Nexen Air Champ WCB120 Bedienungsanleitung

(i)

Water Cooled Brakes

Series WCB120 and WCB130

FORM NO. L-20162-B-0601

(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 ---------------------------------------------------------------------------------------------------------------------------------------- 1

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

Lubrication----------------------------------------------------------------------------------------------------------------------------------------- 4

Cooling Water Connections ---------------------------------------------------------------------------------------------------------------4

Troubleshooting --------------------------------------------------------------------------------------------------------------------------------- 5

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

Replacement Parts ----------------------------------------------------------------------------------------------------------------------------8

Parts List -------------------------------------------------------------------------------------------------------------------------------------------8

Warranties-----------------------------------------------------------------------------------------------------------------------------------------9

1FORM NO. L-20162-B-0601

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.

Nexen’s double piston design WCB Series brakes provide a wide range of precision torque control in an air actuated,

water cooled brake. A special water jacket design with copper alloy disc produces high thermal horsepower.

The special copper alloy disc and friction facing are engineered for constant slip applications, thus providing extended

life and stable slip torque, while the multiple disc feature allows increased torque capacity in a compact unit.

A copper membrane coats the surface of the water path in the water jacket to prevent rust and extend the life of the

brake.

INSTALLATION

WCB PREPARATION

1. Remove two Socket Head Cap Screws from Main

Body (See Fig. 1).

2. Disassemble WCB into the following components;

Water Jacket Flange, Cylinder Assembly, Hub, and

Friction Disc (See Fig. 2).

FIGURE 1

Remove Socket

Head Cap Screw

Remove

Socket

Head Cap

Screw.

FIGURE 2

Cylinder

Assembly

Friction

Disc Hub

Water Jacket

Flange

2FORM NO. L-20162-B-0601

MACHINE PREPARATION

Drill mounting holes in machine surface (See Figs. 3 & 4

for mounting hole pattern).

FIGURE 3

WCB120 Mounting Bolt Pattern FIGURE 4

WCB130 Mounting Bolt Pattern

CAUTION

Machine shaft must be perpendicular

to mounting surface to within 0.002"

[0.05mm] and centered within mounting

bolt pattern within 0.004" [0.10 mm].

11.02" [280 mm]

dia. Bolt circle

(4) 9/16 [14.2 mm]

dia. holes

14.96" [380 mm]

dia. Bolt circle

(6) 21/32 [16.5 mm]

dia. holes

MOUNTING WCB120

1. Insert key into machine shaft keyway.

2. Slide Hub onto machine shaft until back of Hub is

approximately 1.34" [34 mm] from machine

mounting surface (See Fig. 5).

3. Tighten customer supplied set screws securing Hub

to machine shaft to torque recommended by set

screw vendor.

NOTE: Set screws must be flush with Hub or

slightly recessed into Hub to avoid damage

to WCB Brake.

4. Apply Never-Seez® or equivalent anti-seize lubricant

to Hub.

5. Slide Water Jacket Flange over Hub and machine

shaft (See Fig. 5).

CAUTION

Water Jacket outlet must be aligned to

the twelve o’clock up position and inlet

must be aligned to the six o’clock down

position. This alignment eliminates air

pockets and/or hot spots

FIGURE 5

Cylinder

Assembly

Friction

Disc

Water Jacket

Flange

Hub

Water

Outlet

6. Position Friction Disc on Hub (See Fig. 5).

7. Slide Cylinder Assembly into position, aligning holes

in Cylinder Assembly with holes in Water Jacket and

machine mounting surface.(See Fig. 5).

8. Tighten Socket Head Cap Screws securing WCB

Brake to mounting surface to 122 ft. lbs.

3FORM NO. L-20162-B-0601

MOUNTING WCB130

1. Insert key into machine shaft keyway.

2. Slide Hub onto machine shaft until back of Hub is

approximately 1.38" [36 mm] from machine

mounting surface. (See Fig. 6).

3. Tighten customer supplied set screws securing Hub

to machine shaft to torque recommended by set

screw vendor.

NOTE: Set Screws must be flush with Hub or

slightly recessed into Hub to avoid damage

to WCB Brake.

4. Apply Never-Seez®or equivalent lubricant to Hub.

5. Slide Water Jacket Flange over Hub and machine

shaft (See Fig. 6).

CAUTION

Water Jacket outlet must be aligned to

the twelve o’clock up position and the

inlet must be aligned to the six o’clock

down position.

6. Insert Cap Screws (Item 25) into counter sunk holes

in Water Jacket Flange, and secure Water Jacket

Flange to machine mounting surface.

