HRF Manual - Hayward Gordon Ltd
Contents
1. DESCRIPTION STUFFING BOX FLANGE ASSEMBLY GLAND PLATE PACKING GLAND STUD NUT PACKING RINGS LANTERN RING RELIEVE PLUG GREASE FITTING For Material type refer to unit assembly drawing Mounting flange is ANSI raised face on alloy units only Steel units are ANSI flat face HAYWARD GORDON LTD Page 18 Rev 1 HRF Series Mixers Date 11 99 Section RF SINGLE MECHANICAL SEAL John Crane Type 32 depicted DESCRIPTION GLAND ROTATING FACE O RINGS HEX HEAD BOLT 4 HAYWARD GORDON LTD HRF Series Mixers SINGLE MECHANICAL SEAL John Crane Double Type 8 depicted Na gj a Ws ie Wh Page Rev 19 1 Date 11 99 Section J WALD N DESCRIPTION E UPPER STATIONARY FACE LOWER STATIONARY FACE ROTATING ASSEMBLY 4 O RING ROTATING FACE 2 P SEAL HOUSING 1 FLUSH OUTLET 174 N P T STRIGHT THREADED2. Please have the following information to hand if you require the assistance of our customer service e Nameplate data complete e Type and extent of the fault e Time and circumstances of the fault e Possible cause 26 R 7 F 7 K 7 S 7 Spiroplan W Gear Units Operating Instructions General comments on mounting positions Used symbols The following table contains all the symbols used in the mounting position sheets and their meaning Symbol Meaning Gee Breather valve AN Gd Oil level control plug A A GEJ Oil drain plug gt LLI XX See notes on page XXI Churning losses There is a possibility of increased churning losses vvith some mounting positions indi cated by an asterisk in the mounting position sheets Please contact SEW when m XX dealing with the following combinations Mounting position Gear unit type Gear unit size Input speed rpm 7 107 2 M2 M4 R 97 10 gt 2500 gt 107 gt 1500 E 97 107 gt 2500 gt 107 gt 1500 M2 M3 M4 M5 M6 k 77 107 gt 2500 gt 107 gt 1500 s 77 97 gt 2500 R 7 F 7 K 7 S 7 Spiroplan W Gear Units Operating Instructions RF17 RF167 04 041 000 8 3 RF17 RF167 Normal E i 180 j Normal a as Normal LL 29 R 7
3. The mixer itself has been designed to accept the bending moments and torque reactions produced by the impeller s operating in the fluid These loads will be transmitted to the support and therefore the mounting system must be strong enough to support all the loads produced by the mixer The support structure must also be rigid enough to prevent dynamic deflections greater than 0 25 in any direction Size the support structure to accommodate the bending moment torque reaction and static weight shown on the general arrangement drawing MOTORS Ample circulation of air during operation is very important in obtaining full performance and long life from an electric motor Minimize obstructions to free circulation in areas where motors are installed Avoid choking off the suction inlets on fan cooled motors The life of the motor will be decreased if its temperature during operation exceeds its nameplate ambient rating Overload protection should always be provided to avoid motor damage during temporary overloads jams or other mishaps Prior to permanently wiring the electric motor check the output shaft rotation with the rotation indicated on the drive nameplate DO NOT OPERATE UNIT WITHOUT CHECKING ROTATION For standard 3 phase motors the rotation may be reversed by changing any two leads For complete details refer to the attached manufacturer s manual GEAR DRIVES The gear drive has been shipped from the factory filled with the proper g
4. CLP mineral oil HLP hydraulic oil 53 R 7 F 7 K 7 S 7 Spiroplan W Gear Units Operating Instructions Installation Instructions Set Screw an Skwezloc Locking SEALMASTER Ball Bearing zone hardened extended inner races are ground for a sliding fit over the shaft Set screw locking bearings are easily and securely locked to the shaft by means of two self locking cup point socket head set screws A positive race to shaft lock is attained when the ground threads of the set crews are securely tightened through the soft extended ends of the inner race The hardened cup point penetrates the shaft surface trapping the shaft material The cup has flat faceted surfaces inside which prevent the set screw from backing out during operation Skwezloc locking units are locked by tightening a single socket head cap screw in the collar Uniform clamping pressure in a concentric grip is attained which does not intend to mar the shaft Mounting Instructions Set Screw Locking 1 Use clean shafting free of nicks and burrs If old shafting is used locate SEALMASTER bearing on an unused section 2 Make certain set screws are clear of bore 3 Slide SEALMASTER bearing into position on shaft Never hammer the ends of the inner race as they may be damaged If necessary to apply force use a brass bar or pipe against the inner race only to drift bearing into place Never strike the housing as it may damage the baring 4 Bolt Housing t
5. 1 2 5 8 3 4 7 8 1 42 82 140 330 460 1 1 4 1 1 2 Dia 1 4 3 8 Torque ft lb 4 8 17 43 85 130 200 270 400 500 730 15 1 11 99 RF HAYWARD GORDON LTD Page 16 Rev 1 HRF Series Mixers Date 11 99 Section RF STUFFING BOX INSTRUCTIONS GENERAL The purpose of a stuffing box packing is NOT TO STOP leakage but to limit it to a practical amount If the gland is tightened to prevent leakage packing life will be shortened and shaft damage may occur For best stuffing box performance lubricant should be introduced CONTINUOUSLY at pressures between 5 to 15 psi above tank pressure If intermittent lubrication is provided by means of a grease gun care must be taken to prevent over lubrication An amount of grease that fills the lubricant cavity and is distributed evenly throughout the packing area is sufficient for proper lubrication PACKING SPECIFICATIONS The type packing furnished for this unit is specified on the main assembly drawing If the packing furnished is not satisfactory for the service conditions it should be replaced LUBRICATION The stuffing box is shipped without lubricant because of federal regulations and the danger of using a lubricant that may contaminate the product Low pressure stuffing boxes 0 25 psi have been impregnated with lubricant and are not supplied with lantern rings NOTE Before using please check that packing and lubricant is of high quality
