Hayward HRF Service Instructions Manual
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
OFFICES IN:
MONTREAL
514-697-6445
FAX: (905) 693-1452
CALGARY
403-253-2737
VANCOUVER
604-986-8764
HAYWARD GORDON LTD Page 1
HRF Series Mixers Date 11/99
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
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Section: RF
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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Section: RF
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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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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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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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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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.-lbs.)
Size Dry Lubricated
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
6
12
20
55
110
180
260
350
4.5
9.5
15
40
85
135
200
270
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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 200oF. Grease should be non-reactive,
oxidation resistant to ball bearings and should not separate below 300oF. 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 200oF
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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