Hibon Tri Lobe Blower Manual

Installation, Operation and Maintenance Manual

INSTALLATION, OPERATION AND MAINTENANCE

MANUAL

POSITIVE DISPLACEMENT BLOWERS

HIBON Inc. 1-800-862-2389 1-888-70-HIBON (704-4266)

rev 01, 15/08/98

Installation, Operation and Maintenance Manual

Table of contents GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

OPERATING CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

TRANSPORT AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

HEALTH AND SAFETY - RECOMMENDATIONS - ROTATING MACHINERY . . . . . . . . . . . . . .

7

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 OPERATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 APPENDIX '' A '' (ALIGNMENT AND TENSION OF TRANSMISSION BELTS) . . . . . . . . . . . . . . . . APPENDIX " B " (ALIGNMENT OF COUPLINGS) APPENDIX " C " (BLOWER CONCRETE SLAB & ANCHORING INSTRUCTIONS) APPENDIX " D-01 " (HH 4200 / 4300 SERIES) LUBRICATION AND PART LIST APPENDIX " D-02 " (HH 2000 SERIES) LUBRICATION AND PART LIST APPENDIX " E " (XN TWO LOBE & THREE LOBE) LUBRICATION AND PART LIST APPENDIX " F-01 " (SNH / V TWO AND THREE LOBE) LUBRICATION AND TWO LOBE PART LIST APPENDIX " F-02 " (SNH / V THREE LOBE) PART LIST APPENDIX " F-03 " (SNH / V 8 - 12 - 812 TWO & THREE LOBE) LUBRICATION AND PART LIST APPENDIX " G-01 " (VTB 810 - 20 - 820 TWO & THREE LOBE) LUBRICATION AND THREE LOBE PART LIST APPENDIX " G-02 " (SIAV, VTB, AIR INJECTION TWO & THREE LOBE) LUBRICATION AND PART LIST APPENDIX " G-03 " (SIAV TWO & THREE LOBE) SPECIAL INSTRUCTIONS FOR INSTALLATION ON TRUCKS APPENDIX " G-04 " SIAV MAINTENANCE FOR TRUCK APPENDIX " H " GUARANTEES AND LIMIT OF LIABILITY

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Installation, Operation and Maintenance Manual

GENERAL Although HIBON blowers are sturdy precision-engineered machines which are quality controlled to prevent manufacturing defects, there are several relatively simple but basic installation and maintenance procedures that must be observed to ensure optimum performance. As there is no guesswork in the manufacture of these highly advanced units, there must be none in preparing them to get the job done in the field. It is the purpose of this manual to help you properly install, maintain and service your HIBON blower. Follow the instructions carefully and you will be rewarded with years of trouble-free operation. Some principles of correct installation and maintenance are identical or similar for all series of HIBON blowers. In such cases instructions for all models are treated compositely in various subsections. Some of the data is particular only to the specific series described in the cover of this manual. Hence, it is important that no section be overlooked when preparing to install your blower. The manual is prepared in sections covering: Operation, Installation, Maintenance, and Trouble shooting Before delivery the blowers are subjected to a run test in our factory. The test record may be sent on request. The oil casings are drained after the test. The blowers are delivered WITHOUT OIL. Each blower is provided with a name plate showing the machine type and the serial number. Any unauthorized modification of the machine or any failure to observe the installation or operation requirements specified in this Instruction manual shall be the sole responsibility of the client and shall cancel any guarantee rights.

OPERATING CHARACTERISTICS Read the appropriate working instructions BEFORE running the machine. The rotary lobe blower is a positive displacement type unit, whose volumetric capacity is determined by the size of the unit, the operating speed, the differential pressure and the atmospheric conditions. It employs two bi-lobe or two tri-lobe impellers mounted on parallel shafts and rotating in opposite directions within a cylinder closed at the ends by headplates. As the impellers rotate, air is drawn into one side of the cylinder and forced out the opposite side against the existing pressure. Therefore, the pressure developed depends on the resistance of the discharge system. Effective sealing of the blower inlet area from the discharge area is accomplished by use of very small internal clearances. The resulting absence of contacts between moving parts eliminates the need for any internal lubrication. Clearances between the impellers during rotation are maintained by a pair of accurately machined timing gears mounted on the two shafts extended outside the air chamber. No attempt should ever be made to control capacity by means of a throttle valve in the intake or discharge piping. This will not only increase the power load on the driver, but can also overload and seriously damage the blower. Likewise, if a possibility exists that flow to the blower inlet may be cut off during normal operation of a process, then an adequate vacuum relief valve or protection switch must be installed near the blower. A pressure type relief valve in the discharge line near the blower is also mandatory for protection against cut-off or blocking in this line. When a belt drive is employed, blower speed can usually be adjusted to obtain desired capacity by changing the diameter of one or both sheaves. In a direct coupled arrangement, a variable speed motor or transmission is required, or excess air may be blown off through a manually or controlled unloading valve and silencer. If returned to the blower inlet, air must go through a cooled by-pass arrangement. rev 01, 15/08/98 Page 3 of 15

Installation, Operation and Maintenance Manual

Before making any changes in blower capacity, or operating conditions, contact the nearest Hibon Sales Office for specific information applying to your particular blower. In all cases, operating conditions must be maintained within the approved range or pressures, temperatures and speed. Also, the blower must not be used to handle air containing liquids or solids, since serious damage to the rotating parts will result.

TRANSPORT AND STORAGE Before packing and shipment of the machine, all external machined parts are coated with a rust preventive film and the nozzles are closed with protective caps to avoid any introduction of foreign matter or water. When receiving the machine, it must be checked for any damages due to transport. Before any handling, all contact surfaces must be protected with wood pieces and appropriate slings or cables should be used. All base plates have four lifting lugs. The blower, when alone, may be handled with slings under the side plates or under the cylinder (blower body) on both sides of the flanges. Never use the integral cast lugs of side plates and gear castings. The blower and accessories should be stored in a dry, heated and suitably protected place. The rust preventive coating or oil shall be renewed or changed, if necessary. During storage, it is essential to prevent the machine from being subjected to vibration produced by the operation of nearby machines and propagated via the bearing surfaces. Vibrations applied for long periods could damage the machine and motor bearings.

For a long storage time :

- Loosen any transmission belts - Fill the castings with rust preventive oil up to sight glass, and rotate the shaft a few revolutions - Spray rust preventive oil in the compression chamber - Rotate the shaft three or four revolution every two weeks to avoid any damaging of the bearing. - It is also recommended to place a bag of silica gel or another groscopic substance inside the inlet opening and inside the outlet opening, immediately replace the respective covers.

At the end of the storage time, the compression chamber should be cleaned using a solvent (Alcohol, White Spirit). The casting must be drained.

Rust preventive oil : a)

External : parts

* TECREX 39 (MOBIL OIL) * RUST BAN 324 (ESSO) V-Product 9703 (SHELL)

b)

Internal : * parts * * *

Mobilarma 523 or 524 (MOBIL OIL) ESSO LUB MZ 20 W/20 (ESSO) Ensis Motor oil 20 (SH) Nox-rust VC 110 or equivalent

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Installation, Operation and Maintenance Manual

OPERATION 1.

Two lobe blowers

The basic operation of a rotary two lobe type positive displacement blower is illustrated (Figure 1) as follows : In position 1 Air flow enters from the right in the inlet side towards the left to the discharge side of the blower. With the lower impeller rotating clockwise, (changing the rotation will change the flow direction) the blower is delivering a known volume (A) to the discharge, while space (B) between the upper impeller and cylinder wall is being filled.

POSITION 1 In position 2 Counterclockwise rotation of the top impeller then traps equal volume (B), and further rotation delivers it to the discharge in Position 3.

POSITION 2

In position 3 At the same time, another similar volume is forming under the lower impeller, and will be discharged when rotation reaches Position 1 again.

POSITION 3

One complete revolution of the driving shaft alternately traps four equal and known volumes of air (by each impeller) and pushes them through to the discharge. The volumetric capacity of a lobe blower operating at a constant speed therefore remains relatively independent of reasonable inlet or discharge pressure variations. The blower is used as an air blower, and may be used for handling air or gas in either pressure or vacuum applications.

Figure 1. N.B. All blowers are available with either side/side or top and bottom connection.

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Installation, Operation and Maintenance Manual

2.

Three lobe blowers

The Hibon three lobe rotor blowers benefit from the latest technological developments which provides them with several major advantages: • Better balanced and more resistant rotors for better withstanding of fatigue. • Progressive unloading channels reduce pulsation. Fundamental frequency is increased to six times the revolution making noise attenuation easier. • Volumetric efficiency is increased. The basic operation of a rotary three lobe type position displacement blower with precompression passage is illustrated (Figure 2.) as follows:

POSITION 1

POSITION 2

In position 1 Flow is top to bottom from blower inlet to discharge, the left impeller is mounted on the driving shaft then rotates counterclockwise and delivers a volume into the discharge pressure side. At the same time, space (B) between the impeller and the cylinder wall is filling with another and equal volume at inlet pressure. It is about to be sealed off by the counterclockwise rotation of this impeller. The space (C) is progressively filled and compressed with discharge volume through the precompression passage. In position 2 The inlet area sealed in (B) and discharge pressure starts to enter space (A) through the precompression passage as rotation continues.

POSITION 3

POSITION 4

Figure 2. N.B. All blowers are available with either side/side or top and bottom connection.

In position 3 Volume (C) is delivered to the discharge pressure side in the same manner as volume (A). Because of the almost complete pressure equalization through the precompression passage, no sudden shock will occur. In position 4 The inlet area volume sealed in (C) and the discharge pressurized volume entering space (B) start to enter through the precompression passage in (C). Volume (A) is delivered to the discharge side and the volume in (B) will also start delivering with (A) as soon as the rotation reaches the outlet side.

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Installation, Operation and Maintenance Manual

HEALTH AND SAFETY - RECOMMENDATIONS - ROTATING - MACHINERY DON’T Run the machine unless all GUARDS are in position • The Health & Safety at Work Act requires manufacturers to fit guards on all exposed rotating shafts, glands, couplings and belt drives, etc... It is incumbent upon the operator to ensure that these are in position before the machine is operated.

DO Wear suitable HEARING PROTECTION when working in the vicinity of noisy machinery. • The noise levels emitted by rotary machinery may vary depending on rotational speed, application, and environment, and on certain installations these noise levels can be sufficiently high to cause hearing damage if exposure is prolonged. On such installations, correct hearing protection must always be worn if working in the immediate vicinity.

DO NOT Attempt maintenance work or adjustments unless wearing suitable PROTECTIVE CLOTHING. • Rotary equipment may cause severe injuries if incorrect clothing is worn when maintenance work is attempted if machines are in operation.

Temperature

• Blower casing and associated piping and accessories may become hot enough to cause major skin burns on contact.

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Installation, Operation and Maintenance Manual

• GENERAL It is important that plant operators are made aware of the responsibilities incumbent upon them to take all necessary precautions to ensure their health and safety, and also that plant authorities implement the procedures necessary towards this end, i.e. by providing relevant protective clothing and devices, and by bringing to the attention of the operators the official safety recommendations. • DON'T Attempt any maintenance work until all electrical gear has been isolated. Isolate all electrical supplies before removing any guards, covers or accessories from any rotating machinery installation. Before re-connecting the electrical supply ensure that all guards, covers and accessories are correctly replaced.

