Nexen AIR CHAMP WCB230 Series User manual

(i)
Water Cooled Brake
Series WCB230
FORM NO. L-20163-B-0601
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---------------------------------------------------------------------------------------------------------------------------------2
Lubrication----------------------------------------------------------------------------------------------------------------------------------------- 3
Cooling Water Connections ---------------------------------------------------------------------------------------------------------------3
Troubleshooting --------------------------------------------------------------------------------------------------------------------------------- 4
Parts Replacement ----------------------------------------------------------------------------------------------------------------------------5
Replacement Parts ----------------------------------------------------------------------------------------------------------------------------7
Parts List -------------------------------------------------------------------------------------------------------------------------------------------7
Warranties-----------------------------------------------------------------------------------------------------------------------------------------8

1FORM NO. L-20163-B-0601
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.
Nexen’s double piston design WCB Series brakes provide a wide range of precision torque control in an air actuated,
water cooled brake. A special water jacket design with copper alloy disc produces high thermal horsepower.
The special copper alloy disc and friction facing are engineered for constant slip applications, thus providing extended
life and stable slip torque, while the multiple disc feature allows increased torque capacity in a compact unit.
A copper membrane coats the surface of the water path in the water jacket to prevent rust and extend the life of the
brake.
INSTALLATION
WCB PREPARATION
1. Remove two Socket Head Cap Screws from Main
Body (See Fig. 1).
2. Disassemble WCB into the following components;
Water Jacket Flange, Cylinder Assembly, Hub,
Intermediate Water Jacket Assembly, and two
Friction Disc.
FIGURE 1
Remove
Socket
Head Cap
Screw.
Remove Socket
Head Cap Screw.
MACHINE PREPARATION
Drill mounting holes in machine surface (See Fig, 2 for
mounting hole pattern).
CAUTION
Machine shaft must be perpendicular
to mounting surface to within 0.002"
[0.05 mm] and centered within mounting
bolt pattern within 0.004" [0.10 mm].
14.96" [380 mm] Dia. Bolt
Circle (6) 21/32 [16.5 mm]
Dia. Holes
45o
45o45o
45o
22o 30'
22o 30'
FIGURE 2
MOUNTING CB230
1. Insert key into machine shaft keyway.
2. Slide Hub onto machine shaft until back of
Hub is approximately 1.38" [35 mm] from machine
mounting surface.

2FORM NO. L-20163-B-0601
TABLE 1
WCB230 Use Piston
2084 ft. lbs. “L” + “S”
1393 ft. lbs. “L”
725 ft. lbs. “S”
Note: Torque Ratings Based on 80 P.S.I.
3. Tighten customer supplied set screws securing Hub
to machine shaft to torque recommended by set
screw vendor.
NOTE: Set screws must be flush with Hub or
slightly recessed into Hub to avoid damage
to WCB Brake.
4. Apply Never-Seez®or equivalent lubricant to Hub.
5. Slide Water Jacket Flange, Intermediate Spacer
Ring, and Intermediate Housing over Hub and
machine shaft (See Fig. 3).
CAUTION
Water Jacket outlet must be aligned to
the twelve o’clock up position and inlet
must be aligned to the six o’clock down
position.
6. Insert Cap Screws into counter sunk holes in Water
Jacket Flange, and secure Water Jacket Flange to
machine mounting surface.
7. Tighten two Cap Screws to 184 ft. lbs.
torque.
8. Position first Friction Disc on Hub.
Water Outlets Water Jacket
Flange
Spacer Ring
Cylinder
Assembly
Intermediate
Housing
FIGURE 3
9. Position first Pressure Water Jacket in place on
Torque Pins.
10. Position second Friction Disc on Hub.
11. Slide Cylinder Assembly into position, aligning holes
in Cylinder Assembly with holes in Water Jacket
Assembly and machine mounting surface.
12. Tighten four remaining Socket Head Cap Screws
securing Cylinder Assembly to Water Jacket
Assembly and machine to 184 ft. lbs. torque.
AIR CONNECTIONS
All Nexen pneumatically actuated devices require clean
lubricated air for maximum performance and long life.
Your local Nexen distributor carries filters, regulators,
and lubricators specifically designed to operate with
Nexen products.
For quick response, short air lines between the control
valve and the WCB Brake are recommended. Where
long air lines are required, a Quick Exhaust Valve
(Nexen Product No. 945100) is recommended to
ensure rapid disengagement.
NOTE: Do not use rigid pipe or tubing when making air
connections to the WCB Brake.
Air inlets for the WCB Brake’s “S” Piston and “L” Piston
are located in the Air Chamber and are tapped 1/4 NPT
(See Fig. 4).
The Dual Piston design of the WCB Brake allows
multiple torque ranges (See Table 1).
"S" "L"
FIGURE 4

