INSTALLATION, OPERATION AND MAINTENANCE MANUAL FOR HAYDEN OIL COOLERS

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LIMITED WARRANTY Hayden Industrial Products, LLC, Corona, California, warrants that; A. All Hayden Industrial Products (Hayden) parts are guaranteed to be free from defects of workmanship and materials when applied within the scope of Hayden approved applications. Merchandise found to be defective will be repaired or replaced free of charge. No other warranty expressed or implied is made. The manufacturer shall not be liable for any damage or injury to property (other than the product itself) or any commercial loss or damage. Requests for return of defective merchandise must be submitted to the factory. A RGA will be issued as authorization to return merchandise, freight prepaid, for factory inspection and disposition. All replacements are F.O.B. factory and will be made subject to factory inspection report, a copy of which is available on customer request. Requests to the factory for the above purposes shall be made within twelve months from the date of original sale.

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LIMITATION OF WARRANTY AND LIABILITY This warranty does not apply to any such Hayden products and parts which have failed as a result of faulty installation or abuse, or incorrect connections or alterations, made by others, or use under abnormal operating conditions or misapplication of the products and parts. Hayden will not approve for payment any repairs made outside its factory without prior written consent of its Corona, CA office.

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The foregoing shall constitute our sole and exclusive warranty and our sole and exclusive liability and is in lieu of all other warranties, whether written, oral, implied or statutory. There are no warranties which extend beyond the description on the page hereof. Seller does not warrant that said goods and articles are of merchantable quality or that they are fit for any particular purpose. The liability of seller on any claim of any kind, including negligence, for any loss or damage arising out of or connected with, or resulting from the sale and purchase of the products and parts covered by this proposal, acknowledgment, order or from the performance or breach of any contract pertaining to such sale or purchase, or from the design, manufacture, sale, delivery, resale, installation, technical direction of installation, inspection, repair, operation or use of any products or parts covered by this proposal, acknowledgement, order or furnished by seller shall, in no case exceed the price allocable to the products or parts thereof which give rise to the claim and shall terminate one (1) year after the shipment of said products and parts. In no event, whether as a result of breach of contract, or warranty or alleged negligence, defects, incorrect advice or other causes, shall seller be liable for special or consequential damages, including, but not limited to, loss of profits or revenue, loss of use of the equipment or any associated equipment, cost of capital, cost of substitute equipment, facilities or services, down time costs, or claims of customers of the purchaser for such damages. Hayden neither assumes nor authorizes any person to assume for it any other liability in connection with the sale of its products and parts. Some states do not allow the exclusion or limitation of incidental or consequential damages so all of the above limitations or exclusions may not apply to you.

SAFETY ACCESSORIES WARNING The responsibility for providing safety accessories for equipment supplied by Hayden is that of the installer and user of this equipment. Hayden sells its equipment with and without safety accessories, and accordingly, it can supply such safety accessories upon receipt of order. The user, in making its determination as to the appropriate safety accessories to be installed, and any warning notices, should consider (1) the location of the installation, (2) the accessibility of employees and other persons to this equipment, (3) any adjacent equipment, (4) applicable building codes, and (5) requirements of the Federal Occupational Safety and Health Act.

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Users and installers of any Hayden equipment that includes fans or blowers should read RECOMMENDED SAFETY PRACTICES FOR AIR MOVING DEVICES which is published by Air Movement and Control Association, 30 West University Drive, Arlington Heights, IL 60004.

GENERAL SAFETY INSTRUCTION 1. Follow all local electrical and safety codes, the National Electrical Code (NEC) and Occupational Safety and Health (OSHA). Replace or repair any damaged or mechanical parts or electrical wiring immediately. Keep all body parts (hands, feet) from coming in contact with fan blades or motor drive operation. Never exceed maximum operating conditions as outlined in specifications.

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Installation, Operation & Maintenance Manual

INTRODUCTION The purpose of this manual is to aid in the proper installation and operation of coolers manufactured by Hayden Industrial Products (Hayden). These instructions are intended to supplement good general practices and are not intended to cover detailed instructions or procedures, because of the wide variety and types of units manufactured by Hayden. It is the responsibility of the purchaser to assure that the installation and maintenance of this equipment are handled by qualified personnel experienced in such work and equipment. Contact your local representative for details. Read instructions carefully before attempting to assemble, install, operate, or service these Hayden heat exchangers. Protect yourself and others by observing all information and additional instructions included with this equipment. Failure to comply with instructions could result in personal injury and/or property damage. Retain these instructions for future reference. For additional copies or if there are any questions, please contact Hayden Industrial Products, Corona, California.

