Installation Manual 6000MM Page 1 of 9 May 2019 Tuf-Lite IV Fans 6000MM Series Hub INSTALLATION MANUAL Adjustable Pitch Fan Assembly 34’ Diameter Hudson Tuf-Lite IV fan blades Hudson Tuf-Lite IV fan blades are of single piece fiberglass reinforced plastic (FRP) construction op- timized for performance, reliability, noise, and cost effectiveness.
Tuf-Lite IV® Fans 6000MM Series Hub INSTALLATION MANUAL Adjustable Pitch Fan Assembly 34' Diameter Hudson Tuf-Lite IV® fan blades Hudson Tuf-Lite IV® fan blades are of single piece fiberglass reinforced plastic (FRP) construction optimized for performance, reliability, noise, and cost effectiveness. Tuf-Lite IV® fan blades are constructed of light weight, corrosion-resistant, fiberglass reinforced vinyl-ester resin, with materials, thickness, and processes determined from finite element analysis modeling. Tuf-Edge® provides superior resistance against leading edge erosion and UV inhibited pigmentation yields longer life. The individually balanced blades can be replaced independently - matched sets are not required. Installation Manual 6000MM Page 1 of 9 May 2019 RECOMMENDED TOOLS · Long T-Handle Allen Wrench Set (3/16" to 3/8") · Medium Size Flat Head Screw Driver · Brass Ball Peen Hammer · Flat Bastard File · 240 Grit Sand Paper · Anti-Seize Lubricant · WD-40 · 12" Crescent Wrench · Shop Towels · Exact-A-Pitch® Digital Protractor (P/N 62375) · 25 ft. Measuring Tape · Pencil or Marker · Open/Box End Wrench Set (1/2" - 1-1/2") · Socket Set for 1/2" Drive (1/2" - 1-1/2") · Torque Wrench(s) Rated for 0-300 ft-lb. INSTALLATION PROCEDURES ASSEMBLY WITH BUSHING Clean all mating surfaces between hub, bushing and shaft. All grease and lubricant should be removed, leaving the mating surfaces dry. If there is no shoulder on shaft to prevent bushing from sliding down shaft, slide spacer/sleeve (not provided) on shaft before bushing or use a thrust retainer (optional equipment) on top of hub. Slide bushing and key onto shaft until flush with end of shaft. The shaft size determines the bushing type. Lock bushing on shaft by tightening the set screw in flange with an Allen Wrench. Line up key and set hub on bushing. Engage the four (4) cap screws in flange of bushing into hub spool, using a torque wrench with a socket, and tighten evenly. Use the following table to determine the proper tools and torque values. ASSEMBLY WITH STRAIGHT SHAFT (NO BUSHING) Clean all mating surfaces between the hub and the shaft. If there is no shoulder on shaft to prevent hub from sliding down shaft, slide spacer/sleeve (not provided) on shaft before hub or use a thrust retainer (optional equipment) on top of hub. Install key in shaft. Line up key and keyway and set hub on shaft. Tighten set screw(s) in hub. ASSEMBLY WITH TAPERED SHAFT (NO BUSHING REQUIRED) Clean all mating surfaces between the hub and shaft. Bushing Size W1 Allen Wrench Size 1/4" Cap Screw Size 3/4" Socket Size 1-1/8" Torque (ft-lb) Dry 250 Align keyways and install hub. Install retainer plate and cap screw(s) with lock washer(s). Shaft size determines what size cap screw is necessary. Using a torque wrench with a socket, evenly tighten cap screw to recommended standard per table below. Cap Screw Size 5/8" NC 3/4" NC 1" NC Socket Size 15/16" 1-1/8" 1-1/2" Torque Value (ft-lb) Lubricated Dry 100 110 125 130 150 160 