INSTALLATION, OPERATION

AND
MAINTENANCE MANUAL
FOR HAYDEN HEAT EXCHANGERS

LIMITED WARRANTY
Hayden Industrial Products, Corona, California, warrants that:
A.

All Hayden parts are guaranteed to be free from defects of workmanship

and materials when applied within the scope of Hayden approved
applications. Merchandise found to be defective will be repaired or
replaced free of charge. No other warranty expressed or implied is made.
The manufacturer shall not be liable for any damage or injury to property
(other than the product itself) or any commercial loss or damage.

B.

Requests for return of defective merchandise must be submitted to the

factory. An RGA will be issued as authorization to return merchandise,
freight prepaid, for factory inspection and disposition. All replacements
are F.O.B. factory and will be made subject to factory inspection report, a
copy of which is available on customer request.

C.

Requests to the factory for the above purposes shall be made within
twelve months from the date of original sale.

LIMITATION OF WARRANTY AND LIABILITY

This warranty does not apply to any such Hayden products and parts which have
failed as a result of faulty installation or abuse, or incorrect connections or
alterations, made by others, or use under abnormal operating conditions or
misapplication of the products and parts.
Hayden will not approve for payment any repairs made outside its factory without
prior written consent of its Corona, CA office.
The foregoing shall constitute our sole and exclusive warranty and our sole and
exclusive liability and is in lieu of all other warranties, whether written, oral,
implied or statutory. There are no warranties that extend beyond the description
on the page hereof. Seller does not warrant that said goods and articles are of
merchantable quality or that they are fit for any particular purpose. The liability of
seller on any claim of any kind, including negligence, for any loss or damage
arising out of or connected with, or resulting from the sale and purchase of the
products and parts covered by this proposal, acknowledgment, order or from the
performance or breach of any contract pertaining to such sale or purchase, or
from the design, manufacture, sale, delivery, resale, installation, technical
direction of installation, inspection, repair, operation or use of any products or
parts covered by this proposal, acknowledgement, order or furnished by seller
2

shall, in no case exceed the price allocable to the products or parts thereof which
give rise to the claim and shall terminate one (1) year after the shipment of said
products and parts.
In no event, whether as a result of breach of contract, or warranty or alleged
negligence, defects, incorrect advice or other causes, shall seller be liable for
special or consequential damages, including, but not limited to, loss of profits or
revenue, loss of use of the equipment or any associated equipment, cost of
capital, cost of substitute equipment, facilities or services, down time costs, or
claims of customers of the purchaser for such damages. Hayden neither
assumes nor authorizes any person to assume for it any other liability in
connection with the sale of its products and parts. Some states do not allow the
exclusion or limitation of incidental or consequential damages so all of the above
limitations or exclusions may not apply to you.
SAFETY ACCESSORIES WARNING
The responsibility for providing safety accessories for equipment supplied by
Hayden is that of the installer and user of this equipment. Hayden sells its
equipment with and without safety accessories, and accordingly, it can supply
such safety accessories upon receipt of order.
The user, in making its determination as to the appropriate safety accessories to
be installed, and any warning notices, should consider (1) the location of the
installation, (2) the accessibility of employees and other persons to this
equipment, (3) any adjacent equipment, (4) applicable building codes, and (5)
requirements of the Federal Occupational Safety and Health Act.
Users and installers of any Hayden equipment that includes fans or blowers
should read RECOMMENDED SAFETY PRACTICES FOR AIR MOVING
DEVICES which is published by Air Movement and Control Association, 30 West
University Drive, Arlington Heights, IL 60004.
GENERAL SAFETY INSTRUCTION
1.

Follow all local electrical and safety codes, the National Electrical Code
(NEC) and Occupational Safety and Health (OSHA).

2.

Replace or repair any damaged or mechanical parts or electrical wiring

immediately.

3.

Keep all body parts (hands, feet) from coming in contact with fan blades or
motor drive operation.

4.

Never exceed maximum operating conditions as outlined in specifications.

