SUPPORTED BY DANA CORPORATION

WARNER ELECTRIC
The Warner Electric Motors and Controls Division of Dana Corporation is a global leader in the engineer-
ing and manufacturing of motor and control products for industrial applications. All Warner Electric
products and services are backed by highly specialized engineers and service people who can help solve
your production challenges. Warner Electric’s capabilities and products have improved operations for
hundreds of companies around the world.

Warner Electric® stepper motors and controls, servo motors and controls, voltage conditioning products,
engineered systems, and AC/DC drives are available worldwide through an extensive authorized distribu-
tor network. These distributors provide convenient service by offering technical support, replacement
Bronco II
parts, and literature, as well as an extensive inventory of off-the-shelf models for the fastest possible 160 Series DC Drives
delivery and service. Call your nearest distributor for ordering and application information.

IN U.S.A. AND CANADA

WARNER ELECTRIC MOTORS AND CONTROLS DIVISION

◆ Sales: 734-669-4700
◆ Customer Service: 800-787-3532
◆ Product Application: 800-787-3532
◆ Product Literature Request: 800-787-3532
◆ Fax: 800-766-6366 or 860-589-2136
◆ Web Site: www.warnernet.com

SERVO CONTROLS STEPPER CONTROLS VOLTAGE CONDITIONING ENGINEERED SYSTEMS AC/DC DRIVES
WARNER ELECTRIC MOTORS AND CONTROLS DIVISION
Division Office Bristol Plant Systems Center International - Europe
640 Avis Drive, Suite 200 383 Middle Street 13500-J South Point Blvd. Lausanne, Switzerland
Ann Arbor, MI 48108 Bristol, CT 06010 Charlotte, NC 28273 La Pierreire
CH-1029 Villars-Ste-Croix,
Switzerland

©1999 Warner Electric Division

C3004 9/99 Printed in U.S.A.

Bronco II Coverall 1 10/21/99, 18.47

 ADDITIONAL WARNER ELECTRIC DC DRIVES & CONTROLS

A Total Commitment Through

Distribution

• Throughout the North American Conti- • An extention of the commitment to product

nent distributors provide one stop product service is carried to each and every customer
availability and expertise through the dedicated distributor network.

• Each Distributor is a Market specialist • A carefully oriented plan is made with each
to meet local and immediate needs. distrubutor to insure optimum coverage and
service for each market area.
SE2000 DC Drives QUADRALINE 7000 DC Drives
• Literally thousands of sales and service
This non-regenerative DC drive is designed to control Designed for full wave, regenerative applications, the
personnel form the total team commitment for
shunt wound or permanent magnetic field DC motors Quadraline 7000 is designed for either permanent magnet
from ¼ to 5 HP. It offers isolated 4-20mA or 0-10 VDC or wound feild DC motors from ¼ to 5 HP. It features product and sales assurance.
control signal, tachometer generator feedback, circuit fullwave 4-quadrant operation, seven selectable perfor-
protection, diagnostic capabilities, control relay, torque mance features, electronic reversing and seven control
and slope control, and overcurrent protection. Jumper adjustments, positioning accuracy. Chassis or NEMA 4/12
selectable to program drives for specified motor or enclosures available and UL listed.
application. Horsepower range 115 VAC to 230 VAC.
Open chassis available and UL listed.

M4000 Digital 3-Phase DC Drives DS9000 Digital Drive Speed Controller

The M4000 Series Digital 3-Phase DC Drive is a The DS9000 Digital Speed Controller features long term
programmable, microprocessor based variable speed DC speed accuracy, control and stability. It offers 16-bit
drive. It allows keypad control of each parameter. Digital microprocessor based, AC or DC drive control, ± .01% YOUR DISTRIBUTOR IS:
readout provides on-line monitoring of drive operation. accuracy, digital master or follower, analog or digital
Ideal for many drive applications including wire and input, and two selectable sets of programmable param-
cable, packaging/converting, machinery and material eters. Front panel controls include a 4-digit LED readout,
handling. Improved circuit board technology has added keypad controls and four LED status indicators.
standard features, including serial communications and a
field-weakening controller for constant power and
extended speed range applications.

*Contact Warner Electric for information on our complete line of AC drives

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 Bronco II Bronco II

Contents

Contents

Features and Benefits . . . . . . . 2

Applications . . . . . . . . . . . . . . . 4

Specifications . . . . . . . . . . . . . 6

How to Order . . . . . . . . . . . . . . 9

Selection Information . . . . . . 10

Options . . . . . . . . . . . . . . . . . 11

Remote Operator
Stations . . . . . . . . . . . . . . . . . 12

Isolation Transformers . . . . . 12

Standard DC Motors . . . . . . . 13

Washdown Duty
DC Motors . . . . . . . . . . . . . . . 16

Dimensions . . . . . . . . . . . . . . 17

Connection Diagrams . . . . . . 18

Recommended Spare
Parts . . . . . . . . . . . . . . . . . . . 19

Service . . . . . . . . . . . . . . . . . 19

Bronco II Bronco II

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 Bronco II Bronco II
Replacement parts list for all models
Features Check out these outstanding standard features Recommended
of the Bronco II 160 Series from Warner Electric Motors and Controls...
and Warner Electric
Spare Parts
Benefits Description Old
Part Number
New

Speed/Torque Adjust Pot. 2K APT2026–00 224552-000

Start/Run/Stop Switch ASW3010–00 224554-000
Forward/Reverse Switch ASW1051–01 224579-001
Auto/Manual or Run/Jog Switch ASW1079–00 224551-000
Water Tight Boot (For all Switches) HMI 1103-00 224639-000
Water Tight Nut (For all Pots) HMI1012–00 224638-000
Fuse, 20 Amp PFU1010–07 104364-025
Isolation Follower Card BWC36015–00 –
Power Module ATY4001–03 224544-001
PC Board Assembly SPD36006–00 –

Service Service
It is intended that the Bronco II
should be serviced by replacing
Listed Field programmable jumpers Jog at potentiometer speed
major sub-assemblies. The
Allow the Bronco II to be quickly Set your Bronco II speed Replacement Parts List lists all of
Listed for use in Canada modified to match available plant potentiometer at the desired the sub-assemblies required to
line voltage, select motor HP, and speed and you can jog the motor service Bronco II drives. It is
Speed regulation to select the feedback signal allowing easy set up of your recommended that users keep
Regulation by armature voltage required. machine process. these parts readily available to
feedback or tachometer support the drive’s critical
generator feedback (non- AC line protection fuse Field supply for shunt wound
field motors applications.
reversing models only). Fault protection...eliminates a For additional assistance or the
costly replacement. Permanent magnet field or shunt name of your closest authorized
Dual voltage input wound field motors...Bronco II is
(115/230 VAC) Full wave power conversion service center, contact Warner
the right one. Electric Motors and Controls
Each model can be connected to circuit with 2 SCR’s and 3
diodes providing NEMA Totally enclosed, cast customer service at
either of two line voltages 1/4, 1/2, 800-787-3532.
3/4 and 1HP motors @115VAC Code K, DC armature supply aluminum enclosure meets
input or 1, 1-1/2 and 2 HP motors Insures optimum motor NEMA 4, NEMA 12 and
@ 230VAC. performance, cooler motor NEMA 4X standards
operation and longer life. Incredibly rugged DC drives for
Circuit protection the most critical industrial
Transient voltage protection by IR compensation adjustment environment–dust tight, oil tight
MOV. Improves speed regulation in and water resistant.
armature voltage feedback mode.
Torque control Maximum and minimum
Controls motor armature current Control relay with 3-wire speed adjustments
for applications requiring torque start/stop circuit Establishes minimum and
or tension control. Prevents automatic restart after maximum speeds.
power outage for increased
Local or remote operator safety. (May be reconnected for Adjustable acceleration
control line start operation if required.) (1 to 5 seconds)
Flexible, compact...fits where you Easy-to-set for smooth, linear
want it. speed control.
Open chassis unit availability
For convenient mounting of one
or several drives in your
enclosure.

