Performance Plus
Preassembled Clutch/Brake Module
P-273-3
819-0358
Installation Instructions
2
Warner Electric • 800-234-3369 P-273-3 • 819-0358
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . .2
Installation Instructions . . . . . . . . . . .2-5
Electrical Coil Data . . . . . . . . . . . . . . . .5
Mechanical Data . . . . . . . . . . . . . . . . . .5
Overhung Load Data . . . . . . . . . . . . . . .5
Burnishing . . . . . . . . . . . . . . . . . . . . . . .6
Maintenance . . . . . . . . . . . . . . . . . . . . .6
Troubleshooting . . . . . . . . . . . . . . . . . . .6
Repair and Replacement . . . . . . . . . . . .7
Ordering Information . . . . . . . . . . . . . . .7
Dimensions UM-1020-C . . . . . . . . . . . .8
Base Motor Mount . . . . . . . . . . . . . . . .8
Dimensions UM-2030-C . . . . . . . . . . . .9
Warranty . . . . . . . . . . . . . . . . .Back Page
Failure to follow these
instructions may result in product damage,
equipment damage, and serious or fatal
injury to personnel.
Introduction
Performance Plus versions of Warner Electric
Unimodules are completely assembled
clutch/brake packages for out of box use. They
are engineered for easy installation, while providing extra long life over standard units.
Technically advanced ceramic friction material
provides exceptional wear resistance and
enhanced performance making Performance
Plus Unimodule clutch/brakes ideal for high
cycle rate applications.
Performance Plus clutch/brake combinations are
offered in two configurations. The "1020" has a
hub input and a male shaft output. The "2030"
has a male shaft extension for both input and
output. These two configurations are offered
with various mounting accessories to make
ceramic friction faced Performance Plus
Unimodules adaptable to many power transmission systems.
This manual covers installation, wiring and troubleshooting of the ceramic faced models which
are offered in clutch/brake sizes 50, 180 and
210.
Follow the installation instructions in this manual
carefully to ensure safe, reliable operation. All
stated or implied manufacturer warranties are
voided if this product is not installed in accordance with these instructions.
Make sure all power is turned
off to this equipment when installing, as
injury (or even death) may result from contact with live wires or rotating shafts.
Installation
Note: Before installing the unimodule to a motor
or reducer, make certain that the UM size and
NEMA frame dimensions match according to
Table 1 below.
Corresponding
NEMA Frame Sizes
C-Face
UM Old New Shaft Pilot
Size NEMA NEMA Dia. Dia.
50 56 C 48 Y 5/8" 4 1/2"
180 182 C 143 TC 7/8" 4 1/2"
184 C 145 TC
210 213 C 182 TC 1-1/8" 8 1/2"
215 C 184 TC
Install your specific modular combination
according to the installation steps specified in
the table. Use only those steps indicated for
each combination.
For These UM Combinations Use These
Installation Steps:
UniModule Clutch/Brake Between 1, 2, 3, 4, 7
C-Face Motor and Reducer - 1020
UniModule Clutch/Brake - 2030 4, 7
Motor Mount UniModule Clutch- 1, 2, 3, 6, 7
Brake on a C-Face Motor 1020-M
Base Mounted 5, 7
UniModule Clutch-Brake - 2030-B
3
Note: The equipment covered by this service
manual must be installed in accordance with
these instructions. Failure to do so may damage
the equipment and void the warranty.
Mounting to a Motor
Step 1
Note: The 1020 Unimodule is furnished with a
special hardened key. It is strongly recommended that this key be used with the motor shaft to
avoid damage to the shaft and rotor hub.
Note: Size 210 Unimodules require an adapter
ring to be mounted to the motor prior to mounting the 1020 Unimodule. Adapter and mounting
hardware are provided with each Unimodule
assembly.
Note: Before mounting, check the motor shaft
for endplay. If the shaft can be moved axially
.030" or more, excessive thrust may occur
between the rotor and field. The
motor should be replaced unless the endplay
can be reduced.
Note: If the optional fan accessory is being
used, it should be installed prior to mounting the
Unimodule to a motor or reducer. Follow the
instructions provided with the fan
accessory.
Replace the existing motor shaft key with the
hardened key provided with the unit. If necessary, prick punch the keyway of the motor shaft
to keep the key from moving in the keyway.
