 on ø 34 equidistant 12,7
MPC15M-12-24 12 4 x 20 3 x M5 on ø 51 equidistant 12,7
MPC70M-19-24 19 6 x 25,4 4 x M5 on ø 107 equidistant 16
MPC120M-19-24 19 6 x 25,4 4 x M6 on ø 122 equidistant 19

Models A Pilot ø B C D E F G H

MPC2M-6-24 53,59 19,05 - 19,03 94,74 46,99 1,52 28,46 22,35 22,35
MPC15M-12-24 75,39 28,59 - 28,56 132,3 71,12 1,78 42,93 34,3 23,4
MPC70M-19-24 116,46 41,29 - 41,26 166,37 93,22 2,54 52,83 34,29 34,29
MPC120M-19-24 133,35 62,01 - 61,99 178,31 101,6 2,54 60,96 38,1 34,3
Magnetic particle clutches and brakes

The magnetic particle unit combines

the resilience of a fluid coupling with
the locked-in stability of a friction
clutch. Torque is transmitted by a spe-
cially alloyed dry ferromagnetic pow-
der, it apparent viscosity may be
changed by modulation of the field coil
current.

The units can sustain continuous slip

(under maximum heat ratings) at a pre-
cise and stable torque value, which is
determined by excitation level.

Slip between input and output mem-

bers is not necessary in order to trans-
mit torque, and provided load torque
does not exceed the torque for which
a unit is excited to transmit, locked-in
synchronous operation will take place.

Conversely, if load torque exceeds the

energised torque level, slip will occur It should be noted that use of a dry coil is energised. The resultant flux which
in an absolutely smooth manner at the powder rather than a fluid-suspended is generated, passed through the pow-
predetermined torque value. For all powder medium promotes consistency der, causing it to align with the flux path,
practical purposes, static and dynamic and accuracy of torque control. and thereby creates a driving bond
coefficients of friction are sensibly between input and output members, the
equal; also, output torque is indepen- Briefly, the unit include two concentric strength of which is only determined by
dent of speed, or slip speed. members, the body or input member the value of DC current applied to the
containing the field coil, and within it, coil.
Powder performance is unaffected by and separated by a small annular gap,
temperature rise on the working sur- an inner rotor, or output member. The
faces, and units will, have at all times, annular gap contains a ferromagnetic
a torque directly proportional to current. powder, which is activated when the

Operating characteristics The torque transmitted by powder units is proportional to field cur-
rent, and is infinitely variable from maximum design rating down to
practically zero in all models.
Torque/current characteristic curves can vary by 5 % dependent on
whether current is increasing or decreasing. This is due to magnetic
hysteresis.

For all practical purposes torque is independent of speed, either with

or without the presence of slip, and can be maintained within an accu-
racy of 5 % for speeds within the recommended operating range
50 to 2600 RPM.

De-energised drag torque due to residual iron circuit magnetism, bear-

Torque (Da/Nm)

ing and seal friction, is less than 1 % of design torque rating for any
unit.

Response time to torque is determined by field coil inductance to

resistance ratio plus a magnetic delay due to eddy current loss.

Note: to ensure satisfactory operation, all clutches and brakes must

Absorption (A) be mounted in horizontal axis. For vertical use, please consult us.
Magnetic particle clutches and brakes

BRAKE selection 1000

When min. roll speed and max. torque are known for the BB500
application, select the unit from theses charts.

Torque (Nm)
BB250
For continuous slip applications, as tension control in an
unwind or rewind application, slip watts are calculated BB170-1
using the following formula: BB120-1
100
Slip Watts = BB65-1
0,103 · max. torque (Nm) · min. roll speed (RPM)
BB35

BB12-1
10

Brakes Series BB
1
10
20
30
40
60
80
110
150
200
300
400
550
800
1200
1600
1800
2200
2600
3000
Speed (RPM)

1000 1000

BBR500 BBV500
Torque (Nm)

Torque (Nm)

BBR250 BBV250
BBR170-1 BBV170-1
BBR120-1 BBV120-1
100 100
BBR65-1 BBV65-1

BBR35 BBV35

BBR12-1 BBV12-1
10
10

Brakes Series BBR Brakes Series BBV

1
1
10
20
30
40
60
80
110
150
200
300
400
550
800
1200
1600
1800
2200
2600
3000

10
20
30
40
60
80
110
150
200
300
400
550
800
1200
1600
1800
2200
2600
3000

Speed (RPM)
Speed (RPM)

47
Magnetic particle clutches and brakes

CLUTCH selection 10000

For continuous slip applications, as tension control in a

rewind application, slip watts are calculated using the

W (Watts)
following formula:

Slip Watts =
0,103 · max. torque (Nm) · slip speed (RPM) BC500
1000
In rewind applications the motor RPM should be higher
(10 %) than the fastest spool RPM.
BC250
BC170-1
In applications with the web running over a pulley or in a BC120-1
nip roll application use the pulley diameter as the roll diam-
eter.
BC65-1
In rewind application, don’t forget to always mount the BC35
100
motor output to the exterior flange of clutch to enable
BC12
maximum heat dissipation as drawing below.

Clutches Series BC
10
0 500 1000 2000
Speed (RPM)

10000
W (Watts)

BCR500

BCR250
1000
BCR170-1
BCR120-1

Mounting example for clutches (in line) BCR65-1

BCR35

BCR12
100
Output

Clutches Series BCR

10
0 500 1000 2000
Speed (RPM)

48
Magnetic particle brakes

Quick selection
BRAKES Torque (Nm) Dissipation (W) Page CLUTCHES Torque (Nm) Dissipation (W) Page
BB2 2 35 49 BC12 12 120/150 62
BBR2 2 55 50 BCR12 12 440/550 62
BB5 5 70 50 BC35 35 200/250 63
BBR5 5 160 51 BCR35 35 640/800 63
BB12 12 100 51 BC65-1 65 280/350 64
BBR12 12 200 52 BCR65-1 65 960/1200 64
BBV12 12 400 52 BC120 120 800/1000 65
BB35 35 150 53 BCR120 120 1600/2000 65
BBR35 35 280 53 BC170-1 170 1000/1250 66
BBV35 35 600 54 BCR170-1 170 2200/2750 66
BB65-1 65 170 54 BC250 250 1440/1800 67
BBR65-1 65 400 55 BCR250 250 2600/3250 67
BBV65-1 65 800 55 BC500 500 2250/3500 68
BB120-1 120 400 56 BCR500 500 4480/4800 68
BBR120-1 120 800 56
BBV120-1 120 1600 57
BB170-1 170 500 57 XXR = Radiator
BBR170-1 170 1000 58 XXV = Fan
BBV170-1 170 2000 58
BB250 250 600 59
BBR250 250 1200 59
BBV250 250 2400 60
BB500 500 1600 60
BBR500 500 3200 61
BBV500 500 4800 61

