Nexen AIR CHAMP W-1000 User manual

(i)
Water Cooled Brake
Model W-1000
FORM NO. L-20074-E-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 and Water Connection------------------------------------------------------------------------------------------------------------------- 2
Operation ------------------------------------------------------------------------------------------------------------------------------------------ 3
Lubrication----------------------------------------------------------------------------------------------------------------------------------------- 3
Maintenance -------------------------------------------------------------------------------------------------------------------------------------- 3
Parts Replacement ----------------------------------------------------------------------------------------------------------------------------- 4
Replacement Parts ----------------------------------------------------------------------------------------------------------------------------- 6
Parts List ------------------------------------------------------------------------------------------------------------------------------------------- 6
Warranties ----------------------------------------------------------------------------------------------------------------------------------------- 7

1FORM NO. L-20070-C-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.
CAUTION
This unit has rotating parts. Nexen recommends using a guard that will not restrict
the flow of cooling air around the unit if the unit is installed where injury to an oper-
ator could occur. Contact your local Nexen Distributor for information about guards
designed for ''Air Champ'' brakes.

2FORM NO. L-20070-C-0501
INSTALLATION
1. Place the Key (Item 5) in the shaft keyway and slide
the brake onto the shaft over the key.
NOTE: Position the brake so the port marked
WATER INLET is located at the bottom.
Water must enter at the bottom to make sure
the brake will be full of water at all times.
2. Secure the brake to a solid support using the four
17/32" [1.3 cm] diameter mounting holes provided in
the Air Chamber (Item 3) flange.
NOTE: If the brake is not flange mounted, use a 7/
8'' [2.2 cm] diameter torque pin in the slot
provided in the Air Chamber flange to
absorb the braking torque. Torque pin
bracket assemblies (product no. 825500)
are available from Nexen or your local
Nexen distributor.
3. Tighten the three Set Screws (Items 15 and 20)
located in the Friction Disc Hub to secure the brake
to the shaft.
AIR AND WATER CONNECTION
The brake’s air inlet is located in the Air Chamber (Item 3)
and is tapped 1/4 NPT. For quick response, connect a
short air line between the brake and the air controls. Air
controls that have at least 1/8" [0.3 cm] ports are recom-
mended and a quick exhaust valve should be used where
long air lines are required. Pneumatically actuated devices
require clean, pressure regulated air for maximum perfor-
mance and long life. It is recommended a filter, regulator,
and lubricator be used on the air line ahead of the air
controls.
The brake’s water inlet and outlet ports are located in the
Water Jacket Assembly (Item 2) and are tapped 1/8 NPT.
To ensure the brake will be full of water at all times, the
water should enter the brake at the bottom and discharge
at the top. Water entering the brake should be free of
contaminants. Use the two Hose Assemblies (Item 6)
supplied with the brake to connect the water lines and
controls to the inlet and outlet ports. The use of rigid
pipe or tubing will prevent proper actuation of the brake.

3FORM NO. L-20070-C-0501
OPERATION
In constant slip of drag applications, the W-1000 Brake
is capable of dissipating a maximum of 8 thermal
horsepower or 264,000 Ft. Lbs. [357,936.5 N•m] of
energy per minute. In cyclic applications, the energy
input increases by the cycle rate. Damage to the brake
will result if the amount of energy input times the number
of engagements per minute exceeds the brake’s thermal
rating. Insufficient water flow will cause the brake to
overheat and result in high friction facing wear, torque
loss, and damage to the friction surface of the Water
Jacket Assembly (Item 2). The correct water flow can be
determined using the formula:
5.1 (HP)
GPMmin = T0-T1
where: GPMmin = Minimum gallons per minute required
HP = Thermal Horsepower requirement
T0= Outlet water temperature
T1= Inlet water temperature
Water inlet temperature should be approximately 700 F
[21° C] and the water outlet temperature should not
exceed 1500F [66° C]. Water flow can be automatically
controlled using a system with a water tempering valve
(See Figure 1). If a manual control is desired, use a ON/
OFF valve and flow meter on the water inlet to maintain a
proper flow of cooling water.
FIGURE 1
Water Inlet
Inlet Filter
ON/OFF Ball Valve
Flexible Tubing
Water Tempering
Valve
Flexible Tubing
Water Exit
LUBRICATION
The Ball Bearing (Item 8) in the W-1000 Brake is
prelubricated, sealed, and does not require lubrication.
MAINTENANCE
Water flow through the brake’s water jacket could become
restricted by scale and rust. If there is a noticeable restriction,
flush the water jacket with and automotive radiator cleaner.
Periodically inspect all mounting bolts, air line fittings, and
water line connections to make sure they are tightened
securely. Inspect the Friction Facing (Item 4) and replace it if
it is worn to the metal backing plates.

