Nexen AIR CHAMP 1625 Bedienungsanleitung

FORM NO. L-21070-E-0614

FLANGE MOUNTED CLUTCH BRAKE

Model 1625

AIR CHAMP PRODUCTS

FORM NO. L-21070-E-0614

Nexen Group, Inc.

560 Oak Grove Parkway

Vadnais Heights, Minnesota 55127

ISO 9001 Certiﬁed

This document is the original, non-translated, version.

Conformity Declaration: In accordance with Appendix II B of CE Machinery Directive (2006/42/EC):

A Declaration of Incorporation of Partly Completed Machinery evaluation for the applicable EU directives was

carried out for this product in accordance with the Machinery Directive. The declaration of incorporation is set

out in writing in a separate document and can be requested if required.

This machinery is incomplete and must not be put into service until the machinery into which it is to be

incorporated has been declared in conformity with the applicable provisions of the Directive.

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, cause injury or death. Comply with

all applicable codes.

DANGER

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

are subject to change without notice. Technical data listed in this manual are based on the latest information 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

FORM NO. L-21070-E-0614

Table of Contents

General Speciﬁcations -------------------------------------------------------------------------------------------------------------------------- 4

General Safety Precautions ------------------------------------------------------------------------------------------------------------------- 4

Installation ------------------------------------------------------------------------------------------------------------------------------------------- 5

Lubrication ------------------------------------------------------------------------------------------------------------------------------------------- 6

Operation --------------------------------------------------------------------------------------------------------------------------------------------- 6

Air Connections ----------------------------------------------------------------------------------------------------------------------------------- 7

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

Replacement Procedure:

Friction Facings --------------------------------------------------------------------------------------------------------------------------------- 9

Female Pilot Bearing ------------------------------------------------------------------------------------------------------------------------ 10

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

Male Pilot Bearings -------------------------------------------------------------------------------------------------------------------------- 12

Input Unit ---------------------------------------------------------------------------------------------------------------------------------------- 13

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

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

FORM NO. L-21070-E-0614

GENERAL SPECIFICATIONS

GENERAL SAFETY PRECAUTIONS

CAUTION

Use lifting aids and proper lifting

techniques when installing, removing,

or placing this product in service.

CAUTION

Watch for sharp features when

interacting with this product. The parts

have complex shapes and machined

edges.

WARNING

This product is capable of emitting

a spark if misused, therefore it is not

recommended for use in any explosive

environment.

Speciﬁcations

Max Static Clutch Torque 2000 in-lb (226 Nm)

Max Static Brake Torque 2400 in-lb (271 Nm)

Actuation Pressure 1 - 80 psi

Service Temperature 4.5 - 104 C (40 - 220 F)

Approximate Weight 148 lbs (67 kg)

CAUTION

Use appropriate guarding for moving

components. Failure to guard could

result in serious bodily injury.

WARNING

Ensure proper guarding of the product is

used. Nexen recommends the machine builder

design guarding in compliance with OSHA 29

CFR 1910 “Occupational Safety and Health

Hazards”.

CAUTION

This product has possible pinch

points. Care should be taken when

interacting with this product.

CAUTION

Use appropriate guarding for moving

components. Failure to guard could

result in serious bodily injury.

CAUTION

The temperature limits for the

product are 4.5-104 degree

Celsius (40-220 degree F).

CAUTION

This product has possible pinch

points. Care should be taken when

interacting with this product.

FORM NO. L-21070-E-0614

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 1) to the motor face using

Nexen supplied socket head cap screws. Tighten cap screws

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

4. Tighten the Set Screw (Item 35) to 175 in-lbs (20 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).

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

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 175 in-lbs (20 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

INPUT

UNIT

19 35

FEMALE PILOT

ASSEMBLY

MOUNTING FOOT

(ITEM 28)

FMCB

ASSEMBLY

MOUNTING FOOT

(ITEM 38)

FIGURE 2

MOTOR

CUSTOMER

SUPPLIED KEY

SET SCREWS

(Item 35)

FMCB

.500-13 SOCKET

HEAD CAP SCREWS

HOUSING

GUARD

(Item 34)

FEMALE PILOT

(Item 1)

GEAR

REDUCER

Key

(Item 33)

SECTION C: OPTIONAL INPUT UNIT AND FEET

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

the FMCB, and secure it using the provided fasteners.

MOTOR

CUSTOMER

SUPPLIED KEY

SET SCREWS

(Item 35) HOUSING

(Item 7)

FMCB

.500-13 SOCKET

HEAD CAP SCREWS

CAP SCREWS

(Item 8)

HOUSING

GUARD

(Item 34)

FEMALE PILOT

(Item 1)

FIGURE 1

FORM NO. L-21070-E-0614

NOTE

Nexen pneumatically actuated devices require clean, pressure regulated air for maximum performance and life.

