Nexen AIR CHAMP WCB230 Series Bedienungsanleitung

(i)

Water Cooled Brake

Series WCB230

FORM NO. L-20163-B-0601

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---------------------------------------------------------------------------------------------------------------------------------2

Lubrication----------------------------------------------------------------------------------------------------------------------------------------- 3

Cooling Water Connections ---------------------------------------------------------------------------------------------------------------3

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

Parts Replacement ----------------------------------------------------------------------------------------------------------------------------5

Replacement Parts ----------------------------------------------------------------------------------------------------------------------------7

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

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

1FORM NO. L-20163-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,

Intermediate Water Jacket Assembly, and two

Friction Disc.

FIGURE 1

Remove

Socket

Head Cap

Screw.

Remove Socket

Head Cap Screw.

MACHINE PREPARATION

Drill mounting holes in machine surface (See Fig, 2 for

mounting hole pattern).

CAUTION

Machine shaft must be perpendicular

to mounting surface to within 0.002"

[0.05 mm] and centered within mounting

bolt pattern within 0.004" [0.10 mm].

14.96" [380 mm] Dia. Bolt

Circle (6) 21/32 [16.5 mm]

Dia. Holes

45o

45o45o

45o

22o 30'

FIGURE 2

MOUNTING CB230

1. Insert key into machine shaft keyway.

2. Slide Hub onto machine shaft until back of

Hub is approximately 1.38" [35 mm] from machine

mounting surface.

2FORM NO. L-20163-B-0601

TABLE 1

WCB230 Use Piston

2084 ft. lbs. “L” + “S”

1393 ft. lbs. “L”

725 ft. lbs. “S”

Note: Torque Ratings Based on 80 P.S.I.

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, Intermediate Spacer

Ring, and Intermediate Housing over Hub and

machine shaft (See Fig. 3).

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.

6. Insert Cap Screws into counter sunk holes in Water

Jacket Flange, and secure Water Jacket Flange to

machine mounting surface.

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

torque.

8. Position first Friction Disc on Hub.

Water Outlets Water Jacket

Flange

Spacer Ring

Cylinder

Assembly

Intermediate

Housing

FIGURE 3

9. Position first Pressure Water Jacket in place on

Torque Pins.

10. Position second Friction Disc on Hub.

11. Slide Cylinder Assembly into position, aligning holes

in Cylinder Assembly with holes in Water Jacket

Assembly and machine mounting surface.

12. Tighten four remaining Socket Head Cap Screws

securing Cylinder Assembly to Water Jacket

Assembly and machine to 184 ft. lbs. torque.

AIR CONNECTIONS

All Nexen pneumatically actuated devices require clean

lubricated air for maximum performance and long life.

Your local Nexen distributor carries filters, regulators,

and lubricators specifically designed to operate with

Nexen products.

For quick response, short air lines between the control

valve and the WCB Brake are recommended. Where

long air lines are required, a Quick Exhaust Valve

(Nexen Product No. 945100) is recommended to

ensure rapid disengagement.

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. 4).

The Dual Piston design of the WCB Brake allows

multiple torque ranges (See Table 1).

"S" "L"

FIGURE 4

3FORM NO. L-20163-B-0601

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.

WCB230 10.4 G.P.M. 40 L.P.M.

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 oil drops 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.

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. 5).

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 54oF.

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

erature does not exceed 108oF. [50oC.] (135oF. [65oC.]

Maximum).

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

material.

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

FIGURE 5

Water Inlets

Water Outlets

4FORM NO. L-20163-B-0601

TROUBLESHOOTING

Symptom Probable Cause Remedy

Failure to Engage Air not getting to WCB Air pressure too low-

Check for controlvalve malfunction

Air leak in WCB Defective or broken O-rings-

Replace O-ring seals.

Friction Disc binding on Hub Lack of lubrication on Hub-

Hub must be lubricated.

Rigid pipe or tubing used for air lines Flexible tubing must be used for air

lines.

Failure to Disengage Unexhausted air Check controls and air lines for

restrictions

Friction Disc binding on Hub Lack of lubrication on Hub-

The Hub musbe lubricated.

Broken or weak Return Springs Replace Return Springs.

Overheating Shortage of cooling water Inspect water lines. Replace if defec

tive.

Inspect water flow controls. Replace if

defective.

Water Jacket restricted by scale Flush Water Jacket with automotive

radiator cleaner.