NOTE: Retaining arrangement varies with gear shaft design. Installation Manual 6000MM Page 2 of 9 May 2019 SEAL DISC HARDWARE INSTALLATION *Seal disc mounting hardware must be installed BEFORE installing blades and blade clamps, due to limited access to seal disc bolt holes. Install seal disc spacer as shown in Figures 1 and 2. Install flat washers and 3/8" bolts on the top hub plate with the threaded portion pointing upwards. Place spacer on bolt, then flat washer, and then tighten 3/8" NC nut to recommended standard of 15 ft-lb (lubricated) or 20 ft-lb (dry). THRUST RETAINER (optional equipment) Install proper load bolt (not provided) into top of fan shaft and tighten (See Figure 3). Install thrust retainer channel on top hub plate using existing hub spool cap screws. Torque cap screws to 60-65 ft-lb. Install thrust retainer eyebolt and jam nut. Hand tighten eyebolt. Tighten jam nut securely against top of thrust retainer channel. Figure 1 Figure 3 BLADE INSTALLATION Remove blade clamp bolts, nuts, lock washers, and blade clamp halves from hub. Assemble blade clamp halves over groove in blade neck, and install into hub (See Figure 4). The thick leading edge will be to your left and thin trailing edge will be to your right as you stand at end of blade. Figure 2 Installation Manual 6000MM Figure 4 Page 3 of 9 May 2019 Install clamp bolts through hub plates and blade clamp, putting bolt heads and flat washer on top, lock washers, flat washers and nuts on bottom. Tighten lightly (See Figure 5). Rotate blade in clamp until digital protractor shows specified pitch angle to within +/-0.2°. Fan pitch angle is shown on fan specification sheet for design duty. After desired pitch angle is set, raise and lower end of fan blade and find midpoint of blade travel. Hold blade at the midpoint. Pull blade outward so that the blade neck flange rests against the back of the blade clamps. Push blade to the right to remove all slack. Use torque wrench to tighten clamp bolts per Table 1 below: Table 1: Clamp Bolt Torque Values Clamp Bolt Type Grade 8, EcoGuard® Torque Value (ft-lb) Lubricated Dry n/a 220 Figure 5 SET PITCH AND TRACK Use Hudson EXACT-A-PITCH® digital protractor (See Figure 6) to set blade pitch. Mount protractor on the trailing edge of the blade and ensure that protractor is long enough to reach at least half across the blade chord. Place the protractor approximately 1" from tip of blade. Note pitch on protractor. Rotate fan 360°, noting high and low pitch readings. Locate place where pitch reading is at mid-point between high and low readings, and set pitch at that point. Re-check pitch setting. Blade must be set within +/-0.2° of desired pitch angle. Tighten clamp bolts evenly. DO NOT OVERTORQUE CLAMP BOLTS. When bolts are tightened, hold a pencil against top end of blade and mark the level onto a fixed object, such as a pole or the fan ring. Install remaining blades at same place as first blade, following the instructions above. After tightening bolts, mark top end of each blade in same place first blade was marked. If marks differ by 1" or more, adjust blade. CHECK TRACK After fan is installed in fan stack cylinder ring, outline top side of each blade onto fan stack cylinder ring with a marker (See Figure 7). The difference between levels of highest and lowest outlines should not be more