Nexen AIR CHAMP 1625 Bedienungsanleitung

FORM NO. L-21070-C-0702

FLANGEMOUNTEDCLUTCHBRAKE

Model 1625

DIST. AUTORIZADO

MEX (55) 53 63 23 31

QRO (442) 1 95 72 60

MTY (81) 83 54 10 18

[email protected]

In accordance with Nexen’s established policy of constant product improvement, the specifications contained in this

manualaresubjecttochangewithoutnotice. Technicaldatalistedinthismanualarebasedonthelatestinformation

available at the time of printing and are also subject to change without notice.

Technical Support: 800-843-7445

(651)484-5900

www.nexengroup.com

NexenGroup,Inc.

560 Oak Grove Parkway

Vadnais Heights, Minnesota 55127

ISO 9001 Certified

Read this manual carefully before installation and operation.

Follow Nexen's instructions and integrate this unit into your system with care.

This unit should be installed, operated and maintained by qualified personnel ONLY.

Improper installation can damage your system or cause injury or death.

Comply with all applicable codes.

DANGER

DIST. AUTORIZADO

MEX (55) 53 63 23 31

QRO (442) 1 95 72 60

MTY (81) 83 54 10 18

[email protected]

Table of Contents

Installation -----------------------------------------------------------------------------------------------------------------------------------------4

Air Connections---------------------------------------------------------------------------------------------------------------------------------6

Lubrication-----------------------------------------------------------------------------------------------------------------------------------------7

Troubleshooting ---------------------------------------------------------------------------------------------------------------------------------8

Replacement Procedure - Friction Facings------------------------------------------------------------------------------------------9

Replacement Procedure - Female Pilot Bearing --------------------------------------------------------------------------------10

Replacement Procedure - Piston Bearing and O-Ring Seals --------------------------------------------------------------11

Replacement Procedure - Male Pilot Bearings-----------------------------------------------------------------------------------12

ReplacementProcedure-InputUnit--------------------------------------------------------------------------------------------------------13

Replacement Parts List --------------------------------------------------------------------------------------------------------------------14

Warranty -----------------------------------------------------------------------------------------------------------------------------------------16

DIST. AUTORIZADO

MEX (55) 53 63 23 31

QRO (442) 1 95 72 60

MTY (81) 83 54 10 18

[email protected]

FORM NO. L-21070-C-0702 (4)

NOTE: Refer to Figure 1.

1. Insert the customer supplied key into the motor shaft

keyway.

2. Remove the four Socket Head Cap Screws, (Item 8), to

separate the Female Pilot, (Item 1), from the Housing

(Item 7).

3. Secure the Female Pilot (Item 7) to the motor face

using Nexen supplied socket head cap screws.

Tighten customer supplied cap screws to 1425 in-lbs

(161 N-m).

4. Tighten the Set Screw (Item 35) to 275 in-lbs (31 N-m).

5. Secure Housing (Item 7) to the Female Pilot (Item 1)

using Socket Head Cap Screws (Item 8). Apply

Loctite® 242 to the threads of Item 8.

6. Tighten Socket Head Cap Screws to 509-662 in-lbs

(57.5-74.8 N-m).

7. Install the Housing Guard (Item 34) over the open

areas of the FMCB, and secure it using the provided

fasteners.

FIGURE 1

FIGURE 2

NOTE: Refer to Figure 2.

1. Insert the Key (Item 33) into the output shaft of the

FMCB-1625.

2. Slide the FMCB output shaft into the gear reducer.

3. Secure the FMCB to the gear reducer using customer

supplied cap screws and lock washers.

4. Complete steps 1-7 from Section A.

INSTALLATION

SECTION A: MOUNTING ON THE SHAFT END OF A MOTOR

SECTION B: MOUNTING BETWEEN A GEAR REDUCER AND MOTOR

MOTOR

CUSTOMER

SUPPLIED KEY

SET SCREWS

(Item 35) HOUSING

(Item 7)

FMCB

.500-13 SOCKET

HEAD CAP SCREWS

CAP SCREWS

(Item 8)

HOUSING

GUARD

FEMALE PILOT

(Item 1)

MOTOR

CUSTOMER

SUPPLIED KEY

SET SCREWS

(Item 35)

FMCB

.500-13 SOCKET

HEAD CAP SCREWS

HOUSING

GUARD

FEMALE PILOT

(Item 1)

GEAR

REDUCER

Key

(Item 33)

(continued...)

DIST. AUTORIZADO

MEX (55) 53 63 23 31

QRO (442) 1 95 72 60

MTY (81) 83 54 10 18

[email protected]

(5) FORM NO. L-21070-C-0702

INSTALLATION (continued...)

NOTE: Refer to Figures 1 and 3.