• DO Ensure that maintenance work on machine handling TOXIC materials is carried out in a well-ventilated atmosphere when toxic fumes have been purged. Also observe all necessary FIRE precautions. On installations involving toxic materials or vapors, operators should ensure that they are familiar with the regulations relating to contact with these materials and vapors, and also the correct procedures in case of fire.

These would normally be supplied pre-set from multiple combinations of any or all of them. They would normally be supplied pre-set from the factory, or they would be finally set, on site, during commissioning. Unauthorized adjustment of any of these safety devices can lead to a potentially dangerous operating condition.

• DO NOT LEAVE ELECTRICAL GEAR LIVE AND UNATTENDED WITHOUT A SUITABLE WARNING NOTICE. Distinctive warning notices must be provided for posting in a conspicuous position to any piece of electrical equipment or machinery on which maintenance is being carried out, and which, for any reason whatsoever, is liable to be left unattended while in a live condition.

• OTHERS Stay clear of open inlet piping of pressure blowers and the open discharge blast from a vacuum blower. Place a strong coarse screen over on an open inlet piping. Do not use an air blower on explosive or hazardous gases, unless the system is designed for the application.

• DO Ensure that all RELIEF VALVES and other SAFETY DEVICES are kept operative and are tested regularly. Rotating machinery installations in the Rotary Compressor, Liquid Ring Pump and Rotary Lobe category should be equipped with standard safety devices to prevent the units being operated outside their design range. These safety devices take the form of spring or weight loaded relief valves for pressure, spring loaded valve only for vacuum relief, high pressure, high vacuum and high temperature switches, low water flow and low oil level switches etc... and normal installations can include individual or multiple combinations of any or all of them.

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Installation, Operation and Maintenance Manual

INSTALLATION EQUIPMENT CHECK Before uncrating, check the packing slip carefully to assure receipt of all parts. Small, but important accessories - relief valves, for instance - can easily be lost. Note that all accessories are listed as separate items on the packing slip. After confirming all items that are shown on the packing slip are included, uncrate carefully. Register a claim with the carrier for lost or damaged equipment immediately. PROTECTION AND CLEANING The internal surfaces of all HIBON units are mist sprayed with a rust preventive to protect the machine during the shipping and installation period. This lubricant does not have to be removed upon initial start-up. It may be removed with a safety solvent for special application: pour the solvent slowly into the inlet side of the machine while running until the unit is visually clean. The shaft extension is protected with special paint which can be removed with any standard solvent. Blower inlets and outlets are temporarily capped to keep out dirt and other contaminants during shipping. These caps must be removed before start-up. LOCATION If possible, install the blower in a light, clean, dry place with plenty of room for inspection and maintenance. Units mounted on steel and other structural materials should be set as close as possible to supporting beams or walls. For an outdoor location please consult the factory for recommendations. FOUNDATION The concrete foundation should be solid, levelled and as smooth as possible, and at least 1.5 times the weight of the equipment. The foundation should be raised 150 mm (6'') for cleaning purposes. See APPENDIX C for type of foundations and installation. LEVELING AND ALIGNMENT Blower equipment with a thrust or locking bearing assembly will function without exact leveling. By controlling the lateral position of the impellers in relation to the headplates, the main purpose of the thrust assembly is to counter thrust not normally found in standard applications. This feature prevents the impellers from floating against the headplates. However, normal precautions should be taken to prevent strain or case warpage. Blowers shipped with a mounted drive must be checked for alignment before start-up. Severe mishandling during transportation can cause misalignment. ANCHORING The package can be properly anchored to the concrete base or mounted on a set of antivibration pads.

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Installation, Operation and Maintenance Manual

ROTATION Rotation of the motor must be checked before installing the blower drive. Blowers are built for reversible operation unless a rotational arrow is located above the drive shaft. If an arrow appears, the unit is timed for rotation indicated and cannot be reversed unless the unit is retimed (See retiming instruction). DRIVE V-Belt : Faces of belt sheaves must be in alignment. Sheaves should be mounted on the blower shaft as close as possible to the drive cover. Mount the driver on slide rails to permit proper belt installation and take-up (SEE APPENDIX A). Check rotation of the motor before installing drive. Direct coupling : If the blower is to be directly connected in the field, follow the coupling manufacturer's specifications for alignment and location. (SEE APPENDIX B). ACCESSORIES Check valve : A check valve is absolutely required when operating more than one machine on a common header to prevent back flow and gas flowing back to the inlet of the machine not in service. It might also create a contra rotation of the machine which will eventually damage the unit. - To be installed on the discharge side when the blower is in pressure operation. - To be installed on the suction or discharge side for vacuum operation. Relief valve : Absolutely required. - For pressure operation : mount the valve on the discharge side before the isolating valve. - For Vacuum operation : mount the valve on the suction side before the check valve. - The relief valve is delivered pre-set. Valve setting should be adjusted when starting machine operation. The relief valve, as a safety device, shall be periodically checked for correct function. Silencer : It is recommended to install a suction and a discharge silencer. The silencers should be mounted as close as possible to the blower. Filter : When atmospheric air is sucked in, filters should be mounted before the blowers. For all other cases we recommend to use a suction filter. Instrument tapping points : Since the blower is delivered without nozzles, the required tappings will have to be provided on the suction and discharge lines by the customer. Flexible connectors : Flexible connectors prevent distortion from the piping and any vibrations due to sound transmission. In general they should not be fitted directly to the machine flanges but after the silencers. In no case should they be used to compensate any excessive or insufficient lengths of the pipings. NOTE : All accessories mounted before or after should be periodically checked for internal conditions, damage and oxidation to prevent any carry-over in the conveying system. rev 01, 15/08/98 Page 10 of 15

Installation, Operation and Maintenance Manual

STAR-DELTA STARTING The torque required to accelerate the rotating parts of any Rotary Positive Blower is quite small. Blowers can be successfully started, even with the reduced torque in the Star circuit that is a characteristic of Star-Delta starting, providing the unit is started against zero line pressure. If however the unit is required to start against an already pressurized line, there will be insufficient torque available in the Star circuit to accelerate the rotating parts up to full speed and at the same time overcome the resistance imposed by the line pressure, and the motor will trip-out. PIPING Inlet and discharge connections on all blowers are large enough to handle maximum volume with minimum friction loss. The diameter of the air transmission lines should be equal to or larger than connection points to minimize noise and air-friction losses. Air velocities should normally not exceed 5,000 feet per minute. (1525m/mn). Excessive weight of piping and fittings can cause internal misalignment and premature wear. Never allow the blower to carry the weight of the pipe. To prevent distortion, a spool or sleeve-type expansion joint should be installed between the unit and the piping. Before connecting piping, remove any remaining anti-rust compound from blower connections. Piping must be clean. In addition, make sure it is free of dirt, scale, cuttings, weld beads, or foreign materials of any kind. To further guard against damage to the blower, especially when an inlet filter is not used, install a substantial screen of 16 mesh backed with hardware cloth at or near the inlet connections. Make provisions to clean this screen of collected debris after a few hours operation. It should be removed when its usefulness has ended, as the wire will eventually deteriorate and small pieces going into the blower may cause serious damage. VENTILATION Customers must assure that the blower room is properly ventilated as a large amount of heat is generated from the motor and the compression heat. OTHERS The above covers most of the usual equipments and accessories with standard blower installations. Other accessories, protection devices etc. are treated separately.

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Installation, Operation and Maintenance Manual

MAINTENANCE LUBRICATION Oil changes: For temperature below 65°F, run the blower for 15 minutes to warm up to oil. On every oil change, clean the drain and filling plugs and renew their sealing by means of TEFLON or pipe sealant. (Loctite PST 56747 or equivalent) Clean the sight glasses and check oil level periodically. First oil change should be conducted after 200 hours of operation. The following oil changes should be done as per the instruction in the appendix. Oil level is correct when it reaches the middle of the sight glass. Oil level can only be checked when the machine is stopped. FOR LUBRICATION METHOD AND QUANTITY OF APPROPRIATED LUBRICANT, PLEASE REFER TO APPENDIX (D) ATTACHED. For low and high temperature applications SYNTHETIC OIL should be used. It is also recommended for lighter ranges of applications. Mineral oil can be used for medium range of operating temperature (consult chart). The use of synthetic oil can reduce oil change frequency by 2 to 3 time .

LUBRICATION RECOMMENDATIONS OIL LUBRICATION SYNSPEC EP 220

SUNEP EP 220 (MINERAL) Pouring point Flash point

-12°C

/

(SYNTHETIC)

10°F

-37°C

/

OUTLET SIDE

TYPE OF OIL

TEMPERATURE

-35°F

219°C / 425°F

225°C / 437°F

40°C / 140°F

220

220

cst 100°C / 212°F

18.7

23

95

125

Viscosity cst

Minimum Viscosity

-40°F / +32°F -40°C /

0°C

+32°F / +150°F 0°C / +65°C -50°F / +325°F -45°C /+163°C MANUFACTURER

Synthetic oil EP/ISO 220 (preferable)

Synthetic EP Synthetic or EP mineral Synthetic EP

Minéral oil EP/ISO 220(not recommended)

ESSO

SPARTAN SYNTHETIC EP 220

SPARTAN EP 220

SUNOCO

SYNSPEC EP 220

SUNEP EP 220

Oil must be EXTREME PRESSURE (EP), non-detergent, anti-foam, and anti-rust. GREASE LUBRICATION (IF APPLICABLE) MANUFACTURER

SYNTHETIC GREASE NLGI

MOBIL OIL CHEVRON

STANDARD GREASE NLGI MOBIL TEMP SHC 100

ULTI-PLEX SYNTHETIC GREASE EP NLGI 1.5

SRI NLGI 2

ESSO

AVIATION GREASE 322

SUNOCO

ULTRA PRESTIGE EP NLGI 2

Grease must be anti-rust. WARNING: Units are shipped without lubricating oil. Do not operate before lubricating.

Check lubricant's compatibility with your dealer before adding.

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Installation, Operation and Maintenance Manual

OPERATING CHECK LIST ❏ Check if equipment delivered corresponds to Hibon scope of supply. ❏ Check general installation of blower package (leveling) ❏ Check if the base is properly anchored ❏ Check if the blower was stored properly (if applicable) ❏ Check if the piping is proper and completed ❏ Check for adequate pipe support ❏ Check if isolation valves are open (if applicable) ❏ Open all valves at the inlet and outlet ❏ Make sure check valves are properly installed and functioning ❏ Check pressure gauge isolating valve ❏ Manually test relief valve (pressure weighted type only) ❏ Make sure the piping on inlet and discharge are clean and free from foreign material (Check inlet screen if applicable) ❏ Make sure there is an inlet filter and check condition ❏ Check filter restriction gauge operation ❏ Check oil levels and (grease if applicable) ❏ Check sheaves alignment and v-belt tension (or coupling alignment) ❏ Measure blower and motor sheaves and compare with design conditions ❏ Turn blower shaft by hand and other safety devices to ensure there is no friction ❏ Make sure all overloads and other safety devices into MCC are operational ❏ Make sure all trades working on the blower system authorize blower start up ❏ Start motor for a few seconds to determine direction of rotation. Ensure motor and blower stop normally ❏ Start the motor and allow the blower to attain full speed ❏ If the system is not in normal operating mode, use valves on the piping to simulate these conditions ❏ Allow the machine to run for 10 minutes or more before taking any measurements ❏ Completely open valves in the piping before stopping the blower

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TROUBLE SHOOTING TROUBLE SHOOTING No matter how well the equipment is designed and manufactured, there may be times when servicing will be required due to normal wear, the need for readjustment, or various external causes. Whenever equipment needs attention, the operator or repairman should be able to locate the cause and correct the trouble quickly. The following Trouble Shooting Chart will assist the operator in these respects. Experience has shown that the most common causes of faulty operation on blower installation are clogged inlet filters, and inaccurate or broken pressure gauges, lack and/or excess of oil and grease. Clogged inlet filters impose a restriction on the suction side of the machine which reduces the air flow, cause overheating of the unit and lost of pressure in the discharge piping. Continued running under these conditions will lead to excise rotor expansion and will ultimately result in total seizure of the unit. The rate at which a filter element will clog depends entirely upon the environmental conditions under which it is required to operate, and the allowable interval between cleaning can only be established from observation on site. It is essential therefore that during the first weeks of operation the cleaning interval for filter elements should be established and then strictly adhered to .

