SERVICE

INSTRUCTIONS

FOR HRF SERIES MIXER

Customer Name:

Tag:

Serial No.: Size/Type:

Reduction Ratio:

Motor HP:

Output RPM:

AGMA S.F.:

Input RPM:

Hayward Gordon

Ltd.

5 BRIGDEN GATE

HALTON HILLS, ON

L7G 0A3 CANADA

PHONE: (905) 693-8595

FAX: (905) 693-1452

MONTREAL

514-697-6445

CALGARY

403-253-2737

VANCOUVER

604-986-8764

HAYWARD GORDON LTD

HRF Series Mixers

TABLE OF CONTENTS

Initial inspection ...................................................................................................... 3

Storage

General ........................................................................................................ 3

Motors and Gear Drives............................................................................... 3

Seals ........................................................................................................... 4

Shafts and Impellers .................................................................................... 4

Installation and Operation

General ........................................................................................................ 4

Mixer Assembly............................................................................................ 5

Mounting ...................................................................................................... 5

Motors .......................................................................................................... 6

Gear Drives .................................................................................................. 6

Seals ........................................................................................................... 6,7

Shafts and Impellers .................................................................................... 7,8

Lubrication

Bearings ....................................................................................................... 9

Motors and Gear Drives............................................................................... 9

Seals ........................................................................................................... 9

Maintenance

Motors .......................................................................................................... 10

Gear Drives .................................................................................................. 10

Trouble Shooting..................................................................................................... 11,12

APPENDIX ........................................................................................................... 13

Parts Lists .................................................................................................... 14

Impeller Blade Bolt and Set Screw Torque.................................................. 15

Stuffing Box Instructions .............................................................................. 16

Stuffing Box, High Pressure......................................................................... 17

Single Mechanical Seal................................................................................ 18

Double Mechanical Seal .............................................................................. 19

Commissioning and Service

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Date 11/99

Section: RF

Copyright 2002 © Hayward Gordon Limited Specifications subject to change without prior notice

HAYWARD GORDON LTD

HRF Series Mixers

HRF MODEL NUMBERING

HRF mixers have model numbers of the format;

HRFX -_ _ -_ _ _

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.

HRFX models include baseplate with lip seal.

HRFS models include mounting flange with stuffing box.

HRFM 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.

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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, 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

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Section: RF unavoidable the seal housing and lubricator 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:

1. Ensure the mixer rotation is correct before permanently wiring the motor.

2. Read all tags, nameplates and this manual prior to operating the unit.

3. Check motor operating amperage against motor nameplate amperage.

4. Do not operate in a fluid with a specific gravity or viscosity higher than that for which the unit is designed.

5. 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.

7. A minimum of 4" radial clearance must be maintained between the impeller and any obstruction.

8. Any anticipated changes in motor horsepower, mixer speed, shaft length, 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.

2. 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.

3. Mixers supplied with in-tank couplings are to be assembled using the hardware supplied and torqued to values shown in Table III (pg. 8).

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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.

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 grade 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

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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 into 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.

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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 NOT 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 heat 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.

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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

Size

¼”-20UNC

5/16”-18 UNC

3/8”-16 UNC

½”-13 UNC

5/8”-11 UNC

¾”-10 UNC

7/8”-9 UNC

1”-8 UNC

Torque Values (ft.-lbs.)

Dry

6

12

20

55

110

180

260

350

Lubricated

4.5

9.5

15

40

85

135

200

270

HAYWARD GORDON LTD

HRF Series Mixers

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Section: RF

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 o

F. Grease should be non-reactive, oxidation resistant to ball bearings and should not separate below 300 o

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 humidity conditions that could cause moisture condensation on the inside walls of the mixer drive.

3.Oil temperatures during mixer operation that exceed 200 o

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.

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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 minutes 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.

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HRF Series Mixers

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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 solution is obvious, contact Hayward Gordon

Limited.

TROUBLE

NOISE

WHAT TO INSPECT

OVERHEATING

1. Motor Overload

2. Is oil level to low?

3. Breather

4. Grade of oil

5. Condition of oil

6. Stuffing Box (if supplied)

1. Inspect impellers

2. Worn or improperly installed or maintained couplings.

3. Are bearings and gears exposed to an abrasive substance e.g., dusty atmosphere?

4. Structure amplification

ACTION 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)

Check oil level to see that housing is filled with lubricant to the specified level.