Installation, Operation & Maintenance Manual

INTRODUCTION
The purpose of this manual is to aid in the proper installation and operation of
heat exchangers manufactured by Hayden Industrial Products (Hayden). These
instructions are intended to supplement good general practices and are not
intended to cover detailed instructions or procedures, because of the wide variety
and types of units manufactured by Hayden.
It is the responsibility of the purchaser to assure that the installation and
maintenance of this equipment are handled by qualified personnel experienced in
such work and equipment. Contact your local representative for details.
Read instructions carefully before attempting to assemble, install, operate, or
service these Hayden heat exchangers. Protect yourself and others by
observing all information and additional instructions included with this equipment.
Failure to comply with instructions could result in personal injury and/or property
damage. Retain these instructions for future reference. For additional copies or
if there are any questions, please contact Hayden Industrial Products, Corona,
California.
DESCRIPTION
Hayden Temp-Troller heat exchangers are compact, lightweight units that
provide reliable temperature control of oils and a wide range of other highly
viscous fluids. Highly efficient heat transfer rates are obtained because Hayden
heat exchangers feature the exclusive Inner Swirl Tabulator design. These
provide dependable fluid temperature control in compact packages.
The Temp-Troller unit provides a self-contained, air-moving device. The
integrated heat transfer assemblies contain fans and power sources to provide
airflow for the heat transfer unit.

SHIPMENT AND RECEIVING

Prior to shipment from Hayden, all products have been thoroughly inspected and
passed Quality Assurance requirements.
All equipment shipped from Hayden is boxed, skidded, or crated to fully comply
with railroad or trucking requirements. Inspect all shipments carefully for
damage. THE RECEIVER MUST NOTE ANY DAMAGE ON THE CARRIERS
BILL OF LADING AND FILE A CLAIM IMMEDIATELY WITH THE FREIGHT
COMPANY, IN THE CASE OF ANY DAMAGE. Keep a record of all equipment
received, including inspection details and date of receipt, because of the
possibility of partial shipments.
If you receive damaged goods, contact your Hayden representative for repair or
replacement service.
HANDLING
Handle your equipment with care. Some units are provided with lifting lugs or
holes for easy handling. Others must be handled using nylon straps or wellpadded chains and cables, which protect the units coating and housing.
Spreader bars should be used when lifting large units.
STORAGE
Units are to be stored in their original containers or equivalent protection and
should be kept in a clean, dry, protected warehouse where exercised control over
temperature, dust, dew point, shock and vibration is reasonably maintained.
A)
B)
C)

Temperatures: between 50o F and 120o F.

Maximum relative humidity of 60%
Shock or vibration: 2 mils maximum to prevent bearings
from binding. Exceeding this limit
will require vibration dampening
material under the units.

Motor bearings (and fan bearings on belt drive units) are to be greased at the
time of going into extended storage. Motor shaft (and fan shaft on belt drive
units) are to be manually rotated every month. Additional grease is to be added,
purging some of that in the bearing cavity every six (6) months.

GREASE IN THE BEARINGS IS TO BE PURGED AT THE TIME OF REMOVAL

FROM STORAGE, MAKING SURE THAT AN AMPLE SUPPLY OF FRESH
GREASE IS IN EACH GREASE CAVITY.
GREASE USED MUST BE
COMPATIBLE WITH THAT ALREADY IN MOTOR AND FAN BEARINGS.
Belts, on belt drive units, should be checked at the time of removal from storage
for proper belt tension. Tighten belts, if necessary. It is recommended that upon
installation, the vibration levels be checked to assure that the levels do not
exceed the levels set forth in this manual (See Table 1).
Storage records complying with the above requirements should be maintained.
GENERAL INFORMATION
1.

Air-cooled oil heat exchangers are built for operation with maximum oil
pressures of 300 PSI and temperatures of 350F unless otherwise
specified.

2.

Air/Oil heat exchangers that are to be installed for utilization of waste heat
for space heating should be mounted 7 to 14 feet above the floor
depending on the structure, for proper heat distribution.