Slide the module assembly onto the motor shaft.
(See Figure 1) Align the key in the motor shaft
with the keyway in the rotor hub.
Do not use force. If the UniModule does
not slide on freely, polish the motor shaft
sufficiently to achieve a slip fit.
Step 2
The housing is provided with vent holes which
are normally placed in the down position. Rotate
the assembly to where the vent holes are toward
the bottom and insert the four long capscrews
(provided) through the mounting holes in the
housing and into the motor face. Tighten alternately and securely. (30 to 35 ft. lbs.)
Figure 2
Step 3
The access hole for the Allen wrench to tighten
the rotor setscrews is shown in Figure 3. Rotate
the clutch rotor as necessary to insert the
wrench into the setscrews. Tighten both screws
alternately and securely. (40 to 45 in. lbs. for 180
size, 80 to 85 in. lbs. for 50 and 210 sizes.)
Figure 3
Figure 1
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Warner Electric • 800-234-3369 P-273-3 • 819-0358
Step 4 – Mounting to a Reducer
The output side of a Unimodule may be mounted directly to a reducer.
A. Align the output shaft and key of the
Unimodule with the corresponding shaft hole
and keyway of the reducer. Slide the assembly together, matching the pilot diameter on
the Unimodule with a pilot diameter on the
reducer.
B. Bolt the Unimodule to the reducer flange. The
four (4) bolts required (3/8 - 16 UNC-2A) are
normally furnished with the reducer. (18 to 22
ft. lbs. for 50 and 180 sizes, 40 to 45 lbs. for
210 size.)
Figure 4
Step 5 – Installing the Base Mount
Unimodule 2030 can be base-mounted (Fig. 5).
Figure 5
A. Mount each Unimodule so that the base is
located below the ventilation holes. A pilot
diameter on the end of each Unimodule
mates with pilot diameters on the base.
B. Secure the base to the Unimodule with the
four (4) bolts provided. (18 to 22 ft. lbs. for 50
and 180 sizes, 40 to 45 ft. lbs. for 210 size.)
Step 6 – Installing the Motor Mount (M)
A. Motor Mount (M) can be installed to the out-
put end of the Unimodule to provide a foot
mounting for the complete assembly of
Unimodule and motor.
Size 50 and 180
A. Remove the two (2) long hex head bolts from
the side of the Unimodule toward the ventilation holes.
B. Mount the Unimodule on the Motor Mount so
that the base of the Motor Mount is underneath the Unimodule and motor (Figure 6). A
pilot diameter on the Unimodule mates with a
pilot diameter on the Motor Mount.
C. Secure the Motor Mount in place with two (2)
longer mounting bolts (30 to 35 ft. lbs.) and
the two shorter bolts (18 to 22 ft. lbs.) all provided in the kit.
Size 210
A. Mount the Unimodule on the Motor Mount so
that the base of the Motor Mount is underneath the Unimodule and motor (Figure 6). A
pilot diameter on the Unimodule mates with
a pilot diameter on the Motor Mount.
B. Secure the Motor Mount to the Unimodule
with three (3) bolts provided. (40 to 45 ft. lbs.)
Figure 6
Step 7 – Electrical Connections
To avoid injury (or even death),
always make certain all power is off before at
tempting to install or service this control or
any electrical equipment.
The Unimodule is provided with one conduit
connection hole, threaded for standard 1/2"
conduit connectors. Both the clutch and the
brake lead wires are brought out through this
opening. The conduit box accessory kit, P/N
5370-101-042, provides two conduit connection
holes for standard 1/2" conduit connectors.
The clutch and brake coils operate on DC voltage. Warner Electric offers a full line of AC voltage powered 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
electrical connections.
Please refer to Figure 7 for the proper
Unimodule electrical connections. Clutch leads
are identified with a white insulator sleeve.
Brake leads have a black insulator sleeve.
Figure 7
After wiring, your Performance Plus Unimodule
is now ready to operate. If your clutch/brake
control has torque control, the torque adjust
potentiometer(s) should be set for rapid and
complete load take up. Excessive slippage of
the brake or clutch can cause overheating and
premature wear. See the following pages for
technical, operating and service information.