79.3
BB2
59

36.5 22.5 20

2
12
0°

11.5
Ø30 -0.05
0.00
50 ±0.1

Ø30
Ø70

Ø8 h7
3

3 x M4, deeph 8 mm equidistant for

mounting Supply cable output ø51
1.8

Specifications Attention : For a correct use of the brake, the operating temperature must not be more than 70° C

Models BB2 Models BB2

Maximum torque Nm 2 Current A 0,8
Power dissipation W 35 Resistance at 20° C Ohm 27
Voltage V 24 Weight kg 0,8

49
Magnetic particle brakes

BBR2 79.3
59
36.5 22.5 20

Ø30 0.00-0.05
0°

2
12

11.5

Ø50±0.1

Ø130

Ø30
Ø70

Ø8 h7
1.8

3 x M4, deeph 8 mm equidistant for 34

mounting
Supply cable output ø51

Specifications Attention : For a correct use of the brake, the operating temperature must not be more than 70° C

Models BBR2 BB5 Models BBR2 BB5

Maximum torque Nm 2 5 Current A 0,8 1,3
Power dissipation W 55 70 Resistance at 20° C Ohm 27 16,5
Voltage V 24 24 Weight kg 1,2 1,8

BB5
104 ±0.1
Ø91

Ø66±0.1 45 28 31

Ø55 ±0.1
3 x M5, deeph
8 mm on dia. 55 mm
equidistant 20 5
for mounting
2.5
Ø40g6

Supply cable
output
Ø12g6

30
4H9

120°
Magnetic particle brakes

BBR5
Ø91 104 ±0.1
Ø66 ±0.1 46 27 31
3 x M5, deeph Ø55 ±0.1
8 mm on dia. 55 mm
equidistant
for mounting

30

Supply cable 20 5
output

2.5
Ø160

Ø40 g6

Ø12 g6
4 H9
120°

Specifications Attention : For a correct use of the brake, the operating temperature must not be more than 70° C

Models BBR5 BB12-1 Models BBR5 BB12-1

Maximum torque Nm 5 12 Résistance à 20° C Ohm 16,5 25
Residual torque Nm - 0,3 Power dissipation W 160 100
Voltage V 24 24 Weight kg 2,2 2,5
Current A 1,3 0,9

3 x M5, deeph 8 mm 6
BB12-1 equidistant for mounting
60°
M5

Ø9

4 +0.10
0
+0.2
0
16.3

Ø103 ±0.10

Ø55h7 -0.03

Ø115
0
60°

Ø15H7

Supply cable
output
41

49

51
Magnetic particle brakes

BBR12-1 48
Supply cable 3 x M5, equidistant
output for mounting

Ø8,6
M5
16.3 +0.2
4 +0.1
-0.0

h7
Ø103 ±0.1
60°

Ø200

+0.00
-0.03
Ø55
Ø15H7

49

Specifications Attention : For a correct use of the brake, the operating temperature must not be more than 70° C

Models BBR12-1 BBV12-1 Models BBR12-1 BBV12-1

Maximum torque Nm 12 12 Resistance at 20° C Ohm 25 25
Residual torque Nm 0,3 0,3 Power dissipation W 200 400
Voltage V 24 24 Weight kg 4,3 4,7
Current A 0,9 0,9 Fan tension V - 24 VDC,115/230 AC

67 61
3 x M5 equidistant for mounting
BBV12-1 11
60°
16.3 +0.2
0.0

Fan cable

0
4 +0.1 Brake cable
h7
Ø103 ±0,1

Ø115
Ø158
Ø182

+0.00
-0.03

60°
Ø55

15H7

4
49
7 128
Magnetic particle brakes

BB35
56 ±0.05

48.4 ±0.1
30°
°
60

+0.1

+0.1
50

0.0 19.7
3 x M5 equidistant
for mounting

+0.1
Ø98 ±0.1
Ø135.5

Ø122 -0.1
Ø55 h7

2.5 2.5
Supply cable
output
6.5 6.5

61.4 ±0.1 17 H7

Specifications Attention : For a correct use of the brake, the operating temperature must not be more than 70° C

Models BB35 BBR35 Modèles BB35 BBR35

Maximum torque Nm 35 35 Resistance at 20° C Ohm 20 20
Residual torque Nm 0,4 0,4 Power dissipation W 150 280
Voltage V 24 24 Weight kg 4,3 7,3
Current A 0,9 0,9

BBR35 60
56 ±0.05

30°
°
60
3 x M5 equidistant
for mounting
48.4 ±0.1
+0.1
+0.1
19.7 0.0

50
Ø135.5

+0.1
Ø122 -0.1
±0.1
Ø55 h7

240
Ø98

2.5 2.5

6.5 6.5

Supply cable
output
17 H7

61.4 ±0.1
Magnetic particle brakes

BBV35
56 ±0.05 Supply cable output

°
60

+0.1
0.0
5 +0.1
Fan

19.7
Ø135.5

+0.1
Ø55 h7
Ø158

Ø162

Ø182
-0.1
Ø122
2.5 2.5

6.5 6.5

13 6 x M5 equidistant
for mounting
61.4 ±0.1 17 H7
63 67
130 4

Specifications Attention : For a correct use of the brake, the operating temperature must not be more than 70° C

Models BBV35 BB65-1 Models BBV35 BB65-1

Maximum torque Nm 35 65 Resistance at 20° C Ohm 20 24
Residual torque Nm 0,4 0,4 Power dissipation W 600 400
Voltage V 24 24 Weight kg 6,4 9
Current A 0,9 1 Fan tension V 24 VDC,115/230 AC -

3 x M5 equidistant for mounting

BB65-1
0 4 56 4 120°
x2
M5
0°

+ 0.2

6 D10
12

0
22.80

Ø75 h7

64
0
x2
5

M5 x 20
M

12
0°

20 H7
30
°

120° 13.5
Ø 144 ±0.10
73.5
Ø144 ±0.1

Supply cable
output
Magnetic particle brakes

BBR65-1

120°
20 H7

30 4
°

12
0°
M5x20 M5x20
22.80+0.2

75h7
0

64

3 0°
1
6D10
20
5x
M

Ø 144 ±0.10
Ø278 66 8.5
Ø157

3 x M5 equidistant
for mounting

Specifications Attention : For a correct use of the brake, the operating temperature must not be more than 70° C

Models BBR65-1 BBV65-1 Models BBR65-1 BBV65-1

Maximum torque Nm 65 65 Resistance at 20° C Ohm 24 24
Residual torque Nm 0,4 0,4 Power dissipation W 400 800
Voltage V 24 24 Weight kg 9,8 8,8
Current A 0,95 1 Fan tension V - 24 VDC,115/230 AC

