Electro-Packs
EP-170, 250, 400, 500, 825, 1000, 1525
P-212
819-0078
Installation Instructions
Contents
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation Instructions . . . . . . . . . . . . . . . . . . 4
Replacing Worn Parts . . . . . . . . . . . . . . . . . . . 4
Burnishing and Maintenance . . . . . . . . . . . . . . 6
Electrical Data Coil Ratings . . . . . . . . . . . . . . . 8
Exploded Views and Parts List
EP-170, 250, 400 . . . . . . . . . . . . . . . . . . . . 9
EP-500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
EP-825 . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
EP-1000 . . . . . . . . . . . . . . . . . . . . . . . . . . 16
EP-1525, 1525 HT. . . . . . . . . . . . . . . . . . . 17
Warranty . . . . . . . . . . . . . . . . . . . . . . Back Page
Base Mounted Clutch/Brake
Combinations in a Rugged Housing
Meets electrical codes
UL Listed or CSA Certified.
Failure to follow these
instructions may result in product damage,
equipment damage, and serious or fatal
injury to personnel.
Heavy duty bearings
Properly aligned for
maximum performance.
Brake output shaft
Pre-packaged
Over 20 major components have been preengineered and
pre-assembled in a
typical Electro Pack.
Ready-to-go, straight
from the box.
Foot mounted
Bolt-it-down and wire-it-up. Allows for
quick replacement/reduced downtime.
Clutch input shaft
Maintenance free
Never needs lubrication.
Self-adjusting for wear of
clutch-brake friction faces.
Consistent performance.
Warner Electric • 800-825-9050 P-212 • 819-0078
2
Clutch/Brake Selection Information
Horsepower vs. Shaft Speed
Selection Procedure
Determine the shaft speed at the Electro
Pack location. The number listed at the
intersection of horsepower and speed is
the size Electro Pack you require.
Part Numbers
Model Voltage
No. DC Part No.
EP-170 6 5633-273-002
24 5633-273-003
90 5633-273-005
EP-250 6 5130-273-031
24 5130-273-032
90 5130-273-034
EP-400 6 5131-273-009
24 5131-273-010
90 5131-273-011
EP-500 6 5230-273-003
24 5230-273-011
90 5230-273-002
EP-825 6 5231-273-003
24 5231-273-004
90 5231-273-002
EP-1000 6 5232-273-003
24 5232-273-005
90 5232-273-002
EP-1525 6 5234-273-003
90 5234-273-002
EP-1525HT 90 5234-273-012
When ordering, specify size, voltage, and
part numbers.
Specifications
Electro-Pack Size Horsepower @ 1800 RPM Static Torque Max. RPM Voltage DC
EP-170 1/8 15 lb. in. 10,000 6, 24 or 90
EP-250 1/2 70 lb. in. 7,500 6, 24 or 90
EP-400 1 270 lb. in. 4.500 6, 24 or 90
EP-500 2 50/40 lb. ft. 4,000 6 or 90
EP-825 7-1/2 125 lb. ft. 3,600 6 or 90
EP-1000 10 240 lb. ft. 3,000 6 or 90
EP-1525 25 700 lb. ft. 1,800 6 or 90
EP-1525HT 40 1350 lb. ft. clutch 1,800 90
700 lb. ft. brake
3
Electro-Packs
The Electro-Pack is a pre-assembled
clutch/brake package complete with input
and output shafts. These units are ready to
be installed in all standard power transmission
systems—V-belts and pulleys, chain and
sprockets, in-line couplings, timing belt drives,
and gear trains.
A. Installing the Electro-Packs
1. Provide a mounting surface for the
Electro-Pack that is rigid and flat with
the following tolerances.
Electro-Pack Mounting Surface to be
Sizes Flat in One Plane Within:
170 .004"
250 .004"
400 .004"
500 .010"
825 .010"
1000 .010"
1525 .010"
2. Connect the Electro-Pack into the drive
system. The input shaft is identified on the
Use care when connecting the units!
unit.
Serious problems will occur if the power input
is connected to the output shaft.
1. Remove the cover from the Electro-Pack unit.
(Figure 1)
Figure 1
2. Disconnect the wires from the magnet
terminals or disconnect the lead wires
(EP-170).
3. Remove the capscrews and washers from the
output end bell and remove the end bell.
(Figure 2)
Dimensions for the input and output shafts
are shown on the illustration drawings,
beginning on page 9.
