Tension Control Clutches
Contents
1. NINO Valve Quick Exhaust AIR PRESSURE 8 BAR 120 PSI ABSOLUTE MAX O BAR 0 PSI ABSOLUTE MIN TABLE 3 Air Line Specifications Min Bend Radius 0 1560 0 106 3 4 1000 PSI nia 4 mm 2 7 mm 19mm 75 F y Push in the push lock collar and it will release 3 gt the air line Pressure FIGURE 11 Housing Item 8 Air Line cut to length Item 16 Item 15 FIGURE 12 FORM NO L 20069 F 0914 OPERATION Ensure proper guarding of the product iS Never exceed life of facing material Facing used Nexen recommends the machine life depends on the volume of material and builder design guarding in compliance the total energy over the life of the unit with OSHA 29 CFR 1910 Occupa Expected life in hrs can be found by tional Safety and Health Hazards Time V0lume Power Wear Rate DO NOT exceed maximum operating The temperature limits for this productline speed See Table 4 If you exceed are 4 5 104 C 40 220 F maximum operating speeds you may damage or decrease the performance and the life of the Tension Control Clutch TABLE 4 Maximum Operating Speeds Check all screws and fasteners for proper tightening torque BEFORE operating the unit See Table 5 Overtighten ing tightening can cause the screws and fasteners to fail Under tightening can reduce the performance of the Tension Control Clutch TABLE 5 Screw amp Fastene2. 4 Install a Friction Facing Item 9 on each caliper half and secure it with the enclosed Machine Screw Item 10 Tighten the Machine Screw to 18 19 in lbs 2 0 2 1 Nm NOTE Internal springs return the Caliper piston to the disengaged position to guarantee clearance between Friction Facing and Rotor when no air pressure is applied The use of this spring is optional the low air pressure setting is more sensitive without the springs To remove the spring refer to the Replacement Parts List 5 Mount the Friction Facing and Caliper assembly on the Housing Item 1 as directed in either the Straight Bore Rotor Hub assembly instructions or the Taper Bore Rotor Hub assembly instructions Center drill 37 64 Dia x 1 Deep Tap 5 8 18 UNF 2A x 25 32 Deep FIGURE 1 FIGURE 2 Caliper Half Tee Fitting Item 16 FIGURE 3 Caliper Half Machine p Screw Item 10 Friction ed Facing Item 9 FIGURE 4 Caliper Half Lock Washers Item 1 AS Y sf Cap Screw i Item 18 gt Housing FIGURE 5 Item 8 FORM NO L 20069 F 0914 STRAIGHT BORE ROTOR HUB ASSEMBLY Please verify that you are in the correct rotor section for your model This is the Straight Bore Rotor Hub instruction section The instructions for the Taper Bore Rotor Hub are l Lock in the following section Wares Item 19 REFER TO FIGURE 6 C S 1 Slide the Housing Assembly on to the shaft and E tighten the Set Scr
3. Bearing Bearing Item 23 Item 23 Retaining Ring Retaining Item 25 Ring Item 24 FIGURE 17 3 Remove all the caliper assemblies and air lines from the housing assembly 4 Remove the Retaining Ring Item 24 from the Hub Item 30 5 Fully support the Housing Item 8 then press the Hub Item 30 out of the Bearings Item 23 O Use a bearing puller to remove the Bearings Item 23 from the Housing Item 8 7 Clean the bore of the Housing Item 8 with fresh safety solvent Make sure that all of the old Loctite residue is removed 00 Apply Loctite 680 or equivalent to the outer race of the new bearing and press the bearings into the Housing NOTE Carefully align the bearing O D with the Housing bore when you install the bearings 9 Support the bearing inner race then press the Hub Item 30 into the Housing Item 8 10 Reinsert the Retaining Ring Item 24 11 Reinstall the Tension Control Clutch 10 FORM NO L 20069 F 0914 REPLACEMENT PARTS LIST The item or balloon number for all Nexen products is used When ordering replacement parts specify model designa for part identification on all product parts lists product tion item number part description and quantity Purchase price lists unit assembly drawings bills of materials and replacement parts through your local Nexen Distributor instruction manuals N I I 7 I I E 7 OJ NE 227277707223 EA
