Models DPC-9T and DPC-11T
Contents
1. 7 I EN RIES A Wie Use lifting aids and proper lifting techniques when installing removing or placing this product in service This product is capable of emitting a 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 ATREA AN wie ees This product has possible pinch points Care should be taken when interacting with this product EIS Y Ali Use appropriate guarding for moving components Failure to guard could result in serious bodily injury FORM NO L 20070 H 1214 ili de ANOS LA INTRODUCTION Nexen s DPC Dual Friction Plate Clutches are designed to mount on shaft ends or through shafts using a customer supplied Q D Quick Detachable Bushing The dual friction plate design eliminates thrust loading of bearings when the DPC Clutch is connected to a bearing supported Flywheel Sprocket or Sheave Five components are combined to install Nexen s DPC Clutch and a Pilot Mount Clutch or as a Sheave Clutch The five basic components each sold separately are Pilot Clutch Assembly Sheave Rotary Air Union Cap O D Bushing and Rotary Air Union The inner and outer assembles of the DPC Clutch rotate independently INSTALLATION NOTE All DPC Clutch in2. Nexen Group Inc 560 Oak Grove Parkway Vadnais Heights Minnesota 55127 ISO 9001 Certified Copyright 2014 Nexen Group Inc FORM NO L 20070 H 1214 il TABLE OF CONTENTS ecic eike cee ei elt aan ee A ee re er 1 General Salely Precaution ee ee 1 INTOQUCIOn ee 2 INS balla LON serisini eaei eeaeee aaeeea eanan 2 Support Bushing Fr E a EEE EEE 2 Pilot Mount O00 o ee ee 3 NENE Mount re A LUBrIC alone ee A A A eee 4 Ar Connections See ee 5 Shall End MOURINHO A O a a glance a 5 ERFOUGN SAS MOUNN ee ee ea AR RO sania ARA 6 UPON S 7 FARS Replacement A ee A en 8 FRE UOR FACIES RR RR AO RO 8 PRINS rr a mas ra ei a sa 9 2ce A a a da a ee 9 REPlAC SIREN FORS A PSP A RBS R ARR ARR SARAS PER E SEA RASAR Br ERA RER SER RAS 11 Waran sio a EEE nn n s 12 iii FORM NO L 20070 H 1214 GENERAL SPECIFICATIONS Specifications Up to 1243 Nm 11000 in Ibs in Ibs 1 5 5 bar 14 5 80 psi 4 5 104 C 40 220 F Approximate Weight Up to 45 5 kg 100 Ibs GENERAL SAFETY PRECAUTIONS Use appropriate guarding for moving components Failure to guard could result in serious bodily injury Watch for sharp features when interacting with this product The parts have complex shapes and machined edges 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 A VEDA A CA SSAA Na 2 8 AS a
3. 1 is loose on the Q D Bushing FIGURE 9 3 Wedge a screwdriver into the saw cut in the Q D Bushing to loosen the Q D Bushing from the Shaft then remove the DPC Clutch 4 Remove Cap Screws Item 28 and Lockwashers Item 27 and Sheave Item 26 in mounted on the DPC Clutch 5 Proceed with steps 1 through 7 for the Friction Facing replacement FORM NO L 20070 H 1214 9 BEARING PARTS REPLACEMENT continued Working with spring loaded or tension loaded fasteners and devices can cause injury Wear safety glasses and take the appropriate safety precautions REFER TO FIGURE 9 6 7 10 11 12 13 14 15 Remove Retaining Ring ltem 17 Fully supporting the Housing ltem 5 press the Hub Item 1 out of the Housing and Bearings Remove Retaining Ring Item 18 Fully supporting the Housing ltem 5 push the Bearing ltem 16 and Spacer Item 17 out of the Housing Clean bearing contact surfaces of both Housing Item 5 and Hub Item 1 with fresh safety solvent Press new Bearings Item 16 and Spacer Item 7 into the Housing ltem 5 NOTE When installing new Bearings carefully align the Bearing O D with the Housing bore Apply Loctite RC 601 or equivalent to the outer race of the new Bearings Install Retaining Ring Item 18 Fully supporting the inner race of the new Bearings press the Hub ltem 1 into the Bearings and Housing Install R
