Nexen AIR CHAMP BMK1800 User manual

FORM NO. L-21697-A-0520
AIR CHAMP®PRODUCTS
User Manual
BMK Compact Caliper Brake
BMK1800, BMK3000, BMK Disc-Hub 150,
BMK Disc-Hub 250

FORM NO. L-21697-A-0520 2
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
Copyright 2020 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.
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

3FORM NO. L-21697-A-0520
Table of Contents
General Specifications ---------------------------------------------------------------------------------------------------------- 4
General Safety Precautions --------------------------------------------------------------------------------------------------- 4
Product Description ------------------------------------------------------------------------------------------------------------- 5
Maintenance------------------------------------------------------------------------------------------------------------------------- 5
Dimensions for Installation ---------------------------------------------------------------------------------------------------- 6
Installation --------------------------------------------------------------------------------------------------------------------------- 8
Air Lubrication ---------------------------------------------------------------------------------------------------------------------- 9
Air Connections -------------------------------------------------------------------------------------------------------------------- 9
Troubleshooting ------------------------------------------------------------------------------------------------------------------- 9
Brake Disassembly / Reassembly ---------------------------------------------------------------------------------------- 10
Warranty --------------------------------------------------------------------------------------------------------------------------- 12

FORM NO. L-21697-A-0520 4
GENERAL SPECIFICATIONS
GENERAL SAFETY PRECAUTIONS
WARNING
Keep indoors. This product is
intended for indoor environments
only. Use of the brake outdoors
will damage components.
Figure 1
BMK1800 BMK3000
Braking Action Air Engaged, Spring Released
Maximum
Disc Speed
With 150mm [5.90in] O.D. Disc-Hub 3800 RPM
With 250mm [9.84in] O.D. Disc-Hub 2200 RPM
Dynamic
Braking
Torque 1
With 150mm [5.90in] O.D. Disc-Hub 99 Nm [876 in-lbs] 172 Nm [1522 in-lbs]
With 250mm [9.84in] O.D. Disc-Hub 172 Nm [1522 in-lbs] 321 Nm [2841 in-lbs]
Dynamic Braking Force 1600 N [360 lbs] 3000 N [674 lbs]
Maximum Air Pressure 6 bar [87 psi]
Maximum BMK Disc-Hub Temperature 1150°C [302°F]
1
Dynamic Braking Torque Rating is Achieved with Brake Facings and Disc-Hub at 100°C [212°F].
Lower operating temperatures should result in 60 to 70% of Dynamic Braking Torque Rating.
DANGER
150mm and 250mm O.D. Disc Hubs with configurable bores are available for purchase.
WARNING
Never exceed maximum operating
speeds listed for your product. See
General Specifications Section.
CAUTION
The temperature limit for this product
line is 150 Degree Celsius (302
Degrees Fahrenheit).
CAUTION
WARNING
CAUTION
Watch for sharp features when
interacting with this product. The
parts have complex shapes and
machined edges.
This product is capable of emitting
a spark if misused, therefore it is
not recommended for use in any
explosive environments.
The Disc-Hub needs to be enclosed with
appropriate guarding. Failure to guard could
result in serious bodily injury. Nexen recommends
the machine builder designs guarding in
compliance with OSHA 29 CFR 1910.
CAUTION
Never exceed life of facing material. Facing
life depends on the volume of material and
the total energy over the life of the unit.
Expected life (in hrs) can be found by:
Time=Volume/(Power*Wear Rate).
Moving parts can crush
and cut. Keep hands
clear.

5FORM NO. L-21697-A-0520
The proper installation and maintenance of these brakes must be observed for proper use of unit and to prevent damage.
PRODUCT DESCRIPTION
NOTE
The BMK caliper brakes engage when air pressure is applied to the unit. The air pressure axially moves the piston in a
manner that levers the arms apart and presses the friction facings into both sides of the disc. When the air pressure is
exhausted from the brake, the brake is held in the released position by the return spring. Flexible configuration of the
disc-hub to match customer shafting specifications ensures the right fit for many applications. BMK brakes can be used
in linear braking applications as well.
MAINTENANCE
The caliper brake is lubricated from the factory.
The following lubrication may be used on all parts of
the brake as specified in the maintenance section of
this manual to lubricate the unit during rebuilds.
BMK Brake Lubrication
BMK 1800 Syowa Shell Co., Ltd., ALBANIA
No. 3 or equivalent
BMK 3000 Kyodo Yushi Co., Ltd., Multemp
AC-D or equivalent
BMK1800 Rebuild Kits
Facing Kit Kit No. 835324 Friction Facing, Qty 2 (Item 5)
Rebuild Kit Kit No. 835323
Friction Facing, Qty 2 (Item 5)
Piston Seal, Qty 1 (Item 8)
Return Spring, Qty 1 (Item 10)
See Figure 9
See Figure 10
BMK3000 Rebuild Kits
Facing Kit Kit No. 835334 Friction Facing, Qty 2 (Item 5)
Rebuild Kit Kit No. 835333
Friction Facing, Qty 2 (Item 5)
Piston Seal, Qty 1 (Item 7)
Return Spring, Qty 1 (Item 8)

