Electro Packs EP-170-C, EP-250-C
Foot Mounted Clutch/Brakes
P-225
819-0357
Installation Instructions
Contents
Installation
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Electrical Connection . . . . . . . . . . . . . . . . . . . . 2
Burnishing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Repair and Replacement . . . . . . . . . . . . . . . . . 4
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications
Mechanical Data . . . . . . . . . . . . . . . . . . . . . 5
Electrical Coil Data . . . . . . . . . . . . . . . . . . . 5
Warranty . . . . . . . . . . . . . . . . . . . . . . Back Page
Failure to follow these
instructions may result in product damage,
equipment damage, and serious or fatal
injury to personnel.
Introduction
The Electro-Pack is a preassembled foot
mounted clutch-brake package complete with
input and output shafts. In the ceramic version,
the conventional friction material has been
replaced with ceramic material. In many high
cycle rate applications, the ceramic units will last
3-5 times longer than standard units. These
units, like the standard Electro-Packs, are ready
to be installed in all standard power transmission
systems with V-belts and pulleys, chain and
sprockets, in line couplings, timing belt drives,
and gear trains.
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"
2. Connect the Electro-Pack into the drive
system. The input shaft is identified on the unit.
Use care when connecting the units!
Serious problems will occur if the power input
is connected to the output shaft.
Dimensions for the input and output shafts are
shown on the dimension drawings on page 5.
Electrical Connection
All electrical current must be off when
making electrical connections to prevent
injury or death which can result from contact
with live wires.
The Electro Pack is provided with one conduit
connection hole which is threaded for standard
1/2" conduit connectors. Both the clutch and
brake lead wires exit through this opening. The
EP-170-C is provided with lead wires already
routed through the conduit connection hole. The
EP-250-C is supplied with terminals that can be
accessed by removing the cover.
Simply make the connections with the terminal
accessory kit supplied.
Warner Electric • 800-825-9050 819-0357
2
The Electro Packs operate on DC power. Warner
C
C
B
B
Clutch/Brake
Control
DC
Voltage
Clutch
Brake
AC
Voltage
Input
Output
Electric offers a full line of AC powered DC output
controls to meet the needs of almost every
clutch/brake application. The service and
installation instructions included with each Warner
Electric control show the proper connections.
Maintenance
Wear Pattern: Wear grooves appear on the
armature and magnet surfaces. This is a normal
wear condition and does not impair proper
functioning of the unit.
Please refer to Figure 1 for typical Electro Pack
electrical connections. The lead wires on the EP170-C are identified with a "C" for clutch and a
"B" for brake. Polarity is not important when wiring
Electro Pack units.
Figure 1
Burnishing
The ceramic faced friction surfaces of these
Electro-Packs are preburnished and performance
tested at the factory to ensure consistent "out of
box" performance. Therefore, no "wearing-in," or
burnishing, is required.
Heat: Excessive heat and high operating
temperatures can cause Electro-Pack failure.
Units, therefore, should be ventilated as efficiently
as possible, especially if the application requires
fast, repetitive cycle operation.
Foreign Materials: When 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 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.
The above checks normally are sufficient. Further
checks may be made as follows: connect a low
range ammeter in series with one magnet lead.
Correct amperage readings for each coil voltage
and unit size are found above. These readings are
with the power on and the potentiometer control in
the maximum position.
Ohmmeter checks should be made with the power
off and the circuit open (to be certain, disconnect
Warner Electric • 800-825-9050 819-0357
one lead to the magnet). Average resistance
3
readings are listed in the chart on page 5 for each
voltage and unit size. A very high or infinite
resistance reading would indicate an open coil.
If the above checks indicate that the proper
voltage and current are being supplied to the
magnet, mechanical parts should be checked to
assure that they are in good operating condition
and properly installed.
Repair and Replacement
Ceramic friction face Electro-Packs will provide
reliable and consistent performance throughout
the exceptionally long life of the friction facings.
Their long life results from the exceptional wear
resistance of the ceramic material. The low wear
rate also results in a longer burnish time to "mate"
the friction surfaces. Alignment of the friction
surfaces of both clutch and brake are also very
critical. Therefore, these units are not field
serviceable. All repair work must be done by the
Factory where alignment and burnishing can be
closely monitored.
nits that eventually wear out can be returned to
U
he factory to be rebuilt. Please note that units
t
with damage to "nonwearing" components, such
as housings and shafts, are not repairable. The
factory will evaluate returns and determine
whether they can be rebuilt. All rebuilt units will be
preburnished and tested to assure consistent "out
of box" torque, so no "wearing in" will be required.
Rebuilt ceramic friction faced Electro Packs carry
a full Factory Warranty. For more information on
rebuilt units, call Warner Electric at 815-389-3771
or contact your Warner Electric distributor.
Electro Pack Assemblies
Unit Size Voltage Part No.
EP-170-C 6 5633-273-016
EP-170-C 24 5633-273-018
EP-170-C 90 5633-273-019
EP-250-C 6 5130-273-051
EP-250-C 24 5130-273-053
EP-250-C 90 5130-273-054
Warner Electric • 800-825-9050 819-0357
4
Dimensions
Output
A
B
C
D
H
E
G
F
E
D
C
B
Input
M
N
L
K
J
I
B
rake
C
lutch
O
All dimensions are nominal, unless otherwise noted.
ABCDEFGHIJKLMNO
Size Key
3/32 x 3/64 .3745
170 .3735 Min. Max. (4 slots) 1.652 1/2 conduit
1/8 x 1/16 .4995
250 .4985 Min. Max. (4 slots) 2.308 1/2 conduit
.750 1.406 2.203 1.500 6.000 .250 Wide 3.437 1.662 .312 1.125 2.250 3.250 14 NPT
Dia.
1.250 2.468 3.312 2.250 8.968 .312 Wide 5.281 2.318 .375 1.625 3.250 4.250 14 NPT
Dia.
Specifications
Mechanical Data
Inertia Inertia
Electro Pack Horsepower Static Max. Voltage Total WR
2
Size @ 1800 RPM Torque RPM D.C. Weight Input Output
EP-170-C 1/8 15 lb. in. 10,000 6, 24 or 90 2.8 lbs. .036 lb.in.
EP-250-C 1/2 70 lb. in. 7,500 6, 24 or 90 7.5 lbs. .293 lb.in.
Electrical Coil Data
2
2
Unit Size EP-170-C EP-250-C
Voltage — DC 6 24 90 6 24 90
Resistance @ 20°C — Ohms 6.96 111.2 1506 5 76.4 1079
Current — Amperes .861 .215 .060 1.2 .314 .084
Watts 5.85 5.16 5.37 7.2 7.5 7.51
Coil Build-Up — Milliseconds 17 17 16 48 48 44
Coil Decay — Milliseconds 87 6 15 15 13
Warner Electric • 800-825-9050 819-0357
2
WR
.031 lb.in.
.331 lb.in.
2
2
5
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 Park Road
815-389-3771
www.warnerelectric.com
P-225 819-0357 8/11 Printed in USA
• Fax: 815-389-2582
• New Hartford, CT 06057
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