PROBLEM

POSSIBLE CAUSES

SOLUTION

Machine does not start

Electrical Rotors rub or damaged Casing distorted

Check electrical supply and protection. Restore clearance. Check piping stresses exerted on casing on the machine. Check leveling of blower. Remove foreign material inside the machine.

Foreign material No air flow

Speed too low Wrong rotation Obstruction in piping By pass open

Low capacity

Speed too low Excessive pressure rise

Obstruction in piping Excessive slip

Excessive power

Speed too high Pressure too high

Impellers rubbing

Check speed and compare with data sheet. Compare actual rotation with required direction. Change driver if wrong. Check piping, valves, silencer, to assure an open flow path. Close by pass. Check drive selection and belt slippage, then readjust tension. Check inlet vacuum and discharge pressure, and compare these figure with predicted operating conditions. Check piping, valves, silencer, to assure an open flow path. Check inside of casing for worn or eroded surfaces causing excessive clearances and re-establish properly. Check speed and compare with rating. Check inlet vacuum and discharge pressure, and compare these figure with predicted operating conditions. Inspect outside of cylinder and headplates for high temperature areas, then check for impeller contacts at these points.

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Installation, Operation and Maintenance Manual

PROBLEM

POSSIBLE CAUSES

SOLUTION

Excessive blower temperature

Filter Clogged Too much oil in gear case or drive cover. Too low operating speed Clogged filter or silencer Excessive pressure differential

Clean or replace filter. Reduce oil level. See filling Procedure.

Worn impeller clearances Overheating of bearings or gears

Inadequate lubrication

Increase blower speed. Remove cause of obstruction. Reduce pressure differential across the blower and accessories (silencers). Restore clearances.

Coupling misalignment Excessive belt tension

Check type and viscosity of oil , and grease in drive end bearings (when applicable). Check oil level. If incorrect, drain and refill with clean oil of recommended grade. Make sure grease is not excessive. Check inlet vacuum and discharge pressure, and compare these figure with predicted operating conditions. Check carefully. Realign if questionable. Readjust for correct tension.

Impeller end or tip drag

Insufficient assembled clearances Case or frame distortion Excessive operating pressure Excessive operating temperature

Correct clearances Check mounting and pipe strain Remove cause Remove cause

Knocking

Unit out of time. Distortion due to improper mounting or pipe strains. Excessive pressure differential or discharge temperature too high

Retime Check mounting alignment and relieve pipe trains. Reduce to manufacturer's recommended pressure. Examine relief valve, re-set if necessary. Replace timing gears See Section III New bearings. Check bearing fit in headplate.

Excessive lubrication

Excessive pressure rise

Worn gears Worn bearings Worn bearing fit Vibration

Misalignment Impellers rubbing

Worn bearings / gears Structural Unbalanced or rubbing impellers

Loss of oil

Abnormal noise

Readjust for correct tension. Inspect outside of cylinder and headplates for high temperature areas, then check for impeller contacts at these points. Check gear backlash and condition of bearings, and replace as indicated. Correct and make proper leveling. Scale or process material may build up on casing and impellers, or inside impellers. Remove build-up to restore original clearances and impeller balance.

Headplate, gear case or drive cover vents plugged. Worn seal.

Clean vents and replace gasket

Rotors rub Gear back lash Damaged bearing

Restore Clearance Replace gears Replace bearings

Replace seals.

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APPENDIX '' A '' ALIGNMENT AND TENSION OF TRANSMISSION BELTS The alignment of the sheaves and the correct tension of the belts enable the useful life of the bearings and the belts themselves to be utilized to the maximum. Misalignment causes asymmetric wear of the belt and does not allow the belts of a set to be uniformly loaded. Generally, it is not worthwhile carrying out regular checks on the alignment as this does not change during operation. On the other hand, alignment must always be carried out when belts are tensioned and whenever they are adjusted. The external faces of the B sheaves must be on the same vertical plane when aligning and this is carried out by placing a straight edge as shown in Fig. A1. The face of the machine sheaves is taken as a reference and the straight edge is placed on it, checking contact at points C and D. The motor is then moved, keeping the 4 fixing screws only slightly loosened and adjusting screws 1,2,3 and 4 until contact at points A and B is also made. Any axial movements can be made by means of small knocks with a lead or rubber mallet, if the motor size allows so, or by means of screws provided for this purpose.

A practical way of streamlining these operations is as follows :

•

carry out a rapid and approximate alignment with the belts loosen ;

•

make a preliminary and approximate tensioning of the belts taking care, however, to turn the tensioning screws equally ;

•

complete alignment with the necessary precision ;

•

complete belt tensioning to the final value, always taking care to ensure that the screws are rotated by the same mount (as, in the final phase, parts of a revolution can be required, it is advisable to mark the head) ;

•

before fully tightening the motor adjusting screws, check the alignment once more which, given the method followed, may require just a small final correction by an axial shift of the motor.

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Installation, Operation and Maintenance Manual

APPENDIX '' A ''

Fig. A.1

Shims are only rarely needed under the motor feet to correct alignment on the horizontal plane of the axes of the motor and machine. Excessive belt tension may result in an unnecessary increase in the load on the bearings and the bending moment on the shaft. In extreme cases, in can even cause the shaft to break due to fatigue. Inadequate tension on the belts causes them to slip, overheat and wear prematurely. In extreme cases, overheating can cause irreversible damage to the sheaves as well. In view of the range of belts on the market and their different characteristics, it is a good idea to have specific data so that belt tension can be set correctly.

Tensioning V-Belt drives

Without exception, the most important factor in the successful operation of a V-Belt drive is proper belttensioning. To achieve the long, trouble-free service associated with V-Belt drives, belt tension must be sufficient to overcome slipping under maximum peak load. This could be either at start or during work cycle. The amount of peak load will vary depending upon the character of the driven machine or drive system. To increase total tension, merely increase the center distance. Before attempting to tension any drive it is imperative that the sheaves be properly installed and aligned. If a V-Belt slips, it is too loose. Add to the tension by increasing the center distance. Never apply belt dressing as this will damage the belt and cause early failure.

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APPENDIX '' A '' a) General Method Step 1:

Reduce the center distance so that the belts may be placed over the sheaves and in the grooves without forcing them over the sides of the grooves. Arrange the belts so that both the top and bottom spans have about the same sag. Apply tension tothe belts by increasing the center distance until the belts are snug. See below Fig. A.2

Fig. A.2

Step 2:

Operate the drive a few minutes to seat the belts in the sheaf grooves. Observe the operation of the drive under its highest load condition (usually starting). A slight bowing of the loose side of the drive indicates proper tension. If the slack side remains taut during the peak load, the drive is too tight. Excessive bowing or slippage indicates insufficent tension. If the belts squeal as the motor comes on or at some subsequent peak load, they are not tight enough to deliver the torque demanded by the drive machine. The drive should be stopped and the belts tightened.

Step 3:

Check the tension on a new drive frequently during the first day by observing the sloose side span. After a few days of operation the belts will seat themselves in the sheaves grooves and it may become necessary to readjust so that the drive again shows a slight bow in the loose side. b) Force Deflection

This method should be used only for tensioning drives on which the grade of belt, rated belt capacity, service factor, design horsepower, etc. are known (if the drive has been designed in strict accordance whith the procedures, instructions and horse-power ratings).

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APPENDIX '' A '' Step 1:

Install belts as per Step 1 of General Method above. Measure span length (t) in inches as shown in Figure A.3 or calculate using formula.

Step 2:

From Figure A.3 the deflection height (h) is always 1/64" per inch of span lenght (t). For example, a 32" span length would require a deflection of 32/64" or 1/2".

Step 3:

Determine the minimum, maximum, and initial recommended pounds force using table 1 or calculate based on the required Static Strand Tension (Ts). Note: the initial recommended force is used only for installing new belts which have not seated themselves into the sheaves grooves and where initial belts stretch has not taken place.

Step 4:

Using a spring scale tensionner, apply a perpendicular force to any ONE of the belts at the mid point of the span as shown in figure A.2. Compare this deflection force with the values found in step 3. a. If the deflection force is below the minimum, the belts are too loose and the tension should be increased by increasing the centre distance. b. If the deflection force is higher than the maximum, the belts are too tight and the tension should be decreased.

When new V-Belts are installed on a drive the INITIAL tension will drop rapidly during the first few hours. Check tension frequently during the first 24 hours of operation. Subsequent retension should fall between the minimum and maximum force. To determine the deflection distance from normal position, use a straightedge or stretch a cord from sheave to sheave to usse as a reference line. On multiple-belt drives an adjacent undeflected belt can bu used as a reference. Minimum deflection force values shown in table 1 are based on assumed average static tensions for drives having multiple belts or on V-band, this eliminationg calculations. (For drives using only one belt or one V-band, the deflection force must be determined by use of engineering formulas). Find the minimum recommended deflection force for the belt section and type based upon the small sheaves diameter, speed and drive ratio. For intermediate sheaves diameters and/or drive ratio combinations the minimum deflection force may be interpolated.

Fig. A.3

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APPENDIX '' A '' Recommended Minimum Force Per Belt

Table 1 BELT SELECTION

ULTRA-V

3V

5V

8V

ULTRA-V COG

3VX

5VX

SMALL SHEAVE

DRIVE RATIO

SPEED RANGE

DIA.

