a a1
mg Air-X-Changers
Harsco
Installation, Maintenance, and Operating Instructions
for
Electric Motor Drive Units
Airexcchangers has prepared this manual for the care and up keep of your
Cooler. With these simple instructions and a few tools, the cwner can performn many
‘maintenance and light tepair procedures such as tightening the V-belts, checking fan
blade angle, greasing bearings, setting the vibration switch, and cleaning fins and
tubes. If more information is needed about a specific component we recommend
that you refer to the attached specific manufactures maintenance instructions i.e.
(motors, fans, and bearings).
Because this manual covers several cooler styles and sizes, the instructions
outlined are general in nature. This should be noted when looking at any illustration
or parts of the manual that may not apply to your cooler.
Good judgement should be used when purchasing either replacement parts or
Products to be used in your repair or maintenance work. Some products may cause
a decrease in performance. All replacement parts should be equivalent to the
‘anufacture’s original parts. Replacement paris ordered from the factory always
‘rary nur required high level of quality. DO NOT take a chance with products that
might not do the job.INSTALLATION AND OPERATION MANUAL
TABLE OF CONTENTS
MANUAL
Equipment Siting and Installation
On Arrival At Site
‘Shipping Damage
Loose Parts a
Unioading Coolers
Lifting Layouts
Prior to Run-in
Fans
Bearings
Lubrication Guide
V-botts .
Tension Tester.
HTD Drives -
Gear Drives |
Louvers -
Runin
Vibration Switches
V-belts
Gear Drives
Process Start-up
Plugs 7
Long Ter
Fin Cleaning
Tube Cleaning
Leaking Tubes
Taper Pins
Fesonmended Spare Parts
Inspection. .
Warranty .....
Limitation of Liability”
For SaleEQUIPMENT SITING AND INSTALLATION
Setting of cooler(s) isthe responsibilty of the purchaser who must insure that
Cooler intake areas are free from obstruction to airflow and sources of hot sir
(including other air coolers). Spacing of air coolers should te adequate to avoid hot
2ir recirculation. Raising and or separating units should compensate for the effects,
of grouping coolers together.
ON ARRIVAL AT SITE SHIPPING DAMAGE
‘The cooler should be thoroughly inspected for damage by receiving
personnel. Damage in transit can be result of dropping or being struck by heavy
objects, any damage should be described on receiving documents presented by
Carrie. Prompt claim fing wil expedite early compensation from the offending
cartier.
Loose Parts
‘The parts list should be checked to see that all parts shipped with the cooler
are present. These parts may be secured to the skid base (ff so designed) or inside
the plenum area. Basically this cooler is completely shop assembled and no
‘assembly atthe job-site is required,
but occasionally special accessory devices willbe required which must be shipped
disassembled to meet height or width limitations.
UNLOADING COOLER
‘Spreader bars are to be used
{or liting when the cooler is eight (8)
fost. The cooler is supplied with liting
Points to be used for aff loading from
‘carer. Lifting by any other point may :
cause damage to the cooler.
Following are some suggested ways of
‘iting. Locate the picture which
resembles the type of unit you ha
and use as a guide on how to unioad
and handle the cooler propery. (See
unit name plate for unit type Le. EH, H,
Fl,ete.)
TUBE BUNDLES“ HUNITS
£
Zz
2?
=
Z-UNITS< ty AWARNING|
‘TURN OFF AND LOCK OUT DRIVER BEFORE ENTERING COOLER
PRIOR TO RUN-IN
NOTE: Check all nuts and bolts for tightness, bolting will loosen during
shipment
+ Fans
Check fan blade bots and hub set screws for tightness. Rotate fan by hand to
insure that shaft, speed reducer, and driver turn freely. The fan should be ch
for adequate tip clearance and blade pitch angle. Slight adjcstment of the tip
clearance can be made by loosening the fan shaft bearing bolts and moving the
Complete fan and fan shaft assembly unt itis centered in the ring. To check the fan.