NOTE: Use Loctite® 242 on all Socket Head Cap Screws.

1. Remove the four Socket Head Cap Screws (Item 8)

and separate the Female Pilot (Item 1) from the

Housing (Item 7).

2. Place Key (Item 19) into the keyway of the Input Unit.

3. Slide the Female Pilot (Item 1) onto the Input Unit.

Secure the Input Unit and the Mounting Foot to the

Female Pilot (Item 1) using four Socket Head Cap

Screws (Items 39 and 40). Tighten the Socket Head

Cap Screws to 1425 in-lbs (161 N-m).

4. Tighten the Set Screw (Item 35) to 275 in-lbs (31 N-m).

5. Secure the second Mounting Foot (Item 38) to the

FMCB Assembly.

6. Secure the Female Pilot (Item 1) assembly to the FMCB

Assembly (Item 7) with the Socket Head Cap Screws

(Item 8). Tighten to 509-662 in-lbs (57.5-74.8 N-m).

FIGURE 3

40 INPUT

UNIT

19 35

FEMALE PILOT

ASSEMBLY

MOUNTING FOOT

(ITEM 28)

FMCB

ASSEMBLY

MOUNTING FOOT

(ITEM 38)

SECTION C: OPTIONAL INPUT UNIT AND FEET

DIST. AUTORIZADO

MEX (55) 53 63 23 31

QRO (442) 1 95 72 60

MTY (81) 83 54 10 18

[email protected]

FORM NO. L-21070-C-0702 (6)

NOTE: Refer to Figure 4

1. If the brake is to be set when the solenoid is de-

energized, connect the port marked 2to the brake and

the port marked 4 to the clutch.

2. Connect the air supply line to the inlet port (marked 1).

FIGURE 5

For a faster response, Nexen recommends a quick exhaust valve and short air lines between the Control Valves and the

FMCB. Align the air inlet ports to a down position to allow condensation to drain out of the air chambers. The FMCB has

1/8 - 27 NPT ports.

AIR CONNECTIONS

NOTE: Refer to Figure 5

1. If the brake is to be set and the clutch is to be OFF

when the solenoid is de-energized, connect the port

marked 4to the brake and the port marked 2to the

clutch.

2. Connect the brake air supply line to the port marked 5

and the clutch air supply line to the port marked 3.

NOTE: Refer to Figure 6

1. Install a 3-Way N.O. Control into the brake inlet port

and a 3-Way N.C. Control into the clutch inlet port.

2. Connect an air supply line to the inlet port (marked IN)

on top of the 3-Way N.O. Control and an air supply line

to the inlet port (marked IN) on the side of the 3-Way

N.C. Control.

FIGURE 4

5-WAY CONTROL VALVE

4-WAY CONTROL VALVE

3-WAY CONTROL VALVES

3-WAY N.C.

CONTROL

AIR TO

CLUTCH

3-WAY N.O.

CONTROL

AIR TO

BRAKE

FIGURE 6

When a 3-Way N.O. Control is de-energized, air flows

directlyto thebrake. When a3-WayN.O. Controlis ener-

gized, air exhausts from the brake.

Whena 3-WayN.C. Control isde-energized, airexhausts

from the clutch. When a 3-Way Control is energized, air

flows to the clutch.

NOTE

DIST. AUTORIZADO

MEX (55) 53 63 23 31

QRO (442) 1 95 72 60

MTY (81) 83 54 10 18

[email protected]

(7) FORM NO. L-21070-C-0702

Pneumatically actuated devices require clean, pressure regulated, and lubricated air for maximum performance and

long life. The most effective and economical way to lubricate the FMCB is with an Air Line Lubricator,which injects oil into

the pressurized air, forcing an oil mist into the air chamber.

Place the lubricator above and within ten feet of the FMCB. Use a low viscosity oil such as SAE-10.

Synthetic lubricants are not recommended.

LUBRICATION

LUBRICATOR DRIP RATE SETTINGS

These settings are for Nexen supplied lubricators. If

you are not using a Nexen lubricator, calibration must

replicate the following procedure.

1. Close and disconnect the air line from the unit.

2. Turn the Lubricator Adjustment Knob clockwise three

complete turns.

3. Open the air line.

4. Close the air line to the unit when a drop of oil forms in

the Lubricator Sight Gage.

5. Connect the air line to the unit.

6. Turn the Lubricator Adjustment Knob counterclockwise

until closed.

7. Turn the Lubricator Adjustment Knob clockwise one-

third of a turn.

