Warner Electric UM-50 User manual

Gen 2 Clutch/Brake UniModule
UM-50, UM-100, UM-180
Service & Installation Instructions
P-273-4-WE
819-0528
Vented
Enclosed Version Optional

2Warner Electric • 800-825-9050 P-273-4-WE • 819-0528
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:
Install your specific UniModule combination
according to the installation steps specified in the
table. Use only those steps indicated for each
combination.
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
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.
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
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

Warner Electric • 800-825-9050 P-273-4-WE • 819-0528 3
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.
Figure 1
If anti-fretting lubricant is used on
the motor shaft for future ease of removal, ensure
that any excess is wiped off before unit assembly
to avoid lubricant contaminating the clutch or
brake friction faces.
3. Secure the UniModule to the motor with the four
(4) long mounting tie-bolts provided. Tighten the
four (4) bolts 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)
Figure 2a
c. Using a torque wrench and long Allen socket,
tighten the two (2) setscrews to: (Figure 2b)
• 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)
Side Vent Access Slots
Set Screws

4Warner Electric • 800-825-9050 P-273-4-WE • 819-0528
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.
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.
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
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-WE • 819-0528 5
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.
Figure 5
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
Transmission Components
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.
Confirm that the belt or chain
tightness meets the maximum side load
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.
Table 2
A
R
Distance Load is Applied from
Maximum
UniModule Housing Face Load Rating
“A” Inches “R” Lbs.
UM-50 1” (Center of Shaft) 177
2” (End of Shaft) 123
3” 95
UM-100 1” (Center of Shaft) 192
2” (End of Shaft) 134
3” 104
UM-180 1” (Center of Shaft) 192
2” (End of Shaft) 134
3” 104

6Warner Electric • 800-825-9050 P-273-4-WE • 819-0528
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
Scan to Watch Clutch & Brake
Electrical Troubleshooting Video
https://p.widencdn.net/byvbde
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.
• If the wires are intact, the problem may be with
the power supply or the switch.
• 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
Clutch Brake Clutch Brake Clutch Brake
Voltage–D.C. 90 90 24 24 6 6
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
Current UM-50 .20 .21 .76 .83 3.2 3.2
(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 6 5 6 5 6 5
Time (ms) UM-100/180 12 10 12 10 12 10
Troubleshooting - Mechanical
Scan to Watch
Airgap Adjustment Video
https://p.widencdn.net/dg6idh
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-WE • 819-0528 7
Through this window, you will be looking between
the two armatures of the clutch and brake. (Figures 6
& 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)
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.
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.
Figure 6
Figure 7
Figure 8

8Warner Electric • 800-825-9050 P-273-4-WE • 819-0528
Note: If you have a Smooth Start UniModule it is
similar to a standard UniModule except 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.
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.
Figure 9
Note: When using this Cover Kit to enclose the
module the vent covers should be assembled as the
final step.
Scan to Watch
Cover Kits Video
https://p.widencdn.net/xrhdfr
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
Inertia - WR - lb.ft.2
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-WE • 819-0528 9
Notes:
Visit Warner Electric’s website at
www.warnerelectric.com for dimensional 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.

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 Specications
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.
P-273-4-WE 819-0528 10/18
www.warnerelectric.com
31 Industrial Park Road
New Hartford, CT 06057
815-389-3771