3. Make the proper electrical connections
between the Electro-Pack and a suitable DC
power supply. Lead wires or terminals are
provided on the clutch and brake for this
purpose. A wiring diagram showing the
proper connections is furnished with each
Warner Electric power supply.
B. Replacing Worn Parts
The normal wearing components of an
Electro-Pack are the magnet, two armatures,
and rotor. The mating components (magnet
and armature or rotor and armature) generally
wear at the same rate and should be replaced
together.
Figure 2
4. Remove and discard the worn armature(s).
5. Remove the used magnet and discard it.
Assemble the new magnet to the end bell.
(Figure 3)
Warner Electric • 800-825-9050 P-212 • 819-0078
4
Figure 3
6. Assemble new armature on the armature hub
with the segmented side toward the magnet.
7. Assemble the second armature in the
opposite direction of the first. (Figure 4)
9. Proceed as follows for EP-825-1525:
a. Slide the rotor and rotor hub assembly
with taperlock bushing over the shaft.
b. Remove the rotor hub from the worn rotor
by unscrewing the capscrews and install
the hub and bushing on the new rotor.
c. Remove any burrs, chips, dirt, or other
foreign material from the field, rotor
assembly, and shaft.
d. Slide the new rotor assembly onto its
shaft the same way it was removed. Note
the line scribed on the O.D. of the field to
help maintain the correct axial clearance
between the rotor and field. Tighten the
bushing to secure the assembly in place
on the shaft.
10. Reassemble the end bell in the
Electro-Pack unit. Reassemble the
capscrews and washers to the unit.
Figure 4
8. Proceed as follows for EP-170 through 500
(go to instruction 9 for EP-825 through 1525):
a. Remove the retainer ring holding the rotor
on the output shaft.
b. Remove the rotor and replace it with a
new one. Replace the retainer ring.
(Figure 5)
11. Set the autogaps by pressing each
armature into contact with its mating
component (either the magnet or rotor)
and then releasing it. (Figure 6)
Figure 6
12. Reconnect the electrical wires to the
magnet.
Figure 5
13. Reassemble the cover to the unit.
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 Materials: 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 accidently reaching the friction
surfaces 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.
Warner Electric • 800-825-9050 P-212 • 819-0078
6
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.
Torque Loss: If a brake or clutch slips or loses
torque completely, the initial check should be the
input voltage to the magnet as follows:
90-Volt Series: Connect a DC voltmeter with a
range of 0-100 or more directly across the
magnet terminals. With the power on and the
potentiometer turned up, a normal reading is
90 volts, although 85 to 95 is satisfactory. The
reading should drop as the potentiometer control
is adjusted counterclockwise.
24-Volt Series: Use a DC voltmeter with a
range of 0-30 volts or more. A normal reading
is approximately 22-26 volts.
6-Volt Series: Use a DC voltmeter of
approximately 0-15 volt range. A normal
reading is from 5.5 to 6.5 volts.
output. Resistance measurements are made with
power off and clutch / brake disconnected from
control, measuring only the clutch coil or the
brake magnet. Resistance measurements should
be + / - 10% of values on chart.
If the above checks indicate that the proper
voltage and current is being supplied to the
clutch and brake, mechanical parts should be
checked to assure that they are in good
operating condition and properly installed.
The above checks normally are sufficient.