4. 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 3 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 Close and disconnect the air line from the unit closed 7 Turn the Lubricator Adjustment Knob Turn the Lubricator Adjustment Knob counterclockwise one third turn counterclockwise three complete turns Open the air line 8 Open the air line to the unit ROTARY AIR UNION LUBRICATION Rotary air unions have an oil reservoir This reservoir must be re filled monthly under normal operation or weekly under high speed operation Use 4 to 5 drops of high quality motor oil only 4 FORM NO L 20070 H 1214 AIR CONNECTIONS All Nexen pneumatically actuated devices require clean and dry air which meets or exceeds ISO 8573 1 2001 Class 4 4 3 quality NOTE For quick response Nexen recomm
5. R PINS SS FIGURE 1 FORM NO L 20070 H 1214 INSTALLATION continued PILOT MOUNT CLUTCH REFER TO FIGURE 2 1 Install Support Bushing if required Ah Weel 2 Thoroughly inspect tapered bore of the Splined Hub RN and tapered surface of the Q D Bushing Remove ADA j EE SONS any dirt grease or foreign material AEK KY vor Do not use lubricants when installing the Q D WIN Bushing a R Kl MOR ZEN 3 Install Q D Bushing into Splined Hub aligning untapped holes on O D Bushing Flange with tapped holes in Splined Hub NOTE Do not strike Q D Bushing to SET it in the FIGURE 2 tapered bore 4 Loosely insert Pull Up Bolts and Lockwashers into Q D Bushing and tapped holes of Splined Hub NOTE Do not use lubricants or thread locking compounds on Pull Up Bolts 5 Measure runout of Motor Shaft Runout must not exceed 0 002 T I R Total Indicator Reading ES SR RAR N x Indicator 6 Insert Key into Motor Shaft Keyway 7 Slide DPC Clutch onto Motor Shaft 8 Alternately and evenly tighten Pull Up Bolts to recommended torque See Table 1 NOTE Do not over tighten Pull Up Bolts If excessive tightening torque is applied bursting pressure is created in the Splined Hub NOTE Runout is minimized if a Dial Indicator is used as the Q D Bushing Pull Up Bolts are tightened Place contact tip of Dial Indicator on the machined surface of the Splined Hub to meas
6. U 1 8 NPT BOTH ENDS 180 APART 90 FROM KWY FIGURE 5 FORM NO L 20070 H 1214 OPERATION The temperature limits for this productline are 4 5 104 C 40 220 F Never exceed life of facing material Facing lite depends on the volume of material and the total energy over the life of the unit Expected life in hrs can be found by Vol Time Pl Power e Wear Rate Before placing the DPC Clutch into service verify that all screws are secured to the proper torque See Table 4 The DPC Clutch engages when air pressure is introduced into the Cylinder Drive Disc Air pressure pushes the Cylinder Drive Disc against the Flange Mount Disc and forces the Cylinder Drive Disc in the opposite direction This engages the Friction Facings with the friction surfaces of the Flange Mount Disc and the Friction Disc Torque is transmitted through the Cylinder Drive Disc and Piston Drive Disc Splines to the Splined Hub attached to the Shaft with a Q D Bushing Heat generated at the friction surfaces is dissipated by windage created by the fins on the Flange Mount Disc and the Friction Disc When air is exhausted from the Cylinder Return Springs pull the Piston to disengaged position FORM NO L 20070 H 1214 Never exceed maximum operating speeds listed for your product See Table 5 Ensure proper guarding of the product is used Nexen recommends the machine builder design guarding in complianc