blade angle, use a level bubble protractor (this can be obtained from the factory),
Loosen the nuts on the bolts and place the protractor on the angle setting mare
the clevis (refer to fan manufactures information for proper Iccation). Using a mallet
‘ap on the shank end of the blade to adjust the angle. Tighten fan blade bolts to the
proper torque (refer to manufactures maintenance instructions) making sure to
tighten evenly. Recheck biade angle. Some coolers are equipped with an automatic
fan. These fans have blade angles controlled by varying the air supply pressure. Ar
bressure should be applied by to the fan before starting to check for proper
operation, Before starting, the motor should be bumped to check for proper direction
of fan rotation,
Bearings
Bearing mounting bolts and set screws should be checked for
tightness, The manufacturer lubricates the bearings and no additional grease is
sary t0 star, When remote lube lines are provided check to insure they are
{ull by loosening at the bearing end, then fil with grease from fiting end. This will
insure that the grease lines are full of grease. During high-speed operation too
uch grease will cause over heating. To protect bearings against entrance of
foreign material when dust and water are present the bearings should contain as
much grease as speed wil alow. Daily lubrication may be required to maintain
Slight leakage at the seals. Under normal conditions use the following table as &
9uide. However, certain conditions may require a change of lubrication periods such
48 the ones described above.Read preceding page before establishing lubrication
schedule
LUBRICATION
GUIDE
[Suggested Lubrication Pariod in
leeks -
HOURS [4 T0 [251 TO]607 TO| 761 TO] 1001 TO] 1801 TO] 2001 TO|2801 TO
PER | 250 | 500 | 750 | +000 | +500 | 2co0 |” 2500 | 3000
PAY) RPM | RPM | RPM | RPM | RPM | RPM | RPM | RPM
a [ae pe wy, 7 5 7 a fe
we) 2] 7 | s | 4 2 2 1 i
a | ow} s {3s | 2 1 1 el Le
6V-Belts
On cooters with an idler or electric motor, the belts should be adjusted
before rurvin. First, loosen the four (4) bolts, which clamp the motor to the sie
‘member, or the four (4) bolls, which secure the motor to the slide base. Then,
Using the adjustment screw, take the slack out of the belts. Following the
instructions below on using the tension tester to property tension the belts,
USING THE V-BELT TENSION TESTER
1, Measure the span length (1). (See sketch on page 8)
2. Position the lower ofthe two O-rings using either of the following methods:
‘3. On the scale reading ‘Deflection Inches’, set the o-ring to show a
deflection equal to 1/64" per inch of span length (t).
. On the scale reading ‘iiches of Span Length’, set the O-ring to show a
election equal tothe inches of measured span length ().
NOTE: Read scales at bottom edge of O-ring in maximum up position,
5. At center of span (t) apply force, with tension tester perpendicular to the span,
large enough to deflect one belt on the drive until the bottom edge of the lower O-
Fing is even with the tops of the remaining belts. A straight edge across the tops
of the belts will insure accuracy of positioning
4. Find the amount of deflection force on upper scale of tension tester. The
Sliding Rubber O-ring “slides down scale as tool compresses’—stays down for
accurate readings of pounds pressure. Read at top edge of ring. (Sliding ring up
before re-using).
5. Compare the deflection force with range of forces in table on
age 8. ifless than minimum recommended deflection force, belts should be
tightened. If more than maximum deftection force, drive ‘tighter than
novessary.
