Warner Electric SFC-1525 User Manual
SFC-825, SFC-1000, SFC-1225, SFC-1525
Heavy Duty Clutch Coupling and SFC-1525
High Torque Heavy Duty Clutch Coupling
P-207
819-0516
Installation Instructions
Contents
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . .2
SFC-825, SFC-1000, SFC-1225, SFC-1525 and
SFC-1525 Hi-Torque
Torque Tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Electrical Coil Data . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Burnishing and Maintenance . . . . . . . . . . . . . . . . . . . .6
Illustration Drawings
SFC-825, SFC-1000 Flange Mounted . . . . . . . . . . .8
SFC-1225, SFC-1525 and SFC-1525
Hi-Torque Flange Mounted . . . . . . . . . . . . . . . . . . .12
SFC-825, SFC-1000 Bearing Mounted . . . . . . . . .18
SFC-1225, SFC-1525 Bearing Mounted . . . . . . . .22
Bushing Part Numbers . . . . . . . . . . . . . . . . . . . . . . .28
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover
Follow the installation instructions
in this manual care ful ly to ensure safe, reliable
operation. All stated or implied manufacturer
warranties are voided if this product is not installed
in accordance with these in struc tions.
Failure to follow these instructions may result in product damage, equipment
damage, and serious or fatal injury to personnel.
Clutch-Coupling Spline Drive Armatures
SFC-825 SFC-1000 SFC-1225 SFC-1525
SFC-1525 Hi-Torque
The illustration drawings, parts lists, and exploded views
for these units can be found beginning on page 8.
A. Aligning the Shafts
In order for the clutch-coupling unit to operate
properly, the mounting shafts of the motor and
reducer or other hardware must be aligned with
respect to each other before the unit is installed.
The two shafts should be con cen tric with each other
within .006 T.I.R., and angular alignment should be
within 1/2 degree. (See to Figure 1)
SFC-825
Bearing Mounted
SFC-825
Flange Mounted
Figure 1
Warner Electric • 800-825-9050 P-207 • 819-0516
2
1. Use a straight-edge to check if the shafts are
Field
Pilot diameter
Mounting Surface
aligned with each other. For a more precise
indication of align ment, use a dial indicator.
2. Adjust the position of the motor, reducer, or
other hardware as required to achieve the
correct align ment.
3. To be sure the shafts stay in alignment, drill
holes for tapered dowel pins through the
mounting bases of the motor, reducer, or
other hardware and into the mounting
surfaces. This procedure will ensure that,
after the clutch-coupling has been installed,
the shafts can easily be placed in proper
alignment again by lining up the holes and
secured by inserting the dow el pins.
B. Installing the Conduit Box
Install the conduit box on the field. Instructions for
this procedure can be found with conduit box.
Installation Manual P-1393 • 819-0200.
C. Mounting the Field-and-Rotor
Assembly
c. The field assembly is then fastened in place
with capscrews and lockwashers. (Figure 3)
Figure 3
d. After the unit is in place the mounting face
and pilot di am e ter must be square and
concentric with the shaft in accordance with
the tolerances listed on the draw ings.
(Fig ure 4)
Flange-Mounted Units
The fields and rotors are shipped separately for
flange-mounted units. On some applications it will
be nec es sary to mount the rotor first, and then
bring the field into position. In other instances, the
field will be mounted first, and then the rotor
(mounted on a shaft) will be inserted into place.
1. Mounting the Field
a. Care must be taken in selecting the
location for mount ing the field assembly.
Pilot diameters are machined on the field
mounting flange to aid in hold ing the field
in the proper position.
b. An appropriate pilot diameter must be
provided on the mounting surface as
well. (Figure 2)
Figure 4
2. Mounting the Rotor
a. Assemble the rotor to the rotor hub with
capscrews and lockwashers. The rotor is
reversible de pend ing on the side from which
the taperlock bushing must en ter. A pilot
di am e ter is machined on the rotor hub to
assure a proper fit.
b. The rotor hub is mounted on the shaft with
a taper lock bushing. Be sure all parts are
clean and free of dirt, chips, and burrs
before assembling.
c. Insert the bushing into the taper bore.
Warner Electric • 800-825-9050 P-207 • 819-0516
Figure 2
d. Loosely assemble the two locking screws
be tween the bushing and rotor.
e. Insert the key into the shaft keyway. Prick
punch the end of the keyway to ensure that
the key can not slide out.
3
f. Slide the rotor assembly over the key and
onto the shaft.
g. Place the edge of the rotor 1/16" - 1/8"
before the line that is inscribed into the O.D.
of the field.
h. Lock the rotor into place by alternately
tightening the two locking screws in the
bushing. As the screws are tight ened, the
rotor normally is pulled 1/16" - 1/8" further
onto the bushing (towards the field).
