Nexen AIR CHAMP 130-19 User manual

FORM NO. L-20179-J-0814
1
Metric Flange Mounted Clutch-Brake
FMCB: 130-19, 130-24, 7-28, 7-38, 8-38, and 8-42

2
FORM NO. L-20179-J-0814
Copyright 2014 Nexen Group, Inc.
Nexen Group, Inc.
560 Oak Grove Parkway
Vadnais Heights, Minnesota 55127
ISO 9001 Certified
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.
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.
DANGER
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
[phone]
www.nexengroup.com

FORM NO. L-20179-J-0814
3
Table of Contents
General Specifications ----------------------------------------------------------------------------------------------------------------------- 4
General Safety Precautions ----------------------------------------------------------------------------------------------------------------- 4
Installation ----------------------------------------------------------------------------------------------------------------------------------------- 5
Lubrication ----------------------------------------------------------------------------------------------------------------------------------------- 6
Air Connections --------------------------------------------------------------------------------------------------------------------------------- 7
Troubleshooting --------------------------------------------------------------------------------------------------------------------------------- 8
Parts Replacement:
Friction Facings:
FMCB 130-19, and 130-24 ----------------------------------------------------------------------------------------------------- 9
FMCB 7-28, 7-38, 8-38, and 8-42 ----------------------------------------------------------------------------------------- 10
Housing Bearing:
FMCB 130-19, and 130-24 --------------------------------------------------------------------------------------------------- 11
Female Pilot Bearing:
FMCB 7-28, 7-38, 8-38, and 8-42 ----------------------------------------------------------------------------------------- 12
Piston Bearing and O-Ring Seals:
FMCB 130-19, and 130-24 --------------------------------------------------------------------------------------------------- 13
Male Pilot Bearings and O-Ring Seals:
FMCB 130-19, and 130-24 --------------------------------------------------------------------------------------------------- 14
FMCB 7-28, 8-38, and 8-42 -------------------------------------------------------------------------------------------------- 15
Male Pilot Bearing:
FMCB 7-28, 8-38, and 8-42 -------------------------------------------------------------------------------------------------- 16
Piston Bearing and O-Ring Seals:
FMCB 7-38 -------------------------------------------------------------------------------------------------------------------------- 17
Male Pilot Bearings:
FMCB 7-38 -------------------------------------------------------------------------------------------------------------------------- 19
Input Unit
FMCB 130-19, and 130-24 --------------------------------------------------------------------------------------------------- 20
FMCB 7-28, 7-38, 8-38, and 8-42 ----------------------------------------------------------------------------------------- 21
Replacement Parts --------------------------------------------------------------------------------------------------------------------------- 22
Parts List
Input Unit
FMCB 130-19 and 130-24 --------------------------------------------------------------------------------------------------- 22
FMCB 7-28, 8-38, and 8-42 -------------------------------------------------------------------------------------------------- 22
FMCB 130-19 and 130-24 --------------------------------------------------------------------------------------------------------- 23
FMCB 7-28 ------------------------------------------------------------------------------------------------------------------------------- 24
FMCB 7-38 ------------------------------------------------------------------------------------------------------------------------------- 25
FMCB 8-38 ------------------------------------------------------------------------------------------------------------------------------- 26
FMCB 8-42 ------------------------------------------------------------------------------------------------------------------------------- 27
Warranty ------------------------------------------------------------------------------------------------------------------------------------------ 28

4
FORM NO. L-20179-J-0814
GENERAL SPECIFICATIONS
GENERAL SAFETY PRECAUTIONS
CAUTION
Use lifting aids and proper lifting
techniques when installing, removing,
or placing this product in service.
CAUTION
This product has possible pinch
points. Care should be taken when
interacting with this product.
WARNING
Ensure proper guarding of the product is
used. Nexen recommends the machine
builder design guarding in compliance
with OSHA 29 CFR 1910 “Occupational
Safety and Health Hazards”.
Specifications
Torque: Clutch: 21-226 Nm
Brake: 24-271 Nm
Actuation Pressure: 1-80 psi
Service Temperature: 4.5-104C (40-220F)
Approximate Weight: Up to 155 lbs.
CAUTION
Working with spring loaded or tension
loaded fasteners and devices can cause
injury. Wear safety glasses and take the
appropriate safety precautions.
CAUTION
The temperature limits for the
product are 4.5-100 degree
Celsius (40-220 degree F).
WARNING
This product has possible pinch
points. Care should be taken when
interacting with this product.
CAUTION
Surface temperature may exceed
safe handling limits during
operation. Do not touch.
WARNING
This product has possible pinch
points. Care should be taken when
interacting with this product.