4. Dial Indicator Model Bushing Tightening Torque FORM NO L 20069 F 0914 FRICTION FACING amp CALIPER ASSEMBLY REFER TO FIGURES 9 10 Friction Machine Facing 1 Place a 1 16 1 6 mm shim between the friction Say Item 9 facings and the Rotor Disc Item 2 As you rotate Item 10 the Rotor Disc past each caliper check for equal clearance at all positions Caliper 2 Use the Machine Screw ltem 10 to secure the Assembly Friction Facing to the caliper and install a Friction Facing Item 9 onto each remaining caliper half Tighten the Machine Screw to 18 19 in lbs 2 0 2 1 Nm FIGURE 9 3 Use Lock Washers Item 19 and Socket Head Cap Screws ltem 18 to attach the caliper halves at each caliper position Tighten the Socket Head Cap Screws to 7 ft lbs 9 5 Nm Tee Fitting 4 Install a Tee Fitting Item 16 or an Elbow Fitting Item 15 into each remaining caliper half FIGURE 10 LUBRICATION NOTE Nexen pneumatically actuated devices require clean pressure regulated air for maximum performance and Hi All seals in Nexen pneumatically operated devices are lubricated for life and do not require additional ubrication 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
5. s current product catalogue or that is accessible at the Nexen website or that is attached to this Quotation and that specifically refers to this Quotation by its number subject in all cases to any limitations and exclusions set out in the drawing NEXEN MAKES NO OTHER WARRANTY EXPRESS OR IMPLIED AND ALL IMPLIED WARRANTIES INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED This warranty applies only if a the Product has been installed used and maintained in accordance with any applicable Nexen installation or maintenance manual for the Product b the alleged defect is not attributable to normal wear and tear c the Product has not been altered misused or used for purposes other than those for which it was intended and d Buyer has given written notice of the alleged defect to Nexen and delivered the allegedly defective Product to Nexen within one year of the date of shipment Exclusive Remedy The exclusive remedy for the Buyer for any breach of any warranties provided in connection with this agreement will be at the election of Nexen a repair or replacement with new serviceably used or reconditioned parts or products or b issuance of credit in the amount of the purchase price paid to Nexen by the Buyer for the Products Agent s Authority Buyer agrees that no agent employee or representative of Nexen has authority to bind Nexen to any affirmation repre
6. 4 4 3
7. Facing squeal or chatter Air pressure too high Reduce air pressure Wrong friction facing for application Check friction facing Noise other than facing squeal Bearing failure Replace bearings Loose fasteners Tighten fasteners Wobble or vibration Improper mounting Remount unit Faulty shaft Replace shaft PARTS REPLACEMENT FRICTION FACING REPLACEMENT REFER TO FIGURES 13 amp 14 Lock 1 Stop the machine and shut off air supply to the unit Washers Item 19 2 Remove the Socket Head Cap Screws ltem 18 and the Lock Washers Item 19 Cap Screw 3 Remove the Caliper Assembly from the Housing Item 8 2 susi Item 8 Item 8 FIGURE 13 4 Remove the Machine Screw Item 10 from back of the Caliper Assembly and remove the Friction Facing Item 9 Friction oti Machine 5 Install the new Friction Facing Item 9 and secure namie o Facing it to the Caliper Assembly with the Machine Screw Item 10 Tighten the Machine Screw to 18 19 In Lbs 2 0 2 1 Nm Item 10 6 Place the Caliper Assembly in position and secure it to the Housing with Socket Head Cap Screws Item 18 and Lock Washers Item 19 FIGURE 14 7 Tighten the Socket Head Cap Screws to 27 ft lbs 36 4 Nm torque 8 FORM NO L 20069 F 0914 PARTS REPLACEMENT continued AIRLINE REPLACEMENT REFER TO FIGURE 15 1 To disconnect an air line first push the fitting collar in and then pull the air line out 2