7. any engineering drawing specifically for the Product that is in Nexen 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 FORA 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 represen
8. d Lockwashers Item 14 Remove the Friction Disc Item 6 Remove Shoulder Screws Item 12 and Springs Item 13 Slide the Piston Drive Disc Item 2 off of the Splined Hub Item 1 Working with spring loaded or tension loaded fasteners and devices can cause injury Wear safety glasses and take the appropriate safety precautions Remove the Retaining Ring Item 10 Slide the Cylinder Drive Disc Item 3 off of the Splined Hub Item 1 Alignment Alignment Mark Mark Alignment JAR VR iN D NSS A re ENS ies Tat one OOO TAN A ANT a LJ Alignment Mark FIGURE 6 Alignment Mark NLA I SN y APIS AR EI Rll tl Su AMA SES RSS o RS 4 we ate te ANA SSP ee aN a y EA N LX PS V FIGURE 7 11 Remove the Machine Screws Item 11 and replace worn Friction Facings Item 4 NOTE On some models of the DPC 9T and DPC 11T the Machine Screws Item 11 are assembled with a green anaerobic thread locking compound If remove is difficult strike the end of the screwdriver with a hammer to break the crystalline structure of this locking compound before attempting to remove the screws The Machine Screws Item 11 that are furnished with new Friction Facings have a locking patch and do not require the use of a thread locking compound Reverse Steps 1 through 7 to reassemble the DPC Clutch noting chalk alignment marks and tighten all screws to the recommen
9. ded torque See Table 4 FORM NO L 20070 H 1214 PARTS REPLACEMENT continued O RINGS ITEMS 8 amp 9 NOTE Replace O rings Items 8 amp 9 if there are noticeable air leaks or a loss of torque REFER TO FIGURE 8 Y 1 Proceed with Steps 1 through 7 for the Friction A 4 Facing Repl t NW ing Replacemen 7 DZ u 2 Remove O rings Items 8 amp 9 and clean o ring contact surfaces with fresh safety solvent 3 Lubricate new O rings and o ring contact surfaces with fresh o ring lubricant 4 Install new O rings Items 8 amp 9 5 Reverse Step 1 to reassemble the DPC Clutch noting chalk alignment marks and tighten all screws FIGURE 8 to the recommended torque See Table 4 BEARINGS ITEM 16 NOTE DPC Clutch Bearings are pre lubricated sealed and do not require further lubrication REFER TO FIGURE 9 1 Disconnect the air supply line and Hose Assemblies at the Piston Drive Disc Elbow Fittings NS SA KAN PRES o 0 42 MOSE u eee MAA hy SJ I NON ALS Wren SS e ro A RET es NOTE If the DPC Clutch is shaft mounted remove the Rotary Air Union Cap Item 25 On through shaft installation remove the Elbow Fittings Item 20 from the shaft un 2 Loosen the Q D Bushing by first removing the Q D Bushing Pull Up Bolts and Lockwashers Then insert Pull Up Bolts into tapped Q D Bushing removal holes and alternately and evenly tighten each until the Splined Hub Item
10. e with OSHA 29 CFR 1910 Occupa tional Safety and Health Hazards TABLE4 Recommended Tightening Torques 9 ft lbs 9 fi lbs Shoulder Screw Item 12 12 Nm 12 Nm 48 ft lbs 48 ft Ibs Cap Screw Item 15 65 Nm 65 Nm DPGC 9T DPC 1iT 13 ft lbs 13 ft lbs Cap Screw Item 24 18 Nm 18 Nm 48 ft lbs 48 ft lbs Cap Screw Item 28 65 Nm 65 Nm 30 ft Ibs Pull up Bolts 41 Nm 15 ft Ibs TABLE5 Maximum Allowable Speed 20 Nm Model Outer Assembly Inner Assembly DPC 9T 2200 RPM 3000 RPM DPC 11T 1800 RPM 2500 RPM PARTS REPLACEMENT The Nexen DPC Clutch has been balanced at the factory During disassembly mark components with chalk alignment marks to insure correct