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 Bronco II Bronco II
Models B160, B163 & B165 Washdown Duty
Connection Models B168 & B169
Features
Diagrams Jumper location
for model 165
A new standard in and
adjustable speed
Jumper location DC Drives. Benefits
for models
160 & 163 1 2 3 1 2 Specifically designed for food
Process – Common processing and other industries
1 2 3 4 5 6 7 8 9 10 TB5 TB4
Follower + Current Input where the motor and control are
TB2 Signal
+ – Input + Volts Input constantly exposed to high
*Optional
Tachometer 1 2 3 4 5 6 7 8 9 10 pressure washdown to maintain
+ – TB2
cleanliness.
+ –
7V/1000 RPM Optional • Rugged
Tachometer • Reliable
*Model
160 Only
– + • Versatile
7V/1000 RPM • Accurate
TB1 TB1
• Economically priced
7 6 5 4 3 2 1 7 6 5 4 3 2 1
• Listed
F2 F1 A2 A1 L1 L2 Gnd F2 F1 A2 A1 L1 L2 Gnd
F2 – A2 – F2 – A2 – • Listed for use in Canada

F1 + A1 + F1 + A1 + The Bronco II Washdown Duty

DC Drives convert single phase
115 or 230 VAC 115 or 230 VAC AC line voltages of either 115 of
50/60 Hz 50/60 Hz
230 VAC to variable DC for
armature voltage speed control
of permanent magnet or shunt
wound DC motors from 1/4 to
2 HP.
Models B161S & B162
Jumper Location for Jumper Location for
Torque Control Operation Speed Control Operation

Totally enclosed cast aluminum epoxy coated FDA

approved white enclosure with gasketed cover and
stainless steel captive screws meets NEMA 4X.
1 2 3 6 9 10
Optional Stop
2-Wire Start
Start + –
TB2 Optional Proven Warner Electric Dependability
Tachometer
• Full Wave power conversion circuit with 2 SCR’s and 3
+ –
Stop diodes with NEMA K configuration allows cooler motor
7V/1000 RPM operation.
Start CW
• IR compensation improves speed regulation in armature
W Torque Control
Speed CW Adjust
voltage feedback mode.
Control W 2K, 2W, 5%
Adjust CCW
• Control relay with 3-wire start/stop circuit prevents
2K, 2W, 5% automatic restart after power outage for increased safety.
CCW TB1 (May be reconnected for line start operation if required.)
7 6 5 4 3 2 1
• Full two year warranty.

F2 F1 A2 A1 L1 L2 Gnd
F2 – A2 –

F1 + A1 +

115 or 230 VAC

50/60 Hz

Bronco II Bronco II

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 Bronco II Bronco II

Applications Enclosed Models B160, B162, B163, B165, B168 & B169
Dimensions

Conveyors Conduit Knockout

1.500 2.000
Ø .875 2 Places
• Simple, variable speed control
• Forward or reverse direction
• Compact and rugged for on
machine mounting 8.125
8.875
9.500
5.625
4.625
3.250

.250

2.500 .688 .313

5.000
.250 W x .375 L Slot
2 Places

Take-up
• Simple center winders
Chassis Model B161S
• Constant Torque Ø .250 4 Places

5.000 7.000

1.000

1.000 .313 .452

5.000 3.000
Mixers
• Variable speed
• Rugged and industrially tough Dimensions are listed in inches
• NEMA 4/12 enclosures

Bronco II Bronco II

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 Bronco II Bronco II

Washdown The Washdown Duty DC Motors

are specifically suited for tough Food Processing Applications
Duty DC environments where washdown is
essential to maintain cleanliness. • Washdown is frequent
Motors These motors are selected to • Cleanliness is critical
function as a companion with the • Rugged, tough environment
appropriate WASHDOWN DUTY
BRONCO II D.C. Drive Controller.

Features
8 standard Washdown Duty DC
Motors
• Epoxy Finished - FDA
approved
• Moisture Resistant Wire
• 90 or 180 VDC Armature
• Permanent Magnet Field
• 1750 RPM
• Totally Enclosed
• Sealed and corrosion protected
to meet the environments
found in food and other
industries demanding high
levels of cleanliness.

DC Motors – Washdown Duty

1/4 to 3/4 Horsepower 90 VDC Armature – PERMANENT MAGNET FIELD – 1750 RPM – Totally Enclosed

NEMA Model Number

HP Motor Frame Enclosure ‘C’ Motor Motor with 7 VDC Chemical Processing
Type Size Face without 7 VDC/1000 RPM Tachometer
Tachometer Tachometer Kit • Corrosive atmosphere
(mounted) • Frequently wet
• Simple mounting
1/4 M 4622 NV 56C MOD6112010 N/A N/A
1/2 M 4660 NV 56C MOF6112010 N/A N/A
3/4 M 4680 NV 56C MOG6112010 N/A N/A
Note: All motors are capable of 20:1 constant torque speed range.

DC Motors – Washdown Duty

1/2 to 2 Horsepower 180 VDC Armature – PERMANENT MAGNET FIELD – 1750 RPM – Totally Enclosed

NEMA Model Number

HP Motor Frame Enclosure ‘C’ Motor Motor with 7 VDC
Type Size Face without 7 VDC/1000 RPM Tachometer
Tachometer Tachometer Kit Waste Water Treatment
(mounted)
• Wet environment
1/2 M 4660 NV 56C MOF7112010 N/A N/A • Compact size
3/4 M 4680 NV 56C MOG7112010 N/A N/A • Minimal maintenance
1 B 435P FC 56C MOH7211300 N/A N/A
1-1/2 B 536P FC 145C MOI7211300 N/A N/A
2 B 548P FC 145C MOJ7211300 N/A N/A
Bronco II Note: All motors are capable of 20:1 constant torque speed range. Bronco II

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 Bronco II Bronco II

Specifications Versatility DC Motors Standard

7 Standard Models 1/4 to 1 Horsepower 90 VDC Armature – 100/50 VDC SHUNT WOUND FIELD – 1750 RPM – Totally Enclosed DC Motors
Model B160 NEMA Model Number
NEMA 4/12 enclosure with Start/ HP Motor Frame Enclosure ‘C’ Motor Motor with 7 VDC
Stop, Run/Jog switches and Type Size Face without 7 VDC/1000 RPM Tachometer
Speed potentiometer mounted on Tachometer Tachometer Kit
enclosure front cover (mounted)
Model B161S 1/4 B 413D FC 56C MOD1211700 MOD1211731 TAC 4001–00
Chassis for mounting in customer 1/2 B 420D FC 56C MOF1211700 MOF1211731 TAC 4001–00
supplied enclosure 3/4 B 428D FC 56C MOG1211700 MOG1211731 TAC 4001–00
Model B162 1 B 535D FC 56C MOH1211700 MOH1211731 TAC 4007–00
NEMA 4/12 enclosure for use
with a remote operator control Note: All motors are capable of 20:1 constant torque speed range.