When the rotor is secured tightly on the
bush ing, the edge of the rotor must be
ap prox i mate ly even with the line
inscribed in the field. The over all axial
di men sion from the face of the rotor to the
back of the field flange is shown on the
illustration draw ings. Squareness and
con cen tric i ty tol er anc es must also be held
as specified on the draw ings to assure that
the unit functions correctly.
Bearing Mounted Units
In bearing-mounted units, the field and rotor are shipped
as an assembly. Either this assembly or the armature and
hub assembly can be mounted on the shaft first,
de pend ing on the characteristics of each application.
D. Assembling the Armature and Hub
These units contain a spline drive armature and hub.
The armatures are shipped with a built-in autogap spring
ac ces so ry. This device automatically maintains a gap of
about 1/32" between the armature and rotor faces for
the life of the units.
These units are shipped with the armature, splined
ar ma ture adapter, and autogap already assembled. The
splined hub, retainer ring, and bushing are shipped as
separate parts.
Follow these instructions to assemble the splined
ar ma ture assembly and hub:
1. Place the armature assembly on a flat surface with
the segmented side up.
2. Push the splined hub, with the retainer ring groove
down, through the autogap spring and splined
armature adapt er (Figure 5). (Considerable force is
required to start the hub through the armature.)
1. Field and rotor assemblies are mounted on the shaft
a taperlock bushing. Insert the bushing into the
tapered bore.
2. Loosely assemble the two locking screws between
the taperlock bushing and the rotor.
3. Insert the key into the shaft keyway. Prick punch the
end of the keyway to ensure that the key cannot
slide out.
4. Slide the rotor assembly onto the shaft over the key.
5. If the armature has been secured to the shaft first,
ad just the rotor's position to allow a 1/32-inch gap
be tween the two faces. (See Figure 8.)
6. Lock the assembly into place by alternately
tight en ing the two locking screws.
7. A tab or torque arm on the field is used to prevent
ro ta tion of the field caused by normal bearing drag.
In sert ei ther a pin in the U-slot or a fork around the
torque arm to prevent this rotation. Under no
cir cum stanc es, however, should the field be so
tightly re strained as to preload the bearing. (For
more in for ma tion on torque tabs, see page 5.)
Figure 5
3. Turn the armature assembly over, and insert the
Figure 6
retainer ring in the groove. (Figure 6)
4. Slide the armature assembly up against the retainer
ring.
Warner Electric • 800-825-9050 P-207 • 819-0516
4
E. Mounting the Armature-Hub Assembly
1/32-inch Gap
Armature
Rotor
Torque Tabs
1. Insert the bushing into the retainer ring side of the
splined hub. The clearance holes in the bushing
flange should line up with the tapped holes in the
splined hub. (Figure 7)
Figure 7
2. Slide the complete assembly on the shaft and place
it in contact with the rotor.
3. Tighten the bushing capscrews, taking a few turns
at a time on each capscrew. As the capscrews are
tight ened, the armature will back away slightly from
the rotor. There should be a clearance of 1/16"
be tween the ar ma ture and rotor when the
capscrews are com plete ly tight.
Clutches
Many Warner Electric clutch assemblies have a bearing
mounted stationery field. By design the bearing
main tains its proper position between the field and rotor
mak ing it easy for the customer to mount the field-rotor
as sem bly. However, the bearing has a slight drag which
tends to make the field rotate with the rotor if not
re strained. And, since the field has lead wires attached,
it must be restrained to prevent rotation and pulling of
these wires. To counteract this rotational force, the field
has a “torque tab” to which the customer must attach
an ap pro pri ate 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 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 1 and preload the bearing. The recommended
methods are il lus trat ed in Illustrations 2, 3, and 4. The
method selected is primarily a matter of customer
preference or con ve nience.
4. When the assembly has been secured on the shaft,
push the armature against the rotor face. When the
ar ma ture is released, it will spring back about 1/32".
(Fig ure 8)
Figure 8
Once this gap is set, it will be automatically maintained
for the life of the unit.
Illustration 1
Rigid Member
Illustration 2
Rigid Member
Straddling Tab
Illustration 3
Pin In Hole Loosely
Warner Electric • 800-825-9050 P-207 • 819-0516
Illustration 4
Flexible Strap
5
Electrical Coil Data
Unit Size SF-825 SF-825 Brg. SF-1000
Voltage–DC 6 24 90 6 24 90 6 24 90
Resistance @ 20°C–Ohms 1.23 20.9 267.0 1.098 14.6 221 1.07 14.4 214.4
Current–Amperes 4.9 1.15 .34 5.464 1.65 .407 5.61 1.67 .42
Watts 29 28 30 33 40 37 34 40 38
Coil Build-Up–Milliseconds 222 200 245 180 200 225 256 275 283
Coil decay–Milliseconds 105 120 100 115 120 130 123 105 90
Unit Size SF-1225 SF-1525 SF-1525 HT
Voltage – DC 6 24 90 6 24 90 6 24 90
Resistance @ 20°C–Ohms 1.21 19.5 268.3 1.11 15.5 239.1 .55 7.63 113.4
Current – Amperes 4.97 1.23 .34 5.41 1.55 .38 10.83 3.14 .794
Watts 30 30 30 32 37 34 65 75 72
Coil Build-Up – Milliseconds 475 440 510 505 535 575 480 535 560
Coil decay–Milliseconds 240 230 220 230 237 215 210 183 160
Notes: Build-up time equals current to approx.* 90% of steady state value and flux to 90%
Decay time equals current to approx.* 10% of steady state value and flux to 10%.