NOTE: there will normally be a rapid drop in tension during the “run-n* period,
Tension new drives with a 1/3 greater deflection force than the maximumn force
recommended,
Ei?DEFLECTION FORGE TABLE
=]
\V-BELT TENSION TESTER
‘SMALL SHEAVE | SWALL SHEAVE RECOMMENDED DEFLECT
DIA. RANGE | RPM RANGE
(INCHES) RANGE DEFLECTION FORCE (Pd)
MINIMUM | MAXIMUM
WK 230 7200-3600 28 Ta
2.36:2.60 +200-3600, 32 a7
2.85280 1200-3600 | 29 35 si |
3.00515, v2o0-s00 | 4 | 38 55
335-365 12003600 | 4 41 60
442500, 990-3600 48 1
5530-690, 900-3600 | 58 85
[SVK 440-465 1200-3600 80 13
490550 41200-3600 10 5
§.90-6.70 1200-3600 20 Ww 7 i
740-800 800-1800 | fo 3 of
8.50-10.90 600-1800 - 14 20
¥%,80-1600 | 400-1200 8 2HTD Drives
Place belt on sprockets and adjust take-up so that belt teeth mesh
securely with sprocket grooves. Measure belt span (). Then tighter belt so that
it deflects 164° /inch of belt span when a force is applied es specified in the
table below.
Gear Drives
Gears are shipped with or without oll depending en the manufacture and
‘must be checked before start-up. Some gears are shipped ‘over-flod’ and the
cil must be drained tothe proper level. Fill gear with approved grade oll (efer to
‘manufactures information for listings of recommended ols),
Measure the pan length (0) as shown
in sketch above
[HTO DEFLECTION FORCE TABLE]
BELT | BELT | FORCE
erréH | worm | tbs)
2amm
30mm
8mm 50mm
5mm
140mm
85mm
‘4mm 85mm
115mm
s7omm__
NOTE: For bolts wider than 2 inch, itis
suggested that a tinch stip of metal
be placed across the belt between the
“tension tester and the beltto prevent
belt distortion,Louvers
Check all mounting brackets and bolts for tightness. On manually
rated louvers, to insure thet the linkage is adjusted property, operate biades
a fully open position toa fully closed position. On a air motor
ie should be applied to actuator to check ‘or proper
raion, and sufficient air supply. See
intenance instrucions fr further information on ait metors,
. - | AWARNING
DO NOT WALK ON LOUVERS
OR USE AS A LADDER!RUN-IN
Vibration Switch (optional) (Murphy & Nelson)
‘ter the switch has been installed, adjust by turning the adjustment screw
in a clockwise direction uni the starting torque does not vp the vibration switch.
For other brends see manufactures information,
V-Belts
un fan and check the tension frequently during tre first twenty-four (24)
hhours of operation, Thereafter, check the belt tension peviodically. Excessive
tension shortens belt and bearing life. Keep belts and sheaves clean of ant
foreign material, which may cause slippage. For instructions on proper belt
tension see V-BELTS page 7.
Gear Drives
Change the original oil after two weeks of operation by draining the
original oil and filing to operating level with flushing oil. Start the fan and shut it
immediately after it reaches operating speed. Drain flushing oil and fil with the
recommended type and amount of ol. Normally the oil should be changed every
six (6) months unless subjected to unusual operating conditions. Check the i
level once a week. Level is accurate only when drive is stopped. Grease the
vertical and horizontal shafts annually under normal operating conditions. For
more information refer to manufactures maintenance instuctions.
Process Start-up
The process star-up should be conducted in a manner that will minimize
{ermal shock of the tube bundles. Over cooling of fluids during periods of low
‘ambient temperature end low heat loads should also be evoided during start up.
Plugs
Header plugs are installed at room temperature in our plant. To correct
‘any minor leaking, it may be necessary to tighten the plugs when the bundle is at
‘operating temperature. WARNING: Do not tighten plugs while the bundle is
Under pressure, If any plugs are removed, the gasket (for shoulder plugs only)
should always be replaced. Replacement gaskets should be ordered from the
factory. When installing the plugs, a thread lubricant and antigaling compound
should be used.LONG TERM
Fin Cleaning
Fins should be kept free of dir and lint, which car be removed by directing
Compressed air perpendicular to the tubes in a direction opposite to the ormal
airflow. Do not use steam or chemicals to clean fins.
