How it Works
Warner Electric
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EP-170
User Manual
20 pgs868.7 Kb0

Warner Electric EP-170, EP-250, EP-400, EP-500, EP-825 User Manual

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Electro-Packs
EP-170, 250, 400, 500, 825, 1000, 1525
P-212 819-0078
Installation Instructions
Contents
Exploded Views and Parts List
EP-170, 250, 400 . . . . . . . . . . . . . . . . . . . . 9
EP-500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
EP-825 . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
EP-1000 . . . . . . . . . . . . . . . . . . . . . . . . . . 16
EP-1525, 1525 HT. . . . . . . . . . . . . . . . . . . 17
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
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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
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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
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