8. I NSSS poe eee ee minm a HE y SS SS SS SS SSS EST V7 s A 23 ZAZIT fy Mia A IA I _ e MOO MAA f PL TZ EN ZZZ XIZ DESCRIPTION Housing Bearing Retaining Ring Retaining Ring Set Screw Hub Friction Facing Machine Screw Cylinder Piston Hub Cover Rotor Disc Diaphragm Elbow Fitting 90 Tee Fitting Air Line Socket Head Cap Screw Cap Screw Hex Nut Square Key Set Screw Lock Washer 1 Specify taper or straight bore Give diameter of straight Cap Screw bore Spring Pin Cap Screw Compression Spring FORM NO L 20069 F 0914 11 ACCESSORIES FRICTION FACING KITS The Friction Facing kit contains two friction facings of the specific coefficient of friction listed in Table 6 One facing kit is required per Caliper Assembly NOTE Caliper Assemblies and Friction Facing Kits are common to all Tension Control Clutch models When ordering replacement kits specify one Caliper Assembly and Friction Facing Kit for each caliper position 12 TABLE 6 Coefficient ETE LOCO 335113 STD 835112 HICO 835111 FORM NO L 20069 F 0914 WARRANTY Warranties Nexen warrants that the Products will a be free from any defects in material or workmanship for a period of 12 months from the date of shipment and b will meet and perform in accordance with the specifications in any engineering drawing specifically for the Product that is in Nexen
9. To install a new air line push the air line into the fitting until it stops DIAPHRAGM REPLACEMENT REFER TO FIGURE 16 1 Disconnect the air line 2 Remove the Socket Head Cap Screws Item 18 and Lock Washers Item 19 3 Remove the Caliper Assembly from the Housing 4 Remove six Cap Screws Item 20 and the Cover Item 13 from the Cylinder Item 11 5 Remove the Diaphragm Item 14 NOTE Internal Compression Springs Item 41 may also be removed atthis time These springs are optional the low air pressure setting is more sensitive without the springs 6 Reinsert the new Diaphragm Item 14 and reassemble the Caliper 7 Tighten the Cap Screw Item 40 to 22 ft lbs 29 6 Nm and the Cap Screw Item 20 to 5 5 ft lbs 7 4 Nm torque FORM NO L 20069 F 0914 Push in the push lock collar and it will release 3 gt the air line FIGURE 15 Diaphragm Item 14 Cover Item 13 Screw Item 40 Compression Cylinder Spring Item 11 Item 41 l Screw FIGURE 16 mao PARTS REPLACEMENT continued BEARINGS REPLACEMENT Hous ousing REFER TO FIGURE 17 Item 8 Retaining 1 Stop the machine and shut off the air supply to the Ring Tension Control Clutch Item 25 2 Remove the Tension Control Clutch NOTE To remove the Q D bushing remove the Cap Screws then reinsert them into the threaded holes and tighten them to push the Rotor off the Q D bushing
10. ailure to guard could techniques when installing removing or result in serious bodily injury placing this product in service Watch for sharp features when This product is capable of emitting a interacting with this product The parts have complex shapes and machined edges spark if misused therefore is not recommended for use in any explosive environment Ensure proper guarding of the product is used Nexen recommends the machine builder design guarding in compliance with OSHA 29 CFR 1910 Occupa tional Safety and Health Hazards This product has possible pinch points Care should be taken when interacting with this product Surface temperature may exceed safe handling limits during operation Do not touch N NI B ZZZZZ LIZZ 5 F IA TIZZLLULITZAD LL e e This product has possible pinch points Care should be taken when interacting with this product FORM NO L 20069 F 0914 4 CALIPERS AND HOUSING ASSEMBLY REFER TO FIGURES 1 5 1 Drill a 37 64 diameter hole 1 deep and tap 5 8 18 UNF 2A by 25 32 deep into the end of the shaft Install a Rotary Air Union into the shaft NOTE Nexen recommends using a Nexen Rotary Air Union part number 835139 2 Use customer supplied cap screws to fasten the customer supplied sheave or sprocket to the pilot diameter of the Housing Item 8 3 Install either an Elbow Fitting Item 15 or a Tee Fitting Item 16 as required on each caliper half