FIGURE 6

Cylinder

Assembly

Friction

Disc

Water Jacket

Flange

Hub

Water

Outlet

7. Tighten two Cap Screws to 184 ft. lbs.torque.

8. Position Friction Disc on Hub (See Fig. 6).

9. Slide Cylinder Assembly into position, aligning holes

in Cylinder Assembly with holes in Water Jacket

Assembly and machine mounting surface (See Fig. 6).

10. Tighten four remaining Socket Head Cap Screws

securing Cylinder Assembly to Water Jacket

Assembly and machine to 184 ft. lbs. torque.

TABLE1

WCB120 WCB130 Use Piston

350 ft. lbs. 1042 ft. lbs. “L” + “S”

233 ft. lbs. 692 ft. lbs. “L”

117 ft. lbs. 350ft. lbs. “S"

"S" "L"

FIGURE 7

AIRCONNECTIONS

All Nexen pneumatically actuated devices require clean

lubricatedair for maximum performance andlonglife. Your

local Horton distributor carries filters, regulators, and lubri-

cators specifically designed to operate with Nexen prod-

ucts.

Forquickresponse,shortairlinesbetweenthecontrolvalve

and the WCB Brake are recommended.

NOTE: Do not use rigid pipe or tubing when making air

connections to the WCB Brake.

Air inlets for the WCB Brake’s “S” Piston and “L” Piston

are located in the Air Chamber and are tapped 1/4

NPT (See Fig. 7).

The Dual Piston design of the WCB Brake allows multiple

torque ranges (See Table 1).

4FORM NO. L-20162-B-0601

LUBRICATION

The most effective and economical way to lubricate the

WCB Brake’s air chamber is with an air line lubricator.

Available from Nexen, the lubricator injects oil into the

pressurized air, forcing a constant oil mist into the air

chamber.

Lubricator drip rate is properly set when an oil drop

starts to form in the sight gage every time the WCB

Brake is cycled or one full drop every twenty cycles.

Locate lubricator above and within ten feet of the WCB

Brake.

For WCB Brakes that are cycled infrequently, apply two

or three drops of oil into the air inlet ports every two

weeks.

Synthetic lubricants are not recommended,

use a low viscosity petroleum base oil such

as SAE-10.

To determine the proper flow of cooling water, use the

following formula:

6.8 (HP)

GPM min = TO- T1

Where: GPM min = Minimum gallons per min required

HP = Thermal horsepower requirement

TO= Outlet water temperature

T1= Inlet water temperature

Insufficient water flow will cause the WCB

Brake to overheat, resulting in excessive

friction facing wear, loss of torque, excessive

friction surface wear and O-ring damage.

Refer to Table 2 for recommended cooling

water flow.

TABLE 2

MAX. RECOMMENDED COOLING WATER FLOW

WCB BRAKE GALLONS PER MIN. LITERS PER MIN.

WCB120 2.6 G.P.M. 10 L.P.M.

WCB130 5.3 G.P.M. 20 L.P.M.

COOLING WATER CONNECTIONS

Water inlet and outlet ports for the WCB Brake are

located in the Pressure Water Jacket and Flange Water

Jacket. To assure that the WCB Brake is filled with

water at all times the water must enter at the bottom and

discharge at the top (See Fig. 8).

NOTE: Use flexible hose for water lines and route water

lines to insure equal flow to inlet and outlet

ports. The use of rigid pipe or tubing will

prevent proper WCB Brake actuation.

Headers installed in the inlet and outlet ports

must be of a type that provide equal flow at

ports.

Water inlet temperature should be approximately 68oF.

[20oC.] or lower and controlled so that the outlet

temperature does not exceed 120oF. [50oC.] (148oF.

[65oC.] Maximum).

Use clean water free from rust, dust, or other corrosive

material.

FIGURE 8 Water Inlet

Water Outlet

5FORM NO. L-20162-B-0601

TROUBLESHOOTING

Air not getting to WCB

Air leak in WCB

Friction Disc binding on Hub

Rigid pipe or tubing used for air lines

Unexhausted air due to faulty control

or restricted air line

Friction Disc binding on Hub

Broken or weak Return Springs

Shortage of cooling water

Water Jacket restricted by scale or

rust

Worn Friction Facing

Measure Gap between

Cylinder and Water Jacket

Pressure Assembly

FIGURE 9

SYMPTOM PROBABLE CAUSE REMEDY

Failure to Engage

Failure to Disengage

Overheating

Loss of torque

Air pressure too low-

Check for control valve malfunction.

Defective or broken O-rings-

Replace O-ring seals.

Lack of lubrication on Hub- Hub must

be lubricated.

Flexible tubing must be used for air

lines.