FORM NO. L-21697-A-0520 6
DIMENSIONS FOR INSTALLATION: CALIPER BRAKE
NOTE: Basic dimensions shown for selection purposes only and subject to change. Visit www.nexengroup.com for detailed
drawings and CAD models before designing into your system.
18.0
.71
2X
ANTI-
SECTION A-A
SECTION B-B
8
THRU
(Rc 1/8)
.27
52.0
2.05
.35
9.0
-HUB
BMK1800
SECTION A-A
SECTION B-B
(Rc 1/8)
-HUB
2X
BMK3000
Figure 2
Figure 3

7FORM NO. L-21697-A-0520
BMK Disc-Hub Dimensions
A
A
-
-
SECTION A-A
150mm
SET SCREWS
(3X) ARE
A
A
SECTION A-A
250mm
NOTE: Basic dimensions shown for selection purposes only and subject to change. Visit www.nexengroup.com for detailed
drawings and CAD models before designing into your system.
150mm Disc-Hub
250mm Disc-Hub
Disc-Hub,
150mm O.D.
Maximum
Bore Diameter
ø 35.00 mm
[ ø 1.375 in ]
Minimum Bore
Diameter
ø 25.00 mm
[ ø 1.000 in ]
Disc-Hub,
250mm O.D.
Maximum
Bore Diameter
ø 60.00 mm
[ ø 2.375 in ]
Minimum Bore
Diameter
ø 40.00 mm
[ ø 1.625 in ]
DIMENSIONS FOR INSTALLATION: DISC-HUB

FORM NO. L-21697-A-0520 8
INSTALLATION
IMPORTANT
Carefully follow Installation
Steps 1 - 5 to ensure a
successful Caliper Brake
installation into your system.
Figure 4 BMK1800 Installation
Model /
Mounting
Method
Qty Customer Supplied
Hardware Description
BMK1800
Screw (Bolt)
Threaded from
Bottom
1 M8 X 1.25 Screw (Bolt), Class 12.9
1 M8 Flat Washer
1 6mm Diameter Spring Dowel Pin
BMK1800
Screw (Bolt)
Thru from Top
1 M6 Screw (Bolt), Class 12.9
1 M6 Flat Washer
1 6mm Diameter Spring Dowel Pin
BMK3000
Screw (Bolt)
Thru from Top
1 M12 Screw (Bolt), Class 12.9
1 M12 Flat Washer
1 5mm Diameter Spring Dowel Pin
1. Remove oil, dust and debris from both faces of the
disc that contact the Friction Facings.
2. Install the disc onto the shaft. Runout between the
disc surface and the shaft should be less than 0.1
mm [.004 in]
3. Install the (Customer Supplied) Spring Dowel Pin (Item
11) into the customer machine frame. The Spring
Dowel Pin keeps the brake aligned with the disc to
prevent interference between the brake’s friction
facings and the disc while the brake is disengaged.
4. Mount the brake so the radius of the disc runs
approximately 1.5 mm past the Friction Facings. Each
Friction Facing should be an equal distance from
the Disc surface. See the Sales CAD Drawing for
specific brake installation dimensions.
5. The BMK1800 brake can be bolted to the customer
machine frame one of two ways:
a. A M8 X 1.25 (Class 12.9) screw with a flat washer,
installed through the customer machine frame and
fastened into the 15 mm [.19 in] deep threaded
hole on either side of the brake’s Pivot Pin (Item 4).
b. A M6 (Class 12.9) screw with a flat washer, installed
through the 6.7 mm [.26 in] diameter through hole in
the brake and threading into the customer machine
frame.
The BMK3000 brake is bolted to the customer
machine frame by a M12 (Class 12.9) screw
with a flat washer, installed through the 12.2 mm
[.48 in] through hole in the brake and fastened into the
customer machine frame. See the Sales CAD Drawing
for specific screw length dimensions.
NOTE: Basic dimensions shown for reference purposes
only and subject to change. Visit www.nexengroup.
com for detailed drawings and CAD models before
designing into your system.
Figure 5BMK3000 Installation
Spring Dowel Pin M8 Screw Disc-Hub
(For the Spring Dowel Pin)
(For the M8 Screw)