BBV65-1
3 x M5 equidistant
13 122 7 for mounting
60
°

69

Câble Câble 6 D10

frein ventilateur
+ 0.10
0
Ø144 ±0.10
Ø75 - 0.04

Ø140

Ø185
+0.05

23.80
0
0
Ø 157

0°
12

4 Ø 20H7

64

142
Magnetic particle brakes

BB120-1 * 5mm/old ref. BB120

+ 0.05
Ø 254 0
4 x ø7 mm equidistant
Ø233 ±0.10 for mounting
58 ±0.10 5 ±0.10

Ø195±0.10
2 ±0.10 2 ±0.10
2 ±0.10 *
7 ±0.10
20
M6x
Scale 2 :1
10 H10
x20
M6

Ø 99 - 0.04
+ 0.10

Ø195 ±0.10
0

Ø 214g6
0

69 ±0.10

90°
31.30

x20
M6
2.50 ±0.10
45°

Ø 28 H7 5 ±0.10

45°
Supply cable 45°
13.50 output
M6x20

73 ±0.10
3
Scale 2 :1
5

Specifications Attention : For a correct use of the brake, the operating temperature must not be more than 70° C

Models BB120-1 BBR120-1 Models BB120-1 BBR120-1

Maximum torque Nm 120 120 Resistance at 20° C Ohm 11 11
Residual torque Nm 0,6 0,6 Power dissipation W 400 800
Voltage V 24 24 Weight kg 18 23
Current A 2 2

BBR120-1
* 5mm/0ld ref. BBR120
4 x ø7 mm equidistant
Ø390 73 ±0.10 for mounting
2 ±0.10 2 ±0.10 Scale 2 :1
Ø233 ±0.10 58 ±0.10

2 ±0.10 *
7 ±0.10
10 H10
Ø99 - 0.04
+0.10

Ø195 ±0.10

Ø214 g6
0
0

69 ±0.10
90°
31.30

Ø 28 H7
45°

45° 45°
Supply cable
output
Scale 2 :1 3 5 ±0.10
5 13
Magnetic particle brakes

BBV120-1
Scale 2 :1 219 Ø233 ±0.10

6 143.50 62 Ø214 g6
* 5mm/old ref. BBV120 Ø195 ±0.10
* 2 ±0.10

7 ±0.10

10 H10

+ 0.10
+ 0.05

Ø 99 - 0.04

0
69
0

90°
0

31.30
Ø 254
Ø 28 H7
81

45°
45°
90.50
Ø 284 3
5 4 x ø7 mm equidistant
Supply cable for mounting
Scale 2 :1 output

Specifications Attention : For a correct use of the brake, the operating temperature must not be more than 70° C

Models BBV120-1 BB170-1 Models BBV120-1 BB170-1

Maximum torque Nm 120 170 Resistance at 20° C Ohm 11 11
Residual torque Nm 0,6 0,7 Power dissipation W 1600 500
Voltage V 24 24 Weight kg 24 24
Current A 2 2 Fan tension V 24 VDC,115/230 AC -

BB170-1
Ø233 ±0.1
Ø212 ±0.1 80±0.1

10 D10
31.3+0.1 0.0

5.5 5.5
Ø99 h8
Ø214
Ø254

Ø197

28 H7 Supply cable
output

4 x ø7 mm equidistant
for mounting
22° 45° 5 74±0.1 5
+0.1
90 -0.1

57
Magnetic particle brakes

BBR170-1 Ø390
Ø233±0.1
Ø212±0.1 80±0.5

10 D10
31.3+0.1 0.0

Ø99 h8
5.5 5.5

Ø197
Ø254

Ø214
28 H7

22° 45°

4 x ø7 mm
equidistant
for mounting 5 5
Supply cable output 74±0.1
+0.1
90 -0.1

Specifications Attention : For a correct use of the brake, the operating temperature must not be more than 70° C

Models BBR170-1 BBV170-1 Models BBR170-1 BBV170-1

Maximum torque Nm 170 170 Resistance at 20° C Ohm 11 11
Residual torque Nm 0,7 0,7 Power dissipation W 1000 2000
Voltage V 24 24 Weight kg 30 28
Current A 2 2 Fan tension V - 24 VDC,115/230 AC

BBV170
180 Brake cable
+0.1 Ø284
90 -0.1
Ø233±0.1
30 Fan cable

5.5 5.5
10 D10
31.3+0.1 0.0
Ø99 h8

Ø254
Ø197
Ø214
Ø254

131

28 H7

22° 45°
80±0.1 19 8
65
237 4 x ø7 mm equidistant
for mounting

58
Magnetic particle brakes

BB250
5 90 5 Ø286
Supply cable
output Ø267±0.1
18 16 D10
45°

Ø150 h8 -0.063
+0.2

0
59.3 0

45°
10 10 Ø55 H7
Ø250+0.10-0.10 80±0.1
8 x M6 equidistant
Ø267+0.1-0.1 100±0.1 for mounting

Specifications Attention : For a correct use of the brake, the operating temperature must not be more than 70° C

Models BB250 BBR250 Models BB250 BBR250

Maximum torque Nm 250 250 Resistance at 20° C Ohm 22 22
Residual torque Nm 1 1 Power dissipation W 600 1200
Voltage V 24 24 Weight kg 32 38
Current A 1,1 1,1

BBR250

Supply cable
output 90±0.05 Ø406
16 D10 18 Ø267±0.1
67
.5°
45°
Ø59.3+0.2-0.0

150 h8 -0.063

5 5
Ø286

10 10
45°

Ø55 H7
8 x M6 equidistant
82±0.1 for mounting
250±0.1
267±0.1 100±0.1
Magnetic particle brakes

BBV250 188
100±0.1
Brake cable Fan 8 x M6 equidistant 16+0.1-0.0
20 cable for mounting

5 5 39

45°
59.3+0.2-0.0
Ø150 h8

Ø315
131
286

10

17 8
10 18
65 55 H7

245
+0.1
267 -0.1

Specifications Attention : For a correct use of the brake, the operating temperature must not be more than 70° C

Models BBV250 BB500 Models BBV250 BB500

Maximum torque Nm 250 500 Resistance at 20° C Ohm 22 27
Residual torque Nm 1 1 Power dissipation W 2400 1600
Voltage V 24 24 Weight kg 38 59
Current A 1,1 0,9 Fan tension V 24 VDC,115/230 AC -

BB500

45° Supply cable

output 120 ±0.1
22.5°

5 5

16 +0.1 0
-0.1
59.3 +0.2-0.0

+0
Ø342 ±0.1

Ø150 h8

110
Ø312

Ø324
Ø360

55 H7

8 x ø8,5 mm equidistant for mounting 110 ±0.1

Magnetic particle brakes

BBR500 Supply cable output

45° 120±0.1
22.5°

5 5

16+0.1 0
59.3+0.2-0.0

Ø312±0.1

Ø342±0.1

Ø324 -0.1

Ø150 h8
+0
110

Ø360
Ø500
55 H7

91

110±0.1
8 x ø8,5 mm equidistant for mounting

Specifications Attention : For a correct use of the brake, the operating temperature must not be more than 70° C

Models BBR500 BBV500 Models BBR500 BBV500

Maximum torque Nm 500 500 Resistance at 20° C Ohm 27 27
Residual torque Nm 1 1 Power dissipation W 3200 4800
Voltage V 24 24 Weight kg 62 62
Current A 0,9 0,9 Fan tension V - 24 VDC,115/230 AC