All seals in Nexen Pneumatically operated devices are lubricated for life and do not require additional lubrication.

However, some customers prefer to use an air line lubricator, which injects oil into the pressurized air, forcing an

oil mist into the air chamber. This is acceptable, but care must be taken to ensure once an air mist lubrication

system is used, it is continually used over the life of the product as the oil mist may wash free the factory

installed lubrication.

Locate the lubricator above and within ten feet of the product, and use low viscosity oil such as SAE-10.

Synthetic lubricants are not recommended.

Nexen product's bearings are shielded and pre-lubricated, and require no further lubrication.

LUBRICATOR DRIP RATE SETTINGS

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

2. Turn the Lubricator Adjustment Knob counterclockwise

three complete turns.

3. Open the air line.

LUBRICATION

CAUTION

These settings are for Nexen supplied

lubricators. If you are not using a Nexen

lubricator, calibration must follow the

manufacturer's suggested procedure.

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 clockwise until

closed.

7. Turn the Lubricator Adjustment Knob counterclockwise

one-third turn.

8. Open the air line to the unit.

WARNING

Never exceed maximum operating

speeds listed for your product.

(See Table 1).

OPERATION

TABLE 1

Size Max RPM

FMCB-1625 1800

CAUTION

The temperature limits for this

product line are 4.5-104 Degree

Celsius (40-220 Degree F).

WARNING

Ensure proper guarding of the product is used.

Nexen recommends the machine builder

design guarding in compliance with OSHA 29

CFR 1910 “Occupational Safety and Health

Hazards”.

CAUTION

Never exceed life of facing material. Facing

life depends on the volume of material and

the total energy over the life of the unit.

Expected life (in hrs) can be found by:

Time=Volume/(Power*Wear Rate).

FORM NO. L-21070-E-0614

3/2 (3 Way) 4/2 (4 Way)

5/2 (4 Way) 5/2 (5 Way)

AIR CONNECTIONS

NOTE

For quick response, Nexen recommends a quick exhaust

valve and short air lines between the Control Valves and

the product. Align the air inlet ports to a down position

to allow condensation to drain out of the air chambers of

the product.

CAUTION

Low air pressure will cause slippage and

overheating. Excessive air pressure will

cause abrupt starts and stops, reducing

product life.

All Nexen pneumatically actuated devices require clean

and dry air, which meet or exceeds ISO 8573.1:2001

Class 4.4.3 quality.

Air Pressure (Gage) Limits

6.9 Bar (100 PSI) Absolute Max.

0 Bar (0 PSI) Absolute Min.

The following are common air supply schemes used with

this product. These are examples and not an all-inclusive

list. All air circuits to be used with this product must be

designed following EN983 guidelines.

FORM NO. L-21070-E-0614

MOTPMYS ESUACELBABORP NOITULOS

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enilpstfahSbutSetacirbuL

.slaeSgnir-Oehtdnuoraskaelri

slaeSgnir-OehtecalpeR

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evlavlortnocaoteudriadetsuahxenU

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dnanoitcnuflamevlavlortnocarofkcehC

.yrassecenfievlavlortnocehtecal

per

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enilpstfahSbutSetacirbuL

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.sgnicaFnoitcirFytridronro

sgnicaFnoitcirFehtecalpeR

TROUBLESHOOTING

AIR

CHAMBER

MALE

PILOT

O-RING

SEALS

SPLINED

DISC

SPRING

HOUSING

SET

SCREW

FEMALE

PILOT

BALL

BEARING

FRICTION

FACING

DISC

DRIVE

AIR TO

BRAKE

AIR TO

CLUTCH

BALL

BEARING

PISTON

KEY

BALL

BEARING

STUB

SHAFT

FIGURE 4

FORM NO. L-21070-E-0614

REPLACEMENT PROCEDURE–FRICTION FACINGS

Refer to Figures 5 and 6.

1. Remove the four Socket Head Cap Screws (Item 15) and

separate the two halves of the FMCB.

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

old Friction Facing (Item 11).

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).

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

second old Friction Facing (Item 13).

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 71 in-lbs

(8.02 N-m) torque.

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

Head Screws (Item 12).

8. Tighten the six new Flat Head Screws (Item 12) to 71 in-lbs

(8.02 N-m) torque.

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

Head Cap Screws (Item 15).

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 5

SET SCREW

(Item 35)

SOCKET HEAD CAP SCREW

(Item 15)

FIGURE 6

Insert screwdriver

to remove second

split Friction Facing.

FORM NO. L-21070-E-0614

FMCB-1625

NOTE: Refer to Figure 7.

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).

REPLACEMENT PROCEDURE–FEMALE PILOT BEARING

FIGURE 7

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

CAUTION

Working with spring loaded or tension

loaded fasteners and devices can cause

injury. Wear safety glasses and take the

appropriate safety precautions.

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