Nexen AIR CHAMP TCB-7 Bedienungsanleitung

(i)

Tension Control Brake

Model TCB-7

FORM NO. L-20169-D-0501

AIR CHAMP PRODUCTS

User Manual

(ii)

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

Nexen Group, 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.

WARNING

(iii)

TABLE OF CONTENTS

Introduction---------------------------------------------------------------------------------------------------------------------------------------- 1

Installation ---------------------------------------------------------------------------------------------------------------------------------------- 2

Air Connections --------------------------------------------------------------------------------------------------------------------------------- 3

Operation ------------------------------------------------------------------------------------------------------------------------------------------ 3

Maintenance -------------------------------------------------------------------------------------------------------------------------------------- 3

Troubleshooting---------------------------------------------------------------------------------------------------------------------------------- 4

Parts Replacement ----------------------------------------------------------------------------------------------------------------------------- 4

Replacement Parts ----------------------------------------------------------------------------------------------------------------------------- 6

Parts List ------------------------------------------------------------------------------------------------------------------------------------------- 7

Accessories --------------------------------------------------------------------------------------------------------------------------------------- 7

Warranties ----------------------------------------------------------------------------------------------------------------------------------------- 8

1FORM NO. L-20169-D-0501

INTRODUCTION

Read this manual carefully, making full use of its explanations and instructions. The “Know How” of safe, continuous,

trouble-free operation depends on the degree of your understanding of the system and your willingness to keep all

components in proper operating condition. Pay particular attention to all NOTES, CAUTIONS, and WARNINGS to avoid

the risk of personal injury or property damage. It is important to understand that these NOTES, CAUTIONS, and

WARNINGS are not exhaustive. Nexen cannot possibly know or evaluate all conceivable methods in which service may

be performed, or the possible hazardous consequences of each method. Accordingly, anyone who uses a procedure

that is not recommended by Nexen must first satisfy themselves that neither their safety or the safety of the product will

be jeopardized by the service method selected.

Per OSHA regulations, Nexen recommends using a guard that will not restrict the flow of cooling

air around the unit if the unit has rotating parts. Contact your local Nexen Distributor for

information about guards designed for the Nexen TCB-7.

2FORM NO. L-20169-D-0501

INSTALLATION

Do not flange mount the TCB-7. Flange

mounting will result in damage to the TCB-7

Housing.

1. Insert the Nexen supplied Key (Item 6) into the

machine shaft (See Figure 1).

2. Slide the TCB-7 onto the machine shaft (See Figure 1).

3. Tighten Set Screws (Item 3) to 7 Ft. Lbs. [9.5 N•m]

torque (See Figure 1).

NOTE: Runout of the Friction Disc Hub (Item 2)

must be less than 0.015'' [0.381 mm] TIR.

Runout is minimized if a dial indicator is used

as Set Screws (Item 3) are tightened. Place

contact tip of dial indicator on machined

surface of Friction Disc Hub to measure

runout.

4. Using the Flat Head Screw (Item 10) provided with

the Friction Facing (Item 9), secure a Friction Facing

to each Caliper Assembly.

5. Using the Spacers (Item 5), Lock Washers (Item 18),

and Socket Head Cap Screws (Item 19), secure

Caliper Assemblies to Housing (Item 1) (See Figure 2).

6. Tighten Socket Head Cap Screws (Item 19) to 27 Ft.

Lbs. [36.4 N•m] torque.

NOTE: The TCB-7 is designed to be held from

rotation by an arm or a linkage sufficient to

prevent rotation, but loose enough to avoid

thrust loads on the bearing or brake housing.

7. Using a customer supplied 5/16 UNC Cap Screw,

secure a Torque Arm to the TCB-7 to prevent

rotation of the TCB-7 (See Figure 3).