6. LUBRICATION BEARINGS The bearing located in the pedestal area of the mixer has been lubricated prior to shipment from the factory however at 6 8 month intervals the bearing should be re greased Using the grease fitting supplied add grease slowly with shaft turning until a slight bead forms at the lip seal The grease used should be a high grade non separating ball bearing grease of NLGI No 2 consistency suitable for operating temperatures to 200 F Grease should be non reactive oxidation resistant to ball bearings and should not separate below 300 F It should not precipitate sediment or contain grit abrasives or fillers MOTORS and GEAR DRIVES Motor bearings are provided with sealed grease packing and do not have grease fittings Refer to the attached Manufactures literature for further details The mixer drive oil should be changed every 10 000 hours of operation or every 2 years which ever is shorter Under extreme environmental conditions or very high operating loads more frequent oil changes are recommended If your mixer operates under such conditions you must pay special attention to regular oil changes and to inspecting the oil for evidence of deterioration If your mixer operates under any of the following conditions more frequent oil changes will be necessary 1 Heavy intermittent loads that cause the mixer drive housing temperature to rise rapidly and then cool when loads decrease 2 Ambient temperature and humidit
7. F 7 K 7 S 7 Spiroplan W Gear Units Operating Instructions Lubricants 9 Lubricants 9 1 Lubricant fill quantities The fill quantities are recommended values The specific values vary depending on number of stages and ratio Pay close attention to the oil level plug to serve as indi cator for the correct amount of oil The following tables list the reocmmended values for the lubricant fill quantities in refe rence to mounting positions M1 M6 Helical R gear units Gear unit Fill quantity in liters type MI M21 M3 M4 M5 M6 R17 R17F 0 25 0 6 0 35 0 6 0 35 0 35 R27 R27F 0 25 0 4 0 7 0 4 0 7 0 4 0 4 R37 R37F 0 3 1 0 9 1 1 1 0 8 1 R47 R47F 0 7 1 5 1 6 1 5 1 7 1 5 1 5 R57 R57F 0 8 1 7 1 9 1 7 2 1 1 7 1 7 R67 R67F 1 1 2 3 2 6 3 5 2 8 3 2 1 8 2 R77 R77F 1 2 3 3 8 4 3 3 6 4 3 2 5 3 4 R87 R87F 2 3 6 6 7 8 4 7 2 7 7 6 3 6 5 R97 4 6 9 8 11 7 14 11 7 13 4 11 3 11 7 R107 6 13 7 16 3 16 9 19 2 13 2 15 9 R137 10 25 28 29 5 31 5 25 25 R147 15 4 40 46 5 48 52 39 5 41 R167 27 70 82 78 88 66 69 Gear unit Fill quantity in liters type MI M21 M3 M4 M5 M6 RF17 0 25 0 6 0 35 0 6 0 35 0 35 RF27 0 25 0 4 0 7 0 4 0 7 0 4 0 4 RF37 0 4 1 0 9 1 1 1 0 8 1 RF47 0 7 1 5 1 6 1 5 1 7 1 5 1 5 RF57 0 8 1 7 1 8 1 7 2 1 7 1 7 RF67 1 2 2 5 2 7 3 6 2 7 3 1 1 9 2 1 RF77 1 2 2 6 3 8
8. 4 1 3 3 4 1 2 4 3 RF87 2 4 6 6 8 7 9 71 7 7 6 3 6 4 RF97 5 1 10 2 11 9 14 11 2 14 11 2 11 8 RF107 6 3 14 9 15 9 17 19 2 13 1 15 9 RF137 9 5 25 27 29 32 5 25 25 RF147 16 4 42 47 48 52 42 42 RF167 26 70 82 78 88 65 71 The larger gear unit in multi stage gear units must be filled with the larger oil quantity Gear unit Fill quantitiy in liters type M1 M2 M3 M4 M5 M6 RX57 0 6 0 8 1 3 1 3 0 9 0 9 RX67 0 8 0 8 1 7 1 9 1 1 1 1 RX77 1 1 1 5 2 6 2 7 1 6 1 6 RX87 1 7 2 5 4 8 4 8 2 9 2 9 RX97 2 1 3 4 74 7 4 8 4 8 RX107 3 9 5 6 11 6 11 9 7 7 ZI Gear unit Fill quantity in liters type M1 M2 M3 M4 M5 M6 RXF57 0 5 0 8 1 1 1 1 0 7 0 7 RXF67 0 7 0 8 1 5 1 7 1 1 RXF77 0 9 1 5 2 4 2 5 1 6 1 6 RXF87 1 6 2 5 4 9 4 7 2 9 2 9 RXF97 2 1 3 6 71 7 4 8 4 8 RXF107 3 1 5 9 11 2 10 5 72 72 R 7 F 7 K 7 S 7 Spiroplan VV Gear Units Operating Instructions Lubricants 9 2 Recommended lubricants for SEW drives Lubrication table for SEW drives synthetic lubricants mineral lubricants 01 805 492e Gear Ambient temperature range Lubricant ISO viscosity 7 s PA unit type resp Mobil XY VA Tribol FUCHS type 450 DIN ISO NLGI class shen LES pr x rn F _ ag Mobilgear Shell Omala Kliberoil Aral Degol BP Energol Tribol Optigear Renolin Ki pe 3 20 63
9. e a higher oil level with synthetic oil Correct the oil level prior to startup see Inspec tion Maintenance on page 24 3 3 Installing the gear unit ge The gear unit or geared motor must be mounted installed in the specified mounting po sition on a level vibration absorbing and torsionally rigid support structure Spiroplan gear units are not dependent on mounting position Do not tighten housing legs and mounting flanges against each other Oil check screws drain screws and breather valves have to be freely accessible At this point of assembly please check that the oil filling is as prescribed for the moun ting position see lubricant fill levels on page 49 or data on nameplate In case of mounting position change adjust lubricant filling quantities accordingly Please consult our service department if the mounting position for K gear units is changed to M5 or M6 or within these mounting positions Please consult our service department if the mounting position of S units in sizes S47 S97 is to be changed to mounting posi tion M2 1 Maximum permitted flatness error for flange mounting approximate values with refer ence to DIN ISO 1101 with gt flange 120 600 mm max error 0 2 0 5 mm R 7 F 7 K 7 S 7 Spiroplan W Gear Units Operating Instructions Installing the gear unit Use plastic inserts 2 3 mm thick if there is a risk of electrochemical corrosion between the gear uni
10. excessive gear and to an abrasive substance e g dusty bearing wear Make necessary provisions to prevent atmosphere entrance of abrasive substance Clean and flush drive thoroughly and refill with new oil Revise maintenance practices to include more frequent changes 4 Structure amplification Steel mounting structures often act as a diaphragm and amplify small amounts of normal noise into excessive noise This can only be corrected by adding additional stiffness to the structure HAYWARD GORDON LTD Page 12 Rev 1 HRF Series Mixers Date 11 99 Section RF TROUBLE SHOOTING continued TROUBLE WHAT TO INSPECT ACTION VIBRATION Inspect Impellers Are all blades and extension arms bolted securely to the impeller hub s in accordance with match marks Bolts tightened Be certain that all mounting and coupling bolts are tightened to the correct wrench torque Mixer support structure Does the mounting arrangement for the mixer provide sufficient support to prevent wobbling or vibration of the assembly from unbalanced hydraulic forces on the impeller Lower agitator shaft Lower agitator should not be bent The rigid coupling halves must be connected according to instructions Steady bearing Has excessive wear occurred to the bearing bushing Is bearing securely bolted to the vessel and properly aligned OIL LEAKAGE Is breather open Breather must be open and clean Worn oil sea