Breather must be open and clean. Clean breather regularly in a solvent.

Oil must be of a grade specified in lubrication instructions. If it is not, flush unit and refill with correct grade.

Check to see if oil is oxidized, dirty, or of high sludge content.

Change oil.

Stuffing box gland must not be over-tightened. See

"Packing Procedure" for proper packing and break-in.

(Included if applicable.)

Be sure clearance between impeller and any in-tank construction (including tank walls for anchors, scrapers, etc) is sufficient to permit unhindered rotation.

Couplings can generate noise which seems to emanate from gear case. Check for proper lubrication, alignment, or worn parts.

Abrasive substance will cause excessive gear and bearing wear. Make necessary provisions to prevent entrance of abrasive substance. Clean and flush drive thoroughly and refill with new oil. Revise maintenance practices to include more frequent changes.

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.

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TROUBLE SHOOTING, continued

TROUBLE WHAT TO INSPECT

VIBRATION

1. Inspect Impellers

2. Bolts tightened

3. Mixer support structure

4. Lower agitator shaft

5. Steady bearing

OIL LEAKAGE

1. Is breather open?

2. Worn oil seals

ACTION

Are all blades and extension arms bolted securely to the impeller hub(s) in accordance with match marks?

Be certain that all mounting, and coupling bolts are tightened to the correct wrench torque.

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 should not be bent. The rigid coupling halves must be connected according to instructions.

Has excessive wear occurred to the bearing bushing?

Is bearing securely bolted to the vessel and properly aligned?

Breather must be open and clean.

Replace defective seals.

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Section: RF

APPENDIX

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ITEM

4.

5.

6.

1.

2.

3.

7.

8.

9.

10.

DESCRIPTION

MOTOR

GEARBOX

PEDSTAL

BASEPLATE

SLEEVE COUPLING

SNAP RING

BEARING

LIP SEAL

ADAPTER PLATE

EXTENSION SHAFT

QTY./UNIT

1

1

1

1

1

1

1

1

1

1

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Section: RF

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.

Liberally coat the shaft with lubricant such as molybdenum disulphide paste for ease of sliding.

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".

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 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 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.

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 keyslot 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.

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.

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 3/8 1/2 5/8 3/4 7/8 1

Torque ft.lb

5.8

11 19 42 82 140 330 460

Impeller Blade Torques (A)

Dia

Torque ft.lb

1/4 3/8 1/2

4.8

17 43

5/8 3/4 7/8 1 1-1/8 1-1/4 1-1/2

85 130 200 270 400 500 730

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HRF Series Mixers

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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, 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.

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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

PART

NO.

DESCRIPTION

3

4

5

6

1

2

STUFFING BOX FLANGE ASSEMBLY * +

GLAND PLATE *

PACKING GLAND *

STUD

NUT

PACKING RINGS *

7

8

LANTERN RING *

RELIEVE PLUG

9 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

HRF Series Mixers

SINGLE MECHANICAL SEAL - (John Crane Type 32 depicted)

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Section: RF

PART

NO.

1

2

3

4

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)

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Section: RF

PART NO.

*1

*2

*3

*4

DESCRIPTION

UPPER STATIONARY FACE

LOWER STATIONARY FACE

ROTATING ASSEMBLY

O RING (ROTATING FACE)

*5

*6

*7

*8

9

10

O RING (STATIONARY FACE)

GASKET (STATIONARY FACE 1/16" THK.)

GASKET (STATIONARY FACE 1/16" THK.)

LIP SEAL

SEAL HOUSING

GREASE FITTING

11 FLUSH OUTLET 1/4 N.P.T.

12 STRIGHT THREADED PLUG

13 HEX HEAD BOLT C/W LOCKWASHER

14 FLUSH INLET 1/4 N.P.T.

* RECOMMENDED SPARE PARTS

1

1

4

1

1

1

1

1

1

1

1

1

2

2

3

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,

• the drive is undamaged (no damage caused by transport or storage) and

• it is certain that the following requirements have been fulfilled:

• with standard gear units: ambient temperature between 0 °C and +40 °C, no oil, acid, gas, vapors, radiation, etc.,

• 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 < 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

• 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).