Model B163
NEMA 4/12 enclosure with Start/
Stop, Run/Jog, Forward/Reverse
switches and Speed Potentio-
meter on enclosure front cover
Model B165
NEMA 4/12 enclosure with torque
control. Start/Stop and Forward/
Reverse switches and Torque
Potentiometer on enclosure front DC Motors
cover
1/2 to 2 Horsepower 180 VDC Armature – 200/100 VDC SHUNT WOUND FIELD – 1750 RPM – Totally Enclosed
Model B168
Same features as Model 169 NEMA Model Number
described below except the front HP Motor Frame Enclosure ‘C’ Motor Motor with 7 VDC
panel mounted Speed Potentio- Type Size Face without 7 VDC/1000 RPM Tachometer
meter trims the speed signal Tachometer Tachometer Kit
when operated in the automatic (mounted)
mode.
1/2 B 420D FC 56C MOF2211700 MOF2211731 TAC 4001–00
Model B169 3/4 B 428D FC 56C MOG2211700 MOG2211731 TAC 4001–00
External isolated signal follower 1 G 146ATC FC 140TC MOH2210800 MOH2210831 TAC 4001–02
in NEMA 4/12 enclosure with B 535D FC 56C MOH2211800 MOH2211831 TAC 4007–01
Start/Stop and Auto/Manual
G L182ACY NV 180C MOH2110100 MOH2110131 TAC 4002–03
switches mounted on enclosure
front. Controls motor speed from 1-1/2 G 148ATC FC 140TC MOI2210800 MOI12210831 TAC 4004–02
either a grounded or ungrounded G L186ACY NV 180C MOI2110100 MOI2110131 TAC 4002–03
signal—4–20mA, 1–5mA, 0–10 B 636D FC 180C MOI2211400 MOI2211431 TAC 4001–15
VDC, 0–14 VDC, 0–100 VDC in
auto mode, or from the speed 2 G 149ATC FC 140TC MOJ2210800 MOJ12210831 TAC 4004–02
potentiometer in manual mode. B 646D FC 180C MOJ2211400 MOJ2211431 TAC 4001–15
G L186ACY NV 180C MOJ2110100 MOJ2110131 TAC 4002–03

Note: All motors are capable of 20:1 constant torque speed range.

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 Bronco II Bronco II

Standard DC Motors Washdown Duty Specifications

6 Standard Models
DC Motors 1/4 to 1 Horsepower 90 VDC Armature – PERMANENT MAGNET FIELD – 1750 RPM – Totally Enclosed
Model B160WD
NEMA Model Number
HP Motor Frame Enclosure ‘C’ Motor Motor with 7 VDC NEMA 4X enclosure with Start/
Type Size Face without 7 VDC/1000 RPM Tachometer Stop, Run/Jog switches and
Tachometer Tachometer Kit Speed potentiometer mounted on
(mounted) enclosure front cover

1/4 G 56HAA NV 56C MOD6110210 N/A N/A Model B162WD

B 320P NV 56C MOD6211200 MOD6211231 TAC 4001–13 NEMA 4X enclosure for use with
a remote operator control
1/2 G 56KAA FC 56C MOF6210210 N/A N/A
B 336P NV 56C MOF6211200 MOF6211231 TAC 4001–13 Model B163WD
NEMA 4X enclosure with Start/
3/4 G 56PAA FC 56C MOG6210210 N/A N/A
Stop, Run/Jog, Forward/Reverse
B 428P FC 56C MOG6211100 MOG6211131 TAC 4001–00 switches and Speed Potentio-
1 G 56SAA FC 56C MOH6210210 N/A N/A meter on enclosure front cover
B 435P FC 56C MOH6211100 MOH6211131 TAC 4001–00 Model B165WD
NEMA 4X enclosure with torque
Note: All motors are capable of 20:1 constant torque speed range. control. Start/Stop and Forward/
Reverse switches and Torque
Potentiometer on enclosure front
cover
Model B168WD
DC Motors Same features as Model 169
described below except the front
1/2 to 2 Horsepower 180 VDC Armature – PERMANENT MAGNET FIELD – 1750 RPM – Totally Enclosed panel mounted Speed Potentio-
meter trims the speed signal
NEMA Model Number when operated in the automatic
HP Motor Frame Enclosure ‘C’ Motor Motor with 7 VDC mode.
Type Size Face without 7 VDC/1000 RPM Tachometer
Tachometer Tachometer Kit Model 169WD
(mounted) External isolated signal follower
in NEMA 4X enclosure with Start/
1/2 G 56KAA FC 56C MOF7210210 N/A N/A Stop and Auto/Manual switches
B 336P NV 56C MOF7111100 MOF7111131 TAC 4001–13 mounted on enclosure front.
3/4 G 56PAA FC 56C MOG7210210 N/A N/A Controls motor speed from either
a grounded or ungrounded
B 336P NV 56C MOG7211100 MOG7211131 TAC 4001–10 signal—4–20mA, 1–5mA, 0–10
1 G 146ATC FC 140TC MOH7210800 MOH7210831 TAC 4004–02 VDC, 0–14 VDC, 0–100 VDC in
G 56SAA FC 56C MOH7210210 N/A N/A auto mode, or from the speed
potentiometer in manual mode.
B 435P FC 56C MOH7211100 MOH7211131 TAC 4001–00
1-1/2 B 536P FC 140TC MOI7211100 MOI7211131 TAC 4007–01
G 148ATC FC 140TC MOI7210800 MOI7210831 TAC 4004–02
2 B 548P FC 140TC MOJ7211100 MOJ7211131 TAC 4007–01
G 149ATC FC 140TC MOJ7210800 MOJ7210831 TAC 4004–02

Note: All motors are capable of 20:1 constant torque speed range.

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 Bronco II Bronco II

Specifications Ratings How to Order Motor chart specify:

Horsepower
Non-Listed Motors
Non-listed motors are available,
Standard
Horsepower Range 115 VAC 1/4–1 HP
230 VAC 1/2–2 HP
Selection charts for DC motors,
available from Warner Electric
Motor Type (Manufacturer) but specific information is DC Motors
AC Line Input Voltage 115 or 230 VAC ±10% Motors and Controls, are listed on
B=Baldor required.
AC Line Frequency 50/60 Hz ± 2 Hz the following pages. For more
G=General Electric 1. Motor horsepower
115 VAC Supply M=Indiana General 2. RPM
complete specifications and
Armature Voltage 0–90 VDC Frame Size 3. Frame size
dimensional information, contact
Field Voltage 50/100 VDC Motor Enclosure 4. Volts, armature
Warner Electric Motors and
230 VAC Supply TE=Totally Enclosed 5. Volts, field or PM
Controls customer service.
Armature Voltage 0–180 VDC TEFC=Fan Cooled 6. Enclosure
Field Voltage 100/200 VDC TENV=Non Ventilated 7. Conduit location, F1, F2 etc.
Service Factor 1.0 ‘C’ Face Size 8. Thermostat
Duty Continuous (For use with Single Phase 9. Accessory endshield
Maximum Load Capacity 150% for 1 minute Controllers only) 10. ‘C’ face
Line Protection Fuse Armature Voltage 11. Delivery requirements
Model Number 12. Special application or
Motor with Tachometer environmental considerations
Operating Conditions (mounted) and other important
Motor without Tachometer information.
Ambient Temperature Tachometer Kit
Chassis Model 0–55°C
Enclosed Models 0–40°C
Relative Humidity 5–95% non-condensing
Altitude To 3300 feet (1000m)

Performance Characteristics
Speed Range 30:1 with armature voltage
feedback
50:1 with tach-generator
feedback
Speed Regulation (As % of motor
base speed) for 95% load change
Armature Voltage Feedback ± 2%
Tachometer Feedback 1/2–1%

Adjustments
Current Range 2.5, 5, 7.5, 10 Amps DC
Nominal
(Adjustable to 150% of each
range)
Maximum Speed 75–110% of motor base speed
Minimum Speed 0–30% of motor base speed
IR Compensation Adjustable
Acceleration 1–5 seconds (Linear, 0 to top
speed)

Options
• External Signal Isolation Follower For installation on chassis or
Kit remote (Standard on Models enclosed units. Allows motor
B168 and B169) Model BWC 36015 speed to be controlled from
• For use with Bronco II M/N B162 a grounded or ungrounded
when required. external signal—4–20mA,
1–5mA, 0–10 VDC, 0–14 VDC,
or 0–100 VDC. There is a
provision for auto/manual
operation if required.