Key

(Item 6)

FIGURE 1

Housing

(Item 1) Spacer

(Item 5)

Lock Washer

(Item 18)

Socket Head

Cap Screw

(Item 19)

FIGURE 2

Torque Arm

Anchoring

Points

FIGURE 3

Set Screw

(Item 3)

3FORM NO. L-20169-D-0501

Never exceed the maximum operating speed

of 4000 RPM. Before placing TCB-7 into

service, check that the Socket Head Cap

Screws (Item 19) are tightened to 27 Ft. Lbs.

[36.4 N•m] torque (See Table 1).

AIR CONNECTIONS

1. Install a Elbow Fitting (Item 15) into one Caliper

Assembly (See Figure 4).

2. Install the Tee Fittings (Item 16) into the remaining

Caliper Assemblies (See Figure 4).

3. Cut the Air Line (Item 17) to length and push it into

the Elbow and Tee Fittings (Items 15 and 16) (See

Figure 4).

4. Connect the remaining length of Air Line to the

control output port or connection (See Figure 4).

5. Connect the air supply to the control input port or

connection (See Figure 4).

OPERATION

For optimum brake operation, connect the controls as

close to the TCB-7 as possible. Nexen Manufacturing

recommends the installation of a filter in the Air Line

ahead of the control.

For automatic tension control, use Nexen’s Electronic

Tension Control System. Contact your local Horton Web

Handling distributor or representative for information

concerning this product.

MAINTENANCE

Inspect all cap screws and set screws on a routine basis

to make sure they are tightened to the recommended

torque.

Tee

Fitting

(Item 16)

Air Line

(Item 17)

Elbow

Fitting

(Item 15)

FIGURE 4

To Control

Inspect Friction Facings and replace them when worn to

approximately 5/32" [4 mm] thick.

4FORM NO. L-20169-D-0501

TROUBLESHOOTING

PARTS REPLACEMENT

FRICTION FACINGS

1. Stop the machine and shut off the air supply to

the TCB-7.

2. Disconnect the Air Lines.

a. To disconnect the Air Line, push in on the

collar of the fitting and pull the Air Line out

(See Figure 5).

b. To reconnect the Air Line, push it into the

fitting until it stops.

3. Remove the Socket Head Cap Screws (Item 19) and

Lock Washers (Item 18) (See Figure 6).

4. Remove the Caliper Assembly from the Housing.

5. Remove the Flat Head Screw (Item 10) from the back

of the Caliper Assembly and remove the old Friction

Facing (Item 9) (See Figure 7).

6. Install a new Friction Facing (Item 9) and secure it to

the Caliper Assembly with a new Flat Head Screw

(Item 10). Tighten the Flat Head Screw to 18-19 In.

Lbs. [2.0-2.1 N•m].

7. Place the Caliper Assembly in position and secure it

to the Housing with the Socket Head Cap Screws

(Item 19) and Lock Washers (Item 18) (See Figure 6).

8. Tighten the Socket Head Cap Screws (Item 19) to

27 Ft. Lbs. [36.4 N•m] torque.

9. Reconnect the Air Lines.

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Lock Washer

(Item 18)

Socket Head

Cap Screw

(Item 19)

FIGURE 5

FIGURE 6

Flat Head

Screw

(Item 10)

Friction Facing

(Item 9)

FIGURE 7

Push collar in

to release.

Caliper

Assembly

5FORM NO. L-20169-D-0501

DIAPHRAGM

1. Proceed with Steps 1 - 4of PARTS REPLACE-

MENT—FRICTION FACINGS.

2. Remove the six Socket Head Cap Screws (Item 20)

and Cover (Item 13) from the Cylinder (Item 11)

(See Figure 8).

3. Remove Diaphragm (Item 14) (See Figure 8).

NOTE: Internal Compression Springs (Item 41)

may also be removed at this time. These

springs are optional; the low air pressure

setting is more sensitive without the springs

(See Figure 8).

4. Install a new Diaphragm with the rubber (not fabric)

on the air side and reassemble the Caliper

Assembly.