3FORM NO. L-20163-B-0601
Insufficient water flow will cause the WCB
Brake to overheat, resulting in excessive
friction facing wear, loss of torque, excessive
friction surface wear and o-ring damage.
Refer to Table 2 for recommended cooling
water flow.
TABLE 2
MAX. RECOMMENDED COOLING WATER FLOW
WCB BRAKE GALLONS PER MIN. LITERS PER MIN.
WCB230 10.4 G.P.M. 40 L.P.M.
LUBRICATION
The most effective and economical way to lubricate the
WCB Brake’s air chamber is with an air line lubricator.
Available from Nexen, the lubricator injects oil into the
pressurized air, forcing a constant oil mist into the air
chamber.
Lubricator drip rate is properly set when oil drops form
in the sight gage every time the WCB Brake is cycled
or one full drop every twenty cycles.
Locate lubricator above and within ten feet of the WCB
Brake.
For WCB Brakes that are cycled infrequently, apply two
or three drops of oil into the air inlet ports every two
weeks.
Synthetic lubricants are not recommended,
use a low viscosity petroleum base oil such
as SAE-10.
COOLING WATER CONNECTIONS
Water inlet and outlet ports for the WCB Brake are
located in the Pressure Water Jacket and Flange Water
Jacket. To assure that the WCB Brake is filled with
water at all times the water must enter at the bottom and
discharge at the top (See Fig. 5).
NOTE: Use flexible hose for water lines and route
water lines to insure equal flow to inlet and
outlet ports. The use of rigid pipe or tubing will
prevent proper WCB Brake actuation.
Headers installed in the inlet and outlet
ports must be of a type that provide
equal flow at ports.
Water inlet temperature should be approximately 54oF.
[20oC.] or lower and controlled so that the outlet temp-
erature does not exceed 108oF. [50oC.] (135oF. [65oC.]
Maximum).
Use clean water free from rust, dust, or other corrosive
material.
To determine the proper flow of cooling water, use the
following formula:
6.8 (HP)
GPM min = To- T1
Where: GPM min = Minimum gallons per min required
HP = Thermal horsepower requirement.
To= Outlet water temperature
T1 = Inlet water temperature
FIGURE 5
Water Inlets
Water Outlets

4FORM NO. L-20163-B-0601
TROUBLESHOOTING
Symptom Probable Cause Remedy
Failure to Engage Air not getting to WCB Air pressure too low-
Check for controlvalve malfunction
Air leak in WCB Defective or broken O-rings-
Replace O-ring seals.
Friction Disc binding on Hub Lack of lubrication on Hub-
Hub must be lubricated.
Rigid pipe or tubing used for air lines Flexible tubing must be used for air
lines.
Failure to Disengage Unexhausted air Check controls and air lines for
restrictions
Friction Disc binding on Hub Lack of lubrication on Hub-
The Hub musbe lubricated.
Broken or weak Return Springs Replace Return Springs.
Overheating Shortage of cooling water Inspect water lines. Replace if defec
tive.
Inspect water flow controls. Replace if
defective.
Water Jacket restricted by scale Flush Water Jacket with automotive
radiator cleaner.
Loss of torque Worn Friction Facing Inspect Friction Facing and replace
when space between Cylinder and
Water Jacket Pressure Assembly is
less than 0.70 [18 mm] (See Fig. 6).
Measure Gap between
Cylinder and Water Jacket
Pressure Assembly.
FIGURE 6

5FORM NO. L-20163-B-0601
PARTS REPLACEMENT
FRICTION DISC
1. Remove four Socket Head Cap Screws (Item 25)
and two Socket Head Cap Screws (Item 24) (See
Fig. 7)
2. Separate all WCB components from Water Jacket
Flange (Item 23).
3. Slide First Friction disc closest to Water Jacket
Flange off Hub.
4. Lubricate Hub (Item 16) spline with Never-Seez or
equivalent.
5. Install first Friction Disc (Item 17) closest to Hub.
6. Starting at the Water Jacket Flange end of WCB,
replace all components up to and including the
Intermediate Housing (Item 19).
7. Install Second Friction Disc (Item 17).
8. Replace remaining WCB components.
Water Jacket
Flange
Remove two
Socket Head
Cap Screws
(one per side).
Remove four
Socket Head
Cap Screws
(two per side).
FIGURE 7
O-RING SEAL REPLACEMENT
1. Remove two Shoulder Screws (Item 15) and
Springs (Item 14) securing Pressure Water Jacket
(Item 10) to Cylinder assembly (See Fig. 8).
2. Remove Pressure Water Jacket Assembly (Item 10)
from Cylinder assembly (See Fig. 8).
3. Separate Large and Small Pistons (Items 4 & 5) from
Cylinder Assembly (See Fig. 8).
4. Remove O-rings (Items 6 & 7) from Large Piston
(Item 4) and O-rings (Items 8 & 9) from Small Piston
(Item 5) (See Fig. 8).
5. Lubricate o-ring grooves of both Pistons and new O-
rings with o-ring lubricant and install new O-rings
into respective grooves of both Pistons (See Fig. 8).
6. Install Large and Small Pistons (Items 4 & 5) back
into Cylinder Assembly.
7. Secure Pressure Water Jacket (Item 10) to Cylinder
Assembly.
NOTE: Inspect Springs (Item 14) for signs of
fatigue and replace Springs if required.
6758910 14 15
4
FIGURE 8
9. Tighten Socket Head Cap Screws (Items 24 & 25)
to 184 ft. lbs. torque.
8. Tighten Shoulder Screws (Item 15) to 9 ft. lbs.
torque.