Check controls and air lines for

restrictions.

Lack of lubrication on Hub-

Hub must be lubricated.

Replace Return Springs.

Inspect water lines. Replace if

defective.

Inspect water flow controls. Replace

if defective.

Flush Water Jacket with automo-

tive radiator cleaner.

Inspect Friction Facing and replace

when space between Cylinder and

Water Jacket Pressure Assembly is

less than 0.55" [14 mm] for WCB120

and 0.63" [16 mm] for WCB130 (See

Fig. 9).

6FORM NO. L-20162-B-0601

Cylinder

Assembly

FIGURE 11

FIGURE 10

Remove Socket Head

Cap Screws (Item 24).

PARTS REPLACEMENT

FRICTION DISC

1. Remove four Socket Head Cap Screws (Item 24)

(See Fig. 10)

2. Separate Cylinder Assembly from Water Jacket

Flange (Item 22) (See Fig. 11).

3. Slide Friction Disc (Item 17) off Hub (Item 16) (See

Fig. 11).

4. Clean and lubricate Hub (Item 16) spline with

Never-Seez® or equivalent (See Fig. 11).

5. Install new Friction Disc.

6. Reverse above procedure to reassemble

WCB120.

7. Tighten four Socket Head Cap Screws (Item 24)

removed in Step 1 to 122 ft. lbs. torque on

WCB120 and 184 ft. lbs. torque on WCB130.

O-RING SEAL REPLACEMENT

1. Remove two Shoulder Screws (Item 15) and

Springs (Item 14) securing Pressure Water Jacket

(Item 10) to Cylinder assembly (See Fig. 12).

2. Remove Pressure Water Jacket Assembly (Item 10)

from Cylinder assembly (See Fig. 12).

3. Separate Large and Small Pistons (Items 4 & 5) from

Cylinder Assembly (See Fig. 12).

4. Remove O-rings (Items 6 & 7) from Large Piston

(Item 4) and O-rings (Items 8 & 9) from Small Piston

(Item 5) (See Fig. 12).

5. Lubricate O-ring grooves of both Pistons and new

O-rings with O-ring lubricant and install new O-rings

into respective grooves of both Pistons (See Fig. 12).

FIGURE 12

7FORM NO. L-20162-B-0601

6. Install Large and Small Pistons (Items 4 & 5) back

into Cylinder Assembly.

7. Secure Pressure Water Jacket (Item 10) to Cylinder

Assembly.

NOTE: Inspect Springs (Item 14) for signs of

fatigue and replace Springs if required.

8. Tighten Shoulder Screws (Item 15) to 9 ft. lbs.

torque.

WATER JACKET (Pressure) O-RING REPLACEMENT

1. Disassemble WCB Brake and remove Water Jacket

(Pressure) (Item 10) from machine.

2. Remove Button Head Cap Screws (Item 26) and

Hex. Nuts (Item 27) securing Copper Plate (Item 13)

to Water Jacket (Item 10) (See Fig. (13).

3. Remove O-rings (Items 11 & 12).

4. Clean surface of Water Jacket (Item (10).

NOTE: Water Jacket coolant path is coated with a

special waterproof paint, if paint is

damaged, repaint coolant path with fresh

waterproof paint.

5. Coat new O-rings with gasket sealant and install

new O-rings.

6. Replace Copper Plate (Item 13) and secure with

Button Head Cap Screws (Item 26) and Nuts

(Item 27).

14 15 13

FIGURE 13

7. Tighten Button Head Cap Screws to 2 ft. lbs.

torque.

8. Pressure test Water Jacket for leaks.

9. Reassemble WCB Brake.

WATER JACKET (Flange) O-RING REPLACEMENT

1. Disassemble WCB Brake and remove Water Jacket

(Flange) (Item 22) from machine.

2. Remove Button Head Cap Screws (Item 26) and

Hex. Nuts (Item 27) securing Copper Plate (Item 19)

to Water Jacket (Item 22) (See Fig. (14).

3. Remove O-rings (Items 19 & 20).

4. Clean surface of Water Jacket (Item (22).

NOTE: Water Jacket coolant path is coated with a

special waterproof paint, if paint is

damaged, repaint coolant path with fresh

waterproof paint.

5. Coat new O-rings gasket sealant and install new

O-rings.

6. Replace Copper Plate (Item 21) and secure with

Button Head Cap Screws (Item 26) and Nuts

(Item 27).

21 19

20 22

FIGURE 14

7. Tighten Button Head Cap Screws to 2 ft. lbs.

torque.

8. Pressure test Water Jacket for leaks.

9. Reassemble WCB Brake.

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