DESCRIPTION Hayden Temp-Troller heat exchangers are compact, lightweight units that provide reliable temperature control of oils and a wide range of other highly viscous fluids. Highly efficient heat transfer rates are obtained because Hayden heat exchangers feature the exclusive new inner swirl design. These provide dependable fluid temperature control in compact packages. This unit provides a self-contained, air-moving device. The integrated heat transfer assemblies contain fans and power sources to provide airflow for the heat transfer unit.

SHIPMENT AND RECEIVING Prior to shipment from Hayden, all products have been thoroughly inspected and passed Quality Assurance requirements.

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All equipment shipped from Hayden is boxed, skidded, or crated to fully comply with railroad or trucking requirements. Inspect all shipments carefully for damage. THE RECEIVER MUST NOTE ANY DAMAGE ON THE CARRIERS BILL OF LADING AND FILE A CLAIM IMMEDIATELY WITH THE FREIGHT COMPANY, IN THE CASE OF ANY DAMAGE. Keep a record of all equipment received, including inspection details and date of receipt, because of the possibility of partial shipments. If you receive damaged goods, contact your Hayden representative for repair or replacement service.

HANDLING Handle your equipment with care. Some units are provided with lifting lugs or holes for easy handling. Others must be handled using nylon straps or wellpadded chains and cables, which protect the units coating and housing. Spreader bars should be used when lifting large units.

STORAGE If units are stored for any length of time, they should be stored in a clean, dry location to prevent rust and corrosion. Outdoor storage is not recommended. When outdoor storage is necessary, they should be protected from the elements as best as possible. Cover the units, grease the bearings, and keep motors dry and clean.

EXTENDED STORAGE Units are to be stored in their original containers or equivalent protection and should be kept in a clean, dry, protected warehouse where exercised control over temperature, dust, dew point, shock and vibration is reasonably maintained. A) B) C) Temperatures: between 50o F and 120o F. Maximum relative humidity of 60% Shock or vibration: 2 mils maximum to prevent bearings from brinelling. Exceeding this limit will require vibration dampening material under the units.

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Motor bearings (and fan bearings on belt drive units) are to be greased at the time of going into extended storage. Motor shaft (and fan shaft on belt drive units) are to be manually rotated every month. Additional grease is to be added, purging some of that in the bearing cavity every six (6) months. GREASE IN THE BEARINGS IS TO BE PURGED AT THE TIME OF REMOVAL FROM STORAGE, MAKING SURE THAT AN AMPLE SUPPLY OF FRESH GREASE IS IN EACH GREASE CAVITY. GREASE USED MUST BE COMPATIBLE WITH THAT ALREADY IN MOTOR AND FAN BEARINGS. Belts, on belt drive units, should be checked at the time of removal from storage for proper belt tension. Tighten belts, if necessary. It is recommended that upon installation, the vibration levels be checked to assure that the levels do not exceed the levels set forth in this manual. (See Table 1). Storage records complying with the above requirements should be maintained.

GENERAL INFORMATION 1. Air cooled oil coolers are built for operation with maximum oil pressures of 300 psi and temperatures of 350o F unless otherwise specified. The motors are guaranteed by the manufacturer for operation in maximum ambient conditions of 104o F and 3000 altitude. Consideration should be given to installation location so motors are not subjected to high temperatures, humidity or corrosive environment above this level. Air/Oil coolers that are to be installed for utilization of waste heat for space heating should be mounted 7 to 14 feet above the floor depending on the structure, for proper heat distribution.

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INSTALLATION INSTRUCTIONS Hayden self-contained oil cooler designs can be adapted to various mounting locations. The most important consideration which must be taken into account when deciding upon the location of a cooler is provision for the supply of air to the cooler and removal of air from the cooler. The performance of the heat exchanger is dependent upon the quantity and the temperature of the air entering the cooler.