11. 0 220 GEM 1 220 BG220 GR XP220 1100 220 Meropa220 py220 CLP 220 3 gt a o lense Mobil Shell Tivela Kl bersynth Aral Degol BPEnersyn Tribol Synlube Optiflex A a2 oa Glygoyle 30 WB GH 6 220 GS 220 SG XP 220 800 220 CLP 220 220 2 o IVG 220 P Mobil Shell Omala Klubersynth Aral Degol Tribol Pinnacle Optigear Syn Renolin Unisyn 8 5 SHC 630 220 HD GEM 4 220 PAS 220 1510 220 EP 220 thetic A 220 CLP 220 z a ka P Mobil 9 Kl bersynth Es SHC 629 GEM 4 150 2 a GIVG 150 P Mobilgear Shell Omala9 Kl beroil Aral Degol BP Energol Tribol Meropa 150 Optigear Renolin S 5 o Q IVG 100 629 100 GEM 1 150 BG 100 GR XP 100 1100 100 p BM 100 CLP 150 5 e a e VG 68 46 T Mobil Shell Tellus1 Kl beroil Aral Degol Tribol Anubia Optigear Renolin o 2 I amp VG 32 D T E 15M T32 GEM 1 68 BG 46 1100 68 EP 46 32 B 46 HVI 5 EI E P Mobil N Kl bersynth Cetus OL ot SHC 624 GEM 4 32 PAO 46 2 8 ns VG 22 d Mobil Shell Tellus 1 ISOFLEX BP Energol Aircraft 2 T E VG15 D T E 11M T15 MT 30 ROT HLP HM 10 Hydr Oil 15 ja SG Mobilgear Shell Omala Kl beroil Aral Degol BP Energol Tribol Optigear Renolin 4 19 O Jo gjyG 680 ese 680 GEM 1 680 BG680 GR XP680 1100 680 Meropa680 Bm 680 CLP 680 n a Mobil Glygoyle Kliibersynth BP Enersyn Tribol Synlube 5 o ygoy y y y 60 pe 1 mes GH 6 680 SG XP 680 800 680 CLP 680 Mobil Shell Omala Kl bersynth o 8 ii ver SHC634 460HD _ GEM 4 460 i Mobil Klubersyn
12. OT add pressure to the vessel until the seal chamber has been pressurized It is very important for satisfactory seal performance that no air is trapped in the seal housing ensure that all air has been bled from the system before starting up unit The seal lubricator level should be checked regularly and refilled as necessary Good operating practice is to flush the lubrication system every 5000 hours or every 12 months which ever occurs first If the unit has been supplied with a single dry running seal consult the enclosed manufacturer s literature SHAFTS AND IMPELLERS The extension shaft of your Hayward Gordon Mixer was straightened to within a few thousandths of an inch prior to shipment from the factory Care should be taken when handling the shaft to see that it is not bent After the unit is installed the shaft straightness should be checked Total shaft run out at the end of the shaft should not exceed 0 003 per foot of shaft extension If the shaft run out is greater than the above figure the shaft can be straightened in the field Place an indicator on the side of the shaft where the maximum positive reading is obtained Apply heat to the shaft at a point 180 from the indicator and just below the first in tank coupling or mounting flange As heat is applied do not allow surface temperature to exceed 450 F dark straw to bluish color the shaft will grow toward the indicator After the shaft has grown 0 030 0 060 remove hea
13. PLUG HEX HEAD BOLT C W LOCKWASHER FLUSH INLET 1 4 N P T RF Before you begin 3 Installation 3 1 Before you begin The drive may only be installed if the entries on the name plate of the drive match the mains power supply e the drive is undamaged no damage caused by transport or storage and e itis certain that the following requirements have been fulfilled with standard gear units ambient temperature between 0 C and 40 no oil acid gas vapors radiation etc e with special versions drive configured in accordance with the ambient conditions with helical worm Spiroplan W gear units no large external mass moments of inertia which could exert a retrodriving load on the gear unit where h retrodriving 2 1 h lt 0 5 self locking 3 2 Preliminary work The output shafts and flange surfaces must be thoroughly cleaned of anti corrosion agents contamination or such like use a commercially available solvent Do not let the solvent come into contact with the sealing lips of the oil seals danger of damage to the material Please note The service life of the lubricant in the bearings is reduced if the unit is stored for more than one year Gear units of the extended storage type have e an oil fill suitable for the mounting position so the unit is ready to run mineral oil Nevertheless check the oil level prior to startup see Inspection Maintenance on page 24
14. S models include mounting flange with stuffing box HREM models include mounting flange with mechanical seal Please provide complete Mixer Model Number and Mixer Serial Number when information or service is required This information should be copied from the mixer nameplate to the front cover of this Service Manual HAYWARD GORDON LTD Page 2 Rev 1 HRF Series Mixers Date 11 99 Section RF INITIAL INSPECTION Care should be exercised in uncrating and handling Miscellaneous parts turbine hubs turbine blades fasteners coupling hubs etc may be boxed separately and attached to the crate or may be wired or bolted to the crate DO NOT DISCARD CRATE without carefully making sure that all mixer parts have been removed The unit should be inspected carefully and any shipping damage reported to Hayward Gordon Limited A claim should be filed immediately with the carrier involved Damage resulting from improper handling can affect the operation and life of your Hayward Gordon mixer Particular care should be taken to prevent bending the shaft which has been straightened within a few thousandths of an inch Never lift or support the unit by the end of the shaft STORAGE GENERAL For storage of the mixer do not remove the protective coating Add additional protective coating as may be required for condition and period of storage MOTORS and GEAR DRIVES Hayward Gordon strongly recommends that mixer gear drives be kept in a dry
