Nexen AIR CHAMP TSE-450 User manual

1FORM NO. L-20077-X-1018
Models TSE-450, TSE-600,
TSE-800-1, and TSE-1000

2
FORM NO. L-20077-X-1018
Copyright 2018 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

3FORM NO. L-20077-X-1018
Table of Contents
General Specifications ----------------------------------------------------------------------------------------------------------------------- 4
General Safety Precautions ----------------------------------------------------------------------------------------------------------------- 4
Installation ----------------------------------------------------------------------------------------------------------------------------------------- 5
Brake Guard Installation ---------------------------------------------------------------------------------------------------------------------- 6
Lubrication ----------------------------------------------------------------------------------------------------------------------------------------- 6
Air Connections --------------------------------------------------------------------------------------------------------------------------------- 7
Operation ------------------------------------------------------------------------------------------------------------------------------------------ 8
Maintenance ---------------------------------------------------------------------------------------------------------------------------------------8
Troubleshooting ----------------------------------------------------------------------------------------------------------------------------------9
Parts Replacement:
Friction Facings -------------------------------------------------------------------------------------------------------------------------- 10
Bearing, Compression Springs, and O-Ring Seals ------------------------------------------------------------------------- 10
Replacement Parts List --------------------------------------------------------------------------------------------------------------------- 12
Accessories ------------------------------------------------------------------------------------------------------------------------------------- 13
Facing and Repair Kits ---------------------------------------------------------------------------------------------------------------------- 13
Warranty ------------------------------------------------------------------------------------------------------------------------------------------ 14

4
FORM NO. L-20077-X-1018
GENERAL SPECIFICATIONS
GENERAL SAFETY PRECAUTIONS
CAUTION
Use appropriate guarding for moving
components. Failure to guard could
result in serious bodily injury.
CAUTION
The temperature limits for the
product are 4.5-104 degree
Celsius (40-220 degree F).
Specifications:
Torque Up to 418 Nm (3700 in-lbs)
Actuation Pressure 1 - 5.5 bar (14.5 - 90 psi)
Service Temperature 4.5 - 104 C (40 - 220 F)
Approximate Weight Up to 32 kg (70 lbs)
CAUTION
Some product assemblies can exceed
70 lbs. Use lifting aids and proper lifting
techniques when installing, removing, or
placing in service.
CAUTION
Watch for sharp features when
interacting with this product. The
parts have complex shapes and
machined edges.
CAUTION
Use appropriate guarding for moving
components. Failure to guard could
result in serious bodily injury.
WARNING
This product is capable of emitting
a spark if misused therefore is not
recommended for use in any explosive
environment.
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”.
CAUTION
This product has possible pinch
points. Care should be taken when
interacting with this product.

