Nexen AIR CHAMP TCB-7 User manual

(i)
Tension Control Brake
Model TCB-7
FORM NO. L-20169-D-0501
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
[phone]
www.nexengroup.com
Nexen Group, Inc.
560 Oak Grove Parkway
Vadnais Heights, Minnesota 55127
ISO 9001 Certified
Copyright 2000 Nexen Group, Inc.
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 --------------------------------------------------------------------------------------------------------------------------------- 3
Operation ------------------------------------------------------------------------------------------------------------------------------------------ 3
Maintenance -------------------------------------------------------------------------------------------------------------------------------------- 3
Troubleshooting---------------------------------------------------------------------------------------------------------------------------------- 4
Parts Replacement ----------------------------------------------------------------------------------------------------------------------------- 4
Replacement Parts ----------------------------------------------------------------------------------------------------------------------------- 6
Parts List ------------------------------------------------------------------------------------------------------------------------------------------- 7
Accessories --------------------------------------------------------------------------------------------------------------------------------------- 7
Warranties ----------------------------------------------------------------------------------------------------------------------------------------- 8

1FORM NO. L-20169-D-0501
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.
Per OSHA regulations, Nexen recommends using a guard that will not restrict the flow of cooling
air around the unit if the unit has rotating parts. Contact your local Nexen Distributor for
information about guards designed for the Nexen TCB-7.

2FORM NO. L-20169-D-0501
INSTALLATION
Do not flange mount the TCB-7. Flange
mounting will result in damage to the TCB-7
Housing.
1. Insert the Nexen supplied Key (Item 6) into the
machine shaft (See Figure 1).
2. Slide the TCB-7 onto the machine shaft (See Figure 1).
3. Tighten Set Screws (Item 3) to 7 Ft. Lbs. [9.5 N•m]
torque (See Figure 1).
NOTE: Runout of the Friction Disc Hub (Item 2)
must be less than 0.015'' [0.381 mm] TIR.
Runout is minimized if a dial indicator is used
as Set Screws (Item 3) are tightened. Place
contact tip of dial indicator on machined
surface of Friction Disc Hub to measure
runout.
4. Using the Flat Head Screw (Item 10) provided with
the Friction Facing (Item 9), secure a Friction Facing
to each Caliper Assembly.
5. Using the Spacers (Item 5), Lock Washers (Item 18),
and Socket Head Cap Screws (Item 19), secure
Caliper Assemblies to Housing (Item 1) (See Figure 2).
6. Tighten Socket Head Cap Screws (Item 19) to 27 Ft.
Lbs. [36.4 N•m] torque.
NOTE: The TCB-7 is designed to be held from
rotation by an arm or a linkage sufficient to
prevent rotation, but loose enough to avoid
thrust loads on the bearing or brake housing.
7. Using a customer supplied 5/16 UNC Cap Screw,
secure a Torque Arm to the TCB-7 to prevent
rotation of the TCB-7 (See Figure 3).
Key
(Item 6)
FIGURE 1
Housing
(Item 1) Spacer
(Item 5)
Lock Washer
(Item 18)
Socket Head
Cap Screw
(Item 19)
FIGURE 2
Torque Arm
Anchoring
Points
FIGURE 3
Set Screw
(Item 3)

3FORM NO. L-20169-D-0501
Never exceed the maximum operating speed
of 4000 RPM. Before placing TCB-7 into
service, check that the Socket Head Cap
Screws (Item 19) are tightened to 27 Ft. Lbs.
[36.4 N•m] torque (See Table 1).
AIR CONNECTIONS
1. Install a Elbow Fitting (Item 15) into one Caliper
Assembly (See Figure 4).
2. Install the Tee Fittings (Item 16) into the remaining
Caliper Assemblies (See Figure 4).
3. Cut the Air Line (Item 17) to length and push it into
the Elbow and Tee Fittings (Items 15 and 16) (See
Figure 4).
4. Connect the remaining length of Air Line to the
control output port or connection (See Figure 4).
5. Connect the air supply to the control input port or
connection (See Figure 4).
OPERATION
For optimum brake operation, connect the controls as
close to the TCB-7 as possible. Nexen Manufacturing
recommends the installation of a filter in the Air Line
ahead of the control.
For automatic tension control, use Nexen’s Electronic
Tension Control System. Contact your local Horton Web
Handling distributor or representative for information
concerning this product.
MAINTENANCE
Inspect all cap screws and set screws on a routine basis
to make sure they are tightened to the recommended
torque.
Tee
Fitting
(Item 16)
Air Line
(Item 17)
Elbow
Fitting
(Item 15)
FIGURE 4
To Control
Inspect Friction Facings and replace them when worn to
approximately 5/32" [4 mm] thick.