15. SERVICE INSTRUCTIONS FOR HRF SERIES MIXER Customer Name Tag Serial No Size Type Reduction Ratio Motor HP Input RPM Output RPM AGMA S F Hayward Gordon Ltd 5 BRIGDEN GATE HALTON HILLS ON L7G 0A3 CANADA PHONE 905 693 8595 FAX 905 693 1452 OFFICES IN MONTREAL CALGARY VANCOUVER 514 697 6445 403 253 2737 604 986 8764 HAYWARD GORDON LTD Page 1 Rev 1 HRF Series Mixers Date 11 99 Section RF TABLE OF CONTENTS Initial inspection Storage General Motors and Gear Drives Shafts and Impellers Installation and Operation General Mixer Assembly Mounting Gear Drives Shafts and Impellers Lubrication Bearings Motors and Gear Drives Maintenance Trouble Shooting APPENDIX Parts Lists Impeller Blade Bolt and Set Screw Torque Stuffing Box Instructions Stuffing Box High Pressure Single Mechanical Seal Double Mechanical Seal Commissioning and Service Copyright 2002 Hayward Gordon Limited Specifications subject to change without prior notice HAYWARD GORDON LTD Page 1 Rev 1 HRF Series Mixers Date 11 99 Section RF HRF MODEL NUMBERING HRF mixers have model numbers of the format The digits in underscore indicate numeric placeholders and provide specific information to Hayward Gordon Depending on the features of your HRF mixer there may be the letter S or the letter M following HRF in the model number HREX models include baseplate with lip seal HRF
16. hine hours check oil at least every six months depending on operating instructions change mineral oil gt Fig 7 at least every three years replace bearing anti fr grease See section 6 3 depending on operating conditions change synthetic oil gt Fig 7 at least every five years replace bearing anti fr grease R RF 17 27 and Spiroplan gear units are lubricated for life and require no maintenance Table 8 Inspection and maintenance periods 6 2 Lubricant replacement schedule 30000 Average value per type of lubricant at 70 C Operating hours 070 80 90 100 110 C 120 Oil bath steady state temperature gt 03357AEN Fig 7 Oil change intervals for standard gear units under normal environmental conditions Change the oil more frequently when using special versions subject to more severe ag gressive environmental conditions 24 R 7 F 7 K 7 S 7 Spiroplan W Gear Units Operating Instructions Inspection and maintenance 6 6 3 Inspection and maintenance Do not mix synthetic lubricants with each other nor with mineral lubricants Oil is the standard lubricant The position of the oil level plug oil drain plug and the breather valve is depen dent on the mounting position The respective position can be determined in the mounting position diagrams see section 8 Checking the oil 1 De energize the drive and secure against unintentional switch on
17. horizontal position before installation If they are to be moved while the shaft is hung vertically a safety rope must be tied securely through one or more bolt holes and tethered from above to prevent dropping or sudden movement Before proceeding remove all scratches and burrs from the shaft over which the hub must pass as well as the hub bore Do not use tools which might contaminate special agitator materials such as metal files on stainless steel Polish the shaft with emery cloth Impeller Blade Torques A 1 2 5 8 3 4 7 8 1 1 1 8 Page Rev Date Section ries Mixers Liberally coat the shaft with lubricant such as molybdenum disulphide paste for ease of sliding Back off all setscrews Rock the hub to loosen and firmly slide the hub away from pin applying an even load on opposite ears The hub may be tapped lightly through a wooden block to aid in this movement Heavier hammer blows may cause the bore to close in and grab the shaft When hub slides clear remove hook key Stop the hub at the first sign of binding on the shaft Forcing the hub may induce galling in some materials making removal even more difficult Back off from the binding spot determine the cause and correct it before continuing If needed moderate heat of about 300 350 F light straw temper color may be applied to the hub O D which will expand the bore for removal over high spots Heat concentrated on the thinner hub section over the key
18. ical re lubrication schedules Relubrication 1 Add grease slowly with shaft rotating until a slight bead forms at the seals 2 Re lubrication is generally accompanied by a temporary rise in operating temperature until the bearing chamber is stabilized with the proper amount of grease 3 It necessary to re lubricate while bearing is stationary refer to SEALMASTER catalog for maximum grease capacity for the size bearing 4 For abnormal operating conditions of high temperature or abnormal environments consult SEALMASTER Engineers TABLE 1 Speed Temperature Cleanliness Greasing Interval 100 RPM Up to 120 F Clean 6 to 12 months 500 RPM Up to 150 F Clean 2 to 6 months 1000 RPM Up to 210 F Clean 2 weeks to 2 Months 1500 RPM Over 210 F Clean Weekly Any Speed Over 150 F Dirty 1 week to month Any Speed Any Temp Dirty Daily to 2 weeks Any Speed Any Temp Extreme Conditions Daily to 2 weeks For normal operating conditions re lubricate with a grease conforming to NLGI No 2 penetration free from chemical impurities such as dust rust metal particles or abrasives SEALMASTER
19. inutes and may result in considerable savings if followed regularly 1 Cleanliness coatings of dirt dust and grease retard the flow of heat to the atmosphere and may cause overheating Wipe the motor clean and apply an inhibitor to rusted parts 2 Temperature allowable temperature is stamped on the motor nameplate Overheating indicates overloading shorts or burned insulation 3 Moisture be sure motor is dry inside and out totally enclosed motors may accumulate condensation under certain conditions Most motors are equipped with a plugged hole to permit drainage 4 Noise unusual noises from a motor mean trouble This may be the first indication of a failing bearing or loose connection GEAR DRIVES Other than periodic lubrication as outlined in the LUBRICATION section no routine operational gear drive maintenance is required In order to assure the longest life from your drive annual shut downs which can correspond with plant shut downs should be planned Gear tooth contact and wear patterns shaft bearing end play alignment bolting and condition of all seals should be checked HAYWARD GORDON LTD Page 11 Rev 1 HRF Series Mixers Date 11 99 Section RF TROUBLE SHOOTING The mixer should be checked often for abnormal temperatures oil leaks abnormal noise vibration etc In the event of difficulties the unit should be shut down immediately The following trouble shooting table should be reviewed and if no solutio