INSTALLATION INSTRUCTIONS
Hayden self-contained heat exchanger designs can be adapted to various
mounting locations. The most important consideration that must be taken into
account when deciding upon the location of a heat exchanger is provision for the
supply of air to the heat exchanger and removal of air from the heat exchanger.
The performance of the heat exchanger is dependent upon the quantity and the
temperature of the air entering the heat exchanger.
The units are adaptable for mounting in a well-ventilated indoor area. Care must
be taken to see that the temperature of the area does not build-up and to ensure
unrestricted airflow to and from the unit.
When installed outdoors, self-contained heat exchangers should be located so
that there is a free flow of air to and from the unit. Horizontal discharge units
require a minimum clearance of twice the width of the unit at the air inlet and
outlet. It is desirable to position the units so that the prevailing summer wind will
blow into the unit inlet. Wind deflectors or air discharge scoops may be mounted

on the discharge side to prevent the direct force of the wind from affecting the air
delivered at the propeller fan.
When units are located on the roof, it is best to mount the heat exchanger near
the edge with the intake facing away from the building, to minimize the possibility
of drawing super-heated air from the roofs surface.
Supports for suspended units must be cross-braced for live load support to
prevent side sway. Refer to installation instructions (Form No. P-12) supplied
with all Temp-Trollers and as Attachment 1.
Temp-Trollers should always be mounted to a flat, level, rigid structure. Shim
the unit where necessary. This will ensure permanent alignment and a smoothrunning, vibration-free unit, as well as minimizing maintenance costs.
Units are supplied complete with headers and connections sized for connecting
to standard commercial pipe. Back-up wrenches should be used on the fittings
when making connections.
All piping practices used when installing self-contained heat exchangers should
be in accordance with the local building and safety codes.
A strainer located ahead of the heat exchanger inlet should be installed to trap
scale, dirt, or sludge that may be present in piping and equipment, or that may
accumulate with use. A thermostatic or spring loaded by-pass relief valve
installed ahead of the heat exchanger or system smart internal relief valves, may
be helpful to speed warm-up and relieve the system of excessive pressures. All
accessories should be considered in the original heat rejection and piping
calculations.
Connect motor only to a power supply of the same specifications as shown on
the motor nameplate. Voltage may vary + 10% of nameplate voltage. Follow
wiring diagram printed on motor nameplate or in terminal box. Before starting
motor, follow motor manufacturer recommendations. Observe operation carefully
after motor is started for the first time.
Connect unit to the system by means of suitable piping or hose, using the
appropriate fittings. Always use a back-up wrench when tightening fittings.
Note: Ensure that the heat exchanger is in the circuit for a pressure lower than
that of the heat exchanger rating. The dry seal fittings should be lubricated with
a lubricant or a thread sealant (pipe thread use Teflon type in hydraulic

systems). Check for air direction and for adequate air intake and discharge
areas around the heat exchanger.
Connect the power sources (AC, DC, or hydraulic) to the motor or the shaft in
case of a belt driver. Once again, verify correct rotation of fan and air direction
through the heat exchanger. Hydraulic motors have a limitation of 200-PSI
backpressure and are bi-rotational. Maximum tip speed of fan blade is 16,000
feet per minute or the limiting rotation of the fan.
STARTUP:
Lock out the power source.
Place the heat exchanger on its rigid foundation or platform. Level the unit using
shims where necessary. Tighten all mounting bolts securely with lock nuts and
lock washers.
Tighten belts, if necessary. NOTE THAT ALL BOLTS, SETSCREWS AND
BELTS SHOULD BE TIGHTENED AGAIN AFTER TWO DAYS OF INITIAL
OPERATION.
Clearance should be checked all around between blade tips and the housing
before starting up. The fan should not strike the housing.
Unless the unit has been in storage for several months, no initial lubrication is
required. Motors have been pre-lubricated by the motor manufacturer and fan
bearings by the fan manufacturer.
Arrows to show direction of rotation and airflow are attached to the fan housings
or fan blades.
The fan should not need balancing, as it was balanced at the factory to be within
vibration levels before shipment. However, there are several things that may
cause vibration, such as rough handling in shipment and erection, weak
foundations, and alignments. It is recommended that the vibration levels be
checked with a vibration analyzer to verify that the vibration is within levels
recommended later in this manual (See Table 1). During maintenance, fans
should be disconnected from their power source.