9FORM NO. L-21697-A-0520
AIR CONNECTIONS
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. 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 chambers of the product.
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 NOT acceptable to for use on this brake.
AIR LUBRICATION
The following is a common 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.
Attach the air supply line to the air inlet or the quick exhaust
valve depending on configuration selected:
Basic Configuration:
Attach a standard air fitting to the brake. Use teflon tape
and/or pipe sealant on the threads. This configuration will
have slower response times.
Standard Configuration:
Attach the optional Quick Exhaust Valve (Nexen Part
#945100) to the brake. Use teflon tape and/or pipe sealant
on the threads. Nexen Part #945100 has female NPT
.125-27 threads, NPT/BSPT adapters will be necessary.
NOTE: Align the air inlet ports in the down position to
allow condensation to drain out of the air chamber.
DANGER
Support the load before disengaging the
brake. Failure to support the load could
result in serious bodily injury.
Filter
Dryer
Exhaust
Quick Exhaust
Filter
Clutch
Dryer
Regulator
High Pressure
Gauge
Supply
Regulator
N.C. Valve
Air
Low Pressure
3/2 (3 Way)
Valve
Gauge
3/2 (3 Way)
Valve
Brake Control Circuit
N.C. Valve
Brake or
Quick
Typical Two Pressure Clutch or



Air
Valve
Brake or
Clutch
Gauge
Regulator
Filter
Dryer
Typical Clutch or Brake Control Circuit
3/2 (3 Way)
N.C. Valve
Supply
Quick Exhaust



Air
for Remote Air Pressure Reservoir
Reservoir
Valve
And/Or
Brake
Controls
Exhaust
Supply
Gauge
To Clutch
Quick
Quick Exhaust Valve as Check Valve



Reservoir
Regulator Quick Exhaust
Valve
Gauge
Quick Exhaust
Regulator
Brake
Valve
5/2 (5 Way)
Inlet
Supply
Inlet
Typical Clutch-Brake Control Circuit
Filter
Valve
Air Dryer
Quick Exhaust
Valve
Clutch



Gauge
Controls
Brake
To Clutch
And/Or
Air
Supply
NOTE: EXPLODE ALL BLOCKS ON YOUR FINISHED DRAWING FOR LITERATURE! THIS ENSURES THAT THE DASHED LINE TYPES DONT SHOW UP AS SOLID INSTEAD ON THE PDF!
Single Acting
Cylinder -
Spring Return
3/2 (3 Way)
N.C. Valve
5/2 (5 Way)
Valve
4/2 (4 Way)
Valve
Double Acting
Cylinder -
Double Rod
Filter
Supply
Gauge
Valve
Quick Exhaust
Valve
Quick Exhaust
Valve
Brake
Dryer
5/2 (5 Way)
Inlet
Air
Inlet
Regulator
Dual Supply Clutch-Brake Control Circuit
Gauge
Regulator
Brake Supply
Circuit
Filter
Supply
Clutch
Circuit
Air Dryer
Clutch Supply



Brake Supply
Filter
ValveValve
Brake
Dual Supply Clutch-Brake Control Circuit
Quick Exhaust
Inlet
Air
Inlet
Gauge
Regulator
Filter
Supply
Regulator
3/2 (3 Way)
Clutch
N.C. Valve
Dryer
N.O. Valve
Gauge
Circuit
3/2 (3 Way)
Circuit
Air Dryer
Supply
Quick Exhaust
Clutch Supply



Quick Exhaust
Valve
Brake
Inlet
Clutch
Inlet
Circuit
Air Dryer
Valve
Typical Clutch-Brake Control
Regulator Gauge
Supply
Filter
Quick Exhaust
Valve
4/2 (4 Way)



N.C. Valve
Filter
Clutch
Inlet
Gauge
Regulator
Air
Valve
Typical Clutch Control Circuit
Dryer
3/2 (3 Way)
Supply
Quick Exhaust



3/2 (3 Way)
N.O. Valve
Air
N.O. Valve
Brake
Inlet
Gauge
Regulator
Filter
Dryer
Brake Control Circuit
Quick Exhaust
Valve
Supply
3/2 (3 Way)