20. level Wait until the gear unit has cooled down Danger of burns 2 For modified mounting positions refer to Section 3 3 3 For gear units with oil level plug remove oil level plug check fill level and correct if necessary install oil level plug Checking the oil 1 De energize the drive and secure against unintentional switch on Wait until the gear unit has cooled down Danger of burns 2 Remove some oil from the oil drain plug 3 Check the oil consistency viscosity if the oil is visibly contaminated it is recommended to change it sooner than recommended by the maintenance intervals under point 6 1 4 For gear units with an oil level plug remove oil level plug check fill level and correct if necessary install oil level plug Changing the oil Only change the oil when the gear unit is at operating temperature 1 De energize the drive and secure against unintentional switch on Wait until the gear unit has cooled down Danger of burns Note Gear unit must still be warm otherwise the high viscosity of excessively cold oil will make it harder to drain the oil correctly Place a container underneath the oil drain plug Remove oil level plug breather plug valve and oil drain plug Drain oil completely Install oil drain plug Fill new oil of the same type through the breather hole otherwise consult our service department amount in accordance with the mounting position see section 8 or data o
21. ls Replace defective seals HAYWARD GORDON LTD Page 13 Rev 1 HRF Series Mixers Date 11 99 Section RF APPENDIX HAYWARD GORDON LTD Page 14 Rev 1 HRF Series Mixers Date 11 99 Section RF x 3 DESCRIPTION QTY UNIT MOTOR 1 PEDSTAL 1 SLEEVE COUPLING 1 BEARING 1 ADAPTER PLATE 1 EXTENSION SHAFT HAYWARD GORDON LTD HRF Se GENERAL Impellers from Hayward Gordon Mixers are normally shipped with hubs mounted on the agitator shaft and with blades shipped loose Blades should be installed in strict accordance with matchmarks if any and with bolts tightened to the torque listed below REPOSITIONING OR REMOVAL Due to adjustment requirements or special installation procedures it may be necessary to relocate or even remove the impeller hub from the shaft Your Hayward Gordon impeller hub to shaft clearance is optimized to provide maximum adjustability and support with a minimum of fretting therefore even slight distortions and scratches may cause the hub to hang up If more than one hub is to be removed check the shaft and hub for matchmarks If none mark clearly with a nonremovable indicator noting which side of the hub is to face up It is safest to remove or relocate hubs while the shaft is in the
22. n nameplate check at the oil level plug 7 Install oil level plug 8 Install breather plug valve DAN ON R 7 F 7 K 7 S 7 Spiroplan W Gear Units Operating Instructions 25 Neer SS KA 7 Troubleshooting 7 Troubleshooting Problem Possible cause Solution Unusual regular running a Meshing grinding noise noise Bearing damage 1 Check the oil section 6 3 b Knocking noise 2 Contact customer service Irregularity in the gearing 1 Check the oil section 6 3 Foreign bodies in the oil 2 Stop the drive contact custo mer service Unusual irregular running noise Oil leaking from the motor flange from the motor oil seal from the gear unit flange from the output end oil seal a Call customer service b Vent the gear unit section 8 a Seal defective b Gear unit not vented a Correct the oil level section 6 3 b Fit the breather valve correctly section 8 a Too much oil Oil leaking b Breather valve not fitted properly from the breather valve c Frequent cold starts oil foams and or high oil level Output shaft is not rotating although the motor is running or the input shaft is rotating Shaft hub connection in the gearbox Send in the gear unit geared motor interrupted for repair 1 Itis normal for small amounts of oil grease to leak out of the oil seal during the running in phase 24 hour running time
23. n is obvious contact Hayward Gordon Limited TROUBLE WHAT TO INSPECT ACTION OVERHEATING Motor Overload a Determine whether specific gravity or viscosity of the process has changed from that originally anticipated b Inspect impeller for material build up c Have additional baffles been added to the vessel or the size of the baffles increased d Check for proper impeller rotation as shown on certified print e See NOISE Below Is oil level to low Check oil level to see that housing is filled with lubricant to the specified level Breather Breather must be open and clean Clean breather regularly in a solvent Grade of oil Oil must be of a grade specified in lubrication instructions If it is not flush unit and refill with correct grade Condition of oil Check to see if oil is oxidized dirty or of high sludge content Change oil Stuffing Box if supplied Stuffing box gland must not be over tightened See Packing Procedure for proper packing and break in Included if applicable Inspect impellers Be sure clearance between impeller and any in tank construction including tank walls for anchors scrapers etc is sufficient to permit unhindered rotation 2 Worn or improperly installed or Couplings can generate noise which seems to maintained couplings emanate from gear case Check for proper lubrication alignment or worn parts 3 Are bearings and gears exposed Abrasive substance will cause
24. ngth impeller diameter or blade width etc should be discussed with Hayward Gordon prior to making changes MIXER ASSEMBLY All units are completely assembled except for the following items 1 The extension shaft must be inserted through the lower bearing replacing the snap ring on the shaft and coupling the shaft with the sleeve coupling All setscrews are then to be tightened refer to page 14 for diagram Impellers turning at speeds higher than 100 RPM are statically balanced and are to be assembled according to the match marks Values shown in Table III pg 8 indicate torquing requirements Mixers supplied with in tank couplings are to be assembled using the hardware supplied and torqued to values shown in Table III pg 8 HAYWARD GORDON LTD Page 2 Rev 1 HRF Series Mixers Date 11 99 Section RF Open tank models are mounted separately from the tank on a steel structure These units include an integral lip seal and bearing cartridge in the base plate Stuffing box models mount with a standard ANSI flange to a nozzle or pad directly on the vessel Mechanical seal models mount with a standard ANSI flange to a nozzle or pad directly on the vessel EXTREME CARE SHOULD BE TAKEN IN HANDLING AND IN INSTALLING TO ENSURE THAT THE SHAFT IS NOT JARRED CAUSING DAMAGE TO THE DELICATE MECHANICAL SEAL PARTS MOUNTING Mixers are mounted in the vertical position only and care should be taken to level the support structure or nozzle