Further checks may be necessary, such as
voltage, amperage and resistance. Refer to chart
on following page for electrical readings on the
clutch / brake you are measuring. Observe all
safety procedures and test equipment
manufacturers operating procedures. The
voltage and amperage measurements are
made with the power on and the control at full
Warner Electric • 800-825-9050 P-212 • 819-0078
7
Electrical Data Coil Ratings
EP-170 Clutch Brake
Voltage – DC 6 24 90 6 24 90
Resistance @ 20˚ C – Ohms 6.96 111.2 1506 6.96 111.2 1506
Current – Amperes .861 .215 .060 .861 .215 .060
Watts 5.16 5.16 5.37 5.16 5.16 5.37
Coil Build up – milliseconds 17 17 16 17 17 16
Coil Decay – milliseconds 876 876
EP-250 Clutch Brake
Voltage – DC 6 24 90 6 24 90
Resistance @ 20˚ C – Ohms 5 76.4 1079 5 76.4 1079
Current – Amperes 1.2 .314 .084 1.2 .314 .084
Watts 7.2 7.5 7.51 7.2 7.5 7.51
Coil Build up – milliseconds 48 48 44 48 48 44
Coil Decay – milliseconds 15 15 13 15 15 13
EP-400 Clutch Brake
Voltage – DC 6 24 90 6 24 90
Resistance @ 20˚ C – Ohms 4.88 73 1087 4.88 73 1087
Current – Amperes 1.230 .332 .083 1.230 .332 .083
Watts 7.69 8.04 7.45 7.69 8.04 7.45
Coil Build up – milliseconds 154 154 154 154 154 154
Coil Decay – milliseconds 62 60 55 62 60 55
EP-500 Clutch Brake
Voltage – DC 6 24 90 6 24 90
Resistance @ 20˚ C – Ohms 1.076 14.9 206.1 1.36 23.8 251.1
Current – Amperes 5.580 1.610 .440 4.400 1.010 .360
Watts 34 39 39 26 24 32
Coil Build up – milliseconds 82 85 90 84 87 93
Coil Decay – milliseconds 40 40 40 38 35 30
EP-825 Clutch Brake
Voltage – DC 6 24 90 6 24 90
Resistance @ 20˚ C – Ohms 1.23 20.9 267 1.27 20.4 223.3
Current – Amperes 4.900 1.150 .340 4.740 1.180 .400
Watts 29 28 30 28 28 36
Coil Build up – milliseconds 222 200 245 170 170 170
Coil Decay – milliseconds 105 120 100 70 75 80
EP-1525 Clutch Brake
Voltage – DC 6 90 6 90
Resistance @ 20˚C. – Ohms 1.11 239.1 1.45 258.4
Current – Amperes 5.410 .380 4.130 .350
Watts 32 34 25 31
Coil Build up – milliseconds 505 575 470 512
Coil Decay – milliseconds 230 215 200 140
EP-1525HT Clutch Brake
Voltage – DC 90 90
Resistance @ 20˚C. – Ohms 113.4 238
Current – Amperes .794 .378
Watts 72 34
Coil Build up – milliseconds 560 512
Coil Decay – milliseconds 160 140
Build-up time equals current to approximately 90%
of steady state value and flux to 90%. Decay time
equals current to approximately 10% of steady state
value and flux to 10%. Approximately because
currently leads or lags flux by small amount.
Warner Electric • 800-825-9050 P-212 • 819-0078
8
Output
A
B
C
D
H
E
G
F
E
D
C
B
Input
Brake
Clutch
O
M
N
L
K
J
I
EP-170, EP-250, EP-400
All dimensions are nominal, unless otherwise noted.
Size A B C Min. D E F G Max. H I J K L M N O
170 3/32 x .3745
.750 1.406 2.203 1.500 6.000 .250 Wide 3.437 1.662 .312 1.110 2.220 3.250 1/2 - 14 NPT
3/64 .3735 (4 slots) 1.652 conduit x 2
Dia.
250 1/8 x .4995 1.250 2.468 3.312 2.250 8.968 .312 Wide 5.281 2.318 .375 1.625 3.250 4.250 1/2 - 14 NPT
1/16 .4985 (4 slots) 2.308 conduit x 2
Dia.
400 3/16 x .7495 1.875 3.515 4.593 2.500 11.781 .312 Wide 6.937 3.474 .500 2.578 5.156 6.000 1/2 - 14 NPT
3/16 x .7485 (4 slots) 3.464 conduit x 2
1-1/2 Dia.
Specifications
Inertia–WR2(lb-in2)
Model Size Voltage DC Static Torque lb. in. Output Input Max. RPM Weight lbs.
EP-170 6 15 .031 .036 10,000 2.5
EP-250 6 70 .331 .293 7,500 7.1
EP-400 6 270 2.566 2.222 4,500 19.7
24 15 .031 .036 10,000 2.5
90 15 .031 .036 10,000 2.5
24 70 .331 .293 7,500 7.1
90 70 .331 .293 7,500 7.1
24 270 2.566 2.222 4,500 19.7
90 270 2.566 2.222 4,500 19.7
9
EP-170, 250, 400 Exploded
11/12/99
page 116
6
7
12
16
13
9
9a
15
14
18
8
17
7-1
20
23
21
3
9
11
9a
13
14
15
16
12
1-1
17
10
8
22
19
25
26
1
2
11
11
24
4
2
5
13a
EP-170, EP-250, EP-400
Warner Electric • 800-825-9050 P-212 • 819-0078
10
EP-170, EP-250, EP-400
Component Parts
EP-170 EP-250 EP-400
Item Description Part No. Qty. Part No. Qty. Part No. Qty.