than 1". Correct blade track by loosening clamp bolts and adjusting blade to match track of other blades. Re-tighten bolts and re-check track and pitch angle setting. Re-tighten blade clamp bolts to recommended standard per Table 1. Figure 6 Installation Manual 6000MM Figure 7 Page 4 of 9 May 2019 CHECK SWEEP Note: Refer to instructions included with seal disc for further Measure the distance from trailing edge at blade tip of one details. blade to trailing edge at blade tip of the adjacent blade (See Figure 7a). This distance should be within 1" of each other for all successive blades. Correct blade sweep by loosening clamp bolts and adjusting blade to match sweep of other blades. Retighten bolts and re-check sweep and pitch angle setting. Retighten blade clamp bolts to recommended standard per Table 1. Figure 8 Figure 7a CHECKING TIP CLEARANCE SEAL DISC ASSEMBLY & INSTALLATION After installing blades, seal disc should be installed on the previously installed seal disc hardware as shown in Figure 8. First install self adhesive rubber gaskets on both flanges of one seal disc half. Bolt two halves of seal disc together, using 3/8" NC bolts, flat washer, lock washer, and nut. Torque to 15 ft-lb (lubricated) and 20 ft-lb (dry). Then, install seal disc on the previously installed seal disc hardware as shown in Figure 8. Install flat washer, then place seal disc on top. Install another flat washer, lock washer, and nut on top. Tighten 3/8" NC nut to recommended standard of 15 ft-lb (lubricated) or 20 ft-lb (dry). If difficulty is encountered, loosen bolts on seal flanges until seal disc can be mounted, then re-tighten Rotate fan in position inside fan stack to check tip clearance (See Figure 9). The recommended tip clearance is between 1" and 2". Check for spots where fan blade clearance is not within the recommended tolerance. If necessary, adjust fan stack by shimming to obtain proper clearance. Tip Clearance NOTE: The purpose of the seal disc is to prevent adverse air recirculation at non-aerodynamic portion of the fan blade, hence increasing efficiency. Figure 9 Installation Manual 6000MM Page 5 of 9 May 2019 OPERATING INSTRUCTIONS Start fan and check rotation. Viewed from top (discharge), fan blades should rotate clockwise. Hudson recommends to re-verify the blade clamp torque after the initial 10-15 minutes of cold operation (i.e., the fan doesn't need to be exposed to the working temperature of the process). This will ensure that the blades are settled within the clamps after the centrifugal forces have acted. Check motor power consumption to be sure fan is pulling desired load. CAUTION: If positive pitch is set in summer to use all available motor amps (nameplate rating), motor could be overloaded in winter. Design pitch angles usually do not use all of the available motor horsepower. This ensures that the motors will not be overloaded at low winter temperatures. For the fans that have remained idle (such as a shut-down or turn-around), it is highly recommended to re-verify the torque on the blade clamps before putting it back into operation. Installation Manual 6000MM Page 6 of 9 May 2019 PART LIST HUDSON PRODUCTS CORPORATION Adjustable Pitch Fan Assembly 34' Diameter Series 6000MM HUB ITEM DESCRIPTION NO. OF BLADES TYPE PART. NO 6 7 8 9 10 11 12 34 Ft. Dia. Fan Up to 7.44" Diameter