FORM NO. L-20179-J-0814
5
INSTALLATION
MOUNTED ON THE SHAFT END OF A MOTOR
Refer to Figure 1.
1. Insert the customer supplied key into the motor shaft
keyway.
2. Slide the FMCB onto the motor shaft, then secure it
to the motor using customer supplied socket head
cap screws and lock washers.
3. Tighten the Set Screw.
Note
On Models 130-19 and 130-24, the Set Screw is Item
27. On all other models, the Set Screw is Item 35.
4. Install the Housing Guard over the open areas of the
FMCB and secure it using the fasteners provided with
the Housing Guard.
Refer to Figure 2.
1. Insert the Key (Item 25 or 33) into the output shaft of
the FMCB.
Note
On Models 130-19 and 130-24, the Key is Item 25.
On all other models, the Key is Item 33.
2. Slide the FMCB output shaft into the gear reducer.
3. Secure the FMCB to the gear reducer using customer
supplied socket head cap screws, lock washers, and
nuts.
4. Insert the customer supplied key into the motor shaft
keyway.
5. Slide the motor into the FMCB and secure it to the
FMCB using customer supplied socket head cap
screws, lock washers, and nuts.
6. Tighten the Set Screw.
Note
On Models 130-19 and 130-24, the Set Screw is Item
27. On all other models, the Set Screw is Item 35.
7. Install the Housing Guard over the open areas of the
FMCB and secure it using the fasteners provided with
the Housing Guard.
MOUNTED BETWEEN A GEAR REDUCER AND
A MOTOR
Figure 1
Motor
Customer
supplied Key
Set Screw
(Item 27 or 35)
Customer supplied socket
head cap screw and lock
washer
Housing
Guard
FMCB
Figure 2
Customer supplied socket
head cap screw, lock washer,
and nut
Motor
Customer
supplied key
Set Screw (Item
27 or 35)
Key (Item 25 or 33) Customer supplied socket
head cap screw, lock
washer, and nut
Gear
Reducer
Housing
Guard
FMCB

6
FORM NO. L-20179-J-0814
NOTE
Note: Nexen pneumatically actuated devices require clean, pressure regulated air for maximum performance
and life. All seals in Nexen Pneumatically operated devices are lubricated for life and do not require additional
lubrication.
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 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
1. Close and disconnect the air line from the unit.
2. Turn the Lubricator Adjustment Knob counterclockwise three
complete turns.
3. Open the air line.
LUBRICATION
CAUTION
These settings are for Nexen supplied
lubricators. If you are not using a Nexen
lubricator, calibration must follow the
manufacturer's suggested procedure.
4. Close the air line to the unit when a drop of oil forms in the
Lubricator Sight Gage.
5. Connect the air line to the unit.
6. Turn the Lubricator Adjustment Knob clockwise until
closed.
7. Turn the Lubricator Adjustment Knob counterclockwise one-
third turn.
8. Open the air line to the unit.

FORM NO. L-20179-J-0814
7
Typical Clutch-Brake Control Circuit
Air
Supply
Filter
Dryer
Regulator
Gauge
Quick Exhaust
Valve
Quick Exhaust
Valve
Brake
Inlet
Clutch
Inlet
4/2 (4 Way)
Valve
Air
Supply
Filter
Dryer
Gauge
Quick Exhaust
Valve
Quick Exhaust
Valve
Brake Inlet
Gauge
Regulator
Filter
Dryer
Air
Supply
Clutch Inlet
Regulator
Dual Supply Clutch-Brake Control Circuit
3/2 (3 Way)
N.C. Valve
3/2 (3 Way)
N.O. Valve
Brake Supply Circuit Clutch Supply Circuit
3/2 (3 Way) 4/2 (4 Way)
5/2 (4 Way) 5/2 (5 Way)
AIR CONNECTIONS
NOTE
For quick response, Nexen recommends a quick exhaust
valve and short air lines between the Control Valves and
the product. Align the air inlet ports to a down position
to allow condensation to drain out of the air chambers
of the product.
CAUTION
Low air pressure will cause slippage and
overheating. Excessive air pressure will
cause abrupt starts and stops, reducing
product life.
All Nexen pneumatically actuated devices require clean
and dry air, which meet or exceeds ISO 8573.1:2001
Class 4.4.3 quality.
Air Pressure (Gage) Limits
6.9 Bar (100 PSI) Absolute Max.
0 Bar (0 PSI) Absolute Min.
Typical Clutch-Brake Control Circuit
Air
Supply
Filter
Dryer
Regulator
Gauge
Quick Exhaust
Valve
Quick Exhaust
Valve
5/2 (4 Way)
Valve
Brake
Inlet
Clutch
Inlet
Air
Supply
Filter
Dryer
Gauge
Quick
Exhaust
Valve
Quick Exhaust Valve
5/2 (5 Way)
Valve
Brake Inlet
Gauge
Regulator
Filter
Dryer
Air
Supply
Clutch Inlet
Regulator
Dual Supply Clutch-Brake Control Circuit
Brake Supply Circuit
Clutch Supply Circuit
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.