1 Magnet Assembly 11
6 volt 5375-631-003 5319-631-002 5115-631-002
24 volt 5375-631-005 5319-631-003 5115-631-003
90 volt 5375-631-007 5319-631-005 5115-631-004
1-1 Terminal Accessory † 5103-101-002 1 5103-101-002 1
2 Armature Assembly with Autogap 110-0111 2 5130-111-008 2 5131-111-001 2
3 Housing 535-0079 1 535-0082 1 535-0083 1
4 Armature Spacer 807-1021 1
5 Splined Armature Hub 540-1250 1 540-1635 1 540-2034 1
6 Rotor Assembly 5603-751-029 1 5103-751-010 1 5104-751-034 1
7 Field Assembly 111
6 volt 5603-451-047 5103-451-002 5104-451-032
24 volt 5603-451-049 5103-451-004 5104-451-033
90 volt 5603-451-051 5103-451-007 5104-451-034
7-1 Terminal Accessory † 5103-101-002 1 5103-101-002 1
8 Ball Bearing 166-0112 2 166-0114 2 166-0116 2
9 Key 590-0095 2 590-0014 2
9a Key 590-0016 2
10 Shaft, Brake 798-0136 1 798-0133 1 798-0131 1
11 Retainer Ring 748-0346 2 748-0347 2 748-0348 2
12 Retainer Ring 748-0042 2 748-0024 2 748-0022 2
13 Key 590-0089 2 590-0088 2 590-0087 1
13a Key 590-0106 1
14 Capscrew 797-1219 8 797-1219 8 797-1220 8
15 Lockwasher 950-0351 8 950-0351 8 950-0355 8
16 Bearing Housing 535-0080 2 535-0081 2 535-0084 2
17 Ball Bearing, with Retainer 166-0111 2 166-0113 2 166-0115 2
18 Shaft, Clutch 798-0135 1 798-0134 1 798-0132 1
19 Cover Plate 686-1017 1 686-1018 1 686-1019 1
20 Screw 797-0015 4 797-0015 4 797-0015 4
21 Dust Plug 680-0037 2 680-0037 2 680-0037 2
22 Gasket 495-0003 1 495-0004 1 495-0005 1
23 Insulator 572-0573 1 572-0572 1 572-0574 1
24 Vertical Mfg. Spring Kit Optional 5603-101-001 1 5103-101-006 1 5104-101-005 1
25 Ground Screw 1 797-1245 1 797-1245 1
26 Terminal 1 900-0116 1 900-0016 1
†Lead wires used on EP-170.
These units meet the standards of UL508 and are listed under guide card #NMTR, file #59164. These units are CSA certified under file #LR11543.
1
11
Brake Clutch
Input
Output
A
D
C
C
EF E
G
B
H
N
M
L
K
J
I
B
C
O
EP-500
All dimensions are nominal, unless otherwise noted.
Size A B C D E F G H N
500 3/16 x .8750 2.218 3.796 4.234 7.000 15.515 .406 8.218 4.004 .500 2.937 5.875 8.734 1/2 - 14 NPT
3/16 x .8745 (4 holes) 3.992 conduit x 2
1-3/4
Dia. Min. Max. Dia. Max. Dia. I J K L M Max. O
Specifications
Model Size Voltage DC Unit Static Torque Inertia–WR2 lb.ft.
EP-500 6, 24 and 90 Clutch 50 .039 4000 56
12
Warner Electric • 800-825-9050 P-212 • 819-0078
Brake 40 .063
2
Max. RPM Weight lbs.
EP-500 Exploded
11/13/99
page 119
8
7
2-1
2-2
22
2-4
2-5
1-1
23
21
20
2-5
2-4
2-3
2-2
2-1
2
2
6-1
6
14
14
12
9
10
11
15
16
13
18
17
16
15
19
10
9
4
3
2-3
1
7
8
5
EP-500
Component Parts
Item Description Part No. Qty.