Shaft W-1 Hub Assy. No. 6906M9.65 6907M9.65 6908M9.65 6909M9.65 6910M9.65 6911M9.65 6912M9.65 Part No. 42470 42471 42472 42473 42474 42475 42476 1 ITEM 62.25" Dia. Hub Plates for 34' Dia. Fans DESCRIPTION W-1 TYPE Part No. PART. NO D6862 D6863 D6864 D6865 D6866 QUANTITY PER ASSEMBLY D6867 D6868 2 Hub Spool W-1 D6854 1 1 1 1 1 1 1 3 Bushing W-1 Specify Bore 1 1 1 1 1 1 1 4 Blade Clamp Half, Powder Epoxy Coated Die Cast Alum. (Standard) Option 1: Powder Epoxy Coated Ductile Iron** Option 2: Coal Tar Epoxy Coated Ductile Iron** D5131 65013 65013C 12 14 16 18 20 22 24 5 Blade Clamp Bolt 3/4"-10 x 10" (Grade 8,EcoGuard®) 42404 24 28 32 36 40 44 48 6 3/4" Lock washer (EcoGuard®) 42405 24 28 32 36 40 44 48 7 3/4" Flat washer (EcoGuard®) 42406 48 56 64 72 80 88 96 8 Hex Nut 3/4"-10 (EcoGuard®) 42407 24 28 32 36 40 44 48 9 Hub Spool Cap Screw 3/4"-11 x 2 1/2"(316 SS) 57027 16 16 16 16 16 16 16 10 3/4" Lock washer (316 SS) 73739 16 16 16 16 16 16 16 11 3/4" Flat washer (316 SS) 73720 16 16 16 16 16 16 16 12 Pin, Grooved, 1/2" X 1-1/2 " 74540 4 4 4 4 4 4 4 13 Stiffener Ring (1 per hub) D6869 1 1 1 1 1 1 1 14 Stiff. Ring Bolt, 5/8"-11 X 2" w/nut (316 SS) 65690 20 20 20 20 20 20 20 15 Stiff. Ring Lock Washer 5/8" (316 SS) 73731 20 20 20 20 20 20 20 16 Stiff. Ring Flat Washer 5/8" (316 SS.) 73719 40 40 40 40 40 40 40 17 Eye Bolt W/ Nut 3/4"-10 x 2" (HDG) 59547 3 3 3 3 3 3 3 18 3/4" Flat Washer (HDG) 16716 6 6 6 6 6 6 6 19 3/4" Lock Washer (HDG) 73738 3 3 3 3 3 3 3 20 88" Diameter Seal Disc Assy Kit * 21 Tuf-Lite IV® Blade (Black) 81126STLIV 1 1 1 1 1 1 1 (Varies) 6 7 8 9 10 11 12 * Includes all hardware (316 SS) to assembly and mount. ** Recommended on concrete and round towers, or corrosive environments. Contact Hudson for pricing. STANDARD MATERIALS & FINISHES Blades: Fiberglass reinforced vinyl ester Hub Spool: Ductile Iron, Coal Tar Epoxy coating Plates: Coal Tar Epoxy coated steel Bushing: Malleable Iron Seal Disc: Fiberglass Reinforced Polyester Blade Clamps: Epoxy Powder Coated Die Cast Alum (Standard) Epoxy Powder Coated Ductile Iron (Option 1) Coal Tar Epoxy Coated Ductile Iron (Option 2) Fasteners: Grade 8 (EcoGuard®) Complete Fan with K500 Monel (Option 1) WHEN ORDERING, SPECIFY FAN DIAMETER, TYPE & NUMBER OF BLADES & SHAFT DIAMETER EXAMPLE: APT Fan Model Adjustable Pitch 34M Fan Diameter & Blade Type (Specify "M" for Tuf-Lite IV® Blades) 8 Number of Blades 6 1/2" BORE Shaft Diameter Installation Manual 6000MM Page 7 of 9 May 2019 Installation Manual 6000MM 20 20 Page 8 of 9 9,10 & 11 14 & 16 THRUST RETAINER 12 (OPTIONAL EQUIPMENT) 17, 18 & 19 5 & 7 21 1 4 15 & 16 2 13 6, 7 & 8 14 & 16 12 9,10 & 11 3 KEY, SET SCREW & CAP SCREWS FURNISHED WITH BUSHING HUDSON PRODUCTS CORPORATION Adjustable Pitch Fan Assembly 34' Diameter Series 6000M HUB May 2019 9660 Grunwald Rd. Beasley, Texas 77417-8600 Phone: 281-396-8100 Fax: 281-396-8388 1-800-634-9160 (24 Hours) EMAIL: hudsonproducts@hudsonproducts.com http://www.hudsonproducts.com Hudson, Auto-Variable, Combin-Aire, Exact-A-Pitch, Fin-Fan, Heatflo, Hy-Fin, Split-Flo, Solo Aire, Stac-Flo, Steamflo, Thermflo, Tuf-Edge, Tuf-Lite, Tuf-Lite II, Tuf-Lite III and Tuf-Lite IV are registered trademarks of Hudson Products Corporation. ©2019 Hudson Products Corp. All Rights Reserved. Installation Manual 6000MM Page 9 of 9 May 2019Microsoft Publisher for Office 365