25. nput and output or motor shaft ends It may be possible to dispense with the thrust bearing on the moun elements ting device Gear unit shaft end Thrust bearing ei U Coupling hub 003371AEN Fig 1 Example of a mounting device Fig 2 displays the correct mounting arrangement of a gear wheel or sprocket to pre vent excessively high overhung loads incorrect correct 03369AEN Fig 2 Correct mounting arrangement or a gear wheel or sprocket Only use a mounting device see Fig 1 for installing input and output elements Use the center bore and the thread on the shaft end for positioning purposes Never drive belt pulleys couplings pinions etc onto the shaft end by hitting them with a hammer damage to bearings housing and the shaft In the case of belt pulleys make sure the belt is tensioned correctly in accor dance with the manufacturer s instructions Power transmission elements should be balanced after fitting and must not give rise to any impermissible radial or axial forces see Fig 2 permitted values see the Geared Motors catalog Note Assembly is easier if you first apply lubricant to the output element or heat it up briefly to 80 100 C R 7 F 7 K 7 8 7 Spiroplan w Gear Units Operating Instructions 6 Inspection and maintenance periods 6 Inspection Maintenance 6 1 Inspection and maintenance periods Time period What to do Section every 3000 mac
26. o support Rotate shaft to make certain it turns freely 6 Tighten self locking cup point set screws securely onto the shaft If a torque wrench is used see Table 2 o Skwezloc Locking 1 The optional SKWEZLOC locking unit is assembled on the shaft as per points 1 through 5 above Then slide the collar into position on the extended end of the inner race seating it squarely against the shoulder Tighten the capscrew to the torque indicated in Table 3 below Do not exceed the indicated Torque Value Table 2 Table 3 Torque for Tightening Set Screws Torque for Tightening Skwezloc Collars Set Screw Hex Size Minimum Recommended Cap Screw Hex Size Minimum Recommended Diameter Across Torque Size Across Torque In Lbs Ft Lbs In Lbs Ft Lbs 1 4 1 8 66 5 5 48 32 1 8 70 5 8 5 16 5 32 126 10 5 UNC 3 A 3 8 3 16 228 19 0 10 24 9 64 90 7 5 7 16 7 32 348 29 0 UNC 3 A 1 2 1 4 504 42 0 1 4 20 3 16 180 15 5 8 5 16 1104 92 0 UNC 3 A 5 16 18 1 4 400 33 3 UNC 3 A LUBRICATION INSTRUCTIONS All SEALMASTER bearing units are pre lubricated with grease chosen for its chemical and mechanical stability SEALMASTER bearings are designed for lubrication with grease Unit furnished with a grease fitting should be periodically re lubricated The re lubrication interval depends on bearing operating conditions speed temperature and environment See Conditions in Table 1 below for typ
27. o the fitting until lubricant is evident at the relief After allowing the packing to run in the gland plate nuts should be snugged but do not over tighten HAYWARD GORDON LTD Page 7 Rev 1 HRF Series Mixers Date 11 99 Section RF Mechanical seal models can be supplied with double face type rotary seals which must be lubricated or with single dry running type which are self lubricating Double mechanical seals require fluid lubrication either DEAD ENDED or CIRCULATED through the seal chamber at a pressure 20 PSI above or 10 higher than the maximum pressure that will be in the mixing tank For longest seal life light mineral oil is the best choice as a seal lubricant Many processes however cannot permit even the slightest oil contamination In these instances we recommend that one of the process components or a compatible fluid be used The chosen lubricant MUST NOT attack the seal components or seal housing If water is used as the lubricant we recommend that a corrosion inhibitor or a small amount of glycerin be added to the water to improve its lubricity For maximum seal life we recommend that the temperature of the seal lubricant be kept below 150 F for oil 125 F for water and 100 F for solvents with a SG of less than 0 7 In most cases the absolute max temperature of the lubricant to avoid seal failure is 350 F The seal chamber pressure must always be greater than the pressure in the mixing vessel Therefore DO N
28. physically and chemically suitable for the service conditions START UP INSTRUCTIONS STUFFING BOXES 1 Prior to initial operation all stuffing boxes should be carefully assembled in accordance with instruction on Packing Procedure Section P1 SB Page 2 01 In addition the run in procedure as outlined below should be followed to insure proper seal operation and increased packing life a Tighten the gland nuts to finger tightness b Start the mixer and run it until the stuffing box has reached a constant operating temperature Stop the mixer and tighten diagonally opposite gland nuts Note When tightening the gland nuts be careful to avoid cocking the gland Even tightening of the gland will seat the packing while it is warm and plastic c Again loosen gland nuts to finger tightness and restart the mixer Leakage may be excessive but do not take up on the gland nut for the first 20 to 30 minutes HAYWARD GORDON LTD Page 17 Rev 1 HRF Series Mixers Date 11 99 Section RF d If after this initial run in period the leakage is still excessive adjust the gland by tightening the nuts evenly one flat or a sixth of a turn at a time This should be done every 30 minutes until leakage is reduced to a normal level e Adjustments must always be done gradually and held to a minimum tightness This procedure may take several hours but will pay dividends in increased packing and shaft life STUFFING BOX HIGH PRESSURE 0 150 PSI