FIGURE 7
NOTES:
1. Use thread sealing tape or a gasket on the air inlet
fitting when installing in the caliper brake. Make sure
there is no air leakage when installing.
2. Avoid seal tape going into the brake.
3. The recommended tightening torque of the BSPT .125-
28 (Rc 1/8) air inlet fitting is 7 to 9 Nm [62 to 80 in-lb].
4. For quick brake engagement response times, air
tubing 200 mm or shorter between the control valve
and the brake is recommended. A quick exhaust
valve is also recommended for fast release times.
TROUBLESHOOTING
Problem Cause Solution
Loss of holding force.
Air leakage due to piston O-ring damage, improper
installation or lack of lubrication. Lubricate and replace and O-ring.
Brake facing gap has become too large due to wear
of the caliper brake friction facing or the disc-hub.
Perform the gap adjustment procedure per
the maintenance section of this user manual.
Polluted air supply / lack of proper air pressure. Verify quality and pressure of air supply.
Verify function of the air control valve.
Brake facings drag on disc. Return spring has been damaged or displaced. Replace return spring.
If the problem with your brake cannot be solved with the solutions above, please contact Nexen.
Maximum Allowable Wear
Amount (Each Facing)
2 mm
[.08 in]
FIGURE 6
BMK1800 & BMK3000:

FORM NO. L-21697-A-0520 10
BRAKE DISASSEMBLY / RE-ASSEMBLY
BMK1800
BMK3000
Introduction
Features
1. Obtain braking force of 3000N with 0.6 MPa.
2. Good radiation due to the heat-resistant friction facings and disc are exposed to the outside.
3. Adjustable breaking force by adjusting the input air pressure to the brake.
4.
Changeable torque by changing the diameter of disc.
5. Non oiling required.
6. The material of friction facings is asbestos-free. It is possible to change it easily.
7.
Be able to fix and install with a bolt and spring pin easily.
Structure/Operation
Technical Data Sheet
BMK Series brake is a caliper brake used in combination with a disc. Air engaged and spring released.
Normal open type (Air engaged/Direct operation).
The Mini Caliper Brakes, the piston pushes Housing B by air pressure and friction facings bring in
contact with both side of the disc with larger force. When the compressed air is exhaused, release the
brake by the return spring.
Mini Caliper Cuta
way
BMK1800
Caliper Cutaway
BMK3000
Secondary Arm
Piston Bushing
Thrust Plate
Friction Facing
Friction Disc-Hub
Friction Disc-Hub Center Line
Piston
Seal
Primary
Arm
Piston
Locating
Pin
Return
Spring
Retaining
Ring
Pivot
Bushing
Pivot Pin/
Mounting Point
(Both Sides)
BMK1800
1
2
3
4
5
6
7
89
11
10
12
BMK 1800 DISASSEMBLY PROCEDURE
1. Remove Retaining Rings (Item 7) that are
attached to each end of the Pivot Pin (Item 4).
2. Remove the Pivot Pin (Item 4) from the Primary
Arm (Item 3) and Secondary Arm (Item 1).
3. The Primary Arm and Secondary Arm will
separate when the Pivot Pin (Item 4) is removed.
Use caution when allowing the Primary Arm and
Secondary Arm to separate as Return Spring
(Item 10) is under load and presents a hazard.
Friction Facings (Item 5) are held in place by the
Return Spring and will come loose.
4. Apply a low amount of air pressure to the air
inlet (BSPT .125-28) to remove the Piston (Item
2). Use caution during this step, the Piston
could exit the Primary Arm with force, and must
be trapped as it exits the Primary Arm.
BMK1800 REASSEMBLY PROCEDURE
1. Components shall be cleaned before re-assembly. Ensure
the Thrust Plate (Item 12) and two Pivot Bushings (Item
6) are secure in the Secondary Arm (Item 1). Ensure the
Piston Bushing (Item 9) and two Pivot Bushings (Item 6)
are secure in the Primary Arm (Item 3).
2. Apply the recommended grease (Syowa Shell Co., Ltd.,
ALBANIA No. 3 or equivalent) to the Piston Seal (Item 8)
and install onto the Piston (Item 2) with the Piston Seal
open end facing towards the air inlet. Both are installed into
the Primary Arm (Item 3).
3. Install Friction Facings (Item 5) into the grooves of Primary
Arm (Item 3) and Secondary Arm (Item 1).
4. Insert ends of Return Spring (Item 10) into the holes of the
Friction Facings (Item 5).
5. Place the Return Spring (Item 10) in Secondary Arm (Item
1) as shown, lining up the Return Spring hole with the
Bushing (Item 6) holes.
6. Insert Pivot Pin (Item 4) into the Bushings (Item 6).
7. Install Retaining Rings (Item 7) on the ends of the Pivot Pin
(Item 4).
Figure 9
CAUTION
Spring contains
stored energy,
use caution
while removing.
*
†
*
Denotes Facing Kit Item
BMK1800 Facing Kit No. 835324
†
Denotes Rebuild Kit Item
BMK1800 Rebuild Kit No. 835323
*
*