Nexen Air Champ TSE 1200 User manual

1FORM NO. L-21089-C-0914
Models TSE 1200 & TSE 1400
AIR CHAMP PRODUCTS

2
FORM NO. L-21089-C-0914
Copyright 2014 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-21089-C-0914
Table of Contents
General Specifications -------------------------------------------------------------------------------------------------------------------------- 4
General Safety Precautions ------------------------------------------------------------------------------------------------------------------- 4
Installation ------------------------------------------------------------------------------------------------------------------------------------------- 5
Brake Guard Installation ------------------------------------------------------------------------------------------------------------------------ 6
Lubrication ------------------------------------------------------------------------------------------------------------------------------------------- 6
Air Connections ----------------------------------------------------------------------------------------------------------------------------------- 7
Operation -------------------------------------------------------------------------------------------------------------------------------------------- 7
Manual Disengagement ------------------------------------------------------------------------------------------------------------------------- 8
Maintenance ---------------------------------------------------------------------------------------------------------------------------------------- 8
Troubleshooting ------------------------------------------------------------------------------------------------------------------------------------ 9
Parts Replacement:
Friction Facings ---------------------------------------------------------------------------------------------------------------------- 10
O-Ring Seals -------------------------------------------------------------------------------------------------------------------------- 11
Replacement Parts List ----------------------------------------------------------------------------------------------------------------------- 12
Accessories --------------------------------------------------------------------------------------------------------------------------------------- 13
Facing and Seal Kits --------------------------------------------------------------------------------------------------------------------------- 13
Warranty -------------------------------------------------------------------------------------------------------------------------------------------- 14

4
FORM NO. L-21089-C-0914
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 900 Nm (8000 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 59 kg (130 lbs)
CAUTION
Some product assemblies can exceed
130 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-21089-C-0914
INSTALLATION
1. Before mounting, ensure Rear Piston Plate (Item 3)
has adequate clearance to move freely (See Figure 1
& 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).
6. Alternately and evenly tighten Q.D. Bushing cap screws
to the recommended torque (See Table 2).
NOTE: There should be a 1/4" - 1/2" [6.4 - 12.7 mm]
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 the Friction
Disc Hub (Item 1) to measure runout. Runout on this
surface must not exceed 0.005" [0.13 mm] TIR when
cap screws are tightened (See Figure 2).
7. Secure brake Air Chamber (Item 4) to prevent
rotation and take up brake torque. A torque pin slot
is provided in the Air Chamber flange (See Figure 2).
NOTE: Keep torque pin as short as possible.
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0021-ESTE ni057.2
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0041-ESTF ni052.3
]mm55.28[ ]mN0.201[bl-tf57
TABLE 2
TABLE 1
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0021-EST]mm525.9[ni573.0
0041-EST]mm525.9[.nI573.0
FIGURE 1
Piston and Piston
Plate move axially
to engage and
disengage. See
Table 1 for
clearance
requirements.
Motor or
Machine Frame
Rear Piston Plate
(Item 3)
Air Chamber Flange
(Item 4)
FIGURE 2
Pull-Up Bolts
Q.D. Bushing
Friction Disc
Hub
(Item 1)
Check runout with
Dial Indicator on
Friction Disc Hub
(Item 1).
Spring
Housing
(Item 4)
Torque
Pin Slot
Piston
Plate
(Item 3)
Torque
Pin
CAUTION
Do not flange mount TSE Brakes.
Bearing preload will result after bushing
is installed and premature bearing
failure will ensue.
CAUTION
Do not install Cap Screws 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.

6
FORM NO. L-21089-C-0914
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 10-24 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-21089-C-0914
OPERATION
Apply increasing amounts of air pressure to the brake until
the Friction Disc Hub turns freely.
The TSE Brake will remain engaged until sufficient air
pressure is applied to release it. The amount of release air
pressure may vary depending upon the length of the air lines,
amount of springs, and the type of controls used.
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.
CAUTION
To avoid unnecessary loading of components,
Nexen recommends not exceeding the air pressure
required to release the brake. The brake seals,
however, have been designed to tolerate up to 7.6
bar (110 PSI) of continuous pressure.
WARNING
Never exceed maximum operating
speeds listed for your product.
(See Table 3).
CAUTION
The temperature limits for this
product line are 4.5-104 Degree
Celsius (40-220 Degree F).
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).
TABLE 3
Sizes: Max RPM
TSE 1200-1400 *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”.

8
FORM NO. L-21089-C-0914
NOTE: Periodically inspect all mounting bolts and air line
fittings to make sure they are securely tightened. Pay
particular attention to the Flange Head Hex Screws (Item
6 or 16). If these screws are loose, the Piston Plate (Item
3) travel will increase, causing the O-ring Seals to leak air.
Tighten the Flange Head Hex Screws (Item 6 and16) to
the recommended torque (See Table 4).
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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Ts
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Ts
euqroTgninethgiT metImetI metI metImetI
0021ES
T]
mN0.86[bl-ni0.57
56
0021ES
T]
mN0.04[bl-ni0.45
36
1
0041ES
T]
mN0.86[bl-ni0.57
56
0041ES
T]
mN0.04[bl-ni0.45
36
1
MAINTENANCE
MANUAL DISENGAGEMENT
1. To manually release the TSE Brake, first the air pressure
supply must be removed. (See CAUTION)
2. Remove the Flange Head Hex Screws (Item 16) from
the Piston (Item 2) and the Socket Head Cap Screws
(Item 6) from the opposing Piston Plate (Item 3).
3. Remove the Piston Plate (Item 3) and all three Spacers
(Item 15).
4. Replace Piston Plate (Item 3) and Socket Head Cap
Screws (Item 6) with longer customer supplied fasteners
(SAE Grade 8, 3/8-16) at least 4" long (TSE 1200)
and 5" long (TSE 1400). Cap screws must be long
enough, with sufficient thread length, to allow full removal
of spring force. Spring travel has been designed to
engage over entire area of friction material. Tighten
Cap Screws alternately and evenly to draw the Piston
Plate (Item 3) and Friction Facing (Item 5) away from
the Friction Disc-Hub (Item 1).
Item 6
Item 16
Item 15
Item 3
Item 4
Item 11
Item 12
Item 2
FIGURE 4
CAUTION
To avoid the possibility of an explosion,
disconnect all air supply lines and valves
from the brake. Before any operations are
performed, air pressure must be removed
from the air chamber.

9FORM NO. L-21089-C-0914
TROUBLESHOOTING
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FIGURE 5
Bearing
Piston Plate
Compression
Spring
Piston
O-ring Seals
Friction Disc
Hub
Friction
Facing
Air Inlet
Piston
Plate
(rear)

10
FORM NO. L-21089-C-0914
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 5). TABLE 5
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euqroTgninethgiT
0021ES
T]
mN2.9[bl-ni18
0041ES
T]
mN2.9[bl-ni18
FIGURE 6
Item 14
Friction
Facing
Item 5
Align holes in
Friction Disc Hub
(Item 1)with
Machine Screws
Friction Facing
Item 5
(continued...)