4FORM NO. L-20169-D-0501
TROUBLESHOOTING
PARTS REPLACEMENT
FRICTION FACINGS
1. Stop the machine and shut off the air supply to
the TCB-7.
2. Disconnect the Air Lines.
a. To disconnect the Air Line, push in on the
collar of the fitting and pull the Air Line out
(See Figure 5).
b. To reconnect the Air Line, push it into the
fitting until it stops.
3. Remove the Socket Head Cap Screws (Item 19) and
Lock Washers (Item 18) (See Figure 6).
4. Remove the Caliper Assembly from the Housing.
5. Remove the Flat Head Screw (Item 10) from the back
of the Caliper Assembly and remove the old Friction
Facing (Item 9) (See Figure 7).
6. Install a new Friction Facing (Item 9) and secure it to
the Caliper Assembly with a new Flat Head Screw
(Item 10). Tighten the Flat Head Screw to 18-19 In.
Lbs. [2.0-2.1 N•m].
7. Place the Caliper Assembly in position and secure it
to the Housing with the Socket Head Cap Screws
(Item 19) and Lock Washers (Item 18) (See Figure 6).
8. Tighten the Socket Head Cap Screws (Item 19) to
27 Ft. Lbs. [36.4 N•m] torque.
9. Reconnect the Air Lines.
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Lock Washer
(Item 18)
Socket Head
Cap Screw
(Item 19)
FIGURE 5
FIGURE 6
Flat Head
Screw
(Item 10)
Friction Facing
(Item 9)
FIGURE 7
Push collar in
to release.
Caliper
Assembly

5FORM NO. L-20169-D-0501
DIAPHRAGM
1. Proceed with Steps 1 - 4of PARTS REPLACE-
MENT—FRICTION FACINGS.
2. Remove the six Socket Head Cap Screws (Item 20)
and Cover (Item 13) from the Cylinder (Item 11)
(See Figure 8).
3. Remove Diaphragm (Item 14) (See Figure 8).
NOTE: Internal Compression Springs (Item 41)
may also be removed at this time. These
springs are optional; the low air pressure
setting is more sensitive without the springs
(See Figure 8).
4. Install a new Diaphragm with the rubber (not fabric)
on the air side and reassemble the Caliper
Assembly.
5. Tighten the Socket Head Cap Screws (Item 20) to
5.5 Ft. Lbs. [7.45 N•m] torque (See Figure 8).
6. Proceed with Steps 7 - 9of PARTS REPLACE-
MENT—FRICTION FACINGS.
FIGURE 8
Cylinder
(Item 11)
Diaphragm
(Item 14)
Compression
Spring
(Item 41) Cover
(Item 13) Socket Head
Cap Screws
(Item 20)

6FORM NO. L-20169-D-0501
BEARING REPLACEMENT
1. Proceed with Steps 1 - 4of PARTS REPLACE-
MENT—FRICTION FACINGS.
2. Loosen Set Screws (Item 3) and remove TCB-7
Housing and Rotor from machine shaft (See
INSTALLATION).
Special attention should be exercised when
working with retaining rings. Always wear
safety goggles when working with spring or
tension loaded fasteners or devices.
3. Remove Retaining Ring (Item 7) (See Figure 9).
4. Fully supporting Housing (Item 1), press the Friction
Disc Hub (Item 2) out of the Bearing (Item 4) and
Housing (Item 1) (See Figure 9).
5. Remove the Retaining Ring (Item 8) (See Figure 9).
Housing
(Item 1)
Bearing
(Item 4)
Retaining Ring
(Item 8)
Retaining Ring
(Item 7)
Friction
Disc Hub
(Item 2)
FIGURE 9
6. Fully supporting Housing (Item 1), press the old
Bearing (Item 4) out of the Housing (Item 1) (See
Figure 9).
7. Clean the bearing bore of the Housing with safety
solvent making sure all Loctite®residue is removed.
8. Apply an adequate amount of Loctite®680 to evenly
coat the outer race of the new Bearing (Item 4); then,
align the new Bearing with the bore of Housing and
press the new Bearing into place.
9. Install Retaining Ring (Item 8) (See Figure 9).
10. Slide Friction Disc Hub (Item 2) into Bearing (Item 4)
and Housing (Item 1) (See Figure 9).
11. Install Retaining Ring (Item 7) (See Figure 9).
12. Proceed with Steps 7 - 9of PARTS REPLACE-
MENT—FRICTION FACINGS.
13. Install TCB-7 (See INSTALLATION).
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.

7FORM NO. L-20169-D-0501
ITEM DESCRIPTION QTY
1 Housing 1
2 Friction Disc Hub 1
3 Set Screw (Not Shown) 3
4 Bearing 1
5 Spacer 2
6 Key (Not Shown) 1
7 Retaining Ring (Ext.) 1
8 Retaining Ring (Int.) 1
9 Friction Facing 3
10 Flat Head Screw 3
11 Cylinder 11
12 Piston 11
13 Cover 11
14 Diaphragm 11
15 Elbow Fitting (Not Shown) 1
16 Tee Fitting (Not Shown) 1
17 Air Line (Not Shown) --
18 Lock Washer (Ext. Tooth) 6
19 Socket Head Cap Screw 6
20 Socket Head Cap Screw 6
21 Spring Pin 21
40 Socket Head Cap Screw 21
41 Compression Spring 21
1Quantity shown is for one (1) Caliper Assembly only.
FIGURE 11
CALIPER ASSEMBLY
174825
See
Figure 11
18 19
FIGURE 10
10 9
40 41 12 11
21
14
13 20
PARTS LIST
ACCESSORIES
Per OSHA regulations, Nexen recommends
using a guard that will not restrict the flow of
cooling air around the unit if the unit has
rotating parts. Contact your local Nexen
Distributor for information about guards
designed for the Nexen TCB-7.
FIGURE 12
TCB-7 HOUSING GUARD P/N 835186