MAINTENANCE:
Periodic inspection of all components is the key to good maintenance and
trouble-free operation. Frequency of inspection must be determined by the user
and is dependent upon the severity of the application. Prepare a maintenance
schedule and make sure it is strictly adhered to.
NEVER SERVICE OR ADJUST ROTATING EQUIPMENT WHILE IT IS IN
OPERATION. LOCK OUT THE POWER SOURCE BEFORE PERFORMING
MAINTENANCE.
Regular fan and oil heat exchanger maintenance should include the following
items and should be done at least once a year or every 500 hours of operation,
whichever occurs first:
1)

Check the fan blade for any buildup of foreign material or wear from
abrasion. Both can cause excessive vibration, which will lead to damage
of the fan blade and other fan components. Replace the fan blade if
excessive wear is noticed. Carefully clean the fan blade of any foreign
material.

2)

Check V-belt drives for proper alignment, tension, and excessive wear.

3)

Lubricate the fan and motor bearings.

4)

Consult the trouble-shooting guide for excessive vibration or noise,

insufficient performance, or when the fan does not operate (See Table 2).

5)

Tighten all bolts and set screws.

6)

Heat Transfer Surface:

Dirt and dust should be removed (recommended at least once a year) by
brushing the fins and tubes and blowing loose dirt off with a low pressure
(<150 PSI) air hose. Should the surface be greasy, the motor should be
removed and the fins and tubes brushed or sprayed with a mild alkaline
solution or a non-flammable degreasing fluid. Follow with a hot water
rinse and dry thoroughly. A steam cleaner may also be used effectively.
Check for damaged headers (manifolds) and tubes as they can reduce

heat transfer and increase pressure drop through the heat exchanger.
Bent fins should be straightened out with a fin comb.
7)

Casing, Fan and Motor:

Dirt and grease should be removed from these parts. Rusty or corroded
surfaces should be sanded clean, primed, and repainted.

BEARINGS AND LUBRICATION:

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

10

IMPORTANT:

Do not increase the fan speed before first contacting

Hayden. Arbitrarily speeding up the fan can cause motor
overload, failure, and potential fan blade failure.

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

TABLE 1
Vibration displacement in mils, Double Amplitude
Fan RPM
870
1160
1750
3450

Good

Fair

1.7
1.2
.75
.50

3.3
2.5
1.5
.9

Slightly
Rough
6.5
5.0
3.5
2.0

Rough
Above 6.5
Above 5.0
Above 3.5
Above 2.0

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

11

TABLE 2
PROBLEM

Trouble-Shooting Chart
POSSIBLE CAUSES

INADEQUATE COOLING

EXCESSIVE PRESSURE DROP

INSUFFICIENT AIR

EXCESSIVE VIBRATION

12

Lower flow rate of oil than design

Lower air velocity than design
Higher ambient temperature than
design
Lower inlet oil temperature to inlet
air temperature than design
Higher oil viscosity than design
Undersized heat
exchanger/misapplication
Clogged fins/damaged fins
Bent return or header bends
Higher elevation than design
Incorrect fluid high viscosity
Contaminants in heat exchanger
Incorrect piping or fittings
Incorrect (lower) voltage on electric
motors
Low oil flows on hydraulic drives
Incorrect pitch on fan blade
Incorrect fan rotation
Excessive air restriction (e.g.
louvers or ducting)
Damaged finned section
Buildup of foreign material on fins
Higher elevation than design of heat
exchanger
Buildup on fan blade
Accumulation of material on fan
blade
Worn or corroded fan blade
Bent shaft
Fan blade or sheaves loose on shaft
Motor out of balance
Fan blade out of balance
Sheaves eccentric or out of balance
Bearing or drive misalignment
Mismatched belts
Belts too loose or too tight

TABLE 2 CONTINUED
PROBLEM

Trouble-Shooting Chart
POSSIBLE CAUSES
-

AIRFLOW TOO MUCH

FAN DOES NOT OPERATE

EXCESSIVE NOISE

13

Loose or worn bearings

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

TABLE 2 CONTINUED
Trouble-Shooting Chart
PROBLEM
Excessive Noise (Continued)