5
Electrical Coil Data
Clutch Brake Clutch Brake Clutch Brake
Voltage–D.C. 90 90 24 24 6 6
Resistance UM-50-C 452 452 31.8 26.8 1.86 1.77
(OHMS) UM-180-C 392 309 26.7 22.8 1.80 1.54
UM-210-C 248 222 17.9 15.4 1.22 1.04
Amperes UM-50-C .199 .233 .755 .894 3.23 3.39
UM-180-C .230 .291 .896 1.05 3.30 3.90
UM-210-C .363 .405 1.34 1.56 4.90 5.78
WATTS UM-50-C 18 21 18 21 19 20
UM-180-C 21 26 21.5 25 20 23
UM-210-C 33 36 32 37 30 35
Build Up UM-50-C 52 53 52 53 52 53
(Milli.) UM-180-C 72 75 72 75 72 70
UM-210-C 120 100 120 100 110 100
Decay UM-50-C 6.2 5.0 6.2 5.0 6.5 5.0
(Milli.) UM-180-C 12 10 12 10 12 10
UM-210-C 20 10 20 10 20 10
Mechanical Data
UM-50 UM-180 UM-210
Static Torque - lb. ft. 16 30 95
Maximum Speed - rpm 3600 3600 3600
Average Weight-lbs.
1020 10 13.2 30.6/31
2030 13 16.5 41.3/42
Inertia – WR (lb. ft.
2
)
Output .017 .041 .231
Input .020 .046 .188
Note: All Data Nominal
Overhung Load Data
Overhung load data is provided in this manual
for the design engineer concerned with specific
requirements in this area. The maximum allowable overhung load which can be applied to the
shaft of an Electro-Module may be determined
from the accompanying chart.
Overhung Load*
Distance Load is
Applied from Maximum
Electro-Module Housing Face Load Rating
Size "A" Inches "R" Lbs.
1" - Center of Shaft 177
UM-50-C 2" - End of Shaft 123
3" 95
1" - Center of Shaft 192
UM-180-C 2" - End of Shaft 134
3" 104
1-3/8" - Center of Shaft 386
UM-210-C 2-3/4" - End of Shaft 271
4-1/8" 208
* Based on 10,000 Hour Life at 3600 RPM.
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Warner Electric • 800-234-3369 P-273-3 • 819-0358
The minimum pitch diameter pulley or sprocket
that can be used, for satisfactory bearing life, is
determined from the formula:
Min. P.D. = 2 T K
R
T - Torque (in.lbs.). This is the torque actually
being transmitted, not necessarily the maximum
torque capacity of the Electro-Module.
Torque = 63025 x HP
RPM
K - The safety factor for the tension in the type
of drive.
Use: 1 for chain and sprocket
1 for timing belt
2 for V-belt
3 for flat belt
R - Radial load allowable (values at various distance from the housing face are given in the
chart).
Example: What is the minimum V-belt pulley
that can be applied to the center of the shaft
of an EM-50 module. The torque requirements
is 112 in. lbs.
Min. P.D. = 2 x 112 x 2 = 2" minimum P.D. pulley
224
Burnishing
The ceramic faced friction surfaces of these
Unimodules are pre- burnished and performance tested at the factory to ensure consistent
"out of box" performance. Therefore, no "wearing in," or burnishing, is required. Full rated performance should be achieved after running for a
few cycles, usually fewer than 50.
Maintenance
Wear Pattern
Wear grooves appear on the friction
surfaces.This is a normal wear condition, and
does not impair functioning of the unit. Never
machine the friction surfaces to remove grooves
or score marks resulting from normal wear.
Heat
Excessive heat and high operating temperatures
can cause premature bearing 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
must be provided to protect the friction surfaces
from oil and grease to prevent serious torque
loss.
Troubleshooting
With the motor at rest and locked out, check the
following:
A. With power off to the clutch and brake, spin
the output shaft by hand. It should turn with
only the light drag of the preloaded armatures.
B. If a brake or clutch slips or loses torque com-
pletely, the initial check should be the input
voltage to the magnet or field as follows:
90-Volt: Connect a DC voltmeter with a range
of 0-100 volt directly across the magnet or
field terminals. With the power on and the
torque control 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: Use a DC voltmeter with a range of
0-30 volts or more. A normal reading is
approximately 22-26 volts, depending on the
power supply.