11. ew Item 26 to the torque Item 18 S recommended in Table 1 gt Housing Item 8 2 Align the Key Item 6 with the Hub keyway and slide FIGURE 6 the Hub and Rotor assembly Items 1 5 onto the shaft Insert the Key Item 6 into the keyway 4 Tighten the Set Screw Item 7 on the Hub Item 1 TABLE1 Tightening Torques to the recommended torque See Table 1 TCC 10 TCC 14 TCC 20 5 Use the Cap Screws ltem 18 and the Lock 23 ft lbs 50 ft lbs 166 ft lbs Washers Item 19 to fasten one half of the Caliper 30 9 Nm 67 5 Nm 224 0 Nm on Item 7 and Friction Facing assembly to the flange side of the Housing Item 8 at each caliper position Housing Set 93 ft lbs 50 ft lbs 166 ft lbs Tighten the Cap Screws to 7 ft lbs 9 5 Nm Screw 30 9 Nm 675 Nm 224 0 Nm Item 26 NOTE Caliper Cap Allow 1 16 16 mm clearance between the Screw a Ne pei a bt friction facings and the Rotor Disc Item 2 Item 18 36 4 Nm 36 4 Nm 36 4 Nm FORM NO L 20069 F 0914 3 Q D TAPER BORE ROTOR HUB ASSEMBLY Please verify that you are in the correct rotor section for your model This is the Q D Taper Bore Rotor Hub section The instructions for the Straight Bore Rotor Hub are in the previous section REFER TO FIGURES 7 8 1 Thoroughly inspect the tapered bore of the splined hub and the tapered surface of the Q D bushing Remove any dirt grease or foreign particles Do not use any lubricants for th
12. hall inspect all shipments of Products upon arrival and shall notify Nexen in writing of any shortages or other failures to conform to these terms and conditions which are reasonably discoverable upon arrival without opening any carton or box in which the Products are contained Such notice shall be sent within 14 days following arrival All notifications shall be accompanied by packing slips inspection reports and other documents necessary to support Buyer s claims In addition to the foregoing obligations in the event that Buyer receives Products that Buyer did not order Buyer shall return the erroneously shipped Products to Nexen within thirty 80 days of the date of the invoice for such Products Nexen will pay reasonable freight charges for the timely return of the erroneously shipped Products and issue a credit to Buyer for the returned Products at the price Buyer paid for them including any shipping expenses that Nexen charged Buyer All shortages overages and nonconformities not reported to Nexen as required by this section will be deemed waived Limitation on Actions No action regardless of form arising out of any transaction to which these terms and conditions are applicable may be brought by the Buyer more than one year after the cause of action has accrued ne gt lt en Nexen Group Inc 800 843 7445 560 Oak Grove Parkway Fax 651 286 1099 Vadnais Heights MN 55127 www nexengroup cor ISO 9001 Certified FORM NO L 20069 F 091
13. is installation Align the untapped holes in the bushing with the tapped holes in the hub and assemble the Q D bushing into the splined hub Insert the pull up bolts with Lock Washers into the Q D bushing and hub and then alternate as you tighten them evenly to the recommended torque See Table 2 Do not use lubricants or thread locking compounds on these bolts or they may tighten beyond the limits noted in Table 2 and the splined hub may burst Place the Key in the shaft keyway slide the rotor assembly onto the motor shaft Alternate as you evenly tighten the pull up bolts to the recommended torque See Table 2 The tightening force on the pull up bolts is multiplied by the wedging action of the tapered surface Do not tighten beyond the limits noted in Table 2 or the splined hub may burst Use a Dial Indicator to minimize run out as you tighten the Q D bushing pull up bolts To measure run out place the contact tip of the Dial Indicator on the machined surface of the Rotor Maximum run out must be less than 0 007 18 mm Use the Cap Screws Item 18 and the Lock Washers Item 19 to fasten one half of the Caliper and Friction Facing assembly to the flange side of the Housing Item 8 at each caliper position Tighten the Cap Screws to 7 ft lbs 9 5 Nm Caliper Half Lock Washers Item 19 Cap gt Screw Item 18 FIGURE 7 FIGURE 8 TABLE 2 Tightening Torques Housing Item 8