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 Bronco II Bronco II

Remote Remote Operator Stations (ROS) In determining the components

that comprise a drive system, the
How to Order
Operator Function Model Model Number Suffix
following selections must be
made for features and options.
Stations Number for 10 Turn Speed Pot
Start Pushbutton (1) (3) 1. DC Motor Controller 4. Isolation Transformer
Stop Pushbutton R8005 -10 Select HP and AC input voltage. Select KVA of transformer when
Single Turn Speed Pot The AC input voltage will required by adding the total HP of
Start Pushbutton (1) (3) determine motor armature and all drives to be connected to the
Stop Pushbutton field voltage. transformer. Then select model
Single Turn Speed Pot R8011 -10 number by primary input voltage
AC Input Motor Voltage and secondary output voltage.
Auto-Manual Speed
Voltage Arm/Field
Start-Stop Switch (2) (3)
Run-Jog Switch 115V 90V Arm 5. Options/Accessories
Auto-Man Switch R1001 N/A 50V/100V Field
Single Turn Speed Pot 230V 180V Arm A. The Bronco II provides only
100V/200V Field one option; i.e. the process
Note: follower applicable only to
(1) NEMA 12 Enclosed with wiring to operators B161S or B162 models.
Now select drive configuration,
(2) NEMA 4 Enclosed with wiring to terminal strips B. The isolated follower is factory
chassis or enclosure. If enclo-
(3) Applies to Models B161S and B162 only. installed in the B168 and B169
sure, do you want a blank front
models or field installed in
cover or operators controls.
B161S or B162 models.
Determine which operators are
required (i.e., run/jog, auto/
manual) and whether they will be Example 1
on a remote operators station or A conveyer requires a 1 HP DC
on the drive enclosure. From the motor, 1750 RPM, shunt wound
list of standard option boards, field, TEFC enclosure and a
select those required for your 7V/1000RPM tachometer. The
application. DC drive will be chassis mount,
230 VAC single phase input, to
2. DC Motor be operated from a ROS. ROS to
include start/stop and a speed
With the motor voltage specified potentiometer. Isolation trans-
by the AC input voltage selected former from a 230 VAC input is
above, now determine permanent required.
Isolation Isolation Transformers magnet or shunt wound, frame
Item Qty Part No.
Transformers size, enclosure type (TEFC or
TENV), C face, and whether a 1 1 B161S
tachometer will be required. 2 1 MOH2210831
Single phase NEMA I Enclosed, Dry Type, No Taps, 60 Hz, Type G
3 1 R1001
4 1 TRS21–020
HP KVA Primary Secondary Model Number 5 0 Not Required
Voltage Voltage

1/4 1/2 120/240 120/240 TRS21-005

Example 2
A Food Processing Conveyor
1/2 1 120/240 120/240 TRS21-010 requires a 1 HP DC Motor, 1750
RPM. The operation requires the
3/4 11/2 120/240 120/240 TRS21-015 3. Remote (ROS) Operator selection of start, stop, run or jog,
1 2 120/240 120/240 TRS21-020
Station forward and reverse as well as
speed adjustment. The plant
If a remote operators station will supply voltage is single phase,
11/2 3 240/480 120/240 TRS42-030 be used, select which operators 60 hertz, 230 VAC.
will be used, and the NEMA
2 5 240/480 120/240 TRS42-050 rating required. These apply to Item Qty Part No.
the chassis model B161S or
1 1 B163WD
Model B162. If the application
2 1 MOH7211300
requires reversing a model B163
3 0 Not Required
Bronco II must be selected as
4 0 Not Required
Bronco II models cannot provide
reversing with a remote operator
station.
Bronco II For dimensions and connection information, contact Warner Electric Motors and Controls customer service. Bronco II

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 Bronco II Bronco II

Selection BRONCO II
Options
Select the model that best fits your application needs.
Information Run-Jog Torque External Signal External Signal
Model BWC 36015 Process
Run/Stop
Input HP
Fwd-Rev Control Local Isolation Process Follower Board 0 – 100V
P1
Follower

▲
0 – 14V
Line Remote Local Local Operator w/ Follower J6 0 – 10V
Standard on Models B168 and B169.
Voltage Chassis Enclosed Operator Local Operator Operator Speed Trim Option Kit
Optional for customer installation on
4 – 20mA
1 – 5mA Board
115 VAC 1/4–1 models B161S or B162. 1 1
R27
Min
Spd
R28
Max
Spd
Replacement
Single B161S B162 B160 B163 B165 B169 B168 BWC36015
Phase TB3 TB4 Parts
230 VAC 1/2–2

P1

WASHDOWN DUTY BRONCO II(1)

External Signal R26 R43
Run–Jog Stop Run-Jog Torque External Signal IR Comp Accel
Input HP
Fwd-Rev Control Local Isolation
Line Remote Local Local Operator w/ Follower 2.5A
5A R27
J1 Max Spd
Voltage Enclosed Operator Local Operator Operator Speed Trim Option Kit 7.5A
10A
ARM
R29
115 VAC 1/4–1 SW1 Torque
R28
Single B162WD B160WD B163WD B165WDB B169WD B168WD BWC36015 Tach T1
Phase Min Spd
1 2 3 4 5 6 7 8 9 10
230 VAC 1/2–2 TB2

(1)
Note: J4 230V 230V J5
(+) (G2) (AC2)
Washdown Duty Broncos provide the same features as non washdown models with the exception of the epoxy finish and 115V 115V
stainless exterior hardware. 21
J3
PC Board Assembly 90V 180V

▲
(Standard on all Bronco II models) (–) (G1) (AC1) RC1 F1
D19
Model B160 and B160 WD Model B168 and B168 WD Option P2 P3
NEMA 4/12 enclosure with Start/ Same features as Model 169 External Signal Islolation Follower D20
Stop, Run/Jog switches and described below except the front Kit (Standard on Models B168 P4 P5 TB1
Speed Potentiometer mounted on panel mounted Speed and B169) Model BWC 36015 7 6 5 4 3 2 1
enclosure front cover Potentiometer trims the speed For installation on chassis or
signal when operated in the remote enclosed units. Allows
Model B161S automatic mode. motor speed to be controlled form F2 F1 A2 A1 L2 L1 Gnd
Chassis for mounting in customer a grounded or ungrounded
supplied enclosure Model B169 and B169 WD external signal—4-20mA, 1-5mA,
External isolated signal follower 0-10VDC, 0-14VDC, or 0-
Model B162 and B162 WD in NEMA 4/12 enclosure with 100VDC. There is a provision for
NEMA 4/12 enclosure for use Start/Stop and Auto/Manual auto/manual operation if required.
with a remote operator control switches and Speed
Potentiometer mounted on
Model B163 and B163 WD
enclosure front. Controls motor
NEMA 4/12 enclosure with Start/ speed from either a grounded or
Stop, Run/Jog, Forward/Reverse ungrounded signal—4-20ma,
switches and Speed 1-5ma, 0-10VDC, 0-14VDC,
Potentiometer on enclosure front 0-100VDC in auto mode, or from
cover the speed potentiometer in
Model B165 and B165 WD manual mode.
NEMA 4/12 enclosure with torque
control. Start/Stop and Forward/
Reverse switches and Torque
Potentiometer on enclosure front
cover