4FORM NO. L-20070-C-0501
PARTS REPLACEMENT
FRICTION FACINGS
1. Remove the six Socket Head Cap Screws (Item 14)
and Lock Washers (Item 18) (See Figure 2).
2. Remove the old split Friction Facing (Item 4) (See
Figure 2).
3. Install the new split Friction Facing (Item 4) and
secure it with six new Socket Head Cap Screws
(Item 14) and Lock Washers (Item 18).
FIGURE 2
14,18
4
14,18
4
1. Remove the Retaining Ring (Item 10) (See Figure 3).
Special attention should be exercised when
working with retaining rings. Always wear
safety goggles when working with spring or
tension loaded fasteners or devices.
2. Press the Friction Disc Hub (Item 1) out of the Ball
Bearing (Item 8) (See Figure 3).
3. Alternately and evenly remove the three old Shoulder
Screws (Item 16) and old Return Springs (Item 17)
(See Figure 3).
BALL BEARING, O-RING SEAL, AND RETURN SPRINGS

5FORM NO. L-20070-C-0501
FIGURE 3
10
11
12
13
2
1
16
17
3
8
4. Separate the Air Chamber (Item 3) from the Water
Jacket Assembly (Item 2) (See Figure 3).
5. Remove the old O-ring Seals (Items 12 and 13) and
clean the o-ring seal contact surfaces of the Air
Chamber (Item 3) and the Water Jacket Assembly
(Item 2) with fresh solvent (See Figure 3).
6. Coat the new O-ring Seals (Item 12 and 13) with a
thin film of o-ring lubricant; then, install the new O-
ring Seals on the Water Jacket Assembly.
7. Remove the Retaining Ring (Item 11) and press the
old Ball Bearing (Item 8) out of the Air Chamber (Item
3) (See Figure 3).
8. Clean the bearing bore of the Air Chamber with
solvent, removing all traces of old Loctite® residue.
9. Apply an adequate amount of Loctite®680 to evenly
coat the outer race of the new Ball Bearing (Item 8)
and press the new Ball Bearing into the Air Chamber
(Item 3) (See Figure 3).
10. Install the Retaining Ring (Item 11) (See Figure 3).
11. Slide the Air Chamber (Item 3) and Ball Bearing (Item
8) onto the Water Jacket Assembly (Item 2) (See
Figure 3).
12. Secure the Air Chamber to the Water Jacket
Assembly with three new Return Springs (Item 17)
and Shoulder Screws (Item 16) (See Figure 3).
13. Tighten the Shoulder Screws (Item 16) to 10.42 Ft.
Lbs. [14.12 N•m] torque.1414.12 N
14. Support the inner race of the Ball Bearing (Item 8)
and press the Friction Disc Hub (Item 1) into the Ball
Bearing and Air Chamber (See Figure 3).
15. Install the Retaining Ring (Item 10) (See Figure 3).

6FORM NO. L-20070-C-0501
PARTS LIST
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.
ITEM DESCRIPTION QTY
1 Friction Disc Hub 1
2 Water Jacket Assembly 1
3 Air Chamber 1
4 Friction Facing 1
5Key 1
6 Hose Assembly (Not Shown) 2
7 Connector (Not Shown) 2
8 Ball Bearing 1
10 Retaining Ring 1
11 Retaining Ring 1
12 O-ring Seal 1
13 O-ring Seal 1
14 Socket Head Cap Screw 6
15 Set Screw 2
16 Shoulder Screw 3
17 Return Spring 3
18 Lock Washer 6
20 Set Screw 1
FIGURE 4
13
3
16
5
18,14
20
1
15
4
2
17
10
8
11
12

7FORM NO. L-20070-C-0501
WARRANTIES
Warranties
Nexen warrants that the Products will be free from any defects in material or workmanship for a period of 12 months
from the date of shipment. NEXEN MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED, AND ALL IMPLIED
WARRANTIES, INCLUDING WITHOUT LIMITATION, IMPLIED WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A 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 of the Buyer for any breach of the warranties set out above will be, at the sole discretion of Nexen,
a repair or replacement with new, serviceably used or reconditioned Product, or issuance of credit in the amount of the
purchase price paid to Nexen by the Buyer for the Products.
Limitation of 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
BEENADVISEDOFTHEPOSSIBILITY OR LIKELIHOOD OF SUCH POTENTIAL LOSS OR DAMAGE. For all of
the purposes hereof, the term “consequential damages” shall include lost profits, penalties, delay images, 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 remedy herein fails of its essential purpose.
Limitation of Damages
In no event shall Nexen be liable for any consequential, indirect, incidental, or special damages of any nature whatso-
ever, including without limitation, lost profits arising from the sale or use of the Products.
Warranty Claim Procedures
To make a claim under this warranty, the claimant must give written notice of the alleged defect to whom the Product
was purchased from and deliver the Product to same within one year of the date on which the alleged defect first
became apparent.
Nexen Group, Inc.
560 Oak Grove Parkway
Vadnais Heights, MN 55127
800.843.7445
Fax: [phone]
www.nexengroup.com
ISO 9001 Certified