• a higher oil level with synthetic oil. Correct the oil level prior to startup (see “Inspection / Maintenance” on page 24).

3.3

Installing the gear unit

The gear unit or geared motor must be mounted/installed in the specified mounting position on a level

1)

, 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 mounting 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 position M2.

6

1) Maximum permitted flatness error for flange mounting (approximate values with reference to DIN ISO 1101): with

→

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

Installation in damp areas or in the open

Use plastic inserts (2 – 3 mm thick) if there is a risk of electrochemical corrosion between the gear unit 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.

Gear units are supplied in corrosion-resistant versions for use in damp areas or in the open air. Any damage to the paintwork (e.g. on the breather valve) must be repaired.

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.

• No breather valve will be supplied for gear units in enclosed design.

Activating the breather valve

Usually the breather valve is activated in the plant. Should this not be the case, the transport fixture must be removed from the breather valve prior to the startup of the gear unit!

1. Breather valve with transport

fixture

2. Remove transport fixture 3. Activate breather valve

3

02053BXX 02054BXX 02055BXX

Painting the gear unit

Cover breather valve and oil seals with protective tape prior to painting or partly repainting the drive. Remove adhesive strips when the paint job is finished.

"R..7, F..7, K..7, S..7 , Spiroplan

®

W Gear Units" - Operating Instructions

7

4

Required tools / Material

4 Assembly / Disassembly

4.1

Required tools / Material

• Set of spanners

• Torque wrench (for shrink discs, AQ adapters without keyway, input shaft assembly with centering shoulder)

• Mounting device

• Shims and distance rings if necessary

• Fixing devices for input and output elements

• Lubricant (e.g. NOCO

®

fluid)

• Agent for securing screws, e.g. Loctite 243 (for input shaft assembly with centering shoulder)

Mounting tolerances

Shaft end

Diametric tolerance in accordance with

DIN 748

• ISO k6 for solid shafts with d, d1

≤

50 mm

• ISO m6 for solid shafts with d, d1 > 50 mm

• ISO H7 for hollow shafts

• Center hole according to DIN 332,

shape DR..

Flanges

Centering shoulder tolerance according to

DIN 42948

• ISO j6 with b

1

≤

230 mm

• ISO h6 with b

1

> 230 mm

8

"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 input and output elements

Fig. 1 is an example of a mounting device for mounting couplings or hubs onto gear unit or motor shaft ends. It may be possible to dispense with the thrust bearing on the mounting device.

Gear unit shaft end Thrust bearing

4

Coupling hub

003371AEN

Fig. 1: Example of a mounting device

Fig. 2 displays the correct mounting arrangement b

of a gear wheel or sprocket to prevent excessively high overhung loads.

Hub Hub

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 accordance 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, S..7 , Spiroplan

®

W Gear Units" - Operating Instructions

9

6

Inspection and maintenance periods

6 Inspection / Maintenance

6.1

Inspection and maintenance periods

Time period What to do?

every 3000 machine hours at least every six months check oil depending on operating instructions

(

→

Fig. 7) at least every three years change mineral oil replace bearing (anti.-fr.) grease

→

Section

see section 6.3

depending on operating conditions

(

→

Fig. 7) at least every five years change synthetic oil 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

[h]

25000

CLP PG

20000

15000

CLP HC

Average value per type of lubricant at 70° C

10000

CLP

5000

0

70

80

90 100

Oil bath steady-state temperature

110 [°C]

120

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/aggressive environmental conditions!

24

"R..7, F..7, K..7, S..7 Spiroplan

®

W Gear Units" - Operating Instructions

Inspection and maintenance

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 dependent on the mounting position. The respective position can be determined in the mounting position diagrams (see section 8).

Checking the oil level

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. 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

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.

2. Place a container underneath the oil drain plug

3. Remove oil level plug, breather plug/valve and oil drain plug

4. Drain oil completely

5. Install oil drain plug

6. 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 on

nameplate

– check at the oil level plug

7. Install oil level plug

8. Install breather plug/valve

6

"R..7, F..7, K..7, S..7 Spiroplan

®

W Gear Units" - Operating Instructions

25

7

Troubleshooting...