5FORM NO. L-20077-X-1018
INSTALLATION
1. Before mounting, ensure Cylinder (Item 10) has
adequate clearance to move freely (See Figure 1 and
Table 1).
2. Remove any dirt, grease, or foreign material from
the Friction Disc Hub (Item 1) bore and the tapered
surfaces of the Q.D. Bushing.
NOTE: Do not use lubricants when installing
Q.D. Bushing.
Do not strike Q.D. Bushing to “set” it in the bore
of the Friction Disc Hub.
3. Slide Q.D. Bushing into the bore of the Friction Disc
Hub (Item 1) (See Figure 2).
4. Insert cap screws into Q.D. Bushing, aligning them
with the tapped holes in the Friction Disc Hub (Item
1) (See Figure 2).
5. Position TSE Brake on the shaft (See Figure 2).
NOTE: There should be an 1/8 - 1/4" gap between
the Q.D. Bushing flange and the Friction Disc Hub
after the cap screws have been tightened to the
recommended torque.
Runout is minimized if a Dial Indicator is used as
the Q.D. Bushing cap screws are tightened. Place
contact tip of Dial Indicator on smooth surface of
Cylinder moves axially
to engage and disengage.
See Table 1 for clearance
requirements.
FIGURE 1
Friction Disk Hub
(Item 1)
Motor or
Machine
Frame
Cylinder
(Item 10)
FIGURE 2
Friction Disk Hub
(Item 1)
Q.D.
Bushing
Pull-Up
Bolts
Spring Housing
(Item 4)
Torque
Pin Slot
Plate
Check runout with Dial Indicator
on Friction Disc Hub (Item 1).
CAUTION
Do not flange mount TSE Brakes.
Bearing preloadwill resultafter bushing
is installed and premature bearing
failure will ensue.
CAUTION
Do not install bolts into the threaded holes
of the Q.D. Bushing. The threaded holes
in the Q.D. Bushing are only used for
removal of the Q.D. Bushing.
TABLE 1
Model
Minimum
Shaft
Length
Maximum
Shaft
Diameter
(Full KW)
Minimum
Clearance
at the
Rear of
the Brake
QD
Bushing
Size
Pull-up Bolt
Tightening
Torque
Torque Pin
Slot Width
Torque Pin
Diameter
TSE-450 3.68 1.000 .125 JA 5 ft.-lbs. .377 .375
TSE-600 4.10 1.375 .125 SH 9 ft.-lbs. .627 .625
TSE-800-1 4.74 2.125 .125 SK 15 ft.-lbs. .752 .750
TSE-1000 5.98 2.875 .375 E 60 ft.-lbs. .877 .875
All dimensions are inches.
Measure the minimum shaft length from the bulkhead to the outer edge of the QD
Bushing Flange. Embed a torque pin into the bulkhead to prevent brake housing rotation.
the Friction Disc Hub (Item 1) to measure runout.
Runout on this surface must not exceed 0.005 TIR
when cap screws are tightened (See Figure 2).
6. Alternately and evenly tighten Q.D. Bushing cap screws
to the recommended torque (See Table 1).
NOTE: Keep torque pin as short as possible.
7. Secure brake Spring Housing (Item 4) to prevent
rotation and take up brake torque. A torque pin slot
is provided in the Spring Housing flange (See Figure
2).

6
FORM NO. L-20077-X-1018
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.
BRAKE GUARD INSTALLATION
NOTE: Refer to Figure 3.
1. Align the mounting holes of the Brake Guard with the
four tapped holes in the TSE Mounting Flange.
2. Using the four Phillips Head Pan Screws, secure the
Brake Guard to the TSE. Tighten to 35 in-lbs [4 Nm].
3. If the Brake Guard is not through shaft mounting,
place the End Cap over the front of the Brake Guard
and bend the tabs around the Brake Guard to hold
the End Cap in place.
FIGURE 3
Brake Guard
End Cap
TSE Mounting
Flange

7FORM NO. L-20077-X-1018
Air
Supply
Brake
Inlet
Gauge
Regulator
Filter
Dryer
Typical Brake Control Circuit
3/2 (3 Way)
N.C. Valve
Quick
Exhaust Valve
AIR PRESSURE:
8 BAR (120 PSI) ABSOLUTE MAX
0 BAR (0 PSI) ABSOLUTE MIN
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.
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.
NOTE: Refer to Figure 4.
FIGURE 4
Important - Install the Restrictor Valve in the brake
air inlet.
TSE brakes are equipped with three Shoulder Screws
(Item 6) connecting the Piston Plate (Item 3) and the
Cylinder (Item 10).
Springs (Item 7), mounted on the Shoulder Screws prevent
Cylinder vibration when the brake is engaged.
The Shoulder Screws are under tensile stress when the
air is applied to disengage the brake. Cylinder thrust pulls
the Shoulder Screw in one direction at the same time the
engagement Springs are applying a force load on the screw
in the opposite direction.
Restrictor Valve (Item 22) slows the air entering the brake
to eliminate shock loading on the shoulder screw heads.
The Restrictor Valve does not slow the air exhausting from
the Cylinder allowing the brake to engage quickly.
NOTE: The Auxiliary Cooling Option has been
removed from all standard Nexen S, T, and TSE
series brakes. It is a passage for compressed air to
be connected for increased thermal capacity. If you
desire this feature or are replacing a brake that has
this feature please contact Nexen at 1-800-843-7445.
Install
Restrictor (Item 22)
Air Hose Assembly
with 45° Flared x 1/8 NPT
Connector (Item 19)
CAUTION
Never operate brake without the Restrictor
(Item 22) installed.