14. 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 4 Close the air line to the unit when a drop of oil forms in the Lubricator Sight Gage These settings are for Nexen supplied lubricator calibration must follow the manufacturer s suggested procedure 6 Turn the Lubricator Adjustment Knob clockwise until 1 Close and disconnect the air line from the unit closed 2 Turn the Lubricator Adjustment Knob 7 Turn the Lubricator Adjustment Knob counterclockwise three complete turns counterclockwise one third turn 8 Open the air line to the unit NOTE DO NOT lubricate the caliper diaphragms If you use a lubricant on the air line for the controls use a lubricant that is compatible with the silicone diaphragm 3 Open the air line FORM NO L 20069 F 0914 5 AIR CONNECTIONS All Nexen pneumatically actuated devices require clean dry air that meets or exceeds ISO 8573 1 2001 Class 4 4 3 to quality NOTE For quick response Nexen recommends a quick exhaust valve and short air lines between the Control Valves and the unit Align the air inlet ports to a down position to allow condensation to drain out of the air cha
15. mbers of the product Low air pressure will cause slippage and overheating Excessive air pressure will cause abrupt starts and stops reducing product life Use the length of 5 32 4 mm O D nylon air line air line that is supplied to make the connections between the cali pers See Table 3 for Air Line Specifications REFER TO FIGURES 11 12 1 Screw the Rotary Air Union assembly into the shaft end 2 Install the air line by pushing it into the fitting until it stops The Elbow and Tee Fittings Items 15 and 16 are push lock fittings for instant connection and disconnection To disconnect first push the fitting collar in and then pull the air line out Make certain that all fittings are properly tightened NOTE Each caliper comes with one elbow fitting two tee fittings and 13 5 34 3 cm of air line tubing Not all of the fittings are used to make caliper connections Save the extra fittings for replacement parts 2 Route the air lines from the Rotary Air Union to the individual caliper assemblies See Figure 4 Air lines must be the same length for the clutch to balance properly The following is acommon air supply scheme used with this product This is an example and not an all inclusive list All air circuits to be used with this product must be designed following ISO 4414 guidelines Brake Control Circuit Filter Gauge Air Dryer Regulator Supply me y aN 3 2 3 Way
16. ncorpo rated has been declared in conformity with the applicable provisions of the Directive Nexen Group Inc 560 Oak Grove Parkway Vadnais Heights Minnesota 55127 ISO 9001 Certified Copyright 2014 Nexen Group Inc FORM NO L 20069 F 0914 il TABLE OF CONTENTS General E 1 General Safety Precautions emmm 1 Caliper amp Housing ASSEMDIY Aaeeea aaaeeeaa nearen 2 Straight Bore AssemDly srmn nisme REA PARE seceeedeeeaneaneaneeanseneannnnenansnnmsretoeearenae sees 3 OD Rotor Hub Assembly gt cae einn sa snne nate reece a cnenninadensecnmncntanaddesnsnniecanddnnsacmeseasennaaace 4 FACHO FAC Wass y A a A O LUCA A a aeei ee 5 Ar CONNEC HS neta lea aaa a aa i a la a 6 Operation rason tap SERA OO RR a 7 A aa lc ala a 7 Troubleshooting eE 8 Parts Replacement FoC IomEa CNG REDACEMEN a a aaas 8 Airline Replacement srssstensaa ntese sessenseasnedonsandnacegenseeennseestireadeanarmadtosinsrnsundnnenedengsdeenchgendenennenacnndaadas 9 Diaphragm Replacement AAA 9 Beating Replacement Snap nana ORAR RARA CARA ea 10 Replacement Parts List no 11 ACTOS OMS A a a AS 12 Warraniy A AAA a ERA AAA 13 iii FORM NO L 20069 F 0914 GENERAL SPECIFICATIONS Specifications Up to 1175 Nm 10400 in lbs in lbs 1 5 5 bar 14 5 80 psi 4 5 104 C 40 220 F Approximate Weight Up to 76 kg 168 lbs GENERAL SAFETY PRECAUTIONS Use appropriate guarding for moving Use lifting aids and proper lifting components F