BBV500
213.5
120±0.1 8 x ø8,5 mm equidistant
Brake for mounting
28.5 cable Fan
cable

5
39
16+0.1 0
-0.1
Ø324 +0

59.3+0.2-0.0

22.5
Ø150 h8

110
Ø360

Ø254

Ø285

45°

55 H7

22.5 8

12 65 342 +0.1-0.1

270.5
Ø390
Magnetic particle clutches

BC12 60.25 ±0.1 24 3 x M5 equidistant for mounting

52.5 17

A +0.1
4 -0.0

30
°
47

±0.1

+0.1
Ø55 h7
Ø115

120°
Ø103

16.3
3 3

Ø15 H7
41 13

Specifications Attention : the operating temperature must not be more than 70° C
VIEW A - Brushes holder
Models BC12 BCR12
Maximum torque Nm 12 12 61
Residual torque Nm 0,3 0,3 33 44
Voltage V 24 24
Current A 0,9 0,9
25

Resistance at 20° C Ohm 25 25

Power dissipation at 500 RPM W 120 440
Power dissipation at 1000 RPM W 150 550 6 Ø4.5 32
Weight kg 2,8 4,6

60.5 ±0.1 24
BCR12 48

17

6 12
0°

A
16.3 +0.1

4 +0.1
0

-0.0
47
30°
Ø55 h7

±0.1
Ø200
Ø115

3 3
Ø103

53 3 x M5 equidistant
Ø15H7 for mounting
Magnetic particle clutches

BC35 56 ±0.05 33.5

+0.1
17.5 0° 50
12

+0.1
48.4 ±0.1

19.7 0.0
30°

+0.1
-0.1
6
Ø135.5

Ø55 h7

Ø122
2.5 2.5

6.5 6.5

61.4 ±0.1 17 H7
3 x M5 equidistant
+0.1
68 -0.1 for mounting

Specifications Attention : the operating temperature must not be more than 70° C
VIEW A - Brushes holder
Models BC35 BCR35
Maximum torque Nm 35 35 61
Residual torque Nm 0,4 0,4 33 44
Voltage V 24 24
Current A 0,9 0,9
25

Resistance at 20° C Ohm 20 20

Power dissipation at 500 RPM W 200 640
Power dissipation at 1000 RPM W 250 800

32
6 Ø4.5
Weight kg 4,7 7,7

60
BCR35 56 ±0.05

33.5
17.5 0° 5 +0.1
12 0

A
+0.1
0.0

48.4 ±0.1
30°

19.7

Ø240

6
Ø135

+0.1
Ø122 -0.1
Ø55 h7

2.5 2.5

6.5 6.5
3 x M5 equidistant
for mounting
17 H7

61.4 ±0.1
+0.1
68 -0.1
Magnetic particle clutches

BC65-1
Ø156
58
36,5 Ø144
44 ±0,10
20

4
A
Ø5 6 D10

25

30°
32

Ø75 - 0,04

0,1
22,8 +0
64 9
0

Ø20H7

56 14
75,5 3 x M5 at 120° for mounting

110,5

Specifications Attention : the operating temperature must not be more than 70° C
VIEW A - Brushes holder
Models BC65-1 BCR65-1
Maximum torque Nm 65 65 61
Residual torque Nm 0,4 0,4 33 44
Voltage V 24 24
Current A 1 1
25

Resistance at 20° C Ohm 24 24

Power dissipation at 500 RPM W 280 960
Power dissipation at 1000 RPM W 350 1200 6 Ø4.5 32
Weight kg 7,5 10,5

BCR65-1 111,5 Ø278

Ø159
58 Ø144 ±0,10

44 ±0,10 29,5
21,5

6 D10
A
Ø 5
30°
+ 0,10
0

64 9
22,8

Ø20H7

66 10,3 3 x M5 at 120° for mounting

76,3
Magnetic particle clutches

+ 0.05
BC120-1 Scale 2 :1
* 5mm/old ref. BC120 Ø 254 0
Ø 215 ±0.10
Ø 233 ±0.10
+ 0.005
Ø 80 + 0.015 2 ±0.10
Ø 214 g6
44 ±0.10 58 ±0.10 Ø 195 ±0.10

* 2 ±0.10 9
7 ±0.10 10 H10
A
31.79

Ø5

+ 0.10
Ø 99- 0.04

0
69
0

90°

31.30
45°

Ø 28 H7

0° 4 x ø7 mm
22.5 5 ±0.1 equidistant 45°
Ø 28 H7 45°
for mounting
20.50
Scale 2 :1
3 40.50
5 65.50 55.50

Specifications Attention : the operating temperature must not be more than 70° C
VIEW A - Brushes holder
Models BC120-1 BCR120-1
Maximum torque Nm 120 120 61
Residual torque Nm 0,6 0,6 33 44
Voltage V 24 24
Current A 2 2
25

Resistance at 20° C Ohm 11 11

Power dissipation at 500 RPM W 800 1600
Power dissipation at 1000 RPM W 1000 2000

32
6 Ø4.5
Weight kg 19 24

* 5mm/old ref. BCR120

BCR120-1 Scale 2 :1
Ø233 ±0.10
Ø390
2 ±0.10 Ø214 g6
Ø215 ±0.10
+0.005
Ø80 +0.015 Ø195 ±0.10
44 ±0.10

* 2 ±0.10
9
7 ±0.10
31.79

10H10
A
+0.10
Ø99 - 0.04

Ø5
31.30 0
0

90°

69
45°

5
Ø28H7
3
°
.50
22 45°
45°

5 ±0.10
Scale 2 :1
20.50 4 x ø7 mm equidistant
for mounting
58 ±0.10 40.50
65.50 55.50
Magnetic particle clutches

BC170-1 Ø233 ±0.1

Ø212 ±0.1
14 34
Ø156 ±0.1
80 ±0.05
10 D10

19

6
A
31.3 +0.1 0.0

Ø99 h8
5.5

Ø214
Ø254
5.5

Ø197
Supply cable
output

4 x ø7 mm
equidistant
for mounting 28 H7 5 74±0.1 5
22° 45°
100.8

Specifications Attention : the operating temperature must not be more than 70° C
VIEW A - Brushes holder
Models BC170-1 BCR170-1
Maximum torque Nm 170 170 61
Residual torque Nm 0,7 0,7 33 44
Voltage V 24 24
Current A 2 2
25

Resistance at 20° C Ohm 11 11

Power dissipation at 500 RPM W 1000 2200
Power dissipation at 1000 RPM W 1250 2750