Tube Cleaning
‘The intemal cleaning of tubes can be done three differert ways:
1. Mechanical Cleaning:
This consists of using drils, (or wire brushes), on ‘ong rods. And rotating
them with air or electic motors. This is normally followed by a water wash or ar
purge. -
2. Chemical Cleaning
‘This consists of circulating hot chemical solution through the tubes. The
solution contains inhibitors to avoid corrosion of the tube walls
High Pressure Water Sprays:
This consists of placing a high-pressure water jet head at the end of the
hollow rods and pushing through the individual tubes.
NOTE: Tho last two processes will not work on tubes that are plugged, they
‘must be driled out mechanically
Leaking Tubes
‘Tube leaks can be two types: (1) leaks through the tube wall and (2) leaks
inthe tube attachment. In the fist case it Is most practical to plug both ends of
the tube. Only a limited number of tubes can be sealed off in this manner before
performance is affected. When performance drops below acceptable limis, tube
bundle must be retubed. If leaks develop in the tube end attachment, reroling of
the tube willbe necessary. Care must be taken in selecting the proper tube
‘expander for the size and gauge of tube to be rolled. When roling a tube, ov
rolling must be avoided, Consult the factory for information on taper pins to plug
the tubes and roller tube sizes,
2.INSTRUCTIONS FOR USING TAPER PINS FOR SEALING
LEAKING TUBES
1. Remove plug from one end of leaking tube (do not switch plugs i holes).
2. Insert taper pin through plug hole into tube and tap lightly with hammer until
‘seated firmly, but not too tight to be removed.
3. Measure plug for depth it was originally screwed into ‘he plug sheet.
4. Measure the distance that the tape pin protrudes from the plug sheet in
seated position,
5. Add the distance measured in Steps 3 and 4 then suttract 1/8*. This will be
the length which should be cut off the large end of the taper pin
D ; =
or — ZA
PLUG sweet
Remove the taper pin rom the end of the tube.
Saw a piece off the large end ofthe taper pin, the leng:h figured in Siep 5. Be
careful not to cut the pin too short.
& Re-insert the taper pin in the tube and drive well into place.
8. Lubricate plug (see PLUGS page 12) and replace in plug sheet, Run up
tightly. The plug should now seat and help hold the taper pin in place.
10.Repeat operation on opposite end of tube,
NOTE: ifthe plug removed does not seal replace it and the gasket if so
equipped,
13.Recommended Spare Parts
We suggest that one each of the parts, which are designated by an
asterisk (*) on the pars list be cartied in your stock of spare parts. The down
time caused by waiting for delivery of a spare part usually cost more in lost
Production or Service than the cost of the part itself
Spare parts orders should be specified in accordance with the parts list
description and the Job numberof the uni
P.0. |aTY. | DESCRIPTION OF COMPONENTS.
—_[ SECTONS IN RCGORDANGE WITH SPECIFICATION SHEET DATED.
—__ STRUCTURES)
SET|s) SHUTTERS
SET(S) TURNING VANES
< | FaNis) roa. BLADE:
"SORE Witt >,
“| FaWsHAFT(sy “01a x _”LONG wiTH_
KEYWAY LENGTH
"FAN BEARING(S):
"IDLER BEARING(S>
IDLER SHAFT(S) _"DIA X_—*LONG WIT "50 KEV ‘ONG ONE Eno,
OUER PIVOT SHAFT(S) "DIA. X__ "LONG, CRS, WHH ONEHIOLE DRILeeo con ve"
(COTTER PIN 22"FROM THE END,
| SETS) __TVPE IDLER FRAME PARTS; PULLROO LENGTH
MiNi
THREAD LENGTH.
VIBRATION SWICKES Heke ___ one.