1.0

1.5

2.0

1200-3600 1200-3600 1200-3600 1200-3600 1200-3600 900-1800 900-1800 900-1800 700-1200 900-1800 900-1800 700-1500 700-1200 400-1000 1200-3600 1200-3600 1200-3600 1200-3600 1200-3600 1200-3600 1200-3600 1200-3600 1200-3600 1200-3600 900-1800 900-1800

2.65 3.65 4.75 5.60 6.90 7.10 9.00 14.00 21.20 12.50 14.00 17.00 21.20 24.80 2.20 2.50 3.00 4.12 5.30 6.90 4.40 5.20 6.30 7.10 9.00 14.00

2.0 2.8 3.8 4.2 4.6 8.5 10.0 12.0 14.0 18 21 24 28 31 2.2 2.6 3.1 3.9 4.6 5.0 6.5 8.0 9.5 10 12 14

2.4 3.6 4.2 4.6 5.0 9.5 11.0 13.0 15.0 21 23 26 30 32 2.5 2.9 3.5 4.3 4.9 5.4 7.5 9.0 10 11 13 15

2.6 3.8 4.4 4.8 5.2 10 12 14 16 23 24 28 32 34 2.7 3.1 3.7 4.5 5.1 5.6 8.0 9.5 11 12 14 16

4.0 AND OVER 3 4.2 4.8 5.4 5.6 11 13 15 17 25 28 30 34 36 3.0 3.6 4.2 5.1 5.7 6.2 9.0 10 12 13 15 17

➣

Always install a complete new set

When one or two belts in a set become worn or damaged, there is a big temptation to replace only the useless belts. The trouble is that the remaining belts have been stretched, through use, beyond their original length. The newer, shorter belts will carry most of the load. A severe shock or load strain will easily break these new belts. For this reason, it is always better to install a new matched set rather than replace V belts one at a time. Used belts from a given drive can be put on a drive requiring a smaller set.

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Installation, Operation and Maintenance Manual

APPENDIX '' B '' COUPLING ALIGNMENT The correct alignment of the coupling allows the machine to operate at minimum vibration levels and prolongs the bearings life.

Alignment is carried out as follows: •

Place the axes of the two shafts coupled on the same vertical plane or on two parallel vertical planes, with a specified distance between them;

•

Place the axes of the two shafts coupled on the same horizontal plane or on two parallel horizontal planes, with a specified distance between them;

•

Keep a specified distance between the ends of the two coupled shafts or better between the two faces of the half couplings.

1. RADIAL MISALIGNMENT

2. ANGULAR MISALIGNMENT Fig. B.1

Radial mis-alignment and angular mis-alignment are shown in fig. B.1 . These can be present at the same time. Due to thermal expansion and other causes such as the lubricating oil film in the plain bearings, radial thrusts by the gears etc., the position of the two shafts coupled with the machine in normal operation can be very different from their position when the machine is off and cold. Therefore when aligning cold, radial mis-alignment values, can be calculated so as to obtain perfect alignment when the machine is running in normal operation.

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APPENDIX '' B ''

If no specific instructions are given, the shafts must be aligned cold so as to obtain the minimum possible value of radial and angular mis-aligment. The distance between the faces of the half couplings can be taken from the drawing. Maximum admissible mis-alignment when hot can vary depending on the type of coupling; however, if no specific instructions are given, the following tolerances must be used: - distance between the half coupling faces: - radial mis-alignment (T.I.R.): - angular mis-alignment:

0.10 mm (.0035") 0.10 mm (.0035") 0.50°

The distance between the half coupling faces where there is a spacer can be measured by means of a caliper or an internal micrometer or otherwise by a thickness gauge.

Radial misalignment can be checked by means of a set square or a straight bar wich is sufficiently rigid and long, but it is preferable to use a gauge fitted as shown in fig. B.3(A). The T.I.R. reading (Total Indicator Reading) given by the gauge for a 180° rotation represents double the actual misalignment. With reference to fig. B.1, half of the reading for a 108° rotation from 0° to 180° rotation from 90° to 270° provides the distance between the two vertical planes on wich the shaft axes are placed. Angular misalignment can be checked by a calliper, internal micrometer or a thickness gauge, but it is preferable to use a gauge fitted as shown in fig. B.3 (B). The ratio between the T.I.R. reading (Total Indicator Reading) provide by the gauge for a 180° rotation and the diameter of the circle described by the rotoation of the tracer point axis represents the tangent of the misalignment angle. Fig. B.2

With reference to fig. B.2, from the reading for a 180° rotation from 0° to 180°, the angular misalignment is determinated by the height of the couplings. From the reading for a 180° rotation from 90° to 270°, the angular mis-alignment is determined by the transversal position of the couplings. Machines and / or motors are moved laterally by means of appropriate adjustment screws provided. A lead mallet may be needed for smaller machines without adjustment screws.

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APPENDIX '' B ''

Machines and/or motors are moved vertically by using shims placed under the feet as required. When adjusting the height of machines and/or motors with shims, the following precautions are recommended : •

ensure that the feet, their bearing surfaces and every individual shim used are as clean as possible ;

•

ensure that all the anchoring screws have been tightened before taking readings ;

•

ensure that all the feet are completely in contact with the shims and that the tightening of the anchoring screws does not produce any deformation to the base-plate and/or the machine of motor.

A good practical method for alignment is as follows : 1.

Study the machine, the height and position of which needs to be considered fixed with regard to the base-plate.

2.

Check that its anchoring screws are centered in the holes, i.e. that it is possible to move it in all directions.

3.

Completely tighten the anchoring screws.

4.

Check that the height of the shaft is greater than or equal to the minimum required, correcting with shims if necessary.

5.

Place a gauge with a magnetic base-plate on the base-plate and a tracer point on the machine feet close to one of the anchoring screws and set it to zero.

6.

Loosen the anchoring screws and check that the gauge does not indicate movements of more than 0.005 mm [.001''] (a movement greater than the given value requires the insertion of corrective shims).

7.

Repeat the operation for all the anchoring points to the base-plate.

8.

Loosen the anchoring screws of the other machine.

9.

Measure the distance between the faces of the half couplings and move the machine in an axial direction until the prescribed value is reached.

10.

Tighten the adjusting screws.

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APPENDIX '' B '' 11.

While rotating the two half couplings at the same time measure the radial mis-alignment and: - move the machine transversally until the prescribed value is obtained (T.I.R. 90° - 270°); - shim all the machine feet until the prescribed value is obtained (T.I.R. 0° - 180°);

12.

While rotating the two half couplings at the same time measure the angular misalignment and: - move the machine transversally until the prescribed value is obtained (T.I.R. 90° - 270°); - shim two of the feet of the machine until it comes within the prescribed tolerance (T.I.R. 0° - 180°).

Operations 11 and 12 affect each other reciprocally and therefore must be repeated alternately until the correct result is obtained.

13.

Repeat on this machine the operations described in items 5,6 and 7.

Fig. B.3

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Installation, Operation and Maintenance Manual

APPENDIX '' C '' BLOWER CONCRETE SLAB & ANCHORING INSTRUCTION A foundation design is very important to insure the proper installation and life of the HIBON equipment. The size of machine and package generally dictate the foundation required. - CONCRETE SLAB When possible pour directly on the ground with a raised portion approximately 150 mm (6") high and, at least 150 mm (6") exceeding the overall base dimensions, the surface should be leveled and smooth to mount the package directly. - INSTALLATION ON FOUNDATIONS (CONCRETE SLAB) FOR SMALL MACHINES (Up to 60 hp) The concrete foundation shall be solid, leveled and as smooth as possible. Before setting the machine on the foundation, the parts in contact with concrete must be cleaned of any oil or grease traces. When installing the blower (base) on the concrete foundation, insert shims between the foundation and the base plate if required to accommodate any uneven surface of concrete. NEVER INSERT SHIMS BETWEEN THE BLOWER AND BASE PLATE TO CORRECT ANY LEVELING DEFECTS. Max. horizontal deviation is 0.2 mm/m (.010"/ft). Drill a hole in the concrete foundation from the size of Hilti anchor bolts selected, insert Hilti in place, then tighten the anchor bolts firmly. The same procedure is to be followed when the blower base is mounted with elastic supports. See fig. C.1 and C.2 . 1. Insert the elastic pads under the base plate and bolt to the base plate. 2. Drill holes in the concrete. 3. Hilti (anchor bolts) to be tightened firmly. 4. Isolation.

Fig. C.1

Fig. C.2

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Installation, Operation and Maintenance Manual

APPENDIX '' C '' - INSTALLATION ON AN ISOLATED CONCRETE FOUNDATION (Generally recommended for medium (25 HP to 125 HP) and large (150 HP and up) size machines). This type of foundation isolates the machine from the rest of the foundation and reduces vibration transmission to the structure and other equipment. The mass should if possible be equivalent to 1.5 times the weight of the equipment. 1/2" (12 mm) cork is generally used as isolation and the surfaces are left rough for grouting purposes. The use of anchor bolts, commonly used for machinery with relatively high installed power, involves the use of a concrete foundation isolated from the rest of the building to prevent the transmission of vibration. Where anchor bolts are used, the base- plate shall be fitted in accordance with the following instruction: *

*

The concrete foundation, if possible, should be made to be isolated from the rest of the building. The surfaces shall be left rought so as to provide a better adhesion for grouting (which is carried out subsequently). Lower the base-plate to approximately 200 mm (8") from the plinth, centering the machine. Position the 100 X 100 X 20 mm (4 X 4 X 7/ 8") plates under the leveling screws.

Lower until the leveling screws come in contact with the plates. Position the base-plate in its final location, longitudinally and transversally. Centre the plates under the leveling screws. Wedge the plates which are not in contact with the adjustment screws. *

* *

* * *

Check that the base-plate is level by using a spirit level sensitive to 0.1 mm/m (.005"/y). This check shall be made longitudinally and transversally on all finished surfaces. It shall be level 0.1 mm/m (.005"/y). It is adjusted by using the spirit level on the finished surface as shown in fig. C.3 and using the leveling screw. Each leveling screw can be used to raise or lower the base-plate and therefore the edge of the finished surface relative to adjacent one. All surfaces are to be leveled transversally and longitudinally as specified. Clean the surfaces of the plinth and prepare it for grouting. Provide an enclosure as shown in fig. C.3 . If it is being installed in the open air, provide proper drainage for rainwater, taking account of the base-plate share. Pour grout under the base to the level indicated in fig. C.3 . Avoid the use of mechanical vibrators so as not to disturb the level surface obtained. Instead, promote grout with the use of bars or chains. Cure the grout adequately for an appropriate number of days. Drill the holes as per the anchor bolt manufacturer's recommendation. Install the anchor bolts, generally "Hilti chemical type", when the equipment is settled. Loosen the leveling screws. Tighten all the anchor bolt nuts and the associated lock nuts before fitting the machines. • Size or anchor bolts and leveling screws are indicated on the general arrangement drawing.

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Installation, Operation and Maintenance Manual

APPENDIX '' D-01 '' (HH 4200 / 4300 SERIES) LUBRICATION

WARNING: Units are normally shipped without lubricating oil. Do not operate before lubricating. Note: See parts lists identification number Timing gears (6) and bearings (01,02) are lubricated by a simple but effective splash system. At the drive end, oil is distributed by an oil slinger (25) attached to the drive shaft (11). At the gear end, gear teeth are lubricated by being partially submerged. The gear teeth serve as oil slingers for the gear end bearings (1).

FILLING PROCEDURE: Remove fill plugs (A) from top of each headplate (13). Using the grade of lubricant recommended, fill gear end until oil reaches midpoint in sight glass (34.04), fill drive end up to red line on sightglass (34.05). Do not overfill. Replace fill plugs. Always maintain oil level within sight in the glasses (34), this should be checked when the machine is not operating. Oil should be changed every 1500 hours under normal service, or more frequently if inspection indicates it is necessary. The oil drain plug is located under each headplate. (B) rev 01, 15/08/98 Page 1

Installation, Operation and Maintenance Manual

APPENDIX '' D-01 '' (HH 4200 / 4300 SERIES) LUBRICATION OIL CAPACITIES.