7
6-Volt: 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
on page 5. These readings are taken 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 one lead to the magnet.)
Compare resistance to the data on page 5.
If the above checks indicate that the proper
voltage and current is being supplied to the
coil, mechanical parts should be checked to
assure that they are in good operating condition and properly installed.
Repair and Replacement
Performance Plus Unimodules 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.
Please note that units with damage to the nonwearing components, such as housings and
shafts, are not repairable. The factory will evaluate returns and determine if they can be
repaired.
Ordering Information
Unit Model Voltage Part Number
UM-50-1020-C 6 5370-273-077
UM-50-1020-C 24 5370-273-078
UM-50-1020-C 90 5370-273-079
UM-50-2030-C 6 5370-273-085
UM-50-2030-C 24 5370-273-086
UM-50-2030-C 90 5370-273-087
UM-180-1020-C 6 5370-273-073
UM-180-1020-C 24 5370-273-074
UM-180-1020-C 90 5370-273-075
UM-180-2030-C 6 5370-273-081
UM-180-2030-C 24 5370-273-082
UM-180-2030-C 90 5370-273-083
UM-210-1020-C 6 5371-273-035
UM-210-1020-C 24 5371-273-036
UM-210-1020-C 90 5371-273-037
UM-210-2030-C 6 5371-273-039
UM-210-2030-C 24 5371-273-040
UM-210-2030-C 90 5371-273-041
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Warner Electric • 800-234-3369 P-273-3 • 819-0358
Size A B C D E F G H I
50 6.750 4.844 1.813 6.750 .625 .937 2.203 7.687 7.274
180 6.828 4.844 1.812 6.750 .875 .937 2.203 7.687 7.274
210 *9.391 *6.422 2.500 9.250 1.125 *1.125 2.203 10.187 9.297
*Dimension includes the .500 thick adapter required for C face mounting to a motor.
All dimensions are nominal, unless otherwise noted.
Dimensions
1020-C Unimodules
Base Motor Mount
Base (B):
Size A B C D E F G Part No.
UM-50-B 6.000 5.000 5.672 4.000 .750 x .406 3.500 2.000 5370-101-004
UM-180-B 6.625 5.000 5.672 4.000 .750 x .406 4.500 3.000 5370-101-002
UM-210-B 9.000 7.750 8.203 6.000 .750 x .531 5.250 3.385 5371-101-001
Motor Mount (M):
Size A B C D E F Part No.
UM-50-M 3.500 9.250 8.250 8.000 11.000 .796 x .406 5370-101-004
UM-180-M 4.500 9.250 8.250 8.000 11.000 .796 x .406 5370-101-012
UM-210-M 5.250 11.500 10.500 9.000 12.000 .750 x .406 5371-101-012
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Warner Electric • 800-234-3369 P-273-3 • 819-0358Warner Electric • 800-234-3369 P-273-3 • 819-0358
Dimensions
2030 – C Unimodules with Base (B):
Size A B C D E F G H
50 5.719 9.516 1.813 .625 5.672 .844 4.000 .344
Min
180 5.719 9.656 1.890 .875 5.672 .844 4.000 .344
Min
210 7.719 12.969 2.500 1.125 8.203 1.094 6.000 .437
Min
Size I J K L M N O P Q R S T U V
50 6.688 3.500 6.844 2.000 6.000 .500 5.000 3.125 2.188 75° 5.531 4.438 1.125 2.203
180 6.688 4.500 7.844 3.000 6.625 .500 5.000 3.125 2.188 75° 5.531 4.438 1.125 2.203
210 9.688 5.250 9.906 3.375 9.000 .625 7.750 3.125 2.188 70° 6.859 5.766 1.625 2.203
All dimensions are nominal unless otherwise noted.
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 notied 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 specic legal
rights and you may also have other rights which vary from state to state.
Changes in Dimensions and Specifications
All dimensions and specications shown in Warner Electric catalogs are subject to change without
notice. Weights do not include weight of boxing for shipment. Certied prints will be furnished
without charge on request to Warner Electric.
Warner Electric LLC
31 Industrial Park Road • New Hartford, CT 06057
815-389-3771 • Fax: 815-389-2582
www.warnerelectric.com
P-273-3 819-0358 • 10/05 Printed in USA
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