BETS cg: NPE" CENTERDISTANCE, _Hp EACH, MATCHED SeTS OF _
= | sheave SETS
GROVES, "FAN SHEAVE _—* OD, BORE WITH __"x__"KEYWAY
FITCH, MOTOR SHEAVE: "Fon, "Gore wind. >X\7Reyway
+ | Motor y HP, __ RPM, _ PHASE, Hz, __VOLTS, “ENGL, VARIABLE
TORQUE, SINGLEVINDING, “SHAFT, "MOUNTING, "FRawe~” \“Subeease,
UST. SPECIFICATIONS _| HOTOR DATAREQUIRED ._, WIRING DIAGHANS
* RECOMMENDED SPARE PARTS
14.INSPECTION
Tubes :
“Tubes are to be inspected for intemal and external corrosion and/or
erosion periodically. This depends on the severity of service and atmosphere
{thatthe tubes are in. Inspection ofthe tubes should be performed every six
months. Tube wall thickness can be checked externally using the ultrasonic
technique,
Fans
Fans should be inspected for wear (pitting, eracks and corrosion) on all
surfaces. These inspections should be preformed every six months. in addition
'o surface inspections, al bolts and nuts must be checkéd for proper torque.
Motors
‘The motors should be kept free of ol, dust, dirt, weter and chemicals. itis
Particularly important to Keep the air intake cpenings free of foreign material. Do
ot block air outlet or inlet. The following
maintenance procedures should be performed regularly:
1. Bearing lubrication
2. Insulation resistance check
3. Cleaning
‘These inspections should be done at least every six (6) months.
Bearings
In ation o bearing checks as recommenced by the manufacture; he
‘mounting bolts should be checked for proper torque and cignment, "These
checks should be done at least every six (2) months
Structure
AA general inspection ofthe structure should be performed every six (6)
‘months. This inspection should include checks for corrosion, damaged members
‘and sheeting, and for loose bolting,
Headers
Headers should be inspected for corrosion, This corrosion should not be
allowed to proceed past the stated corrosion allowance as stated on the
specification sheet.WARRANTY
Ark changers warrants that
the apparatus it manufactures is free
of defects in material and
workmanship, when operated in
‘accordance with conditions stated,
for @ period of one (1) year after
start-up not to exceed fiteen months
from shipment. Such warranty shall
‘ot apply to any equipment, which
thas been altered or repaired by other
than the Company's personnel. The
Company's obligation under this
warranty is limited, however, to =
repairing or, ifin the Company's
judgement it seems more
‘appropriate, to furnishing without
charge, F.0.8. the Company's
factory, a similar part to replace any
Part which after examination shall, to
It's own satisfaction be determined to
have been defective at the time it
was shipped. This warranty applies
only ifthe Company received an
immediate written notice upon
discovery of such defect. The
Company makes no warranties
‘covering deterioration of fallure due
{o corrosion, erosion or fouling or
due to improper installation or
operation. EXCEPT AS.
‘SPECIFICALLY STATED ABOVE,
AIRX-CHANGERS HEREBY
DISCLAIMS ANY AND ALL
WARRANTIES, EXPRESS OR
IMPLIED, WHETHER OF
MERCHANTABILITY, FITNESS
FORA PARTICULAR PURPOSE,
OR OTHERWISE,
LIMITATION OF LIABILITY
THE REMEDIES SET FORTH
HEREIN ARE EXCLUSIVE. AIRX-
CHANGERS SHALL NOT BE
UABLE, INEXCESS OF THE
PURCHASE PRICE OF THE
EQUIPMENT, FOR ANY
DAMAGES, WHETHER IN
CONTRAG", IN TORT OR ON ANY
OTHER BASIS, SUSTAINED BY
‘THE CUSTOMER OR ANY OTHER
PERSON ARRISING FROM OR
RELATED TO THE DELIVERY, USE
OR FAILURE OF THE EQUIPMENT
OR FOR ANY DELAY, SPECIAL,
INCIDENTAL, CONSEQUENTIAL
INDIRECT OR COMMERCIAL
DAMAGES WHETHER DUE TO
LOST PROFITS OR OTHERWISE
RESULTING FROM THE
DELIVERY, USE OR FAILURE OF
THE EQUIPMENT.