5. Tighten the Socket Head Cap Screws (Item 20) to

5.5 Ft. Lbs. [7.45 N•m] torque (See Figure 8).

6. Proceed with Steps 7 - 9of PARTS REPLACE-

MENT—FRICTION FACINGS.

FIGURE 8

Cylinder

(Item 11)

Diaphragm

(Item 14)

Compression

Spring

(Item 41) Cover

(Item 13) Socket Head

Cap Screws

(Item 20)

6FORM NO. L-20169-D-0501

BEARING REPLACEMENT

1. Proceed with Steps 1 - 4of PARTS REPLACE-

MENT—FRICTION FACINGS.

2. Loosen Set Screws (Item 3) and remove TCB-7

Housing and Rotor from machine shaft (See

INSTALLATION).

Special attention should be exercised when

working with retaining rings. Always wear

safety goggles when working with spring or

tension loaded fasteners or devices.

3. Remove Retaining Ring (Item 7) (See Figure 9).

4. Fully supporting Housing (Item 1), press the Friction

Disc Hub (Item 2) out of the Bearing (Item 4) and

Housing (Item 1) (See Figure 9).

5. Remove the Retaining Ring (Item 8) (See Figure 9).

Housing

(Item 1)

Bearing

(Item 4)

Retaining Ring

(Item 8)

Retaining Ring

(Item 7)

Friction

Disc Hub

(Item 2)

FIGURE 9

6. Fully supporting Housing (Item 1), press the old

Bearing (Item 4) out of the Housing (Item 1) (See

Figure 9).

7. Clean the bearing bore of the Housing with safety

solvent making sure all Loctite®residue is removed.

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

coat the outer race of the new Bearing (Item 4); then,

align the new Bearing with the bore of Housing and

press the new Bearing into place.

9. Install Retaining Ring (Item 8) (See Figure 9).

10. Slide Friction Disc Hub (Item 2) into Bearing (Item 4)

and Housing (Item 1) (See Figure 9).

11. Install Retaining Ring (Item 7) (See Figure 9).

12. Proceed with Steps 7 - 9of PARTS REPLACE-

MENT—FRICTION FACINGS.

13. Install TCB-7 (See INSTALLATION).

REPLACEMENT PARTS

The item or balloon number for all Nexen products is used

for part identification on all product parts lists, product

price lists, unit assembly drawings, bills of materials, and

instruction manuals.

When ordering replacement parts, specify model

designation, item number, part description, and quantity.

Purchase replacement parts through your local Nexen

Distributor.

7FORM NO. L-20169-D-0501

ITEM DESCRIPTION QTY

1 Housing 1

2 Friction Disc Hub 1

3 Set Screw (Not Shown) 3

4 Bearing 1

5 Spacer 2

6 Key (Not Shown) 1

7 Retaining Ring (Ext.) 1

8 Retaining Ring (Int.) 1

9 Friction Facing 3

10 Flat Head Screw 3

11 Cylinder 11

12 Piston 11

13 Cover 11

14 Diaphragm 11

15 Elbow Fitting (Not Shown) 1

16 Tee Fitting (Not Shown) 1

17 Air Line (Not Shown) --

18 Lock Washer (Ext. Tooth) 6

19 Socket Head Cap Screw 6

20 Socket Head Cap Screw 6

21 Spring Pin 21

40 Socket Head Cap Screw 21

41 Compression Spring 21

1Quantity shown is for one (1) Caliper Assembly only.

FIGURE 11

CALIPER ASSEMBLY

174825

See

Figure 11

18 19

FIGURE 10

10 9

40 41 12 11

13 20

PARTS LIST

ACCESSORIES

Per OSHA regulations, Nexen recommends

using a guard that will not restrict the flow of

cooling air around the unit if the unit has

rotating parts. Contact your local Nexen

Distributor for information about guards

designed for the Nexen TCB-7.

FIGURE 12

TCB-7 HOUSING GUARD P/N 835186

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