*Approx. because current leads or lags flux by a small amount.
Burnishing and 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
fac to ry with the friction material slightly undercut to
assure good initial contact.
Normally, the desired wearing-in process occurs nat u ral ly
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
in stal la tion, the unit should be burnished by slipping
the friction surfaces together at reduced voltage. It is
rec om mend ed that the burnishing 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 volt age
should be set at approximately 30% or 40% 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
as sem bled and installed, no further servicing, lubrication,
or maintenance should be required throughout the life of
the unit.
Maintenance
Wear Pattern: Wear grooves appear on the armature
and rotor surfaces. This is a normal wear condition, and
does not impair functioning of the unit. Normally, the
rotor 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
rec om mend ed. If a replacement armature is to be used
with a used rotor, it is necessary to remachine the worn
rotorface. In refacing a rotor: (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
.002''-.004'' below the metal poles.
Heat: Excessive heat and high operating temperatures
are causes of rapid wear. Units therefore, should be
ven ti lat ed as efficiently as possible, especially if the
ap pli ca tion requires fast, repetitive cycle operation.
Foreign Materials: If units are used on machinery
where fine, abrasive dust, chips or grit are dispelled into
the at mo sphere, shielding of the brake or clutch may be
nec es sary if maximum life is to be obtained.
Warner Electric • 800-825-9050 P-207 • 819-0516
6
Where units are used near gear boxes or transmissions
requiring frequent lubrication, means should be pro vid ed
to protect the friction surfaces from oil and grease to
pre vent serious loss of torque.
Oil and grease accidentally 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.
If the friction materials have been saturated with oil or
grease, no amount of cleaning will be completely
ef fec tive. 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 field as follows:
90-Volt Series: Connect a DC voltmeter with a range of
0-100 or more directly across the field 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
ad just ed 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.
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: a low range ammeter,
when connected in series with one field lead, will
normally in di cate approximately .40 amperes for the 90
volt units, 1.0 ampere for the 24 volt, and 3.5 amperes
for the 6 volt series. 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 one lead
to the field). Average resistance for the 90 volt series is
220 ohms; for the 24 volt, 20 ohms; and for the 6 volt
series, 1.5 ohms. A very high or infinite resistance
read ing would indicate an open coil.
If the above checks indicate that the proper voltage and
current is being supplied to the magnet, mechanical
parts should be checked to assure that they are in good
op er at ing condition and properly installed.
Warner Electric • 800-825-9050 P-207 • 819-0516
7
SFC-825 Clutch Coupling Flange Mounted Drawing I-25564
See page 28 for details
on Bushings.
1.546
.921
5.656
Armature View
3.750 Max.
Removable plug in ends for
1/2" conduit.
3.503/3.501
6.812
.358/.338 dia.
(4) holes
equally spaced
on 8.875 dia. *
.350/.341 dia. (6) holes equally
spaced on 2.875 dia. **
Pilot Dia.
.358/.338 dia.
(6) holes
equally
spaced on
4.250 dia. *
9.749/9.747
Pilot Dia.
Field View
(Inside & Outside Mounted)
Customer Shall Maintain:
1. Concentricity of field mounting pilot diameter with
rotor mounting shaft within .006 T.I.R.
2. Squareness of field mounting face with rotor shaft
within .006 T.I.R. mea sured at field
mounting bolt circle.
8.656
Max.
Dia.
* Mounting holes are within .010 of true po si tion relative to pilot
diameter.
** Mounting holes are within .008 of true po si tion relative to pilot
diameter.
4.250
Dia.
2.500
Dia.
.156
1.250
1.765
.531
1.00
.062
1.312
4.406 Max.
.687
.281
5/16-18
UNC-3A
.602/.586
2.253
2.251
Pilot
Dia.
.562 Max.
Arm Shaft .500 – 1.500
Rotor Shaft .500 – 1.250
Static Torque 125 lb. ft.
Maximum Speed 4,000 rpm
Standard Voltage D.C. 6, 24, 90
All dimensions are nominal unless otherwise noted.