The machine size can be read off the individual nameplate mounted on the headplate at the non drive end of the blower unit, this plate also contains the unique serial number for the machine that should be quoted when ordering spares. OIL QUANTITIES ARE LITRES / PINTS (USA) Horizontal Build Blower Unit - Vertical Gas Flow Tick Selection

MACHINE SIZES

GEAR CENTRES

4242, 4243, 4344, 4342, 4343 & 4344 4252 , 4253, 4254, 4352, 4353 & 4354 4262, 4263, 4264, 4362, 4363 & 4364 4282, 4283, 4284, 4382, 4383, & 4384

4” 102 (MM) 5” 127 (MM) 6” 152 (MM) 8” 204 (MM)

GEAR END OIL CAPACITY LITRES (PINTS)

DRIVEN END OIL CAPACITY LITRES (PINTS)

0.65 (1.37)

0.32 (.67)

1.50 (3.17)

0.60 (1.27)

2.40 (5.07)

1.20 (2.53)

4.20 (8.88)

1.90 (4.0)

GEAR END OIL CAPACITY LITRES (PINTS)

DRIVEN END OIL CAPACITY LITRES (PINTS)

0.28 (.60)

0.14 (.30)

0.50 (1.06)

0.20 (.42)

0.90 (1.90)

0.50 (1.06)

1.80 (3.80)

0.90 (1.90)

Vertical Build Blower Units - Horizontal Gas Flow Tick Selection

MACHINE SIZES

GEAR CENTRES

4242, 4243, 4344, 4342, 4343 & 4344 4252 , 4253, 4254, 4352, 4353 & 4354 4262, 4263, 4264, 4362, 4363 & 4364 4282, 4283, 4284, 4382, 4383, & 4384

4” 102 (MM) 5” 127 (MM) 6” 152 (MM) 8” 204 (MM)

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APPENDIX '' D-01 '' (HH 4200 SERIES TWO LOBE) PARTS LIST

ITEM 25 21 19 17

QTY 1 2 2 1

PART DESCRIPTION OIL SLINGER GASKET BEARING RETAINER DRIVE COVER

16 15 13 12 11

1 1 2 4 1

10

1

*6 *4 *3 *1

2 1 4 4

GEAR CASE IMPELLER CASE HEADPLATE SHAFT SLEEVE LONG SHAFT IMPELLER ASSEMBLY SHORT SHAFT IMPELLER ASSEMBLY TIMING GEAR DRIVE SEAL MAIN SEAL MAIN BEARING STANDARD PARTS LIST

Notes

ITEM *94 *81 36 34.04 34.05 *33 32 28 27 26

QTY 2 4 4 1 1 1 2 1 1 2

PART DESCRIPTION GEAR LOCKING KIT SEALING RING FOOT OIL LEVEL SIGHT GLASS OIL LEVEL SIGHT GLASS OIL SLINGER 'O'RING LIFTING EYE DRIVE KEY NAMEPLATE FILLER PLUG

1. When ordering spare or replacement parts, please specify the following: Unit Size / Serial Number / Part Description / Item Number 2. Items marked * are factory recommended spare parts

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APPENDIX '' D-01 '' (HH 4300 SERIES THREE LOBE) PARTS LIST

ITEM *01 *02 *04 *06 99 98 12 13 84 16 17 19 20 21 22

Notes

QTY 2 2 1 2 1 1 4 2 1 1 1 2 1 2 2

PART DESCRIPTION MAIN BEARING DRIVE END MAIN BEARING GEAR END DRIVE SEAL TIMING GEAR SHORT SHAFT ASSEMBLY (3 LOBE) LONG SHAFT ASSEMBLY (3 LOBE) SHAFT SLEEVE HEADPLATE IMPELLER CASE (3 LOBE) CAST GEAR CASE CAST DRIVE COVER BEARING RETAINER GEAR BAFFLE PLATE GASKET CLEARANCE SETTING SHIM SET

ITEM 25 26 27 28 32 33 34 & 34a 36 65 71 72 73 74 *81 *94

QTY 1 2 1 1 4 1 1 4 1 2 2 4 2 8 2

PART DESCRIPTION MAIN BEARING DRIVE END VENT BREATHER NAMEPLATE (NOT SHOWN) DRIVE KEY (NOT SHOWN) LIFTING EYE OIL SLINGER 'O' RING OIL SIGHT GLASS (G.E & D.E) FOOT (2-LEFT, 2-RIGHT) OIL SLINGER GRIP RING OIL THROWER (GEAR END) OIL THROWER (DRIVE END) OIL SHIELD OIL SHIELD RETAINING SPRING SEALING RING GEAR LOCKING KIT

1. When ordering spare or replacement parts, please specify the following: Unit Size / Serial Number / Part Description / Item Number 2. Items marked * are factory recommended spare parts

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Installation, Operation and Maintenance Manual

APPENDIX '' D-02 '' (HH 2000 SERIES) LUBRICATION

WARNING: Units are normally shipped without lubricating oil. Do not operate before lubricating. Note: See parts lists identification number Timings gears (6) and bearings (1) (gears end) are lubricated by a simple but effective spash system, gear teeth are lubricated by being partially submerged. The gear teeth serve as an oil slingers for the gear end bearings. The drive end bearing are grease lubricated. FILLING PROCEDURE: Remove fill plug (A) at the top of the headplate. Using the grade of lubricant recommended, fill gear end until oil appears at the oil level plug at point (B). Do not overfill. Replace this level should be checked when the machine is not operating. Oil should be changed every 1500 hours under normal service, or more frequently if inspectection indicates it is necessary. The oil drain plug is located under the headplate (C). Bearings on drive end of the blower require grease lubrication every 500 hours of operation. Bearing which require grease lubrication have a grease fitting (D) at each bearing. When regreasing, the old grease will be forced out of the vents during operation. To prevent damage to seals, these vents must be kept open at all times. OIL QUANTITIES Oil Quantities are given in LITRES (PINTS USA) MACHINE SIZE

DRIVEN SIDE (gear oil) GEAR DRIVE SIDE DRIVEN SIDE (gear oil) DRIVE SIDE

2022 2023

2031 2032 2033 VERTICAL ARRRANGMENT 0.07 (.15) 0.07 (.15) GREASE GREASE HORIZONTAL ARRRANGMENT 0.21 (.44) 0.36 (.76) GREASE GREASE

2041 2042 2043

2051 2052

0.28 (0.59) GREASE

0.36 (.76) GREASE

0.36 (.76) GREASE

0.71 (1.50) GREASE rev 01, 15/08/98 Page 1

Installation, Operation and Maintenance Manual

APPENDIX '' D-02 '' (HH 2000 SERIES) PARTS LIST

DETAIL NO.

NO. REQ,D

*1(**) *1A *3 *4 *6 ***10 11 ***13 ***14 15 16 ***17 20 21 26 ***27 34 39 42 43 59 95

3 1 4 1 2 1 1 1 1 1 1 1 1 1 2 1 1 2 1 1 1 2

DESCRIPTION MAIN BEARINGS BEARINGS DRIVE SHAFT MAIN SEAL DRIVE SEAL TIMING GEARS SHORT SHAFT ASSMBLY LONG SHAFT ASSEMBLY DRIVE HEAD PLATE (VERTICAL GEAR HEADPLATE (VERTICAL) IMPELLER CASE GEAR CASE DRIVEN SHAFT COVER GEAR BEARING PLATE GEAR CASE GASKET VENT PLUG (BREATHER) IDENTIFICATION NAME PLATE OIL LEVEL SIGHT GLASS THREADED TAPER PIN GEAR HEADPLATE (HORIZONTAL) DRIVE HEADPLATE (HORIZONTAL) DRIVER COVER GREASE FITTING

Notes: 1. When ordering spares or replacement parts, please specify the following: Unit Size / Serial Number / Part Description / Item Number 2. Item marked * are factory recommended spare parts (**) 2022 and 2023 has four identical bearing. Not shown on drawing. *** Not shown on drawing. rev 01, 15/08/98 Page 2

Installation, Operation and Maintenance Manual

APPENDIX '' E '' (XN TWO & THREE LOBE) LUBRICATION Clockwise rotation

A- Cover B- Oil filling plug C- Oil casing D- Oil sight glass E- Oil drain plug

Counter Clockwise rotation

NOTE: Depending upon the installation position, oil filling and draining plugs as well as sight glasses shall be positioned in the proper location.

WARNING: Units are normally shipped without lubricating oil. Do not operate before lubricating. Note: See parts lists identification number Timing gears (023) and bearings (019) are lubricated by a simple but effective splash system. At the gear end, gear teeth are lubricated by being partially submerged. The gear teeth serve as oil slinger for the gear end bearings (019). The drive side bearings are permanent factory lubricated. FILLING PROCEDURE: Remove fill plugs (B) from top of gear end headplate. Using the grade of lubricant recommended, fill gear end until oil reaches midpoint in sight glass (D). Do not overfill. Always maintain oil level within sight in the glasses (544), this should be checked when the machine is not operating. The drive side bearings are permanent factory lubricated. If bearings are removed the bearings shall be lubricated with grease MOBIL TEMP SHC 100 or equivalent. Oil should be changed every 2000 hours under normal service, or more frequently if inspection indicates it is necessary. The oil drain plug is located under gears headplate(E). OIL QUANTITIES (DRIVEN SIDE) Oil Quantities are given in LITRES (PINTS USA) Machine size XN XN XN XN

0,8 1,3 / 1,8 / 2,5 803 / 8045 806 / 809 / 815

Position V 0.07 (0.15) 0.15 (0.32) 0.35 (0.79) 0.55 (1.16)

approximative oil quantity Position H 0.15 (0.32) 0.29 (0.61) 0.75 (1.57) 1.05 (2.20)

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APPENDIX '' E '' (XN TWO AND THREE LOBE) PARTS LIST

ITEM 1 2 3 4 5 6 7 8 9 11 12

Notes

DESCRIPTION Blower cylinder Driven shaft Driving shaft Side plate, rear side Side plate, drive side Oil casing Cover Cover Bushing Gear train Spacer with piston rings Bearing, drive side

QTY 1 1 1 1 1 1 1 1 1 4 2

ITEM 13 14 18 19 16 22 23 20 21

DESCRIPTION Bearing, rear side Piston ring SKF locknut SKF locknut V-ring seal Hex. socket screw Taper pin Oil sight glass Drain plug

QTY 2 4 2 2 1 16 4 1 2

1. When ordering spare or replacement parts, please specify the following: Unit Size / Serial Number / Part Description / Item Number 2. Items marked * are factory recommended spare parts

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APPENDIX '' F-01 '' (SNH / V TWO AND THREE LOBE) EXCEPT MODELS 8 & 12 LUBRICATION A- Oil filling plug B- Oil drain plug C- Oil level indicator D- Plug for cleaning the compression chamber and the rotors. (SNV only) E- Compression chamber drain plug (SNV only) F- Pressure gauge tapping point

WARNING: Units are normally shipped without lubricating oil. Do not operate before lubricating. NOTE:

See parts lists indentification number

Timing gears (9-10) and bearings (18-19-20) are lubricated by a simple but effective splash system. At the drive end, oil is distributed by an oil slinger (14) attached to the drive shaft (3). At the gear end, gear teeth are lubricated by being partially submerged. The gear teeth serve as oil slingers for the gear end bearings. FILLING PROCEDURE: Remove fill plugs (A) from top of each casing. Using the grade of lubricant recommended, fill both end until oil reaches midpoint in sight glass (C). Do not overfill. Replace fill plugs. Always maintain oil level within sight in the glasses (C), this should be checked when the machine is not operating. Oil should be changed every 2000 hours under normal service, or more frequently if inspection indicates it is necessary. The oil drain plug is located under each headplate. (B)

Oil quantities: as shown in the table below in litres / (pints) (U.S.A.)

