Warner Electric EC-375, EC-475, EC-650, EC-825, EC-1000 User Manual

Electro-Clutch EC-375, EC-475,

EC-650, EC-825, EC-1000, EC-1225

P-210
819-0041

Installation Instructions

Contents

Installation Instructions . . . . . . . . . . . . . . . . . . .2

Torque Tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Electrical Coil Data . . . . . . . . . . . . . . . . . . . . . . .5

Burnishing and Maintenance . . . . . . . . . . . . . . .6

Illustration Drawings

EC-375 EC-475 EC-650 . . . . . . . . . . . . . . .8

EC-825 . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

EC-1000 EC-1225 . . . . . . . . . . . . . . . . . . .16

Warranty . . . . . . . . . . . . . . . . . . . . . .Back Cover

Installation Instructions

Electro-Clutch

A. Mounting the Electro-Clutch

1. Ideally, the Electro-Clutch should be mounted
on a through-shaft for firm support. In the
case of a stub shaft, the stub should be as
long as the clutch assembly, although for
moderate duty applications a shaft which is
2/3 or more the length of the assembly
normally provides adequate support.

2. Insert the key in the shaft. If the keyseat is
opened at one end of the shaft, prick punch
the shaft to prevent the key from working out.

3. Slide the assembled Electro-Clutch on the
shaft. (When the Electro-Clutch is mounted
on a stub shaft, the set collar end of the
clutch should be toward the support
bearings.) Tighten the setscrews in the set
collar. (Figure 1)

Failure to follow these
instructions may result in product damage,
equipment damage, and serious or fatal
injury to personnel.

Figure 1

4. Secure the torque arm to the tab on the field
and rotor assembly. Secure the other end of
the torque arm to a solid base. Under no
circumstances should the torque arm be
pinned down so tightly that it preloads the
bearing. For more information on torque
tabs, see page 4.

Warner Electric • 800-825-9050 819-0041 • P-210

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B. Assembling the Sheave, Pulley, or
Sprocket and Clutch

1. Install the key in the outer diameter of
the Electro-Clutch hub. (A special key is
furnished.)

2. Mount a standard sheave, pulley, or sprocket
to the Electro-Clutch with a standard tapered
bushing. Note: Only standard tapered

bushings are recommended for this
purpose. A straight bore drive component
mounted with set screws will damage the
Electro-Clutch bearings.

3. Install the belt on the sheave, pulley, or
sprocket. Keep the belt tensions within the
recommendation of the sheave or pulley
manufacturer.

C. Electrical Installation

1. Remove the mounting screws and lockwash­ers that hold the armature carrier assembly to
the sleeve. (Figure 2)

Figure 2

2. Remove the rotor mounting screws.

3. Insert two of the rotor screws in the removal
holes of the rotor to back the rotor off the
bearing. (Figure 3)

Each Warner Electric control is furnished with a
wiring diagram showing the correct electrical
connections between the control and the clutch.
Two straps are provided on the clutch torque
arm to hold the clutch lead wires in place.
(Service Manual P-239 contains complete
information on all standard power supplies.)

D. Replacing Worn Parts

The two main wearing parts, the armature and
the rotor, may be easily replaced. For stub shaft
mounted applications, these parts can be
replaced without removing the Electro-Clutch
from the shaft. The rotor and the armature usu­ally wear at the same rate and should be
replaced together.

Figure 3

4. Install the new rotor on the clutch assembly.

®

Dip the mounting screws in Loctite

before

reinserting them.

5. Install the new armature assembly. Dip the
mounting screws in Loctite before reinserting
them.

Warner Electric • 800-825-9050 819-0041 • P-210

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Torque Tabs

Many Warner Electric clutch assemblies have
a bearing mounted stationary field. By design
the bearing maintains its proper position
between the field and rotor making it easy for
the customer to mount the field-rotor assembly.
However, the bearing has a slight drag which
tends to make the field rotate with the rotor if
not restrained. Since the field has lead wires
attached, it must be restrained to prevent rota­tion and pulling of these wires. To counteract
this rotation force, the field has a "torque tab" to
which the customer must attach an appropriate
anti-rotational restraint.