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 Bronco II Bronco II

Selection BRONCO II
Options
Select the model that best fits your application needs.
Information Run-Jog Torque External Signal External Signal
Model BWC 36015 Process
Run/Stop
Input HP
Fwd-Rev Control Local Isolation Process Follower Board 0 – 100V
P1
Follower

▲
0 – 14V
Line Remote Local Local Operator w/ Follower J6 0 – 10V
Standard on Models B168 and B169.
Voltage Chassis Enclosed Operator Local Operator Operator Speed Trim Option Kit
Optional for customer installation on
4 – 20mA
1 – 5mA Board
115 VAC 1/4–1 models B161S or B162. 1 1
R27
Min
Spd
R28
Max
Spd
Replacement
Single B161S B162 B160 B163 B165 B169 B168 BWC36015
Phase TB3 TB4 Parts
230 VAC 1/2–2

P1

WASHDOWN DUTY BRONCO II(1)

External Signal R26 R43
Run–Jog Stop Run-Jog Torque External Signal IR Comp Accel
Input HP
Fwd-Rev Control Local Isolation
Line Remote Local Local Operator w/ Follower 2.5A
5A R27
J1 Max Spd
Voltage Enclosed Operator Local Operator Operator Speed Trim Option Kit 7.5A
10A
ARM
R29
115 VAC 1/4–1 SW1 Torque
R28
Single B162WD B160WD B163WD B165WDB B169WD B168WD BWC36015 Tach T1
Phase Min Spd
1 2 3 4 5 6 7 8 9 10
230 VAC 1/2–2 TB2

(1)
Note: J4 230V 230V J5
(+) (G2) (AC2)
Washdown Duty Broncos provide the same features as non washdown models with the exception of the epoxy finish and 115V 115V
stainless exterior hardware. 21
J3
PC Board Assembly 90V 180V

▲
(Standard on all Bronco II models) (–) (G1) (AC1) RC1 F1
D19
Model B160 and B160 WD Model B168 and B168 WD Option P2 P3
NEMA 4/12 enclosure with Start/ Same features as Model 169 External Signal Islolation Follower D20
Stop, Run/Jog switches and described below except the front Kit (Standard on Models B168 P4 P5 TB1
Speed Potentiometer mounted on panel mounted Speed and B169) Model BWC 36015 7 6 5 4 3 2 1
enclosure front cover Potentiometer trims the speed For installation on chassis or
signal when operated in the remote enclosed units. Allows
Model B161S automatic mode. motor speed to be controlled form F2 F1 A2 A1 L2 L1 Gnd
Chassis for mounting in customer a grounded or ungrounded
supplied enclosure Model B169 and B169 WD external signal—4-20mA, 1-5mA,
External isolated signal follower 0-10VDC, 0-14VDC, or 0-
Model B162 and B162 WD in NEMA 4/12 enclosure with 100VDC. There is a provision for
NEMA 4/12 enclosure for use Start/Stop and Auto/Manual auto/manual operation if required.
with a remote operator control switches and Speed
Potentiometer mounted on
Model B163 and B163 WD
enclosure front. Controls motor
NEMA 4/12 enclosure with Start/ speed from either a grounded or
Stop, Run/Jog, Forward/Reverse ungrounded signal—4-20ma,
switches and Speed 1-5ma, 0-10VDC, 0-14VDC,
Potentiometer on enclosure front 0-100VDC in auto mode, or from
cover the speed potentiometer in
Model B165 and B165 WD manual mode.
NEMA 4/12 enclosure with torque
control. Start/Stop and Forward/
Reverse switches and Torque
Potentiometer on enclosure front
cover

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Remote Remote Operator Stations (ROS) In determining the components

that comprise a drive system, the
How to Order
Operator Function Model Model Number Suffix
following selections must be
made for features and options.
Stations Number for 10 Turn Speed Pot
Start Pushbutton (1) (3) 1. DC Motor Controller 4. Isolation Transformer
Stop Pushbutton R8005 -10 Select HP and AC input voltage. Select KVA of transformer when
Single Turn Speed Pot The AC input voltage will required by adding the total HP of
Start Pushbutton (1) (3) determine motor armature and all drives to be connected to the
Stop Pushbutton field voltage. transformer. Then select model
Single Turn Speed Pot R8011 -10 number by primary input voltage
AC Input Motor Voltage and secondary output voltage.
Auto-Manual Speed
Voltage Arm/Field
Start-Stop Switch (2) (3)
Run-Jog Switch 115V 90V Arm 5. Options/Accessories
Auto-Man Switch R1001 N/A 50V/100V Field
Single Turn Speed Pot 230V 180V Arm A. The Bronco II provides only
100V/200V Field one option; i.e. the process
Note: follower applicable only to
(1) NEMA 12 Enclosed with wiring to operators B161S or B162 models.
Now select drive configuration,
(2) NEMA 4 Enclosed with wiring to terminal strips B. The isolated follower is factory
chassis or enclosure. If enclo-
(3) Applies to Models B161S and B162 only. installed in the B168 and B169
sure, do you want a blank front
models or field installed in
cover or operators controls.
B161S or B162 models.
Determine which operators are
required (i.e., run/jog, auto/
manual) and whether they will be Example 1
on a remote operators station or A conveyer requires a 1 HP DC
on the drive enclosure. From the motor, 1750 RPM, shunt wound
list of standard option boards, field, TEFC enclosure and a
select those required for your 7V/1000RPM tachometer. The
application. DC drive will be chassis mount,
230 VAC single phase input, to
2. DC Motor be operated from a ROS. ROS to
include start/stop and a speed
With the motor voltage specified potentiometer. Isolation trans-
by the AC input voltage selected former from a 230 VAC input is
above, now determine permanent required.
Isolation Isolation Transformers magnet or shunt wound, frame
Item Qty Part No.
Transformers size, enclosure type (TEFC or
TENV), C face, and whether a 1 1 B161S
tachometer will be required. 2 1 MOH2210831
Single phase NEMA I Enclosed, Dry Type, No Taps, 60 Hz, Type G
3 1 R1001
4 1 TRS21–020
HP KVA Primary Secondary Model Number 5 0 Not Required
Voltage Voltage

1/4 1/2 120/240 120/240 TRS21-005

Example 2
A Food Processing Conveyor
1/2 1 120/240 120/240 TRS21-010 requires a 1 HP DC Motor, 1750
RPM. The operation requires the
3/4 11/2 120/240 120/240 TRS21-015 3. Remote (ROS) Operator selection of start, stop, run or jog,
1 2 120/240 120/240 TRS21-020
Station forward and reverse as well as
speed adjustment. The plant
If a remote operators station will supply voltage is single phase,
11/2 3 240/480 120/240 TRS42-030 be used, select which operators 60 hertz, 230 VAC.
will be used, and the NEMA
2 5 240/480 120/240 TRS42-050 rating required. These apply to Item Qty Part No.
the chassis model B161S or
1 1 B163WD
Model B162. If the application
2 1 MOH7211300
requires reversing a model B163
3 0 Not Required
Bronco II must be selected as
4 0 Not Required
Bronco II models cannot provide
reversing with a remote operator
station.
Bronco II For dimensions and connection information, contact Warner Electric Motors and Controls customer service. Bronco II

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 Bronco II Bronco II

Specifications Ratings How to Order Motor chart specify:

Horsepower
Non-Listed Motors
Non-listed motors are available,
Standard
Horsepower Range 115 VAC 1/4–1 HP
230 VAC 1/2–2 HP
Selection charts for DC motors,
available from Warner Electric
Motor Type (Manufacturer) but specific information is DC Motors
AC Line Input Voltage 115 or 230 VAC ±10% Motors and Controls, are listed on
B=Baldor required.
AC Line Frequency 50/60 Hz ± 2 Hz the following pages. For more
G=General Electric 1. Motor horsepower
115 VAC Supply M=Indiana General 2. RPM
complete specifications and
Armature Voltage 0–90 VDC Frame Size 3. Frame size
dimensional information, contact
Field Voltage 50/100 VDC Motor Enclosure 4. Volts, armature
Warner Electric Motors and
230 VAC Supply TE=Totally Enclosed 5. Volts, field or PM
Controls customer service.
Armature Voltage 0–180 VDC TEFC=Fan Cooled 6. Enclosure
Field Voltage 100/200 VDC TENV=Non Ventilated 7. Conduit location, F1, F2 etc.
Service Factor 1.0 ‘C’ Face Size 8. Thermostat
Duty Continuous (For use with Single Phase 9. Accessory endshield
Maximum Load Capacity 150% for 1 minute Controllers only) 10. ‘C’ face
Line Protection Fuse Armature Voltage 11. Delivery requirements
Model Number 12. Special application or
Motor with Tachometer environmental considerations
Operating Conditions (mounted) and other important
Motor without Tachometer information.
Ambient Temperature Tachometer Kit
Chassis Model 0–55°C
Enclosed Models 0–40°C
Relative Humidity 5–95% non-condensing
Altitude To 3300 feet (1000m)

Performance Characteristics
Speed Range 30:1 with armature voltage
feedback
50:1 with tach-generator
feedback
Speed Regulation (As % of motor
base speed) for 95% load change
Armature Voltage Feedback ± 2%
Tachometer Feedback 1/2–1%

Adjustments
Current Range 2.5, 5, 7.5, 10 Amps DC
Nominal
(Adjustable to 150% of each
range)
Maximum Speed 75–110% of motor base speed
Minimum Speed 0–30% of motor base speed
IR Compensation Adjustable
Acceleration 1–5 seconds (Linear, 0 to top
speed)

Options
• External Signal Isolation Follower For installation on chassis or
Kit remote (Standard on Models enclosed units. Allows motor
B168 and B169) Model BWC 36015 speed to be controlled from
• For use with Bronco II M/N B162 a grounded or ungrounded
when required. external signal—4–20mA,
1–5mA, 0–10 VDC, 0–14 VDC,
or 0–100 VDC. There is a
provision for auto/manual
operation if required.

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Standard DC Motors Washdown Duty Specifications

6 Standard Models
DC Motors 1/4 to 1 Horsepower 90 VDC Armature – PERMANENT MAGNET FIELD – 1750 RPM – Totally Enclosed
Model B160WD
NEMA Model Number
HP Motor Frame Enclosure ‘C’ Motor Motor with 7 VDC NEMA 4X enclosure with Start/
Type Size Face without 7 VDC/1000 RPM Tachometer Stop, Run/Jog switches and
Tachometer Tachometer Kit Speed potentiometer mounted on
(mounted) enclosure front cover

1/4 G 56HAA NV 56C MOD6110210 N/A N/A Model B162WD

B 320P NV 56C MOD6211200 MOD6211231 TAC 4001–13 NEMA 4X enclosure for use with
a remote operator control
1/2 G 56KAA FC 56C MOF6210210 N/A N/A
B 336P NV 56C MOF6211200 MOF6211231 TAC 4001–13 Model B163WD
NEMA 4X enclosure with Start/
3/4 G 56PAA FC 56C MOG6210210 N/A N/A
Stop, Run/Jog, Forward/Reverse
B 428P FC 56C MOG6211100 MOG6211131 TAC 4001–00 switches and Speed Potentio-
1 G 56SAA FC 56C MOH6210210 N/A N/A meter on enclosure front cover
B 435P FC 56C MOH6211100 MOH6211131 TAC 4001–00 Model B165WD
NEMA 4X enclosure with torque
Note: All motors are capable of 20:1 constant torque speed range. control. Start/Stop and Forward/
Reverse switches and Torque
Potentiometer on enclosure front
cover
Model B168WD
DC Motors Same features as Model 169
described below except the front
1/2 to 2 Horsepower 180 VDC Armature – PERMANENT MAGNET FIELD – 1750 RPM – Totally Enclosed panel mounted Speed Potentio-
meter trims the speed signal
NEMA Model Number when operated in the automatic
HP Motor Frame Enclosure ‘C’ Motor Motor with 7 VDC mode.
Type Size Face without 7 VDC/1000 RPM Tachometer
Tachometer Tachometer Kit Model 169WD
(mounted) External isolated signal follower
in NEMA 4X enclosure with Start/
1/2 G 56KAA FC 56C MOF7210210 N/A N/A Stop and Auto/Manual switches
B 336P NV 56C MOF7111100 MOF7111131 TAC 4001–13 mounted on enclosure front.
3/4 G 56PAA FC 56C MOG7210210 N/A N/A Controls motor speed from either
a grounded or ungrounded
B 336P NV 56C MOG7211100 MOG7211131 TAC 4001–10 signal—4–20mA, 1–5mA, 0–10
1 G 146ATC FC 140TC MOH7210800 MOH7210831 TAC 4004–02 VDC, 0–14 VDC, 0–100 VDC in
G 56SAA FC 56C MOH7210210 N/A N/A auto mode, or from the speed
potentiometer in manual mode.
B 435P FC 56C MOH7211100 MOH7211131 TAC 4001–00
1-1/2 B 536P FC 140TC MOI7211100 MOI7211131 TAC 4007–01
G 148ATC FC 140TC MOI7210800 MOI7210831 TAC 4004–02
2 B 548P FC 140TC MOJ7211100 MOJ7211131 TAC 4007–01
G 149ATC FC 140TC MOJ7210800 MOJ7210831 TAC 4004–02

Note: All motors are capable of 20:1 constant torque speed range.

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 Bronco II Bronco II

Specifications Versatility DC Motors Standard

7 Standard Models 1/4 to 1 Horsepower 90 VDC Armature – 100/50 VDC SHUNT WOUND FIELD – 1750 RPM – Totally Enclosed DC Motors
Model B160 NEMA Model Number
NEMA 4/12 enclosure with Start/ HP Motor Frame Enclosure ‘C’ Motor Motor with 7 VDC
Stop, Run/Jog switches and Type Size Face without 7 VDC/1000 RPM Tachometer
Speed potentiometer mounted on Tachometer Tachometer Kit
enclosure front cover (mounted)
Model B161S 1/4 B 413D FC 56C MOD1211700 MOD1211731 TAC 4001–00
Chassis for mounting in customer 1/2 B 420D FC 56C MOF1211700 MOF1211731 TAC 4001–00
supplied enclosure 3/4 B 428D FC 56C MOG1211700 MOG1211731 TAC 4001–00
Model B162 1 B 535D FC 56C MOH1211700 MOH1211731 TAC 4007–00
NEMA 4/12 enclosure for use
with a remote operator control Note: All motors are capable of 20:1 constant torque speed range.