1 Magnet Assembly 1
6 volt 5300-631-009
24 volt 5300-631-010
90 volt 5300-631-011
1-1 Terminal Accessory 5311-101-001 1
2 Armature Assembly 5230-111-002 2
2-1 Armature 5230-111-001 2
2-2 Retainer Ring 748-0355 2
2-3 Spring 808-0412 2
2-4 Retainer Plate 748-0364 2
2-5 Screw 797-1430 12
3 Mounting Frame 174-0028 1
4 Splined Hub 540-2035 1
5 Rotor 5230-751-001 1
6 Field 1
6-1 Terminal Accessory 5311-101-001 1
6 volt 5230-451-003
24 volt 5230-451-005
90 volt 5230-451-002
7 Capscrew 797-0416 8
8 Lockwasher 950-0107 8
9 Ball Bearing 166-0125 2
Item Description Part No. Qty.
10 Key 590-0020 2
11 Retainer Ring 748-0361 1
12 Shaft, Brake 798-0022 1
13 Key 590-0022 1
14 Retainer Ring 748-0335 2
15 Capscrew 797-0418 8
16 Lockwasher 950-0107 8
17 Endbell Housing 535-0010 2
18 Ball Bearing 166-0127 2
19 Key 590-0021 1
20 Shaft, Clutch 798-0023 1
21 Cover Drip Proof 287-0068 1
22 Capscrew 797-1288 6
23 Lockwasher 950-0102 6
*NS Clamp Wire Speed Nut 263-0016 2
*NS Wire Assembly (Red) 5232-954-003 2
*NS Wire Assembly (Black) 5232-954-004 2
*NS Screws 797-1007 2
*NS Insulator Bushing 572-0522 1
*NS - Not Shown
These units meet the standards of UL508 and are listed under guide card
#NMTR, file #59164. These units are CSA certified under file #LR11543.
13
EP-825 Dim
11/19/99
page 120
B
CC
D
G
F
E
N
M
L
K
J
I
Output
A
Brake Clutch
Input
H
B
EP-825
Output
Brake
Clutch
Input
A
C
E
F
H
C
G
B
D
N
I
J
K
L
M
B
All dimensions are nominal, unless otherwise noted.
Size A B Dia. C Min. D Max. Dia. E F G Max. H I J K L M N Max.
825 1/4 x 1.1250
1/4 x 2 1.1245 (4 holes) 5.252
Specifications EP-825
Model Voltage Unit Static Inertia–WR2 (lb-ft2) Max. Weight
Size DC Torque Output Side Input Side RPM lbs.
EP-825 6, 24 Clutch 125 .897 .510 3600 123
2.875 5.000 5.734 8.500 20.031 .406 Dia. 10.812 5.254 .562 4.250 8.500 11.609
& 90 Brake 125
Specifications EP-1000
Model Voltage Static Inertia–WR2 (lb-ft2) Max. Weight
Size DC Torque Output Side Input Side RPM lbs.
EP-1000 6 240 lb.ft. 1.45 1.01 3000 288
24 240 lb.ft. 1.45 1.01 3000 288
90 240 lb.ft. 1.45 1.01 3000 288
All dimensions are nominal, unless otherwise noted.
Size A B Dia. C Min. D Dia. E F G Max. H I J K L M N Max.
1000 1/2 x 1.875
1/2 x 1.874 (4 holes) 6.241
3-3/4
4.750 5.687 8.250 12.250 28.750 .656 Dia. 12.500 6.255 .718 5.000 10.000 12.875
EP-1000
Warner Electric • 800-825-9050 P-212 • 819-0078
14
1-1
2-3
1
27
28
26
15
14
13
12
16
19
20
21
23
22
21
20
25
16
15
14
12
13
17
24
17
2-4
2-2
11
2-5
4
5-1
5-2
5-5
5-3
5-4
5-6
6
7
8
10
11
9
2-1
2
3
5
18
EP-825
Component Parts
Item Description Part No. Qty.
1 Magnet Assembly 1
6 volt 5311-631-002
24 volt 5311-631-003
90 volt 5311-631-004
1-1 Terminal Accessories 5311-101-001 1
2 Armature Assembly & Splined Adapter 5321-111-001 1
2-1 Screw 797-0272 3
2-2 Autogap Accessory 5321-101-006 1
2-3 Splined Adapter 104-0008 1
2-4 Armature 5321-111-022 1
2-5 Locknut 661-0004 3
3 Frame 174-0019 1
4 Splined Hub 540-0320 1
5 Armature & Splined Adapter 5201-111-001 1
5-1 Locknut 661-0004 3
5-2 Splined Adapter 104-0008 1
5-3 Autogap Accessory 5321-101-006 1
5-4 Spacer 748-0333 3
5-5 Armature 5321-111-022 1
5-6 Screw 797-0341 3
6 Bushing, 1-1/4" Bore 180-0113 1
7 Rotor Hub 540-0013 1
8 Rotor 5201-751-003 1
9 Field 1
6 volt 5201-451-006
24 volt 5201-451-008
90 volt 5201-451-010
Item Description Part No. Qty.