32
6 Ø4.5
Weight kg 25 29

Ø390
BCR170-1 Ø233 ±0.1
Ø212 ±0.1
80 ±0.05
Ø156 ±0.1

10 D10 14 34

19
6
A
31.3 +0.1/0.0

Ø99 h8
Ø254

Ø197
Ø214

5.5 5.5

4 x ø7 mm
equidistant Supply cable
for mounting 28 H7
output

22° 45°
5 74 ±0.1 5
100.8

66
Magnetic particle clutches

BC250

33 Ø286
Supply cable
output 17 Ø267 +0.1-0.1
100 ±0.1 16 D10
45° 90 ±0.05

A
67
°

6
+0.2

Ø150 h8 5 5
059.3

45°
8 x M6
250 +0.1-0.1 18 equidistant Ø55 H7
10 for mounting
Ø267 +0.1-0.1 80 ±0.1 14

Specifications Attention : the operating temperature must not be more than 70° C
VIEW A - Brushes holder
Models BC250 BCR250
Maximum torque Nm 250 250 61
Residual torque Nm 1 1 33 44
Voltage V 24 24
Current A 1,1 1,1
25

Resistance at 20° C Ohm 22 22

Power dissipation at 500 RPM W 1440 2600
Power dissipation at 1000 RPM W 1800 3250

32
6 Ø4.5
Weight kg 33 40

BCR250
33
Supply cable output 17
100 ±0.1
8 x M6
90 ±0.05 equidistant 16 D10
for mounting
67
.5°

A
45°
45°

Ø59.3 +0.2-0.0
Ø150 h8 -0.063

6
5 5
0
Ø286

Ø250 ±0.1
Ø267 ±0.1 18 10 Ø55 H7
Ø408 10 80±0.1 14 Ø267 +0.1-0.1
Magnetic particle clutches

BC500
34
18
Supply cable 16 +0.1 0
output 14

59.3 +0.2-0.0
A
45°
22.5°

Ø342 ±0.1
6

Ø150 h8
110

324 -0.1
Ø312

+0
360
5 5

8 x ø8,5 mm equidistant
for mounting 110 ±0.1
55 H7 120 ±0

Specifications Attention : the operating temperature must not be more than 70° C
VIEW A - Brushes holder
Models BC500 BCR500
Maximum torque Nm 500 500 61
Residual torque Nm 1 1 33 44
Voltage V 24 24
Current A 0,9 0,9
25

Résistance at 20° C Ohm 27 27

Power dissipation at 500 RPM W 2250 4480
Power dissipation at 1000 RPM W 3500 4800 6 Ø4.5 32
Weight kg 62 65

BCR500 34
18
16 +0.1 0 14
Supply cable
output
45°

59.3 +0.2-0.0

A
22.5°

Ø312 ±0.1

6
Ø342 ±0.1

Ø324 -0.1

Ø150 h8
+0

110
Ø360
Ø500

5 5

8 x ø8,5 mm 55 H7 91
equidistant
for mounting 110 ±0.1
120±0.1
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

Rotating centre disc
Fast, precise torque adjustment
Multiple pole high
Low drag seals energy magnets
❐ Torque is set with a large knurled adjust-
ment ring
❐ Infinite adjustability between minimum
Dichromate Precision ball
and maximum settings. This allows units coating for bearings. There
to be fine tuned to your unique require- improved are no other
corrosion mechanical
ment. resistance wear parts or
electrical com-
ponents to fail
Torque is constant with respect to speed

❐ By using the Precision Tork™ unit, you can

solve almost any torque control problem
❐ Torque is extremely consistent and
smooth at low, as well as high speeds

No external control or power source

Hollow shaft
for direct
Easy-to-read
❐ Simple to install mounting
graduations
❐ Nothing to monitor
❐ Unaffected by power interruption or
power fluctuation Bolt circles on both Torque adjustment ring establishes
ends for versatile position of permanent magnets to
❐ Safe to use mounting vary the amount of torque

Dependable performance

❐ Smallest possible transition from static to

dynamic torque
❐ Virtually eliminates the “stick-slip” pheno- SPECIAL APPLICATIONS
menon associated with friction devices
❐ Long life. The only wearing parts are the
ball bearings Specials are our business. . .
❐ Extremely accurate. Precision Tork™ units
out-perform all other devices at low RPM ❐ Special shaft bores and keyways
❐ Shaft extensions
Versatile mounting: Easy to retrofit ❐ System retrofits
❐ Fixed torque units
❐ 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
❐ Brakes are available with solid shaft
outputs

Stainless steel

MC4D
Long shaft extension
Magnetic brakes - MB

2,54 (MB5 only)

C E
F I

MAX
5
WARNER ELECTRIC®

3 4
TORQUE SETTING
A D H

1 2
Model: MB
Torque:

0
MIN
*
B

*Set screw adjustment Drawing C

Specifications

Standard Stainless steel Max. Max. heat Inertia of Bending Max. Weight
models models torque dissipation output shaft moment speed
(Nm) (W) (kgm2) (Nm) (RPM) (kg)

MB1M-5 MB1MS-5 0,0078 3 2,5 x 10-7 0,11 3600 0,057

MB2M-6 MB2MS-6 0,16 10 6,3 x 10-6 0,56 3600 0,31
MB3M-8 MB3MS-8 0,68 18 4,9 x 10-5 1,13 1800 0,9
MB4M-14 MB4MS-14 1,24 22 9,7 x 10-5 1,13 1800 1,13
MB4M-15 MB4MS-15 1,24 22 9,7 x 10-5 1,13 1800 1,13
MB5M-19 MB5MS-19 3,4 72 5,8 x 10-4 2,82 1800 4,08
MB5M-24 MB5MS-24 3,4 72 5,8 x 10-4 2,82 1800 4,08
MB5.5M-19 MB5.5MS-19 5,6 110 8,8 x 10-4 2,82 1800 4,99
MB5.5M-24 MB5.5MS-24 5,6 110 8,8 x 10-4 2,82 1800 4,99
MB6M-19 MB6MS-19 7,9 150 1,4 x 10-3 2,82 1800 5,44
MB6M-24 MB6MS-24 7,9 150 1,4 x 10-3 2,82 1800 5,44
MB6DM-24 - 15,8 300 2,5 x 10-3 2,82 1800 11,37
MB9M-24 - 33,9 345 19 x 10-3 5,65 1200 20,38

Dimensions (mm)

Models Drawing A B C E F Pilot ø H

MB1M-5 C 25,1 34,8 21,59 13,2 - 10,01 - 10,06
MB2M-6 C 46,99 59,9 34,29 24,4 - 22,25 - 22,30
MB3M-8 C 69,6 76,71 50,2 26,5 0,76 35,08 - 35,13
MB4M-14 C 82,04 75,6 51,1 22,2 2,29 47,04 - 47,09
MB4M-15 C 82,04 75,6 51,1 22,2 2,29 47,04 - 47,09
MB5M-19 C 118,11 114 67 41,3 3,1 61,98 - 62,00
MB5M-24 C 118,11 114 67 41,3 3,1 61,98 - 62,00
MB5.5M-19 C 134,1 114,6 67,1 47,5 6,2 61,98 - 62,00
MB5.5M-24 C 134,1 114,6 67,1 47,5 6,2 61,98 - 62,00
MB6M-19 D 153,5 113,7 51,2 52,4 4,57 61,98 - 62,00
MB6M-24 D 153,5 113,7 51,2 52,4 4,57 61,98 - 62,00
MB6DM-24 ** ** ** ** ** ** 82,50 - 82,55
MB9M-24 D 238,76 137,1 88,65 45,72 3,3 82,50 - 82,55
** Drawing on request
Magnetic brakes - MB