8
FORM NO. L-20179-J-0814
TROUBLESHOOTING
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FIGURE 3
O-Ring
Seals
Air to
Brake
Female
Pilot Housing
Drive Disc
Ball Bearing
Piston
Friction
Facings
Male Pilot
Stub
Shaft
Splined Disc
Ball
Bearing
Air Chamber
Cylinder
Spring Pin
Ball Bearings
Key
Air to Clutch
Set
Screw

FORM NO. L-20179-J-0814
9
PARTS REPLACEMENT - FRICTION FACINGS
Note:
If an Input Unit is installed on the FMCB, it must be
removed before servicing the FMCB. Loosen the
Set Screw (Item 27) to release the FMCB from the
Input Unit shaft.
1. Remove the four Socket Head Cap Screws (Item 13)
and separate the two halves of the FMCB.
2. Remove the six old Flat Head Screws (Item 7) and the
first old Friction Facing (Item 8).
3. Align the holes in the Splined Disc (Item 9) with the
Flat Head Screws (Item 7) that secure the second
split Friction Facing (Item 11).
4. Remove the six old Flat Head Screws (Item 7) and the
second old Friction Facing (Item 11).
5. Install the first new split Friction Facing (Item 11) and
six new Flat Head Screws (Item 7).
6. Tighten the six new Flat Head Screws (Item 7) to 2.5
Nm [22 in-lb] torque.
7. Install the second new Friction Facing (Item 8) and six
new Flat Head Screws (Item 7).
8. Tighten the six new Flat Head Screws (Item 7) to 2.5
Nm [22 in-lb] torque.
9. Apply a drop of Loctite®242 to the threads of the
Socket Head Cap Screws (Item 13).
10. Install and tighten the four Socket Head Cap Screws
(Item 13) securing the two halves of the FMCB to
33.2 Nm [24.5 ft-lb] torque.
FRICTION FACINGS
FMCB 130-19 AND 130-24
ReFeR to FiguRes 4 & 5.
NOTE: The following sections are arranged by model. Verify that you are in the correct section for your model.
Figure 4
Socket Head Cap
Screw (Item 13)
Set Screw (Item 27)
Figure 5
11
9
11
8
7
Insert screwdriver to
remove second split
Friction Facing.

10
FORM NO. L-20179-J-0814
FRICTION FACINGS continued
FMCB 7-28, 7-38, 8-38, AND 8-42
Refer to Figures 6 & 7.
Note
If an Input Unit is installed on the FMCB, it must be
removed before servicing the FMCB. Loosen the
Set Screw (Item 35) to release the FMCB from the
Input Unit shaft.
On Models 7-28 and 7-38, the Socket Head Cap
Screws are Item 8. On Models 8-38 and 8-42, the
Socket Head Cap Screws are Item 15.
1. Remove the four Socket Head Cap Screws and
separate the two halves of the FMCB.
2. Remove the six old Flat Head Screws (Item 12) and
the first old Friction Facing (Item 11).
3. Align the holes in the Splined Disc (Item 9) with the
Flat Head Screws (Item 12) that secure the second
split Friction Facing (Item 13).
4. Remove the six old Flat Head Screws (Item 12) and
the second old Friction Facing (Item 13).
5. Install the first new split Friction Facing (Item 13) and
new Flat Head Screws (Item 12).
6. Tighten the six new Flat Head Screws (Item 12) to
8.02 Nm [71 in-lb] torque.
7. Install the second new Friction Facing (Item 11), new
Flat Head Screws (Item 12), and Backing Plate (Item
10).
8. Tighten the six new Flat Head Screws (Item 12) to
8.02 Nm [71 in-lb] torque.
9. Apply a drop of Loctite®242 to the threads of the
Socket Head Cap Screws (Item 8 or 15).
10. Install and tighten the four Socket Head Cap
Screws securing the two halves of the FMCB to the
recommended torque (See Table 1).
Figure 6
Socket Head Cap Screw
(Item 8 or 15)
Set Screw (Item 35)
Figure 7
12
13
13
11
12
Insert screwdriver to
remove second split
Friction Facing.
9
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7]
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3-
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83-
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bl-tf5.42[mN2.3
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-]
bl-tf5.94[mN1.76
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-]
bl-tf5.94[mN1.76
Table 1