8. Open the air line to the unit.

NOTE

DIST. AUTORIZADO

MEX (55) 53 63 23 31

QRO (442) 1 95 72 60

MTY (81) 83 54 10 18

[email protected]

FORM NO. L-21070-C-0702 (8)

TROUBLESHOOTING

FIGURE 7

FEMALE

PILOT

SET

SCREW

HOUSING SPLINNED

DISC AIR

CHAMBER O-RING

SEALS MALE

PILOT

SPRING

BALL

BEARING KEY

STUB

SHAFT

PISTON

AIRTO

CLUTCH

BALL

BEARING

AIRTO

BRAKE

FRICTION

FACING

DISC

DRIVE

BALL

BEARING

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DIST. AUTORIZADO

MEX (55) 53 63 23 31

QRO (442) 1 95 72 60

MTY (81) 83 54 10 18

[email protected]

(9) FORM NO. L-21070-C-0702

REPLACEMENT PROCEDURE–FRICTION FACINGS

1. Remove the four Socket Head Cap Screws (Item

15) and separate the two halves of the FMCB (See

Figure 8).

2. Remove the six old Flat Head Screws (Item 12) and

the first old Friction Facing (Item 11) (See Figure 9).

3. Align the holes in the Splined Disc (Item 9) with the

Flat Head Screws (Item 12) that secure the second

split Friction Facing (Item 13) (See Figure 9).

4. Remove the six old Flat Head Screws (Item 12) and the

second old Friction Facing (Item 13) (See Figure 9).

5. Install the first new split Friction Facing (Item 13) and

new Flat Head Screws (Item 12).

6. Tighten the six new Flat Head Screws (Item 12) to 36

in-lbs (4.0 N-m) torque.

7. Install the second new Friction Facing (Item 11) and

new Flat Head Screws (Item 12) (See Figure 9).

8. Tighten the six new Flat Head Screws (Item 12) to 36

in-lbs (4.0 N-m) torque.

9. Apply a drop of Loctite®242 to the threads of the

Socket Head Cap Screws (Item 15) (See Figure 8).

10. Install and tighten the four Socket Head Cap Screws

securing the two halves of the FMCB to 509 in-lbs

(57.5 N-m) torque.

FIGURE 8

FIGURE 9

Insert screwdriver

to remove second

split Friction Facing.

SETSCREW

(Item 35)

SOCKETHEAD CAP SCREW

(Item15)

DIST. AUTORIZADO

MEX (55) 53 63 23 31

QRO (442) 1 95 72 60

MTY (81) 83 54 10 18

[email protected]

FORM NO. L-21070-C-0702 (10)

FMCB 1625

NOTE: Refer to Figure 10.

1. Remove the four Socket Head Cap Screws (Item 8)

and slide the Female Pilot (Item 1), Bearing (Item 2),

and the Drive Disc (Item 4) out of the FMCB.

2. Remove the Retaining Ring (Item 6).

3. Press the Drive Disc (Item 4) out of the Bearing (Item 2)

and the Female Pilot (Item 1).

4. Remove the Retaining Ring (Item 3).

5. Fully supporting the Female Pilot (Item 1), press the

old Bearing (Item 2) out of the Female Pilot (Item 1) .

6. Clean the bearing bore of the Female Pilot (Item 1)

with fresh safety solvent, making sure all old Loctite®

residue is removed.

7. Apply an adequate amount of Loctite®680 to evenly

coat the outer race of the new Bearing (Item 2).

8. Carefully align the outer race of the new Bearing (Item

2) with the bore of the Female Pilot (Item 1).

9. Supporting the Female Pilot (Item 1) and pressing on

the outer race of the new Bearing (Item 2), press the

new Bearing into the Female Pilot.

10. Reinstall the Retaining Ring (Item 3).

11. Support the inner race of the new Bearing (Item 2) and

press the Drive Disc (Item 4) into the new Bearing

(Item 2) and the Female Pilot (Item 1).

12. Reinstall the Retaining Ring (Item 6).

13. Apply a drop of Loctite®242 to the threads of the

Socket Head Cap Screws (Item 8).

14. Slide the Female Pilot (Item 1), Bearing (Item 2), and

Drive Disc (Item 4) into the FMCB and reinstall the four

Socket Head Cap Screws (Item 8).

15. Tighten the four Socket Head Cap Screws (Item 8) to

509 in-lbs (57.5 N-m).

FIGURE 10

REPLACEMENT PROCEDURE–FEMALE PILOT BEARING

Always wear safety goggles when working

with spring or tension loaded fasteners

or devices, such as the retaining rings.

WARNING

Do not reuse the bearing. Applying force to the inner

bearing race to remove a bearing held by the outer

race causes damage to the bearing.

NOTE

DIST. AUTORIZADO

MEX (55) 53 63 23 31

QRO (442) 1 95 72 60

MTY (81) 83 54 10 18

[email protected]

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