A few hints regarding proper torque tab
restraints are in order. First and foremost, it is
important to recognize that the force to be over­come is very small and the tab should not be
restrained in any manner which will preload the
bearing. For example, if the clutch is mounted
with the back of the field adjacent to a rigid
machine member the customer should not
attach a capscrew tightly between the tab and
the machine member. This may pull the tab
back against the rigid member as shown in
Figure 4 and preload the bearing. The recom­mended methods are illustrated in Figures 5, 6,
and 7. The method selected is primarily a matter
of customer preference or convenience.

Figure 4

Rigid Member

with Slot Straddling Tab

Warner Electric • 800-825-9050 819-0041 • P-210

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Figure 5

Rigid Member

Figure 6

Pin In Hole Loosely

Figure 7

Flexible Strap

Electrical Coil Data

EC/EB-375 EC EB

Voltage – DC 90 24 6 90 24 6

Resistance @ 20° C – Ohms 453.5 29.3 2.10 446.8 29.3 1.96

Current – Amperes .198 .82 2.85 .201 .82 3.07

Watts 17 20 17 18 20 18

Coil Build-up – milliseconds 62 60 59 50 60 52

Coil Decay – milliseconds 13 14 15 8 14 10

EC/EB-475 EC EB

Voltage – DC 90 24 6 90 24 6

Resistance @ 20° C – Ohms 368.9 37.8 2.32 443.1 28.8 2.05

Current – Amperes .244 .64 2.58 .203 .88 2.93

Watts 22 15 16 18 21 18

Coil Build-up – milliseconds 92 91 90 80 75 70

Coil Decay – milliseconds 18 17 16 899

EC/EB-650 EC EB

Voltage – DC 90 24 6 90 24 6

Resistance @ 20° C – Ohms 225 17.7 1.16 257.2 18.3 1.24

Current – Amperes .4 1.36 5.19 .35 1.3 4.84

Watts 36 33 31 32 31 29

Coil Build-up – milliseconds 120 115 110 112 108 105

Coil Decay – milliseconds 20 20 20 12 13 14

FB/ER-375, 475, 650 FB-375 FB-475 FB-650

Voltage – DC 90 24 90 24 90 24

Resistance @ 20° C – Ohms 446 29 310 22 235 16

Current – Amperes .201 .822 .300 1.09 .380 1.426

Watts 18 19 27 26 34 34

Coil Build-up – milliseconds 40 40 80 80 90 90

Coil Decay – milliseconds 5 10 8 10 10 10

EC/EB-1000 EC EB

Voltage – DC 90 24 6 90 24 6

Resistance @ 20° C – Ohms 248.7 19.7 1.23 248.7 19.7 1.23

Current – Amperes .36 1.22 4.87 .36 1.22 4.87

Watts 33 29 29 33 29 29

Coil Build-up – milliseconds 250 235 220 235 220 205

Coil Decay – milliseconds 70 75 80 70 75 80

EC/EB-1225 EC EB

Voltage – DC 90 24 6 90 24 6

Resistance @ 20° C – Ohms 207.3 15.1 1.04 261.7 22.3 1.33

Current – Amperes .43 1.59 5.79 .34 1.08 4.5

Watts 39 38 35 31 26 27

Coil Build-up – milliseconds 500 490 480 460 445 435

Coil Decay – milliseconds 220 230 240 190 160 140

ATC, ATTC, ATB, ATTB-25 ATC ATB

Voltage – DC 6 24 90 6 24 90

Resistance @ 20° C – Ohms 1.37 20.2 290 1.37 20.2 290

Current – Amperes 4.38 1.19 .31 4.38 1.19 .31

Watts 26.3 28.6 27.9 26.3 28.6 27.9

Coil Build-up – milliseconds 145 145 145 145 145 145

Coil Decay – milliseconds 888 9 99

ATC, ATTC, ATB, ATTB-55 ATC ATB

Voltage – DC 6 24 90 6 24 90

Resistance @ 20° C – Ohms 1.21 19.6 230 1.21 19.6 230

Current – Amperes 4.96 1.22 .39 4.96 1.22 .39

Watts 29.8 29.3 35.2 29.8 29.3 35.2

Coil Build-up – milliseconds 200 200 200 210 210 210

Coil Decay – milliseconds 20 20 20 35 35 35

ER-825, 1225 ER-825 ER-1225

Voltage – DC 90 35-75

Resistance @ 20° C – Ohms 304 235

Current – Amperes .29 .383

Watts 26 35

Coil Build-up – milliseconds 400 700

Coil Decay – milliseconds 20 20

EC/EB-825 EC EB

Voltage – DC 90 24 6 90 24 6

Resistance @ 20° C – Ohms 221 20.9 1.098 223.3 20.4 1.27

Current – Amperes .407 1.15 5.464 .4 1.18 4.74

Watts 37 28 33 36 28 28

Coil Build-up – milliseconds 225 200 180 170 170 170

