Gen 2
Clutch/Brake UniModule
P-273-4
819-0528
Installation Instructions
UM-50, UM-100, UM-180
Vented
Enclosed Version Optional
An Altra Industrial Motion Company
Contents
Mounting to a C-Face Motor . . . . . . . .3
Mounting to a Reducer . . . . . . . . . . . . .4
Installing the Base Mount . . . . . . . . . . .4
Installing the Motor Mount Bracket . . .5
Mounting to Other Power
Transmission Components . . . . . . . .5
Electrical Connections . . . . . . . . . . . . . .6
Troubleshooting-Electrical . . . . . . . . . . .6
Troubleshooting-Mechanical . . . . . . . . .6
Enclosed UniModule Option . . . . . . . . .8
Warranty . . . . . . . . . . . . . . . . . . . . . . .BC
Failure to follow these
instructions may result in product damage,
equipment damage, and serious or fatal
injury to personnel.
The equipment covered by
this installation manual must be installed in
accordance with these instructions. Failure
to do so may damage the equipment and
void the warranty.
Warner Electric UniModules are designed to
National Electrical Manufacturers Association
(NEMA) standards. They can be mounted to
common NEMA C-Face motors and reducers as
well as common power transmission drive components.
The 1020 and 1040 UniModules are designed to
mount to the face of a C-Face motor as noted in
Table 1.
The 2030 and 3040 UniModules are designed to
mount using a base mounting kit. This allows
the modules to be mounted as a separate drive
unit driven from the prime mover by V-belts,
chain and sprockets, couplings, timing belts and
other standard power transmission components.
(For UniModule sizes 210 and 215 please refer
to Warner Electric manual P-273-1)
For These UM Combinations Use These
Installation Steps:
UniModule Clutch/Brake between
C-Face Motor and Reducer - 1020
UniModule Clutch between
Motor and Reducer - 1040
UniModule Clutch/Brake - 2030
UniModule Clutch - 3040
Motor Mount Module Clutch/Brake
on a C-Face Motor - 1020-M
Motor Mount UniModule Clutch
on a C-Face Motor - 1040-M
Base Mounted
UniModule Clutch/Brake - 2030-B
UniModule Clutch - 3040-B
Mounting to a Motor
Mounting to a Reducer
Electrical Connections
Mounting to other
Power Transmission
Components
Electrical Connections
Mounting to a Motor
Installing the Motor
Mount Bracket
Mounting to other
Power Transmission
Components
Electrical Connections
Installing the Base Mount
Mounting to other
Power Transmission
Components
Electrical Connections
Install your specific UniModule combination
according to the installation steps specified in
the table. Use only those steps indicated for
each combination.
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"
100 56 C 48 Y 5/8” 4-1/2”
180 182 C 143 TC 7/8" 4-1/2"
184 C 145 TC
Table 1
Warner Electric • 800-825-9050 P-273-4 • 819-0528
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Mounting to a C-Face Motor
1. A hardened key is provided with the
mounting hardware for UniModules.
Insert this key onto the motor shaft. It is
recommended to stake the end of the
motor shaft keyway to keep the key from
moving out during operation.
2. Align the keyway in the bore of the
UniModule to the key in the motor shaft
and slide the unit onto the motor shaft.
The normal alignment of the module to the
motor will be with the wire exit/conduit
box in the upright (12 o’clock) position as
shown in Figure 1.
Do not hammer or force the
module into position. To do so may damage
bearings or cause the friction faces to shift out
of alignment.
alternately to ensure even alignment of the
module. Tighten them to 30-35 foot
pounds.
Do not tighten the two (2) clutch
rotor set screws to the shaft before tightening
the four (4) module tie-bolts. This could cause
a preload on the pilot bearing resulting in
premature bearing failure.
4. Next secure the clutch rotor and fan
assembly to the motor shaft by tightening
the two (2) setscrew as follows:
a. There are two (2) access slots on
either side of the UniModule. A long
Allen wrench can be used to tighten
the two setscrews (90° apart) which
secure the clutch rotor and fan
assembly to the motor shaft.
b. Alternately align each setscrew with
one of the access slots by rotating the
clutch rotor and fan assembly through
one of the side vents with a small
screw driver taking care not to damage
the fan. (Figure 2a)
Set Screws
Figure 1
If anti-fretting lubricant is used
on the motor shaft for future ease of removal,
Side Vent
Figure 2a
Access Slots
ensure that any excess is wiped off before unit
assembly to avoid lubricant contaminating the
clutch or brake friction faces.
c. Using a torque wrench and long Allen
socket, tighten the two (2) setscrews
to: (Figure 2b)
3. Secure the UniModule to the motor with
the four (4) long mounting tie-bolts
provided. Tighten the four (4) bolts
• Size 50: 80-85 inch pounds
(Requires 5/32 inch Allen wrench)
• Size 100 or 180: 40-45 inch pounds
(Requires 1/8 inch Allen wrench)
Warner Electric • 800-825-9050 P-273-4 • 819-0528
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Figure 2b
Mounting to a Reducer
1. Warner Electric UniModules are furnished
with a hardened key pre-mounted on the
output shaft.