Model B163
NEMA 4/12 enclosure with Start/
Stop, Run/Jog, Forward/Reverse
switches and Speed Potentio-
meter on enclosure front cover
Model B165
NEMA 4/12 enclosure with torque
control. Start/Stop and Forward/
Reverse switches and Torque
Potentiometer on enclosure front DC Motors
cover
1/2 to 2 Horsepower 180 VDC Armature – 200/100 VDC SHUNT WOUND FIELD – 1750 RPM – Totally Enclosed
Model B168
Same features as Model 169 NEMA Model Number
described below except the front HP Motor Frame Enclosure ‘C’ Motor Motor with 7 VDC
panel mounted Speed Potentio- Type Size Face without 7 VDC/1000 RPM Tachometer
meter trims the speed signal Tachometer Tachometer Kit
when operated in the automatic (mounted)
mode.
1/2 B 420D FC 56C MOF2211700 MOF2211731 TAC 4001–00
Model B169 3/4 B 428D FC 56C MOG2211700 MOG2211731 TAC 4001–00
External isolated signal follower 1 G 146ATC FC 140TC MOH2210800 MOH2210831 TAC 4001–02
in NEMA 4/12 enclosure with B 535D FC 56C MOH2211800 MOH2211831 TAC 4007–01
Start/Stop and Auto/Manual
G L182ACY NV 180C MOH2110100 MOH2110131 TAC 4002–03
switches mounted on enclosure
front. Controls motor speed from 1-1/2 G 148ATC FC 140TC MOI2210800 MOI12210831 TAC 4004–02
either a grounded or ungrounded G L186ACY NV 180C MOI2110100 MOI2110131 TAC 4002–03
signal—4–20mA, 1–5mA, 0–10 B 636D FC 180C MOI2211400 MOI2211431 TAC 4001–15
VDC, 0–14 VDC, 0–100 VDC in
auto mode, or from the speed 2 G 149ATC FC 140TC MOJ2210800 MOJ12210831 TAC 4004–02
potentiometer in manual mode. B 646D FC 180C MOJ2211400 MOJ2211431 TAC 4001–15
G L186ACY NV 180C MOJ2110100 MOJ2110131 TAC 4002–03

Note: All motors are capable of 20:1 constant torque speed range.

Bronco II Bronco II

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 Bronco II Bronco II

Washdown The Washdown Duty DC Motors

are specifically suited for tough Food Processing Applications
Duty DC environments where washdown is
essential to maintain cleanliness. • Washdown is frequent
Motors These motors are selected to • Cleanliness is critical
function as a companion with the • Rugged, tough environment
appropriate WASHDOWN DUTY
BRONCO II D.C. Drive Controller.

Features
8 standard Washdown Duty DC
Motors
• Epoxy Finished - FDA
approved
• Moisture Resistant Wire
• 90 or 180 VDC Armature
• Permanent Magnet Field
• 1750 RPM
• Totally Enclosed
• Sealed and corrosion protected
to meet the environments
found in food and other
industries demanding high
levels of cleanliness.

DC Motors – Washdown Duty

1/4 to 3/4 Horsepower 90 VDC Armature – PERMANENT MAGNET FIELD – 1750 RPM – Totally Enclosed

NEMA Model Number

HP Motor Frame Enclosure ‘C’ Motor Motor with 7 VDC Chemical Processing
Type Size Face without 7 VDC/1000 RPM Tachometer
Tachometer Tachometer Kit • Corrosive atmosphere
(mounted) • Frequently wet
• Simple mounting
1/4 M 4622 NV 56C MOD6112010 N/A N/A
1/2 M 4660 NV 56C MOF6112010 N/A N/A
3/4 M 4680 NV 56C MOG6112010 N/A N/A
Note: All motors are capable of 20:1 constant torque speed range.

DC Motors – Washdown Duty

1/2 to 2 Horsepower 180 VDC Armature – PERMANENT MAGNET FIELD – 1750 RPM – Totally Enclosed

NEMA Model Number

HP Motor Frame Enclosure ‘C’ Motor Motor with 7 VDC
Type Size Face without 7 VDC/1000 RPM Tachometer
Tachometer Tachometer Kit Waste Water Treatment
(mounted)
• Wet environment
1/2 M 4660 NV 56C MOF7112010 N/A N/A • Compact size
3/4 M 4680 NV 56C MOG7112010 N/A N/A • Minimal maintenance
1 B 435P FC 56C MOH7211300 N/A N/A
1-1/2 B 536P FC 145C MOI7211300 N/A N/A
2 B 548P FC 145C MOJ7211300 N/A N/A
Bronco II Note: All motors are capable of 20:1 constant torque speed range. Bronco II

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 Bronco II Bronco II

Applications Enclosed Models B160, B162, B163, B165, B168 & B169
Dimensions

Conveyors Conduit Knockout

1.500 2.000
Ø .875 2 Places
• Simple, variable speed control
• Forward or reverse direction
• Compact and rugged for on
machine mounting 8.125
8.875
9.500
5.625
4.625
3.250

.250

2.500 .688 .313

5.000
.250 W x .375 L Slot
2 Places

Take-up
• Simple center winders
Chassis Model B161S
• Constant Torque Ø .250 4 Places

5.000 7.000

1.000

1.000 .313 .452

5.000 3.000
Mixers
• Variable speed
• Rugged and industrially tough Dimensions are listed in inches
• NEMA 4/12 enclosures

Bronco II Bronco II

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 Bronco II Bronco II
Models B160, B163 & B165 Washdown Duty
Connection Models B168 & B169
Features
Diagrams Jumper location
for model 165
A new standard in and
adjustable speed
Jumper location DC Drives. Benefits
for models
160 & 163 1 2 3 1 2 Specifically designed for food
Process – Common processing and other industries
1 2 3 4 5 6 7 8 9 10 TB5 TB4
Follower + Current Input where the motor and control are
TB2 Signal
+ – Input + Volts Input constantly exposed to high
*Optional
Tachometer 1 2 3 4 5 6 7 8 9 10 pressure washdown to maintain
+ – TB2
cleanliness.
+ –
7V/1000 RPM Optional • Rugged
Tachometer • Reliable
*Model
160 Only
– + • Versatile
7V/1000 RPM • Accurate
TB1 TB1
• Economically priced
7 6 5 4 3 2 1 7 6 5 4 3 2 1
• Listed
F2 F1 A2 A1 L1 L2 Gnd F2 F1 A2 A1 L1 L2 Gnd
F2 – A2 – F2 – A2 – • Listed for use in Canada

F1 + A1 + F1 + A1 + The Bronco II Washdown Duty

DC Drives convert single phase
115 or 230 VAC 115 or 230 VAC AC line voltages of either 115 of
50/60 Hz 50/60 Hz
230 VAC to variable DC for
armature voltage speed control
of permanent magnet or shunt
wound DC motors from 1/4 to
2 HP.
Models B161S & B162
Jumper Location for Jumper Location for
Torque Control Operation Speed Control Operation

Totally enclosed cast aluminum epoxy coated FDA

approved white enclosure with gasketed cover and
stainless steel captive screws meets NEMA 4X.
1 2 3 6 9 10
Optional Stop
2-Wire Start
Start + –
TB2 Optional Proven Warner Electric Dependability
Tachometer
• Full Wave power conversion circuit with 2 SCR’s and 3
+ –
Stop diodes with NEMA K configuration allows cooler motor
7V/1000 RPM operation.
Start CW
• IR compensation improves speed regulation in armature
W Torque Control
Speed CW Adjust
voltage feedback mode.
Control W 2K, 2W, 5%
Adjust CCW
• Control relay with 3-wire start/stop circuit prevents
2K, 2W, 5% automatic restart after power outage for increased safety.
CCW TB1 (May be reconnected for line start operation if required.)
7 6 5 4 3 2 1
• Full two year warranty.