Machine size SNH Drive side Opposite side SNV Drive side Opposite side

1 1,6 2

3-4

6-9-15 806 809-815

7 812

13-20 32 820

0,5 (1.06) 0,5 (1.06) 1 (2.12) 0,7 (1.50) 1,8 (3.8) 0,5 (1.06) 0,3 (0.64) 0,9 (1.90) 0,8 (1.70) 1,5 (3.20)

25-40-60 825 840-842

50-70-90 110-870 890-8110

100-140 170 200

210 280 400

4 (8.45) 3 (6.34)

7 (14.80) 6 (12.68)

9 (19.00) 5 (10.57)

25 (52.80) 13 (27.50)

3 (6.34) 3 (6.34)

6 (12.68) 3 (6.34)

13 (27.50) 7 (14.80)

0,4 (0.85) 0,7 (1.50) 1,1 (2.32) 0,4 (1.06) 1,2 (2.54) 2 (4.23) 0,4 (0.85) 0,3 (0.64) 0,9 (1.90) 0,4 (1.06) 0,9 (1.80) 1,7 (3.60)

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Installation, Operation and Maintenance Manual

APPENDIX '' F-01 '' (SNH / V & TWO LOBE) EXCEPT MODELS 8 & 12 PARTS LIST

QTY 1 2 2 1 4

ITEM 1 2 3 4 5

DESCRIPTION Blower cylinder Rotor Driving shaft Driven shaft Side plate, drive side

QTY 1 2 1 1 1

ITEM 18 19 20 21 22

6

Side plate, rear side

1

23

7 8 9 10 11 12 13 14 15

Oil casing, drive side Oil casing, rear side Driving gear Driven gear Bushing of driven gear Shaft passage cover Bearing box cover, rear side Oil splasher, drive side Oil splasher, rear side Lock washer of driven gear or Lock washer of rear side bearing Oil retaining disk, at shaft outlet*

1 1 1 1 1 1 2 1 1

24 25 26 27 28 29 30 31 32

Spacer between bearing and timing gear

Lockwasher of bearings Spacer with piston ring, rear side Thrower, rear side Bearing box, rear side Lockwasher of rear side splasher Bushing sleeve at shaft passage Thrower, drive side Spacer with piston rings, drive side

2 1 2 2 2 1 1 2 2

2

33

Spacer of shaft outlet bearing

1

1

34

Piston ring

12

16 17

Notes

DESCRIPTION Shaft outlet bearing Drive side bearing Rear side bearing Shaft seal Oil sight glass SKF nut and lockwasher on driving shaft

1

1.When ordering spares or replacement parts, please specify the following: Unit Size / Serial Number / Part Description / Item Number rev 01, 15/08/98 Page 2

Installation, Operation and Maintenance Manual

APPENDIX '' F-02 '' (SNH / V 815, 820, 825, 840 THREE LOBE) PARTS LIST

ITEM 001 005 008 009 010 011 012 014 015 017 018 019 020 021 022

Notes

DESCRIPTION Blower casing Head plate Oil casing drive end Oil casing driven end Shaft seal cover Drive impeller & shaft Driven impeller & shaft Ring holder drive end Ring holder Driven end Retainer drive end Retainer driven end Bearing drive end Driven end bearing Drive shaft bearing Spacer

QTY 1 2 1 1 1 1 1 2 2 2 2 2 2 1 1

ITEM 023 024 028 031 034 035 036 039 042 043 044 045 105

DESCRIPTION Gear set Gear hub Shaft sleeve for seal Bearing holder Bearing plate Shaft seal Piston rings Gear holder plate Holder plate driven end Oil slinger drive end Oil slinger driven end Oil shell drive cover Removable feet

QTY 1 1 1 2 2 1 12 1 2 1 1 1 4

1.When ordering spares or replacement parts, please specify the following: Unit Size / Serial Number / Part Description / Item Number

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Installation, Operation and Maintenance Manual

APPENDIX '' F-02 '' (SNH / V 870, 890, 8110 THREE LOBE) PARTS LIST

ITEM 001 005 008 009 010 011 012 014 015 017 018 019 020 021 022

Notes

DESCRIPTION Blower casing Head plate Oil casing drive end Oil casing driven end Shaft seal cover Drive impeller & shaft Driven impeller & shaft Ring holder drive end Ring holder Driven end Retainer drive end Retainer driven end Bearing drive end Driven end bearing Drive shaft bearing Spacer

QTY 1 2 1 1 1 1 1 2 2 2 2 2 2 1 1

ITEM 023 024 028 031 034 035 036 039 041 042 043 044 045 105 151

DESCRIPTION Gear set Gear hub Shaft sleeve for seal Bearing holder Bearing plate Shaft seal Piston rings Gear holder plate Bearing bloc driven end Holder plate driven end Oil slinger drive end Oil slinger driven end Oil shell drive cover Removable feet Oil slinger driven end

QTY 1 1 1 2 2 1 12 1 1 1 1 1 1 4 1

1.When ordering spares or replacement parts, please specify the following: Unit Size / Serial Number / Part Description / Item Number

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Installation, Operation and Maintenance Manual

APPENDIX '' F-03 '' (SNH / V 8 - 12 - 812 TWO & THREE LOBE) LUBRICATION

A- Oil casing B- Oil sight glass C- Oil filling plug D- Drain plug

(HORIZONTAL GEARS)

(VERTICAL GEARS)

WARNING: Units are normally shipped without lubricating oil. Do not operate before lubricating. NOTE:

See parts lists

Timing gears (18, 19) and bearings (23, 24, 25) are lubricated by a simple but effective splash system. At the driven end, oil is distributed by an oil slinger (5) attached to the drive shaft. At the gear end, gear teeth are lubricated by being partially submerged. The gear teeth serve as oil slingers for the gear end bearings.

FILLING PROCEDURE: Remove (C) plug from top of each headplate. Using the grade of lubricant recommended, fill both end until oil reaches midpoint in sight glass (B), Do not overfill. Replace fill plugs. Always maintain oil level within sight in the glasses (B), this should be checked when the machine is not operating. Oil should be changed every 2000 hours under normal service, or more frequently if inspection indicates it is necessary. The oil drain plug is located under each headplate (D).

Oil quantities are given in LITRES (PINTS) (USA) Position

Drive side

Opposite side

Mounting V

0.58 (1.23)

0.58 (1.23)

Mounting H

1.1 (2.32)

1.1 (2.32)

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Installation, Operation and Maintenance Manual

APPENDIX '' F-03 '' (SNH / SNV 8, 12, 812 TWO & THREE LOBE) PARTS LIST

A

ITEM 001 006 007 008 009 011 012 014 017 018 020 020A 021 023

Notes

DESCRIPTION Blower casing End plate driving end End plate driven end Front cover Cover driven end Driving lobe Driven lobe Piston ring holder Oil thrower gear size Oil thrower Q.PP gear Bearing 3211 Bearing 3310 Bearing NU 309 Gear / Set

QTY 1 1 1 1 1 1 4 2 2 1 1 1 1

ITEM 028 047 035 036 044 047 048 057 058 071 072 143 143A

DESCRIPTION Shaft sleeve Driving gear Spacer Shaft seal Piston rings Oil Slinger Driving gear spacer Driven gear spacer Bearing NU 311 Bearing NU 2211 Bearing retainer Driving lobe Bearing retainer Driven lobe Wavy washer driven Wavy washer driving

QTY 1 1 1 12 2 1 1 1 1 1 1 1

1.When ordering spares or replacement parts, please specify the following: Unit Size / Serial Number / Part Description / Item Number 2.Item marked *are factory recommended spare parts rev 01, 15/08/98 Page 2

Installation, Operation and Maintenance Manual

APPENDIX '' G-01 '' (VTB 810 - 20 - 820 TWO & THREE LOBE) LUBRICATION

A- Oil casing B- Oil sight glass C- Oil filling plug D- Drain plug

(HORIZONTAL GEARS)

(VERTICAL GEARS)

WARNING: Units are normally shipped without lubricating oil. Do not operate before lubricating. NOTE:

See parts lists

Timing gears (18, 19) and bearings (23, 24, 25) are lubricated by a simple but effective splash system. At the driven end, oil is distributed by an oil slinger (5) attached to the drive shaft. At the gear end, gear teeth are lubricated by being partially submerged. The gear teeth serve as oil slingers for the gear end bearings.

FILLING PROCEDURE: Remove (C) plug from top of each headplate. Using the grade of lubricant recommended, fill both end until oil reaches midpoint in sight glass (B), Do not overfill. Replace fill plugs. Always maintain oil level within sight in the glasses (B), this should be checked when the machine is not operating. Oil should be changed every 2000 hours under normal service, or more frequently if inspection indicates it is necessary. The oil drain plug is located under each headplate (D).

Oil quantities are given in LITRES (PINTS) (USA) Position

Drive side

Opposite side

Mounting V

0.58 (1.23)

0.58 (1.23)

Mounting H

1.1 (2.32)

1.1 (2.32)

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APPENDIX '' G-01 '' (VTB 810, VTB 820 THREE LOBE) PARTS LIST

A

ITEM 001 006 007 008 009 011 012 014 017 018 020 020A 021 023

Notes

DESCRIPTION Blower casing End plate driving end End plate driven end Front cover Cover driven end Driving lobe Driven lobe Piston ring holder Oil thrower gear size Oil thrower Q.PP gear Bearing 3211 Bearing 3310 Bearing NU 309 Gear / Set

QTY 1 1 1 1 1 1 4 2 2 1 1 1 1

ITEM 028 047 035 036 044 047 048 057 058 071 072 143 143A

DESCRIPTION Shaft sleeve Driving gear Spacer Shaft seal Piston rings Oil Slinger Driving gear spacer Driven gear spacer Bearing NU 311 Bearing NU 2211 Bearing retainer Driving lobe Bearing retainer Driven lobe Wavy washer driven Wavy washer driving

QTY 1 1 1 12 2 1 1 1 1 1 1 1

1.When ordering spares or replacement parts, please specify the following: Unit Size / Serial Number / Part Description / Item Number 2.Item marked *are factory recommended spare parts rev 01, 15/08/98 Page 2

Installation, Operation and Maintenance Manual

APPENDIX '' G-02 '' (SIAV, Air injection series) LUBRICATION A- Oil filling plug B- Oil drain plug C- Oil level indicator D- Plug for cleaning the compression chamber and the rotors. E- Compression chamber drain plug F- Pressure gauge tapping point

WARNING: Units are normally shipped without lubricating oil. Do not operate before lubricating. FILLING PROCEDURE: Remove plug A from top of each headplate. using the grade of lubricant recommended (synthetic oil is preffered) file dive end and until oil reaches mid point in sight glass.