Coil Decay – milliseconds 130 122 115 80 75 70

Warner Electric • 800-825-9050 819-0041 • P-210

ATC, ATTC, ATB, ATTB-115 ATC ATB

Voltage – DC 6 24 90 6 24 90

Resistance @ 20° C – Ohms 1.02 16.5 182 1.02 16.5 182

Current – Amperes 5.91 1.46 .50 5.91 1.46 .50

Watts 35.4 35 44.6 35.4 35 44.6

Coil Build-up – milliseconds 145 145 145 150 150 150

Coil Decay – milliseconds 40 40 40 45 45 45

5

Burnishing and Maintenance

Maintenance

Burnishing

Intimate metal to metal contact is essential
between the armature and the metal rings
(poles) of the magnet or rotor. Warner Electric
clutches and brakes leave the factory with the
friction material slightly undercut to assure good
initial contact.

Normally, the desired wearing-in process occurs
naturally as the surfaces slip upon engagement.
The time for wear-in, which is necessary to
obtain the ultimate torque of the unit, will vary
depending on speed, load, or cycle duty.

If maximum torque is required immediately after
installation, the unit should be burnished by
slipping the friction surfaces together at reduced
voltage. It is recommended that the burnishings
be done right on the application, if at all pos­sible.

Burnishing at high speed will result in a
smoother wear-in pattern and reduce the time
for burnishing. The voltage should be set at
approximately 30% or 50% of the rated value.

The unit should be cycled on and off to allow
sufficient time between slip cycles to prevent
overheating.

When a Warner Electric brake or clutch is
properly assembled and installed, no further
servicing, lubrication, or maintenance should
be required throughout the life of the unit.

Wear Pattern: Wear grooves appear on the arma­ture and magnet surfaces. This is a normal wear
condition, and does not impair functioning of the
unit. Normally, the magnet and armature, as a
mating pair, will wear at the same rate. It is the
usual recommendation that both components be
replaced at the same time.

Remachining the face of a worn armature is not
recommended. If a replacement armature is to be
used with a used magnet, it is necessary to
remachine the worn magnet face. In refacing a
magnet: (1) machine only enough material to clean
up the complete face of the magnet; (2) hold the
face within .005" of parallel with the mounting
plate; and (3) undercut the molded facing material
.001" - .003" below the metal poles.

Heat: Excessive heat and high operating
temperatures are causes of rapid wear. Units,
therefore, should be ventilated as efficiently as
possible, especially if the application requires fast,
repetitive cycle operation.

Foreign Material: If units are used on machinery
where fine, abrasive dust, chips or grit are
dispelled into the atmosphere, shielding of the
brake may be necessary if maximum life is to be
obtained.

Where units are used near gear boxes or
transmissions requiring frequent lubrication,
means should be provided to protect the friction
surfaces from oil and grease to prevent serious
loss of torque.

Oil and grease accidentally reaching the
frictionsurfaces may be removed by wiping with a
rag dampened with a suitable cleaner, which
leaves no residue. In performing this operation, do
not drench the friction material.

If the friction materials have been saturated with
oil or grease, no amount of cleaning will be com­pletely effective. Once such a unit has been
placed back in service, heat will cause the oil to
boil to the surface, resulting in further torque loss.

Warner Electric • 800-825-9050 819-0041 • P-210

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