Loss of torque Worn Friction Facing Inspect Friction Facing and replace

when space between Cylinder and

Water Jacket Pressure Assembly is

less than 0.70 [18 mm] (See Fig. 6).

Measure Gap between

Cylinder and Water Jacket

Pressure Assembly.

FIGURE 6

5FORM NO. L-20163-B-0601

PARTS REPLACEMENT

FRICTION DISC

1. Remove four Socket Head Cap Screws (Item 25)

and two Socket Head Cap Screws (Item 24) (See

Fig. 7)

2. Separate all WCB components from Water Jacket

Flange (Item 23).

3. Slide First Friction disc closest to Water Jacket

Flange off Hub.

4. Lubricate Hub (Item 16) spline with Never-Seez or

equivalent.

5. Install first Friction Disc (Item 17) closest to Hub.

6. Starting at the Water Jacket Flange end of WCB,

replace all components up to and including the

Intermediate Housing (Item 19).

7. Install Second Friction Disc (Item 17).

8. Replace remaining WCB components.

Water Jacket

Flange

Remove two

Socket Head

Cap Screws

(one per side).

Remove four

Socket Head

Cap Screws

(two per side).

FIGURE 7

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. 8).

2. Remove Pressure Water Jacket Assembly (Item 10)

from Cylinder assembly (See Fig. 8).

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

Cylinder Assembly (See Fig. 8).

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. 8).

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. 8).

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.

6758910 14 15

FIGURE 8

9. Tighten Socket Head Cap Screws (Items 24 & 25)

to 184 ft. lbs. torque.

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

torque.

6FORM NO. L-20163-B-0601

1. Disassemble WCB Brake and remove Water Jacket

(Pressure) (Item 10) and Water Jacket (Intermediate)

(Item 21) from machine.

2. Remove Button Head Cap Screws (Item 27) and

Hex. Nuts (Item 28) securing Copper Plate (Item 13)

to Water Jacket (Item 10 & 21) and Copper Plates

(Item13 & 20) to Water Jacket (Item 10 & 21) (See

Fig. (9).

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

4. Clean surface of Water Jacket (Item (10 & 21).

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 & 20) and secure

with Button Head Cap Screws (Item 27) and Nuts

(Item 28).

PRESSURE WATER JACKET (Item 10) & INTERMEDIATE WATER JACKET (Item 22) O-RING REPLACEMENT

WATER JACKET (Flange) O-RING REPLACEMENT

1. Disassemble WCB Brake and remove Water Jacket

(Flange) (Item 23) from machine.

2. Remove Button Head Cap Screws (Item 27) and

Hex. Nuts (Item 29) securing Copper Plate (Item 13)

to Water Jacket (Item 23) (See Fig. (10).

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

4. Clean surface of Water Jacket (Item (23).

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 27) and Nuts

(Item 28).

11 12

10/21

13/20

FIGURE 9

FIGURE 10

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

torque.

8. Pressure test Water Jacket for leaks.

9. Reassemble WCB Brake.

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

torque.

8. Pressure test Water Jacket for leaks.

9. Reassemble WCB Brake.

7FORM NO. L-20163-B-0601

ITEMITEM

ITEM DESCRIPTIONDESCRIPTION

DESCRIPTIONDESCRIPTION

DESCRIPTION QTY.QTY.

QTY.QTY.

QTY.

1 Cylinder 1

2 Torque Pin 4

3 Lock Nut 4

4 Piston (Large) 1

5 Piston (Small) 1

6 O-Ring 1

7 O-Ring 1

8 O-Ring 1

9 O-Ring 1

10 Water Jacket (Pressure) 1

11 O-Ring 4

12 O-Ring 4

13 Copper Plate 2

14 Spring 2

ITEMITEM

ITEM DESCRIPTIONDESCRIPTION

DESCRIPTIONDESCRIPTION

DESCRIPTION QTY.QTY.

QTY.QTY.

QTY.

15 Shoulder Screw 2

16 Hub 1

17 Friction Disc 2

18 Housing 1

19 Housing (Intermediate) 1

20 Copper Plate 2

21 Water Jacket (Intermediate) 1

22 Spacer Ring 1

23 Water Jacket (Flange) 1

24 Cap Screw 2

25 Cap Screw 4

26 Cap Screw 2

27 Button Head Cap Screw 244

28 Hex. Nut (Not Shown) 244

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.

PARTS LIST

FIGURE 11

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