IMPORTANT NOTE FOR TRUCK INSTALLATION: Blower may be installed at an angle for instance (to match the angle of truck transmission) or in case the truck is not parked on a leveled surface, please observe the following procedure: • Check the oil or both sides of each oil casing (drive and driven side). Proper oil level shall be the middle of the sight glass on either side of the blower. • If the oil level is low on one side, correct oil level to middle of sight glass as required. • As same machines with high shaft, there is only one sight glass on the drive end oil casing. In this particular instance only, fill the sight glass up to the top as shown below: • Maximum operating angle of blower is 15°. DO NOT OVERFILL Replace sealant on fill plugs (use LOCTITE PST56747 or equivalent). Oil shall be changed every 1000 hours (high service) or 2000 hours (industrial use) or every 6 months. Oil may be changed more frequently, if inspection indicates it is necessary. The oil drain plug is located under each oil casing.

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Installation, Operation and Maintenance Manual

APPENDIX '' G-02 '' (SIAV VTB, Air injection series) LUBRICATION OIL CAPACITIES.

The machine size can be read off the individual nameplate mounted on the headplate at the non drive end of the blower unit, this plate also contains the unique serial number for the machine that should be quoted when ordering spares. OIL QUANTITIES ARE GIVEN IN LITRES / PINTS (USA) Horizontal Build Blower Unit - Vertical Gas Flow Tick Selection

MACHINE SIZES VTB 810 VTB 820 SIAV 25 H SIAV 840 H

GEAR CENTRES 5.3” 135 MM 5.3” 135 MM 8.54” 217 MM 8.54” 217 MM

DRIVE END OIL DRIVEN END OIL CAPACITY CAPACITY LITRES (PINTS) LITRES (PINTS USA)

1.1 (2.32)

1.1 (2.32)

1.1 (2.32)

1.1 (2.32)

4.0 (8.45)

3.0 (6.34)

4.0 (8.45)

3.0 (6.34)

Vertical Build Blower Units - Horizontal Gas Flow Tick Selection

MACHINE SIZES SIAV 6 VTB 810 VTB 820 SIAV 25 V SIAV 840 V SIAV 8702 V SIAV 140 V

GEAR CENTRES 5.3” 135 MM 5.3” 135 MM 5.3” 135 MM 8.54” 217 MM 8.54” 217 MM 10.63” 270 MM 13.38” 340 MM

DRIVE END OIL DRIVEN END OIL CAPACITY CAPACITY LITRES (PINTS USA) LITRES (PINTS USA)

1.1 (2.32)

0.9 (1.90)

0.58 (1.23)

0.58 (1.23)

0.58 (1.23)

0.58 (1.23)

2.0 (4.23)

1.7 (3.60)

2.0 (4.23)

1.7 (3.60)

3.0 (6.34)

3.0 (6.34)

6.0 (12.68)

3.0 (6.34)

Above oil quantities are approximative and may very depending upon the tilt angle of blower. Please follow the above procedure to read proper oil level.

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Installation, Operation and Maintenance Manual

APPENDIX '' G-02 '' (SIAV 6, 25, 50, 701, 702 TWO LOBE) PARTS LIST

QTY 1 2 2 1 4

ITEM 1 2 3 4 5

DESCRIPTION Blower cylinder Rotor Driving shaft Driven shaft Side plate, drive side

QTY 1 2 1 1 1

ITEM 18 19 20 21 22

6

Side plate, rear side

1

23

7 8 9 10 11 12 13 14 15

Oil casing, drive side Oil casing, rear side Driving gear Driven gear Bushing of driven gear Shaft passage cover Bearing box cover, rear side Oil splasher, drive side Oil splasher, rear side Lock washer of driven gear or Lock washer of rear side bearing Oil retaining disk, at shaft outlet*

1 1 1 1 1 1 2 1 1

24 25 26 27 28 29 30 31 32

Spacer between bearing and timing gear

Lockwasher of bearings Spacer with piston ring, rear side Thrower, rear side Bearing box, rear side Lockwasher of rear side splasher Bushing sleeve at shaft passage Thrower, drive side Spacer with piston rings, drive side

2 1 2 2 2 1 1 2 2

2

33

Spacer of shaft outlet bearing

1

1

34

Piston ring

12

16 17

Notes

DESCRIPTION Shaft outlet bearing Drive side bearing Rear side bearing Shaft seal Oil sight glass SKF nut and lockwasher on driving shaft

1

1.When ordering spares or replacement parts, please specify the following: Unit Size / Serial Number / Part Description / Item Number rev 01, 15/08/98 Page 3

Installation, Operation and Maintenance Manual

APPENDIX '' G-02 '' (SIAV - 840, THREE LOBE) PARTS LIST

ITEM 001 005 008 009 010 011 012 014 015 017 018 019 020 021 022

Notes

DESCRIPTION Blower casing Head plate Oil casing drive end Oil casing driven end Shaft seal cover Drive impeller & shaft Driven impeller & shaft Ring holder drive end Ring holder Driven end Retainer drive end Retainer driven end Bearing drive end Driven end bearing Drive shaft bearing Spacer

QTY 1 2 1 1 1 1 1 2 2 2 2 2 2 1 1

ITEM 023 024 028 031 034 035 036 039 042 043 044 045 105

DESCRIPTION Gear set Gear hub Shaft sleeve for seal Bearing holder Bearing plate Shaft seal Piston rings Gear holder plate Holder plate driven end Oil slinger drive end Oil slinger driven end Oil shell drive cover Removable feet

QTY 1 1 1 2 2 1 12 1 2 1 1 1 4

1.When ordering spares or replacement parts, please specify the following: Unit Size / Serial Number / Part Description / Item Number

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Installation, Operation and Maintenance Manual

APPENDIX '' G-02 '' (SIAV - 8702 THREE LOBE) PARTS LIST

ITEM 001 006 007 008 009 010 011 012 014 015 017 018 020 021 022

Notes

DESCRIPTION Blower casing Head plate drive end Head plate driven end Oil casing drive end Oil casing driven end Shaft seal cover Drive impeller & shaft Driven impeller & shaft Ring holder drive end Ring holder Driven end Retainer drive end Retainer driven end Driven end bearing Drive shaft bearing Spacer

QTY 1 1 1 1 1 1 1 1 2 2 2 2 2 1 1

ITEM 023 024 028 031 034 035 036 039 042 043 044 045 049 057 059

DESCRIPTION Gear set Gear hub Shaft sleeve for seal Bearing holder Bearing plate Shaft seal Piston rings Gear holder plate Holder plate driven end Oil slinger drive end Oil slinger driven end Oil shell drive cover Bearing spacer driven Bearing drive shaft Bearing driven shaft

QTY 1 1 1 2 2 1 12 1 2 1 1 1 1 1 1

1.When ordering spares or replacement parts, please specify the following: Unit Size / Serial Number / Part Description / Item Number

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Installation, Operation and Maintenance Manual

APPENDIX '' G-03 '' (SIAV BLOWERS) SIAV SERIES : RECOMMENDATIONS FOR INSTALLATION OF HIBON AIR INJECTION PUMPS ON TRUCKS. 1.0

Transport, lifting and storage

2.0

Installation 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8

3.0

Blower base frame Manifold Piping Silencers Filtration Instrumentation Relief valves (pressure mode only) Drives

Discharge temperature test

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APPENDIX '' G-03 '' (SIAV BLOWERS) 1.0 Transport, lifting and storage: Before packing at our plant, all machined surfaces are protected with a rust preventive varnish. This varnish will prevent rusting of the blower internals. It is not suitable for extended storage beyond six months or if storage conditions are not followed . We recommend to stock the blowers indoor in a dry and ventilated area . For long term storage, it is recommended to rotate the shaft of the blower 1/4 turn every month to prevent marking of bearings and consequently sudden bearing failure at start-up. The blower internals shall be checked from time to time and protective oil such as WD 40 or equivalent may be applied as required to prevent rusting. The blower is supplied with flange caps that prevent foreign material from entering the compression chamber. Do not remove the caps until you are ready to bolt inlet piping or discharge manifold to the blower. Do not forget to remove the protectors when installing blower accessories. Each blower is properly crated and protected before shipment. Our standard crate is suitable for road transportation. Please check the blower carefully upon receipt and report any damages immediately. Road freight companies will not file a claim if damage is reported later than 10 days after delivery. To lift the blower, it is recommended not to use the eyebolts located on the blower end-plates, when applicable. Doing so may cause the blower end-plates to shift slightly and modify the internal clearances. The blower end-plates are precisely centered and pined to the casing. This taper pin helps avoid accidental changes of internal clearances but our experience has demonstrated shifting is possible if the blower is not handled correctly. We recommend to lift the blower using slings installed underneath the endplates or the casing. Before beginning to install the blower on the truck, turn the blower by hand to see if it is turning freely. As an added precaution, it is good practice to check the clearances on the blower suction and discharge also and compare them with factory valves. 2.0 Installation 2.1 Blower base frame: The blower is not intended to be used as a stiffener to the truck chassis. Therefore, special attention shall be paid when attaching the blower to the truck chassis. The blower shall be installed on a flat steel base frame. Preferably, the base frame will be machined under blower feet to prevent distortion of the blower casing. The flatness of the blower base frame shall be within 0.0015 inches per foot for blower sizes up to the SIAV 840 and 0.003 inches per foot for larger units. The blower base frame shall be rigid enough not to distort during movement of the truck chassis. Vibration isolators or spring loaded bolts may be installed between the base frame and the chassis to eliminate the transmission of chassis movement to the blower feet. Do not place shims or vibration pads between the blower feet and the steel base frame as this may put too much stress on blower casing and modify internal running clearances, resulting in blower failure. rev 01, 15/08/98 Page 2

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APPENDIX '' G-03 '' (SIAV BLOWERS) If the casing is distorted, blower failure may not occur immediately at start-up but eventually when blower is operated at higher temperatures when metal expansion is greater. 2.2 Manifold: Hibon offers a variety of discharge manifolds made of fabricated steel or cast iron. These manifolds are designed to provide good jet air flow to the blower , resulting in safe operating temperatures. We strongly recommend to use factory approved manifolds for best performance. Should your installation require different manifold configurations, please consult us. We will be pleased to assist you in the design of such manifolds. We will also recommend test procedures to verify performances. Wrong designs of manifolds may result in blower overheating problems not covered by warranty. The blower is designed to support the weight of the manifold only . No forces shall be applied to the manifold flanges since this may distort the blower casing and result in reduced operating clearances. Should the manifold be attached to the truck chassis by mean of a bracket, make sure that the supporting bracket is not transmitting the chassis movement to the manifold and the blower. Such supporting is usually not required if the silencers and discharge / air injection piping are adequately supported. (see chapter on silencers and piping below). We recommend to use a 1/16 ‘’ or 1/8 ‘’ thick high temperature, non-asbestos, hard fiber gasket between the manifold flange and the discharge blower flange. Manifold flange must be machined. Flange on fabricated manifolds shall be made of 1’’ thick steel plate machined down to 3/4’’. The gasket shall be precisely cut to fit the blower ports. 2.3 Piping: It is recommended to use identical piping diameters as the flanged connections on the blower or the manifold. Inlet piping to the blower can be one diameter smaller than the blower with slight loss in free air flow. The smaller and longer the inlet piping, the bigger the losses. It is critical not to downsize any piping connecting the manifold to the silencers. We also recommend to have the shortest run of piping as possible in order to prevent excessive losses resulting in blower overheating. We recommend to incorporate sections of high temperature (260 Deg F) flexible connectors (hose) in the discharge and air injection piping. The hose may be retained by steel clamps. A gap of 1/2’’ between the two sections of the piping prevents loading the manifold and will dampen vibrations. The flexible connectors shall be installed as close as possible to the manifold. Piping shall be properly supported using brackets bolted to the chassis.