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The units are adaptable for mounting in a well-ventilated indoor area. Care must be taken to see that the temperature of the area does not build-up and to ensure unrestricted airflow to and from the unit. When installed outdoors, self-contained oil coolers should be located so that there is a free flow of air to and from the unit. Horizontal discharge units require a minimum clearance of twice the width of the unit at the air inlet and outlet. It is desirable to position the units so that the prevailing summer wind will blow into the unit inlet. Wind deflectors, or air discharge scoops may be mounted on the discharge side to prevent the direct force of the wind from affecting the air delivered at the propeller fan. When units are located on the roof, it is best to mount the cooler near the edge with the intake facing away from the building, to minimize the possibility of drawing super-heated air from the roofs surface. Supports for suspended units must be cross-braced for live load support to prevent side sway. Refer to installation instructions (Form No. P-12) supplied with all Temp-Trollers and as Attachment 1. Temp-Trollers should always be mounted to a flat, level, rigid structure. Shim the unit where necessary. This will ensure permanent alignment and a smoothrunning, vibration-free unit, as well as minimize maintenance costs. Units are supplied complete with headers and oil connections sized for connecting to standard commercial pipe. Back-up wrench should be used on the fittings when making connections. All oil piping practices used when installing self-contained oil coolers should be in accordance with the local building and safety codes. Units should not be located in corrosive atmospheres as rapid deterioration of casing, cooling coil, fan and motor may take place resulting in reduced life.

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A strainer located ahead of the cooler inlet should be installed to trap scale, dirt, or sludge that may be present in piping and equipment, or that may accumulate with use. A thermostatic or spring loaded by-pass relief valve installed ahead of the cooler or system smart internal relief valves, may be helpful to speed warmup and relieve the system of excessive pressures. All accessories should be considered in the original heat rejection and piping calculations. Connect motor only to a power supply of the same specifications as shown on the motor nameplate. Voltage may vary + 10% of nameplate voltage. Follow wiring diagram printed on motor nameplate or in terminal box. Before starting motor, follow motor manufacturer recommendations. Observe operation carefully after motor is started for the first time. Connect unit to the system by means of suitable piping or hose, using the appropriate fittings. Always use a back-up wrench when tightening fittings. Note: Insure that the cooler is in the circuit for a pressure lower than that of the cooler rating. The dry seal fittings should be lubricated with a lubricant or a thread sealant (pipe thread use Teflon type in hydraulic systems). Check for air direction and for adequate air intake and discharge areas around the cooler. Connect the power sources (A.C., D.C., or hydraulic) to the motor or the shaft in case of a belt driver. Once again, verify correct rotation of fan and air direction through the cooler. Hydraulic motors have a limitation of 200 psi backpressure and are bi-rotational. Maximum tip speed of fan blade is 16,000 feet per minute or the limiting rotation of the fan.

STARTUP: Lock out the power source. Place the cooler on it rigid foundation or platform. Level the unit using shims where necessary. Tighten all mounting bolts securely with lock nuts and lock washers.

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Tighten belts, if necessary. NOTE THAT ALL BOLTS, SETSCREWS AND BELTS SHOULD BE TIGHTENED AGAIN AFTER TWO DAYS OF INITIAL OPERATION. Clearance should be checked all around between blade tips and the housing before starting up. The fan should not strike the housing. Unless the unit has been in storage for several months, no initial lubrication is required. Motors have been pre-lubricated by motor manufacturer and fan bearings by the fan manufacturer. Arrows to show direction of rotation and airflow are attached to the fan housings or fan blades. The fan should not need balancing, as it was balanced at the factory to be within vibration levels before shipment. However, there are several things that may cause vibration, such as rough handling in shipment and erection, weak foundations, and alignments. It is recommended that the vibration levels be checked with a vibration analyzer to verify that the vibration is within levels recommended later in this manual. (See Table 1). During maintenance, fans should be disconnected from their power source.