10 Mounting Accessory 5201-101-007 1
11 Mounting Accessory 5321-101-001 2
12 Screw 797-1008 8
13 Oil Seal 795-0023 2
14 Retainer Plate 686-0031 2
15 Ball Bearing 166-0126 2
16 Retainer Ring 748-0336 2
17 Key 590-0019 3
18 Shaft, Brake 798-0019 1
19 Retainer Ring 748-0335 1
20 Capscrew 797-0351 8
21 Lockwasher 950-0354 8
22 Endbell Housing 535-0005 2
23 Ball Bearing 166-0125 2
24 Key 590-0018 1
25 Shaft, Clutch 798-0020 1
26 Cover, Drip Proof 287-0069 1
27 Capscrew 797-1288 6
28 Lockwasher 950-0102 6
*NS Clamp Wire Speed Nut 263-0016 2
*NS Wire Assembly (Red) 5232-954-003 2
*NS Wire Assembly (Black) 5232-954-004 2
*NS Screws 797-1007 2
*NS Insulator Bushing 572-0522 1
*NS - Not Shown
These units meet the standards of UL508 and are listed under guide card
#NMTR, file #59164. These units are CSA certified under file #LR11543.
15
EP-1000
EP-1000 Exploded
11/19/99
page 123
4
6
5
14
13
15
9-3
8
16
2-3
2-4
2-2
3
12
11
9-1
10
9-4
9-6
9-2
7
2-5
2-1
1-3
1-2
1-1
1
9-5
18
17
19
20
21
22
23
25
26
29
28
27
30
22
21
20
19
18
17
23
25
26
29
24
2
9
Component Parts
Item Description Part No. Qty.
1 Magnet Assembly 1
1-1 Wire Assembly (Red) 5232-954-003 1
1-2 Wire Assembly (Black) 5232-954-004 1
1-3 Terminal Accessory 5311-101-001 1
2 Armature & Splined Adapter 5322-111-002 1
2-1 Button Head Screw 797-0272 1
2-2 Autocap Accessory 5322-101-004 1
2-3 Splined Arm, Adapter 104-0009 1
2-4 Armature 5322-111-036 1
2-5 Locknut 661-0004 3
3 Frame 174-0043 1
4 Dust Cover 287-0052 1
5 Button Head Screw 797-1175 8
6 Lockwasher 950-0103 8
7 Splined Armature Hub 540-0061 1
8 Bushing, 1-7/8" Bore 180-0177 1
9 Armature & Splined Adapter 5202-111-001 1
9-1 Locknut 661-0004 3
9-2 Splined Armature Adapter 104-0009 1
9-3 Autogap Accessory 5322-101-004 1
9-4 Spacer 748-0333 3
9-5 Armature 5322-111-036 1
9-6 Cap Screw 797-0341 3
10 Bushing, 2" Bore 180-0179 1
11 Rotor Hub 540-0315 1
12 Rotor 5202-751-003 1
Warner Electric • 800-825-9050 P-212 • 819-0078
16
6 volt 5312-631-004
24 volt 5312-631-005
90 volt 5312-631-006
Item Description Part No. Qty.