2. Align the output shaft and key of the
module with the corresponding bore and
keyway of the reducer. Slide the assembly
together as shown in Figure 3.
Installing the Base Mount
Model 2030 and 3040 UniModules are designed
to be base mounted as shown in Figure 4.
Figure 4
Optional Base Mount Kit,
Warner Electric part numbers:
UM-50/100...........................5370-101-004
UM-180................................5370-101-002
Figure 3
3. Bolt the module to the reducer flange.
The four (4) bolts that are required
(3/8-16UNC2A) are typically provided with
the reducer. Tighten to 18-22 foot pounds
of torque.
1. The pilot diameters on each end of the
UniModule will mate with the pilot
diameters on the base.
2. Secure the base to the UniModule with the
four (4) bolts provided. Tighten to 18 to 22
foot pounds.
Warner Electric • 800-825-9050 P-273-4 • 819-0528
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Installing the Motor Mount Bracket
A Motor Mount Bracket can be installed on the
output end of a 1020 and 1040 UniModule to
provide a foot mounting for the complete
assembly of a UniModule and C-face motor.
Optional Motor Mount Kit,
Warner Electric part numbers:
UM-50/100............................5370-101-078
UM-180.................................5370-101-079
1. Mount the bracket to the face of the
UniModule underneath the UniModule
and motor as shown in Figure 5. A pilot
diameter on the UniModule mates with
a pilot diameter on the bracket.
onfirm that the belt or chain
C
ightness meets the maximum side load
t
capability of the UniModule shown in
Table 2.
Overhung Load Data
(Shaft Side Load)
Overhung load data is provided in this manual for
the design engineer concerned with a specific
problem in this area. The maximum allowable
overhung load which can be applied to the shaft
of an UniModule may be determined by the use of
the accompanying chart.
A
R
Figure 5
UniModule Housing Face Load Rating
2. Secure the motor bracket in place with
four (4) short bolts and washers provided.
Tighten to 18 to 22 foot pounds.
Mounting to Other Power
UM-50 1" (Center of Shaft) 177
UM-100 1” (Center of Shaft) 192
Transmission Components
UM-180 1" (Center of Shaft) 192
Couplings, pulleys, sprockets or similar power
transmission components can be mounted to the
input and output shafts of a UniModule.
When mounting a pulley or
sprocket, ensure that the key is fully engaged
within the device hub or bushing.
Warner Electric • 800-825-9050 P-273-4 • 819-0528
Distance Load is
Applied from Maximum
"A" Inches "R" Lbs.
2" (End of Shaft) 123
3" 95
2” (End of Shaft) 134
3” 104
2" (End of Shaft) 134
3" 104
Table 2
5
Electrical Connections
To avoid injury (or even death),
always make certain all power is off before
attempting to install or service this device or
any electrical equipment.
Warner Electric UniModules are provided with
a conduit hole threaded for a standard 1/2 inch
conduit connection. Both the clutch and brake
lead wires exit this opening. If a Conduit Box is
desired, Warner Electric Conduit Box Kit, part
number: 5370-101-042, can be purchased
separately. The Conduit Box provides two conduit
connection holes for standard 1/2 inch conduit
connectors.
UniModule clutches and clutch/brakes operate on
DC voltage. Warner Electric offers a complete line
of electronic controls to meet the needs of almost
any clutch or clutch/brake application. Each
Warner Electric control will show the proper
wiring connections for its use.
Troubleshooting - Electrical
If the wires are intact, the problem may be
•
ith the power supply or the switch.
w
• Using a voltmeter, check to see that proper
DC voltage is leaving the power supply
and that the switch is sending power to
the clutch or brake.
• Finally, if there is no power leaving the
switch or power supply, check the
incoming AC power to ensure that it is
reaching the power supply.
Electrical Coil Data
lutch Brake Clutch Brake Clutch Brake
C
oltage–D.C. 90 90 24 24 66
V
Resistance UM-50 452 429 31.8 28.8 1.9 1.9
(OHMS) UM-100/180 392 392 26.7 26.7 1.8 1.8
urrent UM-50 .20 .21 .76 .83 3.2 3.2
C
Ampheres) UM-100/180 .23 .23 .90 .90 3.3 3.3
(
Power UM-50 18 19 19 20 20 20
(WATTS) UM-100/180 21 21 22 22 20 20
Coil Build Up UM-50 52 53 52 53 52 53
Time (ms) UM-100/180 72 75 72 75 72 70
Coil Decay UM-50 65 6565
Time (ms) UM-100/180 12 10 12 10 12 10
A UniModule that is not functioning properly may
be caused by other problems. It is best to check
for these problems before replacing it.
A UniModule requires DC power to function. If
power is not reaching the clutch or brake, they will
not engage.