MAINTENANCE: Periodic inspection of all components is the key to good maintenance and trouble-free operation. Frequency of inspection must be determined by the user and is dependent upon the severity of the application. Prepare a maintenance schedule and make sure it is strictly adhered to. NEVER SERVICE OR ADJUST ROTATING EQUIPMENT WHILE IT IS IN OPERATION. LOCK OUT THE POWER SOURCE BEFORE PERFORMING MAINTENANCE. Regular fan and oil cooler maintenance should include the following items and should be done at least once a year or every 500 hours of operation whichever occurs first: 1) Check the fan blade for any buildup of foreign material or wear from abrasion. Both can cause excessive vibration, which will lead to damage of the fan blade and other fan components. Replace the fan blade if excessive wear is noticed. Carefully clean the fan blade of any foreign material.

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2) 3) 4)

Check V-bolt drives for proper alignment, tension, and excessive wear. Lubricate the fan and motor bearings. Consult the trouble-shooting guide for excessive vibration or noise, insufficient performance, or when the fan does not operate. (See Table 2). Tighten all bolts and set screws. Heat Transfer Surface: Dirt and dust should be removed (recommended at least once a year) by brushing the fins and tubes and blowing loose dirt off with an air hose. Should the surface be greasy, the motor should be removed and the fins and tubes brushed or sprayed with a mild alkaline solution or a nonflammable degreasing fluid. Follow with a hot water rinse and dry thoroughly. A steam cleaner may also be used effectively. Check for damaged headers (manifolds) and tubes as they can reduce heat transfer and increase pressure drop through the cooler. Bent fins should be straightened out with a fin comb.

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Casing, Fan and Motor: Dirt and grease should be removed from these parts. Rusty or corroded surfaces should be sanded clean, premiered and repainted.

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Internal Cleaning of the Oil Cooler: At least once a year piping should be disconnected and a non-corrosive, degreasing agent or flushing oil circulated an drained through the unit to remove sludge from turbulators and internal tube surfaces to return the unit to its full thermal capacity. A thorough cleaning of the entire system in the same manner is preferable to avoid carryover from uncleaned piping, pump and accessories. Flush cooler and system again with oil to be used in service to displace the flushing fluid used. Drain the cooler and system before refilling again for use in operation. The strainer or any filtering devices should be removed and serviced following this cleaning operation. Be sure to dispose of the degreasing agent and any other flushing oils or cleaning agents in accordance with all applicable Environmental Health and Safety regulations.

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BACK FLUSHING: Recommended at least once a servicing/maintenance breakdown. 1. year, or at oil change or other

Disconnect the cooler from the hydraulic system. Back flushing should be done at about 100 psi with a flow of 3 gallons per tube (i.e. 54 tubes in 1 pass would require 3 x 54 = 162 GPM or in a 2-pass cooler would require 3 x 54/2 = 81 GPM through cooler). The oil temperature should be between 150 to 160oF. Use low viscosity oil such as Mobil DTE light oil (viscosity about 70 SUS at 160oF). Flush cooler in either direction for 30 minutes. Drain the cooler and flush with the oil to be used in service for at least 15 minutes. Drain the cooler again and re-install in system for use in operation.

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BEARINGS AND LUBRICATION: Selection of the correct bearing grease and greasing intervals depends on several factors. Extreme high or low temperatures, dirty or damp surroundings, and vibration exceeding 1 or 2 mils are all factors that will require more frequent greasing or special greases. The motor bearings and the fan bearings on the belt drive fans should be greased at regular intervals. Motor manufacturers greasing instructions and recommendations should be followed closely. Avoid the use of a pressure greasing system, which tends to fill the bearing chamber completely. Do not over grease. Use only 1 or 2 shots with a handgun in most cases. Maximum handgun rating should be 40 psi. Rotate bearings during lubrication where good safety practice permits. NOTE: On motors with non-regreasable sealed bearings, no lubrication is required for the life of the bearings. The most frequent cause of bearing failure is not greasing often enough, using an excessive quantity of grease, or using incompatible greases. Excessive vibration, especially if the bearing is not rotating, will also cause bearings to fail. Bearings must also be protected from water and moisture to avoid internal corrosion.

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In general, use a high quality medium consistency, ball bearing grease with a polyurethane thickener such as Shell Dolium R grease. IMPORTANT: Do not increase the fan speed before first contacting Hayden, Inc. Arbitrarily speeding up the fan can cause motor overload, failure, and potential fan blade failure.