F2 F1 A2 A1 L1 L2 Gnd
F2 – A2 –

F1 + A1 +

115 or 230 VAC

50/60 Hz

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 Bronco II Bronco II
Replacement parts list for all models
Features Check out these outstanding standard features Recommended
of the Bronco II 160 Series from Warner Electric Motors and Controls...
and Warner Electric
Spare Parts
Benefits Description Old
Part Number
New

Speed/Torque Adjust Pot. 2K APT2026–00 224552-000

Start/Run/Stop Switch ASW3010–00 224554-000
Forward/Reverse Switch ASW1051–01 224579-001
Auto/Manual or Run/Jog Switch ASW1079–00 224551-000
Water Tight Boot (For all Switches) HMI 1103-00 224639-000
Water Tight Nut (For all Pots) HMI1012–00 224638-000
Fuse, 20 Amp PFU1010–07 104364-025
Isolation Follower Card BWC36015–00 –
Power Module ATY4001–03 224544-001
PC Board Assembly SPD36006–00 –

Service Service
It is intended that the Bronco II
should be serviced by replacing
Listed Field programmable jumpers Jog at potentiometer speed
major sub-assemblies. The
Allow the Bronco II to be quickly Set your Bronco II speed Replacement Parts List lists all of
Listed for use in Canada modified to match available plant potentiometer at the desired the sub-assemblies required to
line voltage, select motor HP, and speed and you can jog the motor service Bronco II drives. It is
Speed regulation to select the feedback signal allowing easy set up of your recommended that users keep
Regulation by armature voltage required. machine process. these parts readily available to
feedback or tachometer support the drive’s critical
generator feedback (non- AC line protection fuse Field supply for shunt wound
field motors applications.
reversing models only). Fault protection...eliminates a For additional assistance or the
costly replacement. Permanent magnet field or shunt name of your closest authorized
Dual voltage input wound field motors...Bronco II is
(115/230 VAC) Full wave power conversion service center, contact Warner
the right one. Electric Motors and Controls
Each model can be connected to circuit with 2 SCR’s and 3
diodes providing NEMA Totally enclosed, cast customer service at
either of two line voltages 1/4, 1/2, 800-787-3532.
3/4 and 1HP motors @115VAC Code K, DC armature supply aluminum enclosure meets
input or 1, 1-1/2 and 2 HP motors Insures optimum motor NEMA 4, NEMA 12 and
@ 230VAC. performance, cooler motor NEMA 4X standards
operation and longer life. Incredibly rugged DC drives for
Circuit protection the most critical industrial
Transient voltage protection by IR compensation adjustment environment–dust tight, oil tight
MOV. Improves speed regulation in and water resistant.
armature voltage feedback mode.
Torque control Maximum and minimum
Controls motor armature current Control relay with 3-wire speed adjustments
for applications requiring torque start/stop circuit Establishes minimum and
or tension control. Prevents automatic restart after maximum speeds.
power outage for increased
Local or remote operator safety. (May be reconnected for Adjustable acceleration
control line start operation if required.) (1 to 5 seconds)
Flexible, compact...fits where you Easy-to-set for smooth, linear
want it. speed control.
Open chassis unit availability
For convenient mounting of one
or several drives in your
enclosure.

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Contents

Contents

Features and Benefits . . . . . . . 2

Applications . . . . . . . . . . . . . . . 4

Specifications . . . . . . . . . . . . . 6

How to Order . . . . . . . . . . . . . . 9

Selection Information . . . . . . 10

Options . . . . . . . . . . . . . . . . . 11

Remote Operator
Stations . . . . . . . . . . . . . . . . . 12

Isolation Transformers . . . . . 12

Standard DC Motors . . . . . . . 13

Washdown Duty
DC Motors . . . . . . . . . . . . . . . 16

Dimensions . . . . . . . . . . . . . . 17

Connection Diagrams . . . . . . 18

Recommended Spare
Parts . . . . . . . . . . . . . . . . . . . 19

Service . . . . . . . . . . . . . . . . . 19

Bronco II Bronco II

20 1

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 ADDITIONAL WARNER ELECTRIC DC DRIVES & CONTROLS

A Total Commitment Through

Distribution

• Throughout the North American Conti- • An extention of the commitment to product

nent distributors provide one stop product service is carried to each and every customer
availability and expertise through the dedicated distributor network.

• Each Distributor is a Market specialist • A carefully oriented plan is made with each
to meet local and immediate needs. distrubutor to insure optimum coverage and
service for each market area.
SE2000 DC Drives QUADRALINE 7000 DC Drives
• Literally thousands of sales and service
This non-regenerative DC drive is designed to control Designed for full wave, regenerative applications, the
personnel form the total team commitment for
shunt wound or permanent magnetic field DC motors Quadraline 7000 is designed for either permanent magnet
from ¼ to 5 HP. It offers isolated 4-20mA or 0-10 VDC or wound feild DC motors from ¼ to 5 HP. It features product and sales assurance.
control signal, tachometer generator feedback, circuit fullwave 4-quadrant operation, seven selectable perfor-
protection, diagnostic capabilities, control relay, torque mance features, electronic reversing and seven control
and slope control, and overcurrent protection. Jumper adjustments, positioning accuracy. Chassis or NEMA 4/12
selectable to program drives for specified motor or enclosures available and UL listed.
application. Horsepower range 115 VAC to 230 VAC.
Open chassis available and UL listed.

M4000 Digital 3-Phase DC Drives DS9000 Digital Drive Speed Controller

The M4000 Series Digital 3-Phase DC Drive is a The DS9000 Digital Speed Controller features long term
programmable, microprocessor based variable speed DC speed accuracy, control and stability. It offers 16-bit
drive. It allows keypad control of each parameter. Digital microprocessor based, AC or DC drive control, ± .01% YOUR DISTRIBUTOR IS:
readout provides on-line monitoring of drive operation. accuracy, digital master or follower, analog or digital
Ideal for many drive applications including wire and input, and two selectable sets of programmable param-
cable, packaging/converting, machinery and material eters. Front panel controls include a 4-digit LED readout,
handling. Improved circuit board technology has added keypad controls and four LED status indicators.
standard features, including serial communications and a
field-weakening controller for constant power and
extended speed range applications.

*Contact Warner Electric for information on our complete line of AC drives

Bronco II Coverall 2 10/21/99, 18.49

 SUPPORTED BY DANA CORPORATION
WARNER ELECTRIC
The Warner Electric Motors and Controls Division of Dana Corporation is a global leader in the engineer-
ing and manufacturing of motor and control products for industrial applications. All Warner Electric
products and services are backed by highly specialized engineers and service people who can help solve
your production challenges. Warner Electric’s capabilities and products have improved operations for
hundreds of companies around the world.

Warner Electric® stepper motors and controls, servo motors and controls, voltage conditioning products,
engineered systems, and AC/DC drives are available worldwide through an extensive authorized distribu-
tor network. These distributors provide convenient service by offering technical support, replacement
Bronco II
parts, and literature, as well as an extensive inventory of off-the-shelf models for the fastest possible 160 Series DC Drives
delivery and service. Call your nearest distributor for ordering and application information.

IN U.S.A. AND CANADA

WARNER ELECTRIC MOTORS AND CONTROLS DIVISION

◆ Sales: 734-669-4700
◆ Customer Service: 800-787-3532
◆ Product Application: 800-787-3532
◆ Product Literature Request: 800-787-3532
◆ Fax: 800-766-6366 or 860-589-2136
◆ Web Site: www.warnernet.com

SERVO CONTROLS STEPPER CONTROLS VOLTAGE CONDITIONING ENGINEERED SYSTEMS AC/DC DRIVES
WARNER ELECTRIC MOTORS AND CONTROLS DIVISION
Division Office Bristol Plant Systems Center International - Europe
640 Avis Drive, Suite 200 383 Middle Street 13500-J South Point Blvd. Lausanne, Switzerland
Ann Arbor, MI 48108 Bristol, CT 06010 Charlotte, NC 28273 La Pierreire
CH-1029 Villars-Ste-Croix,
Switzerland

©1999 Warner Electric Division

C3004 9/99 Printed in U.S.A.

Bronco II Coverall 1 10/21/99, 18.47