alignment and balance as the DPC Clutch is reassembled See Figure 6 When reassembling the Nexen DPC Clutch make sure all screws are tightened to the recommended torque See Table 4 in OPERATIONS SECTION FRICTION FACING ITEM 4 NOTE Inspect Friction Facings for wear and replace when they are appropriately 9 32 thick Friction Facings can be replaced without removing the DPC Clutch from the motor shaft REFER TO FIGURE 7 Disconnect the air supply and Hose Assemblies at the Piston Drive Disc Elbow Fittings NOTE Ifthe DPC Clutch is shaft end mounted remove the Rotary Air Union Cap Item 25 On through shaft installation remove the Elbow Fittings Item 20 from the shaft Remove Cap Screws Item 15 an
11. ends 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 chambers of the product Low air pressure will cause slippage and overheating Excessive air pressure will cause abrupt starts and stops reducing product life SHAFT END MOUNTING REFER TO FIGURE 4 1 Install two Elbow Fittings Item 20 into the Rotary Air Union Cap Item 25 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 ISO 4414 guidelines Brake Control Circuit A r Sapo meg Nate mau Supply 3 2 3 Way N O Valve N AIR PRESSURE 8 BAR 120 PSI ABSOLUTE MAX O BAR 0 PSI ABSOLUTE MIN NOTE Do not use rigid pipe or tubing for this connection For fast engagement and disengagement connect air controls as close to the DPC Clutch 2 Install an Adaptor Fitting Item 19 and Elbow Fitting as possible Where long air lines are required Item 20 into each air inlet of the Piston Drive Disc use a quick exhaust valve Item 2 3 Using Cap Screws Item 24 attach the Rotary Air Union Cap Item 25 to the tapped holes of the Splined Hub Item 1 NOTE The Rotary Air Union Cap air outlets must be aligned at approximately 60 to the Piston Drive Disc air inlets f
12. etaining Ring Item 17 Reverse Steps 1 through 5 to reassemble the DPC Clutch Be sure to note the chalk alignment marks and tighten all screws to the recommended torque See Table 4 10 FORM NO L 20070 H 1214 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 s SAA YEO N m y y SA ES IDA DESCRIPTION O Retaining Ring Adapter Fitting Elbow Fitting Rotary Air Union Piston Drive Disc Cylinder Drive Disc Friction Facing Housing Hose Assembly not shown Friction Disc Hose Assembly not shown Rotary Air Union Cap 24 Rotary Air Union Cap 1 25 Cap Screw 3 Sheave Spacer O ring Seal large O ring Seal small Retaining Ring Sheave Lock Washer Cap Screw Machine Screw Shoulder Screw Spring Lockwasher Cap Screw e Bang 26 27 28 Retaining Ring DPC 9T DPC 11T FORM NO L 20070 H 1214 11 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
13. nexen AIR CHAMP PRODUCTS User Manual 20 FORM NO L 20070 H 1214 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 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
14. nexengroup com ISO 9001 Certified 12 FORM NO L 20070 H 1214
15. or proper Hose Item 22 connection 4 Tighten the Cap Screws Item 24 to the recommended torque See Table 3 5 Install Hoses Item 22 6 Install the Rotary Air Union Item 21 FIGURE 4 7 Connect air supply to the Rotary Air Union TABLE3 Recommended Tightening Torques DPC 9T DPC 11T Cap Screw Item 24 a a FORM NO L 20070 H 1214 5 AIR CONNECTIONS continued THROUGH SHAFT MOUNTING REFER TO FIGURE 5 1 Drill a 3 8 diameter hole into the center of the shaft deep enough to reach the desired air outlets NOTE Air outlets should be approximately 3 8 from the end of the Hub 2 Tap the end of the Shaft 5 8 18 by 5 8 deep 3 Drill a 11 32 diameter air outlet hole through the shaft intersecting the