29. r pot should be completely filled with a lubricant compatible with the sealing fluid to be used in service SHAFTS and IMPELLERS The shaft shipped with your unit was straightened at the factory to within a few thousandths of an inch Care should be taken in the storage of the shaft to see that it is fully supported along its entire length and to see that heavy items are not placed on unsupported sections of the shaft For outdoor storage of carbon steel shafts and impellers a suitable grease or rust preventative should be applied to the parts INSTALLATION AND OPERATION GENERAL Proper installation and operation is the key to long trouble free mixer service The following is a list of points to cover during installation and operation Ensure the mixer rotation is correct before permanently wiring the motor Read all tags nameplates and this manual prior to operating the unit Check motor operating amperage against motor nameplate amperage Do not operate in a fluid with a specific gravity or viscosity higher than that for which the unit is designed Do not attempt to start a unit with the impeller buried in solids or in a set up fluid 6 Maintain operating temperatures and pressures of vessel within design limitations for stuffing box and mechanical seal units A minimum of 4 radial clearance must be maintained between the impeller and any obstruction Any anticipated changes in motor horsepower mixer speed shaft le
30. rade and quantity of oil The reducer is provided with a red painted level plug a drain plug located at its lowest spot and a blue painted plug indicating the location for the breather The breather is shipped in a plastic bag attached to the gearbox In the case of gear motors the breather plug is shipped inside the motor terminal box When the installation of the drive is completed the blue plug located at the highest HAYWARD GORDON LTD Page 2 Rev 1 HRF Series Mixers Date 11 99 Section RF spot on the reducer is to be replaced with the breather Before starting the unit check for correct oil level by removing the red oil level plug A small amount oil should trickle from this opening Refer to the attached manufacturer s literature for complete details of the gear reducer SEALS Open tank models are supplied with an integral lip seal and bearing in the mounting plate The main purpose is to prevent any contaminants from running down the shaft into the tank and keeping process fluid splash from contacting the drive This seal may also be used to seal atmospheric vapours Stuffing box seals consist of six rings of packing and a lantern ring Extreme care during installation and operation is required if proper packing life is to be realized The lantern ring distributes lubricant to the packing during operation Prior to operation remove the relief plug and using lubricant which is compatible with the process fluid pump the lube int
31. slot is most effective Never allow the temperature to rise above 450 F dark straw to bluish temper color When using heat handle the hub only with heat protecting gloves REPLACEMENT AND SECURING Before replacing the hub onto the shaft check the bore for burrs or scratches Coat the bore and shaft with molybdenum disulphide paste If the shaft is hung vertically attach a safety tether securely through one or more bolt holes in the hub and support from above Install the hub with the side up as indicated by matchmarks It is usually although not necessarily assembled chamferred side first Slide the hub to a point above its required position and replace the hook key onto the shaft Gently lower the hub onto the key until it seats against the pin Do not drop against the pin Tighten setscrews to torque listed below Install blades and tighten bolts to torques listed below Torque values shown are good for standard carbon and stainless steel hex head bolts as well as nickel monel inconel and Alloys B C and 20 and are based on bolts lightly lubricated in the as received condition If lubricated with molybdenum disulphide paste on threads and nut bearing face bolt torques must be reduced to 75 of those tabulated All bolts should be tightened by turning nut side only All bolts should be re tightened within 1 month after startup and at each scheduled shut down Set Screw Torques B Dia 1 4 5 16 Torque ft lb 5 8 11
32. t and shaft will draw away from the indicator The draw will be greater than the growth After each heating process recheck the shaft straightness until within tolerance HAYWARD GORDON LTD Page 8 Rev 1 HRF Series Mixers Date 11 99 Section RF Hayward Gordon produces a variety of impeller designs for a broad range of mixing applications The impeller assembly normally consists of two parts the hub which is fastened to the shaft by means of a pinned key and blades which are bolted to the hub ears pg 15 Mixers are normally shipped with the hub s mounted on the mixer shaft and blades shipped separately Impellers which are designed to turn at speeds higher than 100 RPM will be match marked at the factory ensure that match marks are located and assembled accordingly In tank fasteners are supplied either with lock washers or double nuts Care should be taken to see that locking devices are properly installed and bolts properly tightened It is recommended that all in tank fasteners be rechecked for tightness after the first 1500 hours of operation and subsequently at each shutdown period Table III gives torque values to which all shaft and impeller bolts should be tightened TABLE III Thread Torque Values ft Ibs Size Lubricated Va 20UNC 5 16 18 UNC 3 8 16 UNC V2 13 UNC 5 8 11 UNC 34 10 UNC 7 8 9 UNC 1 8 UNC HAYWARD GORDON LTD Page 9 Rev 1 HRF Series Mixers Date 11 99 Section RF
33. t and the driven machine connection between different metals such as cast iron and high grade steel Also fit the bolts with plastic washers Ground the housing additionally use the grounding bolts on the motor Installation in Gear units are supplied in corrosion resistant versions for use in damp areas or in the damp areas or in open air Any damage to the paintwork e g on the breather valve must be repaired the open Gear unit venting All gear units are delivered by SEW ready for the mounting position with the breather valve and transport fixture fitted Exception Gear units for pivoting or inclined mounting positions and gear head units are delivered with a screw plug on the vent hole provided Prior to startup the customer must replace the highest screw plug by the supplied breather valve on each individual gear unit With geared motors for long term storage pivoting or inclined mounting positions the supplied breather valve is located in the motor terminal box With gear head units that have to be vented on the input side the breather valve is supplied in a plastic bag e No breather valve will be supplied for gear units in enclosed design Activating the Usually the breather valve is activated in the plant Should this not be the case breather valve the transport fixture must be removed from the breather valve prior to the startup of the gear unit 1 Breather valve with transport 2 Remove transport fixture 3 Acti