13 Field Assembly 1
6 volt 5202-451-004
24 volt 5202-451-006
90 volt 5202-451-007
14 Mounting Accessory 5321-101-001 1
15 Mounting Accessory 5201-101-007 1
16 Mounting Accessory 5321-101-001 1
17 Oil Seal 795-0024 2
18 Button Head Screw 797-1008 8
19 Retainer Plate 686-0047 2
20 Retainer Ring – External 748-0504 2
21 Ball Bearing 166-0130 2
22 Retainer Ring – Internal 748-0375 2
23 Key 590-0024 2
24 Shaft, Brake 798-0026 1
25 Cap Screw 797-0361 8
26 Lockwasher 950-0362 8
27 Bearing Housing 535-0012 2
28 Ball Bearing 166-0131 2
29 Key 590-0025 2
30 Shaft, Clutch 798-0025 1
*NS Clamp Wire Speed Nut 263-0016 2
*NS Wire Assembly (Red) 5232-954-003 2
*NS Wire Assembly (Black) 5232-954-004 2
*NS Screws 797-1007 2
*NS Insulator Bushing 572-0522 1
*NS - Not Shown
These units meet the standards of UL508 and are listed under guide card
#NMTR, file #59164. These units are CSA certified under file #LR11543
EP-1525, EP-1525HT
Output
Brake
Clutch
Input
A
C
E
F
H
C
G
B
D
N
I
J
K
L
M
B
All dimensions are nominal, unless otherwise noted.
Size A B Dia. C Min. D Max. Dia. E F G Max. H I J K L M N Max.
1525 5/8 x 2.375
5.750 7.500 8.468 16.500 33.500 .796 Dia. 18.250 9.005 1.000 7.000 14.000 18.875
5/8 x 2.374 (4 holes) 8.991
4-1/4
1525HT 5/8 x 2.375 5.750 7.500 8.468 16.500 33.500 .796 Dia. 18.250 9.005 1.000 7.000 14.000 18.875
5/8 x 2.374 (4 holes) 8.991
4-1/4
Specifications
Inertia–WR2lb.ft.
Model Size Voltage DC Unit Static Torque lb.ft. Output Input Max. RPM Weight lbs.
EP-1525 6 Clutch 700 7.89 5.68 1800 655
Brake 700
90 Clutch 700 7.89 5.68 1800 655
Brake 700
EP-1525 HT 90 Clutch 1350 7.89 6.41 1800 656
Brake 700
2
Warner Electric • 800-825-9050 P-212 • 819-0078
17
EP-1525, EP-1525HT
EP-1525 Exploded
11/19/99
page 126
4
6
5
15
10-3
9
16
2-4
2-5
3
11
12
10-7
9
10-6
10-1
10-2
8
2-6
2-1
1-3
1-2
1-1
1
10-5
18
19
20
21
22
24
26
27
29
28
25
23
21
20
19
17
18
24
26
27
25
14
13
7
2-2
2-3
10-4
17
23
22
2
10
Warner Electric • 800-825-9050 P-212 • 819-0078
18
EP-1525, EP-1525HT
Component Parts
EP-1525 EP-1525HT
Item Description Part No. Qty. Part No. Qty.
1 Magnet 11
6 volt 5314-631-004
90 volt 5314-631-005 5314-631-005
*1-1 Wire Assembly (Red) 5232-954-003 1 5232-954-003 1
*1-2 Wire Assembly (Black) 5232-954-004 1 5232-954-004 1
*1-3 Terminal Accessory 5311-101-001 1 5311-101-001 1
2 Armature & Splined Adapter 5324-111-001 1 5324-111-001 1
*2-1 Button Head Screw 797-0272 8 797-0272 8
*2-2 Armature Plate 686-0003 1 686-0003 1
*2-3 Autogap Accessory 5323-101-002 1 5323-101-002 1
*2-4 Splined Armature Adapter 104-0011 1 104-0011 1
*2-5 Armature 5324-111-034 1 5324-111-034 1
*2-6 Locknut 661-0004 8 661-0004 8
3 Frame 174-0044 1 174-0044 1
4 Dust Cover 287-1002 1 287-1002 1
5 Button Head Screw 797-1175 8 797-1175 8
6 Lock Washer 950-0103 8 950-0103 8
7 Eye Bolts 171-0006 4 171-0006 4
8 Splined Armature Hub 540-0063 1 540-0063 1
9 Bushing, 2-3/8" Bore 180-0215 2 180-0215 2
10 Armature & Splined Adatper 5204-111-004 1 5204-111-004 1
*10-1 Cap Screw 797-0342 8 797-0342 8
*10-2 Splined Armature Adapter 104-0011 1 104-0011 1
*10-3 Autogap Accessory 5323-101-002 1 5323-101-002 1
*10-4 Retainer Plate 686-0003 1 686-0003 1
*10-5 Armature 5324-111-034 1 5324-111-034 1
*10-6 Spacer 748-0333 8 748-0333 8
*10-7 Locknut 661-0004 8 661-0004 8
11 Rotor Hub 5234-541-001 1 5234-541-001 1
12 Rotor 5204-751-002 1 5204-751-001 1
13 Field Assembly 11
6 volt 5204-451-013
90 volt 5204-451-016 5204-451-006
14 Mounting Accessory 5321-101-002 2 5321-101-002 2
15 Mounting Accessory 5321-101-001 2 5321-101-001 2
16 Mounting Accessory 5321-101-001 2 5321-101-001 2
17 Screw 797-0294 8 797-0294 8
18 Oil Seal 795-0025 2 795-0025 2
19 Retainer Plate 686-0048 2 686-0048 2
20 Retaining Ring – External 748-0503 2 748-0503 2