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APPENDIX '' G-03 '' (SIAV BLOWERS) 2.4 Silencers : Silencers considerably reduce the noise emission of a positive displacement blower. When sizing silencers, information such as gear diameter, natural noise frequency, rotational speed are fundamental to the silencer manufacturer. Please check blower data sheet for more information. Special attention shall be given to silencer pressure losses. Typically, chamber / absorption type silencers from reputable manufacturers have internal pressure losses averaging 6’’ to 10’’ of water column. We recommend not to exceed 8’’ water column losses for two lobe blowers and 10’’ water column losses for tri-lobe blowers when referring to free air flow at maximum speed (250 F at discharge, 100 F at inlet, standard 14.7 PSIA barometric) Because of the higher number of strokes per revolution on the tri-lobe blowers (6 instead of 4 on the two lobe), it will tolerate higher pressure losses while generating less heat of compression. Since tri-lobe blowers tolerate higher pressure losses, this allows you to design more efficient silencers and / or incorporate additional noise abatement system such as enclosures with baffles. Do not hesitate to contact us when designing a new system, we will assist you in getting the appropriate silencers. Inlet of the air injection silencer shall be orientated away from the motor exhaust stack or the discharge silencer to prevent suction of hot air or gas. Make sure that discharge flappers do not blow warm blower discharge air into the air injection silencer. Both silencers shall be fully supported in order not to exert any force on the manifold flanges. 2.5 Filtration: Filtration systems vary from one manufacturer to another. Figure 1 shows a typical mobile filtration system with cyclone, baghouse and final filter. The filtration system may be composed of cyclone and final filter only if the truck is designed to handle water or sludge. A bag-house is added if the blower is handling dry powdered material. The blower may acceptonly a very small amount of dust per cubic foot of air . The maximum size of dust shall not exceed 1/6’’ of the minimum blower clearance. We do not recommend to use a filter at the inlet of the air injection silencer since it may get clogged resulting in blower overheating. 2.6 Instrumentation: The SIAV blowers are designed to operate continuously at maximum vacuum (inlet blanked off) with inlet and air injection air temperatures of 100 Deg. F. Should the inlet temperature be higher than the air injection temperature (e.g. when pumping hot fly ash) the discharge temperature of blower may exceed the maximum allowable discharge temperature.

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APPENDIX '' G-03 '' (SIAV BLOWERS) A temperature switch (with capillary tube) may be installed at the discharge of the blower, and the thermowell shall be placed not more than one foot away from the discharge flange of the manifold. It is not recommended to install the thermowell into the manifold since false readings may occur. The set point shall be 275 Deg. F . The high temperature alarm shall actuate a pneumatic operated vacuum breaker valve. 2.7 Relief valves (pressure mode only) : Relief valves are not necessary if the blower is operating in vacuum mode only. The blower is designed to withstand maximum differential pressure when inlet is blanked off. When the blower is used for pressure unloading, relief valves are necessary. The relief valves shall be set for maximum blower discharge pressure (see blower data sheet) and shall be sized for 10 % pressure accumulation at blower maximum flow. We also recommend to use a temperature switch as described in section 3.6 in addition to the relief valves. 2.8 Drives: All SIAV blowers are fitted with a roller bearing at shaft end. This arrangement is suitable for all types of drive, including V-belt. There is no need for an additional outboard bearing or a jack shaft arrangement when using V-belts. The following recommendations are general. For more information, please ask the manufacturer of your drive system. ➩

Never use a metal hammer to install half couplings or sheave bushings on blower shaft.

➩

Coupling or sheaves must be properly aligned.

➩

Use a 1.6 safety factor when sizing couplings or V belt drives.

➩

Never install shims under blower feet to achieve correct alignment.

➩

Consult blower data sheet for minimum size of sheave. Using smaller sheaves than recommended would result in excessive torque and premature bearing failure.

➩

When using driveshafts and universal joints please make sure that all components of the drive train (blower, transfer case, motor and transmission) lie on the same angle. The driveshaft connecting to the blower shaft shall not transmit any axial force to the blower shaft. Sliding driveshafts are preferable.

➩

Resonance frequencies may cause the blower and/or motor and/or transfer case to vibrate excessively at certain speeds. Please check angle of the transmission (3 to 5 degrees) and make sure that every component is aligned properly. Special couplings mounted on blower shaft are designed to dampen back torsional forces. They will extend the bearing life dramatically and allow smooth blower operation at all speeds.

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APPENDIX '' G-03 '' (SIAV BLOWERS) 3.0 Discharge temperature test The blower discharge temperature will indicate if the blower accessories are properly selected and if the blower is properly installed. We recommend to do at least one complete temperature test every time you modify the blower accessories such as silencers, manifold, filtration, etc... Proceed as follows: ➩

Install a discharge thermometer as directed on paragraph 3.6.

➩

Connect a mercury column gauge to the instrument tapped connection located at blower flange

➩

Make sure that the valves on discharge and air injection silencers are fully opened.

➩

Start blower and close inlet valve to read 15’’ Hg vacuum. Warm up for 10 minutes. Record discharge temperature.

➩

Gradually increase vacuum and read discharge temperature after 5 minutes of operation at a given vacuum level. Record temperature at 18, 20, 22, 23, 24 inches of mercury vacuum. If the discharge temperature does not seem to stabilize and will tend to exceed 280 Deg. F, release the vacuum, run the blower for a couple of minutes for cooling. Check your installation carefully and review selection of the silencers.You may call Hibon for more information.

➩

Blank off blower inlet and record maximum vacuum and temperature after 5 minutes of operation. The maximum vacuum will vary upon blower rotational speed and air leaks.

➩

Carefully check all connections and gaskets on your truck for air leaks. Correct as necessary.

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APPENDIX '' G-04 '' (SIAV AND VTB, Air injection series) MAINTENANCE FOR TRUCK APPLICATIONS Daily:

• Check oil at both ends of blower. Wait 30 minutes to let the oil settle. Use a flashlight for better reading.

If required:

• In case sight glasses are dirty or damaged, clean and/or replace them as required. Replace the gasket or use pipe sealant (use LOCTITE PST 56747 or equivalent). Replace oil as explained above.

If required:

• In case oil is leaking and leakage can not be controlled by simply sealing plugs, please contact Hibon nearest service center. If the operator neglects to monitor oil levels or to report any leakage, damage to the blower will not be covered by Hibon’s warranty.

Daily or more often:

Daily or more often:

• Clean or replace the inlet filter or strainer. • If the filter is rusted, replace it. If parts of the filter get into the blower it may result in major damage that will not be covered by Hibon’s warranty. • Drain the inlet filtration system (secondary trap or cyclonic filter).

If required:

• Should foreign material get into the blower, it may result in major damage that will not be covered by Hibon’s warranty.

If required:

• In case of liquid overflow into the blower, it is necessary to remove the inlet filter and inspect the compression chamber. Clean the compression chamber using a small quantity (1 oz maximum) of diesel fuel or WD 40 oil on a clean cloth. Drain the oil; and replace with new oil as explained above (old oil may be contaminated by foreign liquid).

If required:

• In case of liquid overflow into the blower, there is a strong chance that liquid be present into the discharge and air injection silencers as well. Drain both silencers and let dry. Do not attempt to start the blower if silencers are not drained, clean and dry. Blower generates heat (up to 285°F on pressure mode). It is extremely important not to run the blower if flamable materials (diesel fuel, WD 40 oil, etc...) are still present in the blower or silencers.

While blower is operating:

If required:

• Check the discharge temperature regularly (if the blower is equipped with a temperature gauge). The discharge temperature is a function of inlet air temperature, inlet vacuum and ambient jet air temperature. Operating speed has no influence over discharge temperature when in vacuum mode. If the discharge temperature exceeds 285°F, stop the blower and check the following points: • That inlet and discharge silencers are not clogged and that pressure loss is below 12 inches of water. • That truck engine is not discharging hot fumes into the air injection silencer. • That hot discharge air (blower) is not blowing into the air injection silencer. • That inlet and air injection temperatures are below 100°F. • If the blower does not produce the vacuum, please follow the following procedure. • Run the blower at maximum speed. • Check all gauges and their connection (leakage). • Check the vacuum at the blower inlet flange (see above drawing, “F” Tapping point). • Check for leakage at all connections on the tank and between the tank and the blower (use cigarette smoke to detect leakage). • Check for leakage on the filtration system and cartridge type final filter. • Check blower internal clearances and compare with original values (larger clearances may affect the vacuum by 2 or 3 inches of mercury maximum. Higher vacuum losses invariably originate from the system). rev 01, 15/08/98 Page 1

Installation, Operation and Maintenance Manual

APPENDIX '' H ''

➣

Guarantees

Hibon Blowers and Exhausters, unless otherwise specified when ordering, are guaranteed for twelve months from their start-up, but for no more than eighteen months from their date of delivery to the original purchaser. During this period, Hibon will replace or repair any part free of charge, FOB Hibon works, provided that the tests made reveal material or manufacturing defects. To make a claim under guarantee, the machines and/or systems must have been used for their intended application and in complete with Hibon's instructions. The purchaser loses all guarantee rights if the machines and/or systems are repaired or modified, in whole or in part, by the purchaser or third parties, unless this has been agreed in writing by Hibon, who however do not accept any liability for the repair or modification thus authorized. Transport and labour expenses, including insurance costs, for the defective parts to and from Hibon's works will be borne by the purchaser. The guarantee does not cover damage resulting from incorrect use (operation in unstable conditions, at inadmissible speeds of rotation, at inadmissible pressures or temperatures, etc.), negligence, alterations and incidents. Materials and/or components, such as motors, valves, gearboxes, electrical equipment etc. bought by Hibon from third parties are guaranteed by their respective suppliers and these guarantees are maintained in accordance with the above conditions. Hibon reserves the right to invoice all replacements made due to material or manufacturing defects where repairs are carried out on site at the specific request of the customer.

➣

Limit of liability

Hibon's liability in respect of claims of any kind, including negligence, consequential or associated loss or damage, or loss or damage resulting from the performance, design, manufacture, operation, use and likewise from any installation, maintenance or repair of any machine and/or system supplied, will not under any circumstances exceed the purchase price of the machine and/or system giving rise to that claim and ends at expiry of the guarantee period earlier defined. Under no circumstances, whether due to breach of the guarantee by Hibon or by manifest negligence, shall Hibon be responsible for special and consequential damages including, without this list being exhaustive, losses of profits or proceeds, loss of use of the machines and/or systems themselves or connected machinery, capital cost, cost of replacement machines and/or systems, tooling or services, costs for down time or customers' claims to the purchaser for such damages. Unless expressly stated in writing, the machines produced by Hibon are not intended for use in nuclear systems or activities. Hibon refuses any liability for any damages, injuries and nuclear pollution which may occur as a consequence of such unauthorized use and the customer shall indemnify Hibon for any claims deriving therefrom, including any attributed to negligence. rev 01, 15/08/98 Page 1