Note: The two mating shafts on which the clutch is
mounted must be mounted rigidly to prevent
flexing during engagement. Any flexing will cause
vibration and rapid clutchwear. The drive motor
should not be mounted on the reducer "scoop"
mount or other flexible mounts.
3. Rotor mounting shaft concentric with ar ma ture
mounting shaft within .006 T.I.R.
4. Angular alignment of shafts wtihin 1/2 degree.
Warner Electric • 800-825-9050 P-207 • 819-0516
8
1
2
3
4-1
4-2
4-3
4
(Shipped Assembled)
4-4
4-6
4-5
9A
10A
11
9B
8
7
6
5
10B
11
SFC-825 Clutch Coupling Flange Mounted Inside Mtd. Outside Mtd.
SFC-825, F.M.
Item Description Part Number Qty.
1 Bushing*
1/2" to 1-1/2" Bore 180-0002 to 180-0018 1
2 Retainer Ring 748-0006 1
3 Splined Hub 540-0057 1
4 Armature & Splined Adapter 5201-111-001 1
4-1 Capscrew 797-0341 3
4-2 Splined Adapter 104-0008 1
4-3 Autogap Accessory 5321-101-006 1
4-4 Spacer 748-0333 3
4-5 Armature 5321-111-022 1
4-6 Locknut 661-0004 3
5 Mounting Accessory 5201-101-007 1
6 Rotor 1
Standard Friction Material 5201-751-003
Optional LK Facing 5201-751-007
7 Bushing*
8 Rotor Hub 540-0013 1
9A Field - Inside Mounted 1
9B Field - Outside Mounted 1
1/2" to 1-1/4" Bore 180-0101 to 180-0013 1
6 Volt 5201-451-006
24 Volt 5201-451-008
90 Volt 5201-451-010
6 Volt 5201-451-014
24 Volt 5201-451-016
90 Volt 5201-451-018
SFC-825, F.M.
Item Description Part Number Qty.
10A Mounting Accessory - I.M. 5321-101-001 1
10B Mounting Accessory - O.M. 5321-101-002 1
11 Conduit Box 5200-101-012 1
*See page 28 for specific part numbers.
How to Order:
1. Specify Bore Size for Item 1.
2. Specify Bore Size for Item 7.
3. Specify Voltage for Item 9A or 9B.
4. Specify Inside Mounted for Items 9A and 10A or
Outside Mounted for Items 9B and 10B.
Example:
SFC-825 Clutch Coupling per I-25564 - 90 Volt, Inside
Mounted, 1" Bore (Item 1), 1" Bore (Item 7)
These units, when used in conjunction with the correct
Warner Electric conduit box, meet standards of UL508
and are listed under guide card #NMTR, file #59164.
Warner Electric • 800-825-9050 P-207 • 819-0516
9
SFC-1000 Clutch Coupling Flange Mounted Drawing I-25584
3.750
7.687 MAX
Removeable plug in ends
for 1/2” conduit
.358/.388 dia. (6) holes equally
spaced on a6.125 dia. *
.350/.341 dia. (6) holes
equally spaced on 4.875 dia.**
5.378/5.376
Pilot Dia.
11.500/11.498
Pilot Dia.
.358/.338 dia *(8) holes equally
spaced on 10.625 dia.*
1.560
Ø4.127 ±.001
1.250
.250
.562 MAX
.093
.562
1.375
5/16-18 UNC-3A
6.531
Ø10.328 MAX
HOLE FOR 1/2" CONDUIT
(EACH END)
.500
.910 MAX
5.359 MAX
.062
.234
2.500
2.688
Ø4.094
Ø6.000
PILOT
See page 28 for details
on Bushings.
Armature View
Field View
(Inside & Outside Mounted)
Customer Shall Maintain:
1. Concentricity of field mounting pilot diameter with
rotor mounting shaft within .006 T.I.R.
2. Squareness of field mounting face with rotor shaft
within .006 T.I.R. mea sured at field mounting bolt
circle.
3. Rotor mounting shaft concentric with ar ma ture
mounting shaft within .006 T.I.R.
4. Angular alignment of shafts within 1/2 degree.
* Mounting holes are within .010 of true po si tion relative to pilot
diameter.
** Mounting holes are within .008 of true po si tion relative to pilot
diameter.
Arm Shaft .750 – 2.687
Rotor Shaft .500 – 2.000
Static Torque 240 lb. ft.
Maximum Speed 3,600 rpm
Standard Voltage D.C. 6, 24, 90
All dimensions are nominal unless otherwise noted.
Note: The two mating shafts on which the clutch is
mounted must be mounted rigidly to prevent
flexing during engagement. Any flexing will cause
vibration and rapid clutchwear. The drive motor
should not be mounted on the reducer "scoop"
mount or other flexible mounts.
Warner Electric • 800-825-9050 P-207 • 819-0516
10
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