C E
I
F
Both
ends Ø10,31mm x 7,87mm
deep (2) holes 180° apart
both ends

®
* *

WARNER ELECTRIC
A H D H

Torque: 1–65 lb–in

Model: MB6

*Spanner wrench adjustment Drawing D

Dimensions (mm)

Models Shaft ø Keyway - DIN 6885 Mounting Holes Adjust

D (h7) Width x length) (I) depth screws

MB1M-5 5 4,5 Flat on 10,2 3 x M3 on ø 15,5 equidistant 6,4 M3

MB2M-6 6 5,5 Flat on 19 3 x M4 on ø 32 equidistant 8 M4
MB3M-8 8 7,5 Flat on 22,4 3 x M4 on ø 48 equidistant 11 M4
MB4M-14 14 5 x 19,3 3 x M5 on ø 60 equidistant 11 M4
MB4M-15 15 5 x 19,3 3 x M5 on ø 60 equidistant 11 M4
MB5M-19 19 6 x 25 3 x M6 on ø 80 equidistant 12,7 M5
MB5M-24 24 8 x 25 3 x M6 on ø 80 equidistant 12,7 M5
MB5.5M-19 19 6 x 25 3 x M6 on ø 100 equidistant 15,5 M5
MB5.5M-19 19 6 x 25 3 x M6 on ø 73,3 equidistant 12,7 M5
MB5.5M-24 24 8 x 25 3 x M6 on ø 100 equidistant 15,5 M5
MB5.5M-24 24 8 x 25 3 x M6 on ø 73,3 equidistant 12,7 M5
MB6M-19 19 6 x 25 3 x M6 on ø 100 equidistant 7,9 M5
MB6M-19 19 6 x 25 3 x M6 on ø 73,3 equidistant 7,9 M5
MB6M-24 24 8 x 25 3 x M6 on ø 100 equidistant 7,9 M5
MB6M-24 24 8 x 25 3 x M6 on ø 73,3 equidistant 7,9 M5
MB6DM-24 24 8 x 25 3 x M8 on ø 101,6 equidistant 13 Knob
MB9M-24 24 8 x 25 4 x M6 on ø 149,23 equidistant 12,7 M5
MB9M-24 24 8 x 25 3 x M6 on ø 107,95 equidistant 12,7 M5
Magnetic clutches - MC

2,54 (MC5 only)

E
C I

MAX
5
WARNER ELECTRIC®

3 4
TORQUE SETTING
A D H G

1 2
Model: MC
Torque:

0
MIN
Set screw adjustment

Drawing A

Specifications

Standard Stainless steel Max. Max. heat Inertia of Bending Max. Weight
models models torque dissipation output shaft moment speed
(Nm) (W) (kgcm2) (Nm) (RPM) (kg)

MC2M-6 MC2MS-6 0,16 10 4,9 x 10-6 0,56 3600 0,31

MC3M-8 MC3MS-8 0,68 18 4,6 x 10-5 1,1 1800 0,9
MC4M-8 MC4MS-8 1,24 22 9,4 x 10-5 1,1 1800 1,13
MC4M-14 MC4MS-14 1,24 22 9,4 x 10-5 1,1 1800 1,13
MC4M-15 MC4MS-15 1,24 22 9,4 x 10-5 1,1 1800 1,13
MC4M-16 MC4MS-16 1,24 22 9,4 x 10-5 1,1 1800 1,13
MC4M-001 MC4MS-001 2 22 1,7 x 10-4 1,1 1800 1,58
MC5M-16 MC5MS-16 3,4 72 5,4 x 10-4 2,82 1800 4,08
MC5M-19 MC5MS-19 3,4 72 5,4 x 10-4 2,82 1800 4,08
MC5,5M-16 MC5,5MS-16 5,6 110 8,5 x 10-4 2,82 1800 4,99
MC5,5M-19 MC5,5MS-19 5,6 110 8,5 x 10-4 2,82 1800 4,99
MC6M-16 MC6MS-16 7,9 150 1,4 x 10-3 2,82 1800 5,44
MC6M-19 MC6MS-19 7,9 150 1,4 x 10-3 2,82 1800 5,44
MC6DM-19 - 15,8 300 2,5 x 10-3 2,82 1800 10,84
MC9M-24 - 33,9 345 19 x 10-3 5,65 1200 20,38

Dimensions (mm)

Models Drawing A B C D E F Pilot ø H

MC2M-6 A 46,99 41,1 34,29 9,4 6,8 - 22,25 - 22,30

MC3M-8 A 69,6 56,3 50,2 14,99 6,1 - 35,08 - 35,13
MC4M-8 A 82,04 57,7 51,1 24,99 6,6 - 47,04 - 47,09
MC4M-14 A 82,04 57,7 51,1 24,99 6,6 - 47,04 - 47,09
MC4M-15 A 82,04 57,7 51,1 24,99 6,6 - 47,04 - 47,09
MC4M-16 A 82,04 57,7 51,1 24,99 6,6 - 47,04 - 47,09
MC4M-001 A 82,04 61,95 55,32 24,99 6,6 - 47,04 - 47,09
MC5M-16 A 118,11 80,77 67 35 13,8 - 61,98 - 62,00
MC5M-19 A 118,11 80,77 67 35 13,8 - 61,98 - 62,00
MC5,5M-16 A 134,1 81,7 67,1 35 14,6 - 61,98 - 62,00
MC5.5M-19 A 134,1 81,7 67,1 35 14,6 - 61,98 - 62,00
MC6M-16 B 153,5 80,77 51,82 34,6 19,5 4,57 61,98 - 62,00
MC6M-19 B 153,5 80,77 51,82 35 19,5 4,57 61,98 - 62,00
MC6DM-19 * * * * * * * 82,50 - 82,55
MC9M-24 B 238,76 106,2 88,65 44,8 13,97 3,3 82,50 - 82,55

* Drawing on request
Magnetic clutches - MC

E
C
F 2 Both ends I

Ø10,31mm x 7,87mm
deep (2) holes 180° apart
both ends
4,57
TYP

®
WARNER ELECTRIC
A D H G
* *

Torque: 1–65 lb–in

Model: MC6

*Spanner wrench adjustment Drawing B

Dimensions (mm)