6FORM NO. L-20163-B-0601
1. Disassemble WCB Brake and remove Water Jacket
(Pressure) (Item 10) and Water Jacket (Intermediate)
(Item 21) from machine.
2. Remove Button Head Cap Screws (Item 27) and
Hex. Nuts (Item 28) securing Copper Plate (Item 13)
to Water Jacket (Item 10 & 21) and Copper Plates
(Item13 & 20) to Water Jacket (Item 10 & 21) (See
Fig. (9).
3. Remove O-rings (Items 11 & 12).
4. Clean surface of Water Jacket (Item (10 & 21).
NOTE: Water Jacket coolant path is coated with a
special waterproof paint, if paint is
damaged, repaint coolant path with fresh
waterproof paint.
5. Coat new O-rings with gasket sealant and install
new O-rings.
6. Replace Copper Plate (Item 13 & 20) and secure
with Button Head Cap Screws (Item 27) and Nuts
(Item 28).
PRESSURE WATER JACKET (Item 10) & INTERMEDIATE WATER JACKET (Item 22) O-RING REPLACEMENT
WATER JACKET (Flange) O-RING REPLACEMENT
1. Disassemble WCB Brake and remove Water Jacket
(Flange) (Item 23) from machine.
2. Remove Button Head Cap Screws (Item 27) and
Hex. Nuts (Item 29) securing Copper Plate (Item 13)
to Water Jacket (Item 23) (See Fig. (10).
3. Remove O-rings (Items 11 & 12).
4. Clean surface of Water Jacket (Item (23).
NOTE: Water Jacket coolant path is coated with a
special waterproof paint, if paint is
damaged, repaint coolant path with fresh
waterproof paint.
5. Coat new O-rings with gasket sealant and install
new O-rings.
6. Replace Copper Plate (Item 13) and secure with
Button Head Cap Screws (Item 27) and Nuts
(Item 28).
11 12
15
14
10/21
13/20
27
FIGURE 9
FIGURE 10
23
11
12
13
27
7. Tighten Button Head Cap Screws to 2 ft. lbs.
torque.
8. Pressure test Water Jacket for leaks.
9. Reassemble WCB Brake.
7. Tighten Button Head Cap Screws to 2 ft. lbs.
torque.
8. Pressure test Water Jacket for leaks.
9. Reassemble WCB Brake.

7FORM NO. L-20163-B-0601
ITEMITEM
ITEMITEM
ITEM DESCRIPTIONDESCRIPTION
DESCRIPTIONDESCRIPTION
DESCRIPTION QTY.QTY.
QTY.QTY.
QTY.
1 Cylinder 1
2 Torque Pin 4
3 Lock Nut 4
4 Piston (Large) 1
5 Piston (Small) 1
6 O-Ring 1
7 O-Ring 1
8 O-Ring 1
9 O-Ring 1
10 Water Jacket (Pressure) 1
11 O-Ring 4
12 O-Ring 4
13 Copper Plate 2
14 Spring 2
ITEMITEM
ITEMITEM
ITEM DESCRIPTIONDESCRIPTION
DESCRIPTIONDESCRIPTION
DESCRIPTION QTY.QTY.
QTY.QTY.
QTY.
15 Shoulder Screw 2
16 Hub 1
17 Friction Disc 2
18 Housing 1
19 Housing (Intermediate) 1
20 Copper Plate 2
21 Water Jacket (Intermediate) 1
22 Spacer Ring 1
23 Water Jacket (Flange) 1
24 Cap Screw 2
25 Cap Screw 4
26 Cap Screw 2
27 Button Head Cap Screw 244
28 Hex. Nut (Not Shown) 244
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.
PARTS LIST
FIGURE 11
16
13
15
14
10
18
9
8
5
7
6
4
1
27
12
11
2
3
23
11
12
2
27
22
17
27
20
12
11
13
21
12
11
20
19
17
3
24
25
26