VIBRATION: Excessive fan vibration can be caused by many factors. ALL POSSIBLE SOURCES OF EXCESSIVE VIBRATION MUST BE CHECKED OUT AND CORRECTIVE ACTION TAKEN IMMEDIATELY TO CORRECT THE PROBLEM. See the fan trouble-shooting chart (Table 2) for possible causes of excessive fan vibration. A vibration analyzer will be of great assistance in determining the amount of vibration. The following values give an indication of the fan vibration condition. Vibration readings should be taken on the fan bearings (if possible, on belt drive fans), or motor (on direct drive fans). Horizontal, vertical, and axial readings should be taken.

TABLE 1 Vibration displacement in mils, Double Amplitude Fan RPM 870 1160 1750 3450 Good 1.7 1.2 .75 .50 Fair 3.3 2.5 1.5 .9 Slightly Rough 6.5 5.0 3.5 2.0 Rough Above 6.5 Above 5.0 Above 3.5 Above 2.0

Interpolate for fan speeds other than show above. The fan should not be operated unless the maximum vibration reading is in at least the fair range.

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TABLE 2 Trouble-Shooting Chart PROBLEM INADEQUATE COOLING POSSIBLE CAUSES Lower flow rate of oil than design Lower Air velocity than design Higher ambient temp. than design Lower inlet oil temperature to inlet air temperature than design Higher oil viscosity than design Undersized cooler/misapplication Clogged fins/damaged fins Bent return or header bends Higher elevation than design Incorrect fluid high viscosity Contaminants in cooler Incorrect piping or fittings Incorrect installation of inlet and outlet fittings on system smart coolers Incorrect (lower) voltage on electric motors Low oil flows on hydraulic drives Incorrect pitch on fan blade Incorrect fan rotation Excessive air restriction (e.g. louvers or ducting) Damaged finned section Buildup of foreign material on fins Higher elevation than design of cooler Build upon fan blade Accumulation of material on fan blade Worn or corroded fan blade Bent shaft Fan Blade or sheaves loose on shaft Motor out of balance Fan Blade out of balance Sheaves eccentric or out of balance Bearing or drive misalignment Mismatched belts Belts too loose or too tight

EXCESSIVE PRESSURE DROP

INSUFFICIENT AIR

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EXCESSIVE VIBRATION

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TABLE 2 CONTINUED Trouble-Shooting Chart PROBLEM AIRFLOW TOO MUCH POSSIBLE CAUSES Loose or worn bearings Loose bearing bolts Loose fan mounting bolts Weak or resonant foundation Foundation not flat and level Structures not crossbraced System pulsation (DANGER) fan operation in a stall Blades at different angles on adjustable pitch fans Actual system is less restrictive to flow than expected Fan speed higher than design Blown fuses Broken belts Loose pulleys Electricity turned off or not wired properly Wrong voltage Motor too small and overload protector has tripped circuit No oil flow to hydraulic motor Accumulation of material on fan blade Worn or corroded fan blade Bent shaft Fan Blade or sheaves loose on shaft Fan Blade hitting housing Fan Blade out of balance Bearing or drive misalignment Mismatched belts Belts too loose or too tight Belts hitting guard Loose or worn bearings Belts worn Belts oily or dirty Defective or bad bearings

FAN DOES NOT OPERATE

EXCESSIVE NOISE

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TABLE 2 CONTINUED Trouble-Shooting Chart PROBLEM Excessive Noise (Continued) POSSIBLE CAUSES Bearings need lubrication Loose bearing bolts Loose fan mounting bolts System pulsation or surge Electrical noise Noise from high velocity air system Fan in stall condition (DANGER) Rattle of components in high velocity airstream

It is recommended that the users and installers of this equipment familiarize themselves with AMCA publication #201, Fans and Systems, and publication #202 Trouble-Shooting, which are published by Air Movement and Control Association, 30 West University Drive, Arlington Heights, IL 60004.

SPARE PARTS: Spare parts are not needed for the first year of operation. If spare parts are desired, then it is suggested that a spare motor and fan blade be ordered for direct drive fans. For belt drive fans, in addition to the motor and fan blade, it is suggested that a spare set of bearings, shaft, sheaves, and belts be ordered. When ordering spare parts, specify the parts desired for the cooler model and part number, and if possible the serial number. Contact your local sales representative for price and delivery.

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