IF IT IS EVER NECESSARY
‘TO CONTACT OUR PLANT FOR
SERVICE OR
REPLACEMENTPARTS, IT IS.
ESSENTIAL THAT OUR JOB
NUMBER AND OTHER
IDENTIFYING DATA BE OBTAINED
FROM THE METAL NAMEPLATE
ATTACHED TO THE COOLER, OR
THE NAMEPLATE ATTACHED TO
‘THE TUBE BUNDLE HEADER BOX,
WHICH ALSO CONTAINS THE
DESIGN PRESSURE,
TEMPERATURE, AND
NUMBER.
SERIAL
AIR-X-CHANGERS,
P.0. BOX 1604
Tulsa, OK 74101
(218) 266-1850,
16:FOR SALE
mem DESCRIPTION PRICE AMOUNT
SEAL PINS USED TO SEAL LEAKING TUBES
HANO TUBE ROLLER USED TO ROLL TUBE IN BOX
V-BELT TENSIONER USED TO SET BELT TENSION
SOCKETS FOR PLUGS
TOOL KiT
PROTRACTOR USED TO CHECK FAN BLADE ANGLE’
PROTRACTORBASE USEDON —~ VERTICAL FANS
FINS
PLUG GASKETS
TAPER PLUGS (BR) TAPERED BRASS
TAPER PLUGS (STL) TAPERED STEEL
‘OULDER PLUGS
EAD LUBE LOK-CEASE COMPOUND.
-AEAD LUBE (SS) LIQUID-O-RING #404
NOTE: PRICE INCLUDES ALL SHIPPING ‘TOTAL FROM
AND HANDLING ABOVE
TAX
TOTAL ENCLOSED
PRICES ARE SUBJECT TO CHANGE WITHOUT NOTICE AND WITHOUT
INCURRING OBLIGATION.
WHEN ORDERING PROVIDE FOLLOWING INFORMATION,
JOB NUMBER
MODEL TYPE __
ora!
CUSTOMER
“Afair-x-changers seis"
PARTS LIST
JOBNUMBER: 11614
Sab Bere nad Naa ee tie can
OURS SEAS Gnd
aig] ar DATE DESCRIPTION OF CHANGE —
H
i —
z —— =
Five
Universal Compression Standard
SURFACE PREPARATION: Chemical Clean
PRIMER COAT: ILLS 9267 Gay Primer 1.S.TO 2.8 MILS, DFT.
FINISH CONT: H:£5 91601 Universal Compression Gra, 1.5 10 2.0 MILS, DFT.
FO. QTY. DESCRIPTION OF COMPONENTS
NOTE: AN ASTERIK () IN QUANTITY COLUMN INDICATES A RECOMMENDED SPARE PART
'FECTION(S) IN ACCORDANCE WITH SPECIFICATION SHEET DATED: 7/1201
SET SHUTTERS: TWP Alana FOR SERVICH(S) AC. SQ.T = 16g, WINKAGESETS=1,
Standard, EXTRA FEATURES:
YANG), lh DIAMETER, ZBLADES, RHROTATION, MOOREMAKE, 11 ANGLE Clas 2718
Inch BORE WITH Inch X26 neh KEY WAY. MODEL/PITCH: 27/Manual, HUB-Taper
SHEAVE SETS 2GROOVES, 7 PITCH, —
FANSHEAVE: 226 Inch OD, 2.716 Inch BORE WITH Sf loch X.$/6 Inch KEYWAY
[MOTOR SHEAVE: 67 ch OD, 7-54 Inch BORE WITH ies X 3/16 lc KEYWAY,ma air-x-changers Ynocuws
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