17. nexen WEB CONTROL PRODUCTS User Manual gt gt gt Tension Control Clutches Models TCC 10 TCC 14 TCC 20 4 RoHS compliant 2002 95 EC FORM NO L 20069 F 0914 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 DANGER 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 This document is the original non translated version Conformity Declaration In accordance with Appendix Il 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 i
18. r Tightening Torques For optimum clutch action connect the controls as close to TCC 10 TCC 14 TCC 20 the unit as possible Nexen recommends the installation of i RotorSet osfubs sO ftibs 166 ftlbs an air line filter in the air line ahead of the controls Screw Item 7 30 9 Nm 67 5 Nm 224 0 Nm Housing Set Screw Item 26 For automatic tension control use Nexen s Electronic Tension Control System Contact your local Nexen Web Handling distributor or representative for information con cerning this product 23 ft lbs 50 ft lbs 166 ft lbs 30 9 Nm 67 5 Nm 224 0 Nm Caliper Cap Screw Item 18 27 ft lbs 50 ft lbs 27 ft lbs 36 4 Nm 67 5 Nm 36 4 Nm MAINTENANCE Inspect all cap screws and set screws on a regular basis and make sure they are tightened to the recommended torque Inspect the friction facings regularly and replace them when worn to approximately 5 32 4 mm thick FORM NO L 20069 F 0914 7 TROUBLESHOOTING SYMPTOM PROBABLE CAUSE SOLUTION Failure to engage Air not getting to TCC Clutch Check for control valve malfunction Low air pressure or low air pressure Control malfunction Check controls Failure to disengage Unexhausted air Check for control valve malfunction Control malfunction Check Controls Loss of torque Air leak Check for air leaks Friction facing contamination Check air pressure Low air pressure Replace facings Worn friction facings Friction
19. sentation or warranty concerning the Products other than those warranties expressly set forth herein Limitation on Nexen s Liability TO THE EXTENT PERMITTED BY LAW NEXEN SHALL HAVE NO LIABILITY TO BUYER OR ANY OTHER PERSON FOR INCIDENTAL DAMAGES SPECIAL DAMAGES CONSEQUENTIAL DAMAGES OR OTHER DAMAGES OF ANY KIND OR NATURE WHATSOEVER WHETHER ARISING OUT OF BREACH OF WARRANTY OR OTHER BREACH OF CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE EVEN IF NEXEN SHALL HAVE BEEN ADVISED OF THE POSSIBILITY OR LIKELIHOOD OF SUCH POTENTIAL LOSS OR DAMAGE For all of the purposes hereof the term consequential damages shall include lost profits penalties delay damages liquidated damages or other damages and liabilities which Buyer shall be obligated to pay or which Buyer may incur based upon related to or arising out of its contracts with its customers or other third parties In no event shall Nexen be liable for any amount of damages in excess of amounts paid by Buyer for Products or services as to which a breach of contract has been determined to exist The parties expressly agree that the price for the Products and the services was determined in consideration of the limitation on damages set forth herein and such limitation has been specifically bargained for and constitutes an agreed allocation of risk which shall survive the determination of any court of competent jurisdiction that any remedy herein fails of its essential purpose Inspection Buyer s
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