A good practice to follow is to check for
power at the lead wires to the clutch or brake
using a voltmeter.
• If power is present in the proper voltage
and current (see Electrical Coil data), then
skip ahead to the Mechanical
Troubleshooting section.
• If power is not present, inspect the lead
wires for breaks or cuts.
Troubleshooting - Mechanical
Both clutch and brake armatures are equipped
with an Autogap™ assembly that maintains the
proper airgap between friction faces through the
life of the product. Each UniModule is airgap
adjusted and pre-burnished at the factory, but the
airgaps can shift as a result of rough handling
during shipping and installation.
An airgap that is too large can prevent the
armature from engaging. An airgap that is too
small can cause the armature to rub continuously,
causing higher running temperatures and
decreased wear life.
To reset the airgaps, you will need to access the
armatures. Looking through the vents on either
side of the housing, you will see the fan on the
clutch rotor. Rotate the fan (input) until you see the
1/2 x 1 inch window on the outer periphery of the
fan.
Warner Electric • 800-825-9050 P-273-4 • 819-0528
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hrough this window, you will be looking between
T
the two armatures of the clutch and brake.
(Figures 6 & 7)
Figure 6
Figure 8
Note: When resetting the clutch or FB brake
armature airgap, both the clutch and brake must
be released (the brake energized, and the clutch
not energized).
This is a three step process.
Figure 7
If either armature is too far away from its mating
friction suface, it is possible to move it back into
adjustment using a flat blade screwdriver.
(Figure 8)
1. Simply slide the screwdriver through the
window. By twisting the screwdriver, it works
as a wedge to apply pressure on the back of
the armature pushing it toward its mating
friction surface.
2. Rotate the output of the unit. The rotor and
window should stay in place when you do
this. Only the armatures will move.
3. Alternately repeat steps 1 & 2 to ensure that
the airgap between the armature and its
mating surface is about 1/32 inch and that
the armature remains square to its mating
surface. (If the armature is uneven, it may
engage on just one side giving the appearance of engagement but failing to provide full
torque.)
If there is a scraping or rubbing sound when
the output shaft is rotated, this means that an
armature is dragging and is too close to its mating
surface. Simply repeat steps 1-3 above, but place
the screwdriver between the face of the armature
and its mating friction surface.
Warner Electric • 800-825-9050 P-273-4 • 819-0528
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ote: If you have a Smooth Start UniModule it is
N
imilar to a standard UniModule except
s
Autogaps™ are eliminated from the armatures and
a compression spring is inserted between the
armatures. This results in the armatures being in
continuous contact with the rotor and brake
resulting in light, continuous drag. This
arrangement eliminates the sudden change in
torque that results when auto-gapped armatures
engage.
No adjustment is required for the life of the unit
unless it is jarred, resulting in the armature being
moved away from the mating surface and cocking
on the spline. If this occurs, a slight pry on the
armature usually gets it back into position.
Mechanical Data
UM-50 UM-100/180
Static Torque - lb. ft. 16 30
Maximum Speed - rpm 3600 3600
Average Weight-lbs.
1020 15.6 18.7
1040 14.0 16.6
2030 18.4 21.7
3040 16.8 19.5
Wt/s have been changed for GEN II
Enclosed UniModule Option
Vented Warner Electric UniModules and base
assemblies can be oriented as necessary to keep
contaminants from entering the open housing
vents.
If an Enclosed UniModule is required, an optional
Cover Kit, Warner Electric part number
5370-101-076, can be purchased separately to
enclose the open vents in the housing.
Each Cover Kit includes two (2) vent covers and
four (4) screws needed to convert a vented
UniModule to an enclosed design
(non-washdown) as shown in Figure 9.
Inertia - WR - lb.ft.
Configuration 50 100/180
1020 input .021 .047
1020 output .0195 .050
1040 input .021 .047
1040 output .0105 .027
2030 input .021 .048
2030 output .0195 .050
3040 input .021 .048
3040 output .0105 .027
Warner Electric • 800-825-9050 P-273-4 • 819-0528
8
2
Figure 9
Note: When using this Cover Kit to enclose the
module the vent covers should be assembled as
the final step.
Notes:
Visit Warner Electric’s website at
www.warnerelectric.com
drawings, weights, inertias, and a complete
offering of our products including clutches,
brakes and clutch/brake controls and
service parts.
In addition, Warner Electric module products,
controls, and service parts information can be
found in our catalog P-1234-WE.
Call 815-389-3771 to request any of our catalogs.
for dimensional
Warner Electric • 800-825-9050 P-273-4 • 819-0528
9
Warranty
arner Electric LLC warrants that it will repair or replace (whichever it deems advisable) any
W
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, 31
Industrial Park Road, New Hartford, Connecticut 06057, 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 LLC
31 Industrial Park Road • New Hartford, CT 06057 - USA
815-389-3771 • Fax: 815-389-2582
www.warnerelectric.com
P-273-4 • 819-0528 11/07 Printed in USA
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