8
FORM NO. L-20077-X-1018
The TSE Brake will remain engaged until sufficient air
pressure is applied to release it. Depending upon the
length of the air lines and the type of controls used, the
amount of release air may vary.
Apply increasing amounts of air pressure to the brake until
the Friction Disc Hub turns freely.
1. To manually release the TSE Brake, remove the three
Shoulder or Socket Head Cap Screws (Item 6) and
replace them with customer supplied cap screws (See
Table 4).
2. Tighten the cap screws alternately and evenly to draw
the Plate (Item 3) and Friction Facing (Item 5) away
from the Friction Disc Hub (Item 1).
MAINTENANCE
Periodically inspect all mounting bolts and air line fittings
to make sure they are securely tightened. Pay particular
attention to Shoulder Screws or Socket Head Cap Screws
(Item 6). If these screws are loose, the Cylinder (Item 10)
travel will increase, causing the O-ring Seals to leak air.
Tighten the Shoulder Screws or Socket Head Cap Screws
(Item 6) to the recommended torque (See Table 5).
Inspect Friction Facings (Item 5) for signs of wear and
replace if worn down to where the Machine Screws (Item
14) may score the Friction Disc Hub.
TABLE 4
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TABLE 5
Model Tightening Torques
TSE-450 45 In. Lbs. [6.7 Nm]
TSE-600 230.0 In. Lbs. [26 Nm]
TSE-800-1 450.0 In. Lbs. [50.8 Nm]
TSE-1000 388.0 In. Lbs. [43.8 Nm]
OPERATION
CAUTION
Do not use more air pressure than
required to release the brake (100 psi
maximum).
WARNING
Never exceed maximum operating speeds
listed for your product. (See Table 3).
CAUTION
CAUTION
TABLE 3
The temperature limits for this product
line are 4.5-104 Degree Celsius (40-
220 Degree F).
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).
Sizes: Max RPM
TSE 450-1000 *1800
*Consult Nexen for high speed applications.
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”.

9FORM NO. L-20077-X-1018
TROUBLESHOOTING
FIGURE 5
Friction
Facing
Piston
Plate
Compression
Spring
O-ring Seals
Air Inlet
Piston
Bearing
Friction
Disc Hub
Cylinder
Shoulder Screw
Compression
Spring
Housing/Pin
Assembly
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10
FORM NO. L-20077-X-1018
PARTS REPLACEMENT
FRICTION FACINGS
NOTE: Refer to Figure 6.
1. Align the holes in the Friction Disc Hub (Item 1) with
the Machine Screws (Item 14) holding the split Friction
Facing (Item 5).
2. Remove the old Machine Screws (Item 14).
3. Remove the old split Friction Facings (Item 5).
4. Install the new split Friction Facings (Item 5).
5. Secure the new split Friction Facings (Item 5) using
the new Machine Screws (with locking patch) (Item
14).
6. Tighten the new Machine Screws to the recommended
torque (See Table 6).
FIGURE 6
Align holes in
Friction Disc Hub
(Item 1) with
Machine Screws.
Friction Facing
(Item 5)
Machine
Screw
(Item 14)
TABLE 6
Item 14Item 1 Item 5 Item 3 Item 4 Item 8 Item 9 Item 2 Item 12 Item 11 Item 10
Item 16
Item 7
BEARING, COMPRESSION SPRINGS, AND 0-RING SEALS
FIGURE 7
Item 13
Item 15
Item 24 Item 6
NOTE: Refer to Figure 7.
1. Alternately and evenly remove the Shoulder or Socket
Head Cap Screws (Item 6).
2. Remove the Cylinder (Item 10).
3. Remove the Compression Springs (Item 7).
NOTE: For TSE-800-1 units the Spacer (Item 24)
must also be removed.
4. Remove the O-ring Seals (Items 11 and 12).
5. Remove the Socket Head Cap Screws (Item 16).
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CAUTION
Shoulder and Socket Head Cap Screws
are spring loaded. Always wear safety
goggles when working with spring or
tension loaded fasteners or devices.
CAUTION
Spring Housing and Piston Plate are spring
loaded. Spring Housing and Piston Plate
can spring apart, resulting in personal injury
if Spring Housing and Piston Plate are not
clamped together.