air inlet hole approximately 3 8 from the end of the Hub gt Tap both air outlet holes 1 8 27 NPT by 5 8 deep 5 Install two Elbow Fittings Item 20 into each air outlet hole 6 Install an Adaptor Fitting Item 19 and Elbow Fitting Item 20 into each air inlet of the Piston Drive Disc Item 2 7 Install Hoses Item 22 8 Install the Rotary Air Union Item 21 9 Connect air supply to the Rotary Air Union NOTE Do notuse rigid pipe ortubing for this connection For fast engagement and disengagement connect air controls as close to the DPC Clutch as possible Where long air lines are required use a quick exhaust valve 5 8 18 NF TAP 5 8 DEEP 11 32 DRILL THR
16. remedy herein fails of its essential purpose Inspection Buyer shall 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 nexen Nexen Group Inc 800 843 7445 560 Oak Grove Parkway Fax 651 286 1099 Vadnais Heights MN 55127 www
17. stallations require a Q D Quick Detachable Bushing Refer to Table 1 for Q D Bushing Specifications SUPPORT BUSHING NOTE The Support Bushing provides radial load support at the shaft and is used when bore sizes smaller than standard are required REFER TO FIGURE 1 1 Place DPC Clutch Friction Disc side down and support large end of Splined Hub Item 1 2 Insert Support Bushing into bore of Splined Hub Item 1 3 Apply even pressure around the entire diameter of the Support Bushing and press the Support Bushing into the Splined Hub Item 1 NOTE Do notuse ahammerto install Support Bushing Nexen recommends a small arbor press NOTE On DPC 9T the Support Bushing fits flush with the end of the Splined Hub When mounted on a through shaft the outer clutch as sembly rotates and upon engagement the inner clutch assembly becomes the driven unit When mounted on a continually running shaft the inner clutch assembly rotates and upon engagement the outer clutch assembly becomes the driven member Nexen recommends mounting the DPC Clutch with the outer clutch assembly rotating continuously taking ad vantage of the cooling effect of the fins to dissipate heat generated when the clutch is engaged TABLE 1 Q D Bushing Specifications Bushing Bore Pull up Bolt Type Tightening Torque DPC 9T 2 375 15 ft lbs 20 Nm DPT 11T 2 875 10 ft lbs 41 Nm Support Bushing Vo PRE O
18. tative of Nexen has authority to bind Nexen to any affirmation representation 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
19. ure runout Runout on this surface must be within 0 003 T I R when the Pull Up Bolts are tightened FORM NO L 20070 H 1214 3 INSTALLATION continued SHEAVE MOUNT 26 28 27 NOTE The Sheave Clutch is a combination of the Pilot Clutch and Sheave Assembly both shipped in TE Si 77 RRS a separate container REFER TO FIGURE 3 ToS 1 SAS zu Slide the Sheave Item 26 onto the pilot diameter of the Pilot Clutch Assembly FIGURE 3 Align the mounting holes in the Sheave Item 26 with the tapped holes in the Housing Item 5 TABLE 2 Recommended Tightening Torques ppc ot rer Install the Cap Screws Item 28 and Lockwashers 9 ft lb 9 ft lb Item 27 ne Ne Shoulder Screw ltem 12 12 Nm 12 Nm Tighten the Cap Screws Item 28 to the 48 ft lbs 48 ft lbs recommended torque See Table 2 apena 65 Nm 65 Nm 13 ft Ibs 13 ft Ibs Proceed with Steps 1 through 8 from Pilot Mount Cap Screw Item 24 18 Nm 18 Nm Clutch Installation section on the previous page AS fbe 48 ft lbs Cap Screw ltem 28 65 Nm 65 Nm LUBRICATION NOTE Nexen pneumatically actuated devices require clean pressure regulated air for maximum performance and IE an 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
Download Pdf Manuals
Related Search