21 Ball Bearing 166-0132 2 166-0132 2
22 Bearing Seal 795-0036 2 795-0036 2
23 Retainer Ring – Internal 748-0552 2 748-0052 2
24 Key 590-0028 2 590-0028 2
25 Shaft 798-0027 2 798-0027 2
26 Cap Screw 797-0362 12 797-0362 12
27 Lock Washer 950-0362 12 950-0362 12
28 Bearing Housing 535-0013 2 535-0013 2
29 Ball Bearing 166-0133 2 166-0133 2
**NS Clamp Wire Speed Nut 263-0016 2
**NS Wire Assembly (Red) 5232-954-003 2
**NS Wire Assembly (Black) 5232-954-004 2
**NS Screws 797-1007 2
**NS Insulator Bushing 572-0522 1
* Shipped Assembled
**NS - Not Shown
These units meet the standards of UL508 and are listed under guide card #NMTR, file #59164. These units are CSA certified under file #LR11543.
19
Warranty
Warner Electric LLC warrants that it will repair or replace (whichever it deems advisable) any
product manufactured and sold by it which proves to be defective in material or workmanship
within a period of one (1) year from the date of original purchase for consumer, commercial or industrial use.
This warranty extends only to the original purchaser and is not transferable or assignable without
Warner Electric LLC’s prior consent.
Warranty service can be obtained in the U.S.A. by returning any defective product, transportation
charges prepaid, to the appropriate Warner Electric LLC factory. Additional warranty information
may be obtained by writing the Customer Satisfaction Department, Warner Electric LLC, 449 Gardner Street, South Beloit, Illinois 61080, or by calling 815-389-3771.
A purchase receipt or other proof of original purchase will be required before warranty service is
rendered. If found defective under the terms of this warranty, repair or replacement will be made,
without charge, together with a refund for transportation costs. If found not to be defective, you will
be notified and, with your consent, the item will be repaired or replaced and returned to you at
your expense.
This warranty covers normal use and does not cover damage or defect which results from
alteration, accident, neglect, or improper installation, operation, or maintenance.
Some states do not allow limitation on how long an implied warranty lasts, so the above limitation
may not apply to you.
Warner Electric LLC’s obligation under this warranty is limited to the repair or replacement of the
defective product and in no event shall Warner Electric LLC be liable for consequential, indirect,
or incidental damages of any kind incurred by reason of the manufacture, sale or use of any defective product. Warner Electric LLC neither assumes nor authorizes any other person to give any
other warranty or to assume any other obligation or liability on its behalf.
WITH RESPECT TO CONSUMER USE OF THE PRODUCT, ANY IMPLIED WARRANTIES WHICH
THE CONSUMER MAY HAVE ARE LIMITED IN DURATION TO ONE YEAR FROM THE DATE OF
ORIGINAL CONSUMER PURCHASE. WITH RESPECT TO COMMERCIAL AND INDUSTRIAL
USES OF THE PRODUCT, THE FOREGOING WARRANTY IS IN LIEU OF AND EXCLUDES ALL
OTHER WARRANTIES, WHETHER EXPRESSED OR IMPLIED BY OPERATION OF LAW OR
OTHERWISE, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the
above limitation or exclusion may not apply to you. This warranty gives you specific legal rights and
you may also have other rights which vary from state to state.
Changes in Dimensions and Specifications
All dimensions and specifications shown in Warner Electric catalogs are subject to change without
notice. Weights do not include weight of boxing for shipment. Certified prints will be furnished without charge on request to Warner Electric.
Warner Electric
31 Industrial Road
815-389-3771
www.warnerelectric.com
• New Hartford, CT 06057
• Fax: 815-389-2582
P-212 819-0078 1/12 Printed in USA
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