Models Bore ø Keyway Mounting Holes Adjust

G (H8) (Width) - DIN 6885 (I) depth screws

MC2M-6 6 Roll pin Ø 3 mm 3 x M4 on ø 32 equidistant 8 M3

MC3M-8 8 2 x M4 90° 3 x M4 on ø 48 equidistant 11 M4
MC4M-8 8 7,5 Flat 3 x M5 on ø 60,33 equidistant 11 M4
MC4M-14 14 3 3 x M5 on ø 60,33 equidistant 11 M4
MC4M-15 15 5 3 x M5 on ø 60,33 equidistant 11 M4
MC4M-16 16 5 3 x M4 on ø 60 equidistant 11 M4
MC4M-001 16 5 3 x M5 on ø 60 equidistant 11 M4
MC5M-16 16 5 3 x M6 on ø 80 equidistant 12,7 M5
MC5M-19 19 6 3 x M6 on ø 80 equidistant 12,7 M5
MC5,5M-16 16 5 3 x M6 on ø 100 equidistant 15,5 M5
16 5 3 x M6 on ø 73,03 equidistant 12,7 M5
MC5,5M-19 19 6 3 x M6 on ø 100 equidistant 15,5 M5
19 6 3 x M6 on ø 73,03 equidistant 12,7 M5
MC6M-16 16 5 3 x M6 on ø 100 equidistant 7,9 M5
16 5 3 x M6 on ø 73,03 equidistant 7,9 M5
MC6M-19 19 6 3 x M6 on ø 100 equidistant 7,9 M5
19 6 3 x M6 on ø 73,03 equidistant 7,9 M5
MC6DM-19 19 6 3 x M8 on ø 101,6 equidistant 13 M6
MC9M-24 24 8 4 x M6 on ø 149,23 equidistant 12,7 M5
24 8 3 x M6 on ø 107,95 equidistant 12,7 M5

Typical mounting

Stub shaft
adapter

Flexible
coupling

Brake Clutch Clutch coupling

Typical setup for tensioning wire, film and Typical setup for material handling, soft starts Typical setup for torque limiting protection
fibers. and torque limiting. used for labeling, capping and printing appli-
cations.
Magnetic clutches and brakes

Heat Dissipation Charts

Intermittent operation (50 % duty cycle)

Continuous operation

MB1 MC1.5/MB1.5 MC2/MB2

3600 3600 3600

3000 3000 3000

Slip (RPM)

Slip (RPM)
Slip (RPM)

2400 2400 2400

1800 1800 1800

1200 1200 1200

600 600 600

0 0 0
0,07 0,2 0,35 0,5 0,6 0,8 0,9 0,7 2,1 3,5 4,9 6,3 0 2 5,7 8 11 14
Torque (Ncm) Torque (Ncm) Torque (Ncm)

MC3/MB3 MC4/MB4 MC5/MB5

1800 1800 1800

1500 1500 1500

Slip (RPM)
Slip (RPM)

Slip (RPM)

1200 1200 1200

900 900 900

600 600 600

300 300 300

0 0
0 0,11 0,22 0,33 0,45 0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,9 1 1,1 0 0,5 1,1 1,6 2,26 2,8
Torque (Nm) Torque (Nm) Torque (Nm)

MC5.5/MB5.5 MC6/MB6 MC9/MB9

1800 1800 1800

1500 1500 1500

Slip (RPM)

Slip (RPM)

Slip (RPM)

1200 1200 1200

900 900 900

600 600 600

300 300 300

0 0
0 0,5 1,1 1,6 2,2 2,8 3,4 3,9 4,5 5 0 1 2 3 4 5 6 0 6 15 24 31
Torque (Nm) Torque (Nm) Torque (Nm)
Magnetic clutches and brakes

Torque Setting Charts

MB1 MC2/MB2 MC3/MB3

0,86 15,8 0,79

0,72 12,9 0,67

Torque (Ncm)
Torque (Ncm)

Torque (Nm)
0,56
0,57 10
0,45
0,43 7,2
0,33
0,28 4,32
0,22

0,14 1,44 0,11

0 0 0
0 1 2 3 0 1 2 3 4 5 0 1 2 3 4 5
Unit torque settings Unit torque settings Unit torque settings

MC4/MB4 MC5/MB5 MC5.5/MB5.5

1,35 3,1 5,6

1,1 2,7
4,5

Torque (Nm)
Torque (Nm)
Torque (Nm)

2,26
0,9
1,8 3,3
0,67
1,35
2,2
0,45
0,9
0,22 1,1
0,45

0 1 2 3 4 5 0 1 2 3 4 5 0 1 2 3 4 5
Unit torque settings Unit torque settings Unit torque settings

MC6/MB6 MC9/MB9

8,5 33,9

28,2
6,7
Torque (Nm)
Torque (Nm)

22,6
5,08
17
3,39
11

1,69 5,6

0
0 1 2 3 4 5 0 1 2 3 4 5
Unit torque settings Unit torque settings
Applications

Unwind tension Information required: Check tension range:

control Full roll ø (m) = 0,15 Max. tension =
ø core (m) = 0,1 Torque · 2 / core ø =
Brake mounted on shaft of unwinds Average tension (N) = 18 1,08 · 2 / 0,1 = 21,6 N
spool or bobbin Velocity (m/mn) = 30 Min. tension =
Torque · 2 / full roll ø =
How to size: 1,08 · 2 / 0,15 = 14,4 N
Average radius = (Full roll ø + core Slip watts (watt) =
ø) / 4 = (0,15 + 0,1) / 4 = 0,06 m (Max. 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 MB4 Model
18 · 0,06 = 1,08 Nm

Cycling application
Information required: Select an MC4 Model from the
Bottle
capping Slip = 500 tr/mn specification chart.
Constant torque Torque = 0,90 Nm
provided by a Clutch
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:

*Watts = Torque · slip · 0,25 = 500 · 0,9 · 0,25 = 11,8 watts

9,55 9,55

Nip roll or pulley tension control

Motor Information required:

Pulley or nip roll diameter = 0,1 m
Brake Tension = 26 N
Velocity = 30 m/mn

Bobbin How to size:

Torque = Tension · ø / 2 = 26 · 0,1 / 2 = 1,3 Nm
Coil winding Slip watts = (max. tension · velocity) / 60
Constant tension
provided by = (26 · 30) / 60 = 13 watts
Film tensioning
hysteresis unit Constant tensioning
supplied by hysteresis unit Select MB5 Model

Overload protection / Torque limiting / Soft start

Motor horsepower method Information required:
Power motor = 0,37 kw
Speed motor = 1750 RPM
Stub Shaft Adapter

Conveyor How to size:

Clutch Torque = 9550 · kw / N =
9550 · 0,37 / 1750 = 2 Nm
Coupling Motor
Motor
Select an MC5 Model from the
Torque limiting Material handling specification chart.
Hysteresis clutch provides Hysteresis clutch can provide overload
overload protection protection and soft start
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. These values are usual values for information only,
please check exact tension you need in your application.