7 Troubleshooting...

Problem

Unusual, regular running noise

Possible cause

a) Meshing/grinding noise:

Bearing damage b) Knocking noise:

Irregularity in the gearing

Solution

1.

Check the oil (

→

section 6.3)

2. Contact customer service

Unusual, irregular running noise

Foreign bodies in the oil

1. Check the oil (

→

section 6.3)

2. Stop the drive, contact custo-

mer service

Oil leaking

1) from the motor flange from the motor oil seal from the gear unit flange from the output end oil seal a) Seal defective b) Gear unit not vented a) Call customer service b) Vent the gear unit

(

→

section 8)

Oil leaking from the breather valve a) Too much oil b) Breather valve not fitted properly c) Frequent cold starts (oil foams) and/ or high oil level a) Correct the oil level

(

→

section 6.3) b) Fit the breather valve

correctly

(

→

section 8)

Output shaft is not rotating although the motor is running or the input shaft is rotating

Shaft hub connection in the gearbox interrupted

Send in the gear unit/geared motor for repair

1) It is normal for small amounts of oil/grease to leak out of the oil seal during the

running-in phase (24 hour running time).

Please have the following information to hand if you require the assistance of our customer service:

• Nameplate data (complete)

• Type and extent of the fault

• Time and circumstances of the fault

• 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

Breather valve

Oil level control plug

→

XX

Oil drain plug

See notes on page XX!

Churning losses

*

→

There is a possibility of increased churning losses with some mounting positions (indi-

cated by an asterisk * in the mounting position sheets). Please contact SEW when dealing with the following combinations:

Mounting position Gear unit type

M2, M4

M2, M3, M4, M5, M6

R

F

K

S

Gear unit size

97...107

> 107

97...107

> 107

77...107

> 107

77...97

Input speed [rpm]

> 2500

> 1500

> 2500

> 1500

> 2500

> 1500

> 2500

8

"R..7, F..7, K..7, S..7 Spiroplan

®

W Gear Units" - Operating Instructions

29

RF17-RF167

04 041 000

8.3

RF17-RF167

Normal 270°

0°

Normal

90°

180°

Normal

2

1

Normal

3

M4

*

RF17

M1

M2

*

8

M5

M3

M6

RF17, RF27

RF47, RF57

RF17, RF27

M2, M4

M5

"R..7, F..7, K..7, S..7 Spiroplan

®

W Gear Units" - Operating Instructions

*

→

29

31

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 reference to mounting positions M1...M6.

Helical (R-) gear units

Gear unit type

R17/R17F

R27/R27F

R37/R37F

R47/R47F

R57/R57F

R67/R67F

R77/R77F

R87/R87F

R97

R107

R137

R147

R167

M1

1)

0.25

0.25/0.4

0.3/1

0.7/1.5

0.8/1.7

1.1/2.3

1.2 / 3

2.3 / 6

4.6/9.8

6/13.7

10/25

15.4/40

27/70

M2

1)

0.6

0.7

0.9

1.6

1.9

2.6/3.5

3.8 / 4.3

6.7 / 8.4

11.7/14

16.3

28

46.5

82

Fill quantity in liters

M3 M4

3.6

7.2

11.7

16.9

29.5

48

78

0.35

0.4

1

1.5

1.7

2.8

4.3

7.7

13.4

19.2

31.5

52

88

0.6

0.7

1.1

1.7

2.1

3.2

M5

2.5

6.3

11.3

13.2

25

39.5

66

0.35

0.4

0.8

1.5

1.7

1.8

M6

3.4

6.5

11.7

15.9

25

41

69

0.35

0.4

1

1.5

1.7

2

Gear unit type

RX57

RX67

RX77

RX87

RX97

RX107

Gear unit type

RXF57

RXF67

RXF77

RXF87

RXF97

RXF107

Gear unit type

RF17

RF27

RF37

RF47

RF57

RF67

RF77

RF87

RF97

RF107

RF137

RF147

RF167

1)

M1

1)

0.25

0.25/0.4

0.4/1

0.7/1.5

0.8/1.7

1.2/2.5

1.2 / 2.6

2.4 / 6

5.1/10.2

6.3/14.9

9.5/25

16.4/42

26/70

M2

1)