34. temperature controlled indoor storage area Mixer drives must be sealed from the atmosphere during storage make sure breathers are replaced by plugs Store mixers such that the gear drives are in their normal vertical configuration and fill the gear case completely with the proper grade of oil Rotate input or output shaft several revolutions each month If these conditions are carefully maintained storage durations of up to two years are possible If an indoor area is not available with temperature and humidity control the next best option is indoors without these controls In this case wrap the motor in plastic with desiccant bags inside and replace the desiccant bags monthly Outdoor storage is not recommended If outdoor storage is unavoidable keep all of the mixer components off the ground on skids or platforms and cover the equipment with a waterproof covering Wrap the motor in plastic with desiccant bags inside and replace the desiccant bags monthly SEALS Double mechanical seal housings and mechanical seal lubricators are shipped from the factory coated internally with a rust preventative which is compatible with most sealing fluids The components as shipped are adequately protected for short term storage in heated indoor environment Outdoor storage of mechanical seal units is not recommended however when HAYWARD GORDON LTD Page 5 Rev 1 HRF Series Mixers Date 11 99 Section RF unavoidable the seal housing and lubricato
35. th E Saj 22 SHC 629 GEM 4 150 3 K a GIVG 150 P Mobil Shell Omala1 Kl beroil Aral Degol BP Energol Tribol Meropa 100 Optigear Renolin 3 o 9 VG 100 D T E 18M 100 GEM 1 150 BG 100 GR XP 100 1100 100 p BM 100 CLP 150 2 To Mobil N Kliibersynth Tribol Synlube Optiflex A 3 20 a VG220 1 I Glygoyle 30 GH 6 220 800 220 CLP 220 220 7 a o Wars Mobil N Kl bersynth Cetus ot SHC 624 gt GEM 4 324 PAO 46 sh ab 10 a 4 SAE 75W90 P mobilube SHC z E lt G VG 100 75 W90 LS IL x on x solu Shell Cassida Kl ber l Aral Eural Optileb wg jo 40 22 Q VG460 Fluid GL 460 4UH1 460 Gear 460 GT 460 5 3 Kliiberbio Optisynt o SAR 2 3 Bulle CA2 460 BS 460 Glygoyle Shell Tivela 1 Kliibersynth Multifak d o a S es el 2 z 5 ve 2 Grease 00 Compound A GE 46 1200 6833 EP 00 Eq gz 5 122 loo 2 Mobilux Shell Alvania Aralub BP Energrease Multifak Longtime Renolit EP 004 GL 00 MFL 00 LS EP 00 EP 000 PD 00 SF 7 041 P lubricants supplied at the assembly plants SEW USOCOME F W lubricants supplied at the assembly plants SEW EURODRIVE BRD 1 Helical worm gear units with PG oil Consult SEW Eurodrive 2 Consult SEW Eurodrive for other gear units 3 Special lubricant for Spiroplan gear units only Please note critical startup behaviour at low temperatures CLP PG polyglycol CLP HC synth hydrocarbon E diester oil water contamination class WGK 1 HCE synth hydrocarbons diester oil USDA H1 approval
36. vate breather valve fixture x 02053BXX 02054BXX 02055BXX Painting the gear Cover breather valve and oil seals with protective tape prior to painting or partly re unit painting the drive Remove adhesive strips when the paint job is finished R 7 F 7 K 7 8 7 Spiroplan W Gear Units Operating Instructions Required tools Material 4 Assembly Disassembly 4 1 Required tools Material Set of spanners e Torque wrench for shrink discs AQ adapters without keyway input shaft assembly with centering shoulder e Mounting device e Shims and distance rings if necessary e Fixing devices for input and output elements Lubricant e g NOCO fluid e Agent for securing screws e g Loctite 243 for input shaft assembly with centering shoulder Mounting tolerances Shaft end Flanges Diametric tolerance in accordance with Centering shoulder tolerance according to DIN 748 DIN 42948 e ISO k for solid shafts withd d1 lt 50mm Je ISO j6 with b lt 230 mm e ISO m for solid shafts with d di gt 50 mm ISO h with by gt 230 mm e ISO H7 for hollow shafts e Center hole according to DIN 332 shape DR R 7 F 7 K 7 S 7 Spiroplan W Gear Units Operating Instructions Gear units with solid shaft 4 2 Gear units with solid shaft Installation of Fig 1 is an example of a mounting device for mounting couplings or hubs onto gear unit i
37. y conditions that could cause moisture condensation on the inside walls of the mixer drive 3 Oil temperatures during mixer operation that exceed 200 F 4 Mixer drive exposure to unusually dusty atmospheres or to corrosive or reactive vapors SEALS Stuffing box seals equipped with a lantern ring lube fill fitting and a lube relief plug should be re lubricated on a regular basis 2 3 month intervals for maximum performance Remove the lube relief plug and add new lubricant at the lube fill fitting until new grease is evident at the relief Reinsert the relief plug Any fluid with grease like viscosity which is compatible with the process fluid may be used as stuffing box lubricant Mechanical seals require that the seal cavity at all times be filled with proper lubricant for satisfactory operation see INSTALLATION Seals The lubricant can be any low viscosity fluid with reasonable lubricity which is compatible with the process fluid and which is stable over the full range of pressures and temperatures at which the seal will be operated Common seal lubricants are light mineral oil ethylene glycol and demineralized water with glycerine HAYWARD GORDON LTD Page 10 Rev 1 HRF Series Mixers Date 11 99 Section RF MAINTENANCE MOTORS Each motor should be inspected at regular intervals The frequency and degree of thoroughness depends upon the environment and nature of service The following suggested check list requires only a few m
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