Tension f [N/cm]
4
PAPER WEIGHT *

F = f x width [cm] 2

0
0 20 40 60 80 100 120 140
Weight PW [g/m2]

6
Tension f [N/cm]

ne
4 yet hyle
FOIL* Pol PVC

F = f x width [cm] 2

0
0 0,2 0,4 0,6 0,8 1 1,2 1,4
Thickness [mm]

120
Tension f [N]

CU
80
AL
WIRE *
40

0
0 0,5 1 1,5 2 2,5 3 3,5
* Usual values for information only. Diameter [mm]

MATERIAL DENSITY kg/m3

Paper 920
Paper board 1420
Alu foil 2720
Alu wire 2750
Copper 8550
PVC 400-1050
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: Tel. Fax:

Address: e mail:

City: Country: Date: Business:

MAX. ROLL DIAMETER : m MASS: kg

MIN. ROLL DIAMETER : m

LINE SPEED : m/mn

BRAKE RATIO : i = z2/z1 (Brake on roll axis i = 1)

FIRST CASE : unwind tension known

TENSION FORCE ON TOTAL WEB WIDTH : N max. N min.

SECOND CASE : unwind tension unknown

If unknown precise type of material :

CURRENT VALUES USED :

ALUMINIUM FOIL : 00,7 N/cm / thickness micron PAPER PAPER
CELLOPHANE : 0,05 N/cm/ thickness micron 10 gr/m 2
0,5 N/cm 130 gr/m2 3,1 N/cm
ACETATE : 0,035 N/cm / thickness micron 25 gr/m 2
0,7 N/cm 150 gr/m 2
3,8 N/cm
MYLAR (POLYESTER) : 0,505 N/cm / thickness micron 40 gr/m 2
1 N/cm 200 gr/m 2
5,5 N/cm
POLYETHYLENE : 0,017 N/cm / thickness micron 60 gr/m 2
1,5 N/cm 250 gr/m 2
7,7 N/cm
POLYPROPYLENE: 0,017 N/cm / thickness micron 80 gr/m 2
2 N/cm 330 gr/m 2
11,5 N/cm
POLYSTIRENE : 0,06 N/cm /thickness micron 100 gr/m 2
2,5 N/cm 400 gr/m 2
14,8 N/cm
SARAN : 0,008 N/cm / thickness micron
VINYL : 0,01 N/cm / thickness micron

VALUE PER CENTIMETER WIDTH : N/cm / micron

NUMBER OF MICRON MATERIAL THICKNESS : (Paper note 1)

TENSION FORCE BY CENTIMETER WIDTH : N max. N min.

ROLL WIDTH : cm max. cm min.

TOTAL FORCE ON ROLL WIDTH : N N min.

MAX. ROLL SPEED : RPM

MIN. ROLL SPEED : RPM

THEORIC BRAKE TORQUE : Nm max. Nm min.

SLIDDING TORQUE : Nm

REQUIRED BRAKE TORQUE : Nm max. Nm min.

TOTAL HEAT DISSIPATION : kW

REQUIRED BRAKE SIZE :

NUMBER OF BRAKE PER ROLL :

REQUIRED TENSION CONTROL REGULATION :

Data application form
START - STOP :

t1 = MACHINE STARTING TIME secondes

t2 = ROLL ACCELERATING TIME secondes

t3 = MACHINE DECCELARATING TIME secondes

t4 = BRAKE ACCELARATING TIME secondes

MB (see catalogue MTB-II or TB) or stopping brake applied Nm

ACCELERATION TIME = t2 = m · v/120 · F secondes

(force must accelerate the roll)

Storage length = l = v/120 · (t2 - t1) metres

(if machine is accelerating faster : t1 < t2)

If the dancer load is a mass, Newtons

the tension force will increase = F' = F · v/118 · t1

or

I the dancer load is a mass, Newtons

the tension force will increase = F' = F · v/118 · t2

DECCELERATION :

1) Maintaining the web force, (warning : exact values if MB or t3 defined) :

Braking torque = MB = ( (m · D · v/240 · t4) + F · D/2) · 1/i Nm 0 if MB not defined

Time t4 = m · D · v/240 · (MB · i - F · D/2) secondes 0 if MB not defined

If t4 > t3 necessary lenght = l = v · (t4-t3)/120 metres 0 if t3 not defined

2) Uncontrolled emergency stop :

Emergency stopping time = t = m · D · v/240 · MB · i secondes

Material length spillage = l = v · t/120 metres

Subject to alteration without prior notice

ALTRA
ALTRAINDUSTRIAL MOTION
INDUSTRIAL MOTION
Altra Industrial Motion AMERICA

Altra Industrial Motion, Inc. U.S.A.

14 Hayward Street WARNER ELECTRIC, Gardner Street 449
Quincy, MA 02171, U.S.A. South Beloit, Illinois 61080 U.S.A.
Tel. +01 (617) 328 3300, Fax +01 (617) 689 6202 Tel. +01 (815) 389 3771
Fax +01 (815) 389 2582

EUROPE
OCEANIA
FRANCE
WARNER ELECTRIC EUROPE AUSTRALIA
Siège social et usine WARNER ELECTRIC AUSTRALIA
7, rue Champfleur, BP 20095 Unit 1/11, Packard Avenue
F-49182 St Barthélemy d’Anjou Cedex Castle Hill, N.S.W. 2154
Tél. +33 (0)2 41 21 24 24, Fax +33 (0)2 41 21 24 00 Tel. +612 9894 0133, Fax +612 9894 0368
e-mail: [email protected]

ASIA DISTRIBUTION

HONG KONG + P.R. CHINA Most products are available through authorised local
WARNER - SHUI HING Ltd distributors, please contact your nearest WARNER
Unit 4A, 3rd Floor office for information. Distributors are located in the
Join-In Hang Sing Centre following countries:
71-75 Container Port Road
Kwai Chung, Hong Kong Argentina Greece Portugal
Tel. +852 2615 9313, Fax +852 2615 9162 Austria Holland Scotland
Belgium India Slovakia
INDIA Brazil Ireland Slovenia
M/s. FRANCIS KLEIN & Co. Pvt. Ltd. Croatia Israel South Africa
70/1, Mission Road Bosnia Italy Spain
IND - Bangalore 560 027 Czech Rep. Lithuania Sweden
Tel. +91 802 272781, Fax +91 802 276324 Egypt New Zealand Switzerland
Finland Norway Turkey
KOREA + SINGAPORE France Poland U.S.A.
WARNER ELECTRIC SINGAPORE
30 Pioneer Road
Singapore 628502
Tel. +65 487 4464, Fax +65 487 6674

TAIWAN
WARNER ELECTRIC Ltd
3rd Fl., No. 35, Lane 32
Kwang-Fu South Road
105 Taipei, TAIWAN R.O.
Tel. +886 2 2577 8156, Fax +886 2 2570 6358

THAILAND
WARNER ELECTRIC Co. Ltd
199/19 Soi Anamai
Srinakharin Rd. Prawes
Bangkok 10250, Thailand
Tel. +66 2 322 0481, Fax +66 2 320 2380

www.warnerelectric-eu.com

MC507r-gb-0607 - © 2007