0.6

0.7

0.9

1.6

1.8

2.7/3.6

3.8/4.1

6.8/7.9

11.9/14

15.9

27

47

82

Fill quantity in liters

M3

7.1

11.2

17

29

48

78

0.35

0.4

1

1.5

1.7

2.7

3.3

M4

7.7

14

19.2

32.5

52

88

0.6

0.7

1.1

1.7

2

3.1

4.1

M5

6.3

11.2

13.1

25

42

65

0.35

0.4

0.8

1.5

1.7

1.9

2.4

M6

6.4

11.8

15.9

25

42

71

0.35

0.4

1

1.5

1.7

2.1

3

The larger gear unit in multi-stage gear units must be filled with the larger oil quantity.

M1

0.6

0.8

1.1

1.7

2.1

3.9

M1

0.5

0.7

0.9

1.6

2.1

3.1

M2

0.8

0.8

1.5

2.5

3.4

5.6

M2

0.8

0.8

1.5

2.5

3.6

5.9

Fill quantitiy in liters

M3 M4

1.3

1.7

2.6

4.8

7.4

11.6

1.3

1.9

2.7

4.8

7

11.9

Fill quantity in liters

M3 M4

1.1

1.5

2.4

4.9

7.1

11.2

1.1

1.7

2.5

4.7

7

10.5

M5

M5

0.7

1

1.6

2.9

4.8

7.2

0.9

1.1

1.6

2.9

4.8

7.7

M6

0.9

1.1

1.6

2.9

4.8

7.7

M6

0.7

1

1.6

2.9

4.8

7.2

"R..7, F..7, K..7, S..7 Spiroplan

®

W Gear Units" - Operating Instructions

49

9

Lubricants

9.2

Recommended lubricants for SEW drives

R 32

R 302

R, K, F, S gear units

W gear units

Helical-worm gear units

Helical gear units, helical-bevel gear units, parallel gear units

9

Grease

DIN

51181

Bio oil

Food ind. oil

E HCE

API

GL5

SEW

PG

CLP

HC

CLP

PG

CLP

(CC)

CLP HC

Oil

CLP

PG

CLP

(CC)

HLP

(HM)

CLP

HC

HLP

(PM)

CLP

(CC)

CLP HC

CLP

PG

CLP

(CC)

"R..7, F..7, K..7, S..7 Spiroplan

®

W Gear Units" - Operating Instructions

53

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 selflocking, 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 to support

5. 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.

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

Set Screw

Torque for Tightening Set Screws

Hex Size Minimum Recommended

Diameter Across Torque

1/4

5/16

3/8

7/16

1/2

5/8

1/8

5/32

3/16

7/32

1/4

5/16

In-Lbs

66

126

228

348

504

1104

Ft-Lbs

5.5

10.5

19.0

29.0

42.0

92.0

1/8

Table 3

Torque for Tightening Skwezloc Collars

Cap Screw Hex Size Minimum Recommended

Size Across Torque

In-Lbs

70

Ft-Lbs

5.8

#8-32

UNC-3 A

#10-24

UNC-3 A

9/64 90 7.5

#1/4-20

UNC-3 A

#5/16-18

UNC-3 A

3/16

1/4

180

400

15

33.3

1.

2.

3.

4.

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 typical re-lubrication schedules.)

Relubrication

Add grease slowly with shaft rotating until a slight bead forms at the seals.

Re-lubrication is generally accompanied by a temporary rise in operating temperature until the bearing chamber is stabilized with the proper amount of grease.

It necessary to re-lubricate while bearing is stationary, refer to SEALMASTER catalog for maximum grease capacity for the size bearing.

For abnormal operating conditions of high temperature or abnormal environments, consult SEALMASTER

Engineers.

TABLE 1

Speed

100 RPM

500 RPM

1000 RPM

1500 RPM

Any Speed

Any Speed

Any Speed

Temperature

Up to 120°F

Up to 150°F

Up to 210°F

Over 210°F

Over 150°F

Any Temp,

Any Temp.

Cleanliness

Clean

Clean

Clean

Clean

Dirty

Dirty

Extreme Conditions

Greasing Interval

6 to 12 months

2 to 6 months

2 weeks to 2 Months

Weekly

1 week to month

Daily to 2 weeks

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