POSSIBLE CAUSES
-

Bearings need lubrication

Loose bearing bolts
Loose fan mounting bolts
System pulsation or surge
Electrical noise
Noise from high velocity air system
Fan in stall condition (DANGER)
Rattle of components in high
velocity air stream

It is recommended that the users and installers of this equipment familiarize

themselves with AMCA publication #201, Fans and Systems, and publication
#202 Trouble-Shooting, which are published by Air Movement and Control
Association, 30 West University Drive, Arlington Heights, IL 60004.
SPARE PARTS:
Spare parts are not needed for the first year of operation. If spare parts are
desired, then it is suggested that a spare motor and fan blade be ordered for
direct drive fans. For belt drive fans, in addition to the motor and fan blade, it is
suggested that a spare set of bearings, shaft, sheaves, and belts be ordered.
When ordering spare parts, specify the parts desired for the heat exchanger
model and part number, and if possible the serial number. Contact Hayden for
price and delivery.

14

Integral Horsepower
AC Induction Motors
ODP Enclosure
TEFC Enclosure
Explosion Proof

Installation & Operating Manual

7/01

MN400

Table of Contents
Section 1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2

Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4

Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4

Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4

Section 2
Installation & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

Doweling & Bolting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2

Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2

Conduit Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2

AC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2

First Time Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4

Coupled Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4

Jogging and Repeated Starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4

Section 3
Maintenance & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

Lubrication & Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

Type of Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

Lubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

Lubrication Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5

MN400

Table of Contents i

Section 1
General Information

ii Table of Contents

MN400

Section 1
General Information
Overview

This manual contains general procedures that apply to Baldor Motor products. Be sure to read and
understand the Safety Notice statements in this manual. For your protection, do not install, operate or
attempt to perform maintenance procedures until you understand the Warning and Caution statements. A
Warning statement indicates a possible unsafe condition that can cause harm to personnel. A Caution
statement indicates a condition that can cause damage to equipment.

Important:

This instruction manual is not intended to include a comprehensive listing of all details for all
procedures required for installation, operation and maintenance. This manual describes general
guidelines that apply to most of the motor products shipped by Baldor. If you have a question
about a procedure or are uncertain about any detail, Do Not Proceed. Please contact your Baldor
distributor for more information or clarification.
Before you install, operate or perform maintenance, become familiar with the following:
S
NEMA Publication MG-2, Safety Standard for Construction and guide
for Selection, Installation and Use of Electric Motors and Generators.
S
The National Electrical Code
S
Local codes and Practices

Limited Warranty
1. Baldor Electric motors are warranted for a period of one (1) year, from date of shipment from the factory or factory
warehouse against defects in material and workmanship. To allow for stocking and/or fabrication period and to
provide one year of actual service, the warranty period is extended for an additional period of six (6) months for a
total of eighteen (18) months from the original date of shipment from the factory or factory warehouse stock. In no
case will the warranty period be extended for a longer period. Baldor extends this limited warranty to each buyer
of the electric motor for the purpose of resale and to the original purchaser for use.
2. Baldor will, at its option repair or replace a motor which fails due to defects in material or workmanship during the
warranty period if:
a. the purchaser presents the defective motor at or ships it prepaid to, the Baldor plant in Fort Smith, Arkansas
or one of the Baldor Authorized Service Centers and
b. the purchaser gives written notification concerning the motor and the claimed defect including the date
purchased, the task performed by the Baldor motor and the problem encountered.
3. Baldor will not pay the cost of removal of any electric motor from any equipment, the cost of delivery to Fort Smith,
Arkansas or a Baldor Authorized Service Center, or the cost of any incidental or consequential damages resulting
from the claimed defects. (Some states do not allow the exclusion or limitation of incidental or consequential
damages, so the above exclusion may not apply to you.) Any implied warranty given by laws shall be limited to
the duration of the warranty period hereunder. (Some states do not allow limitations on how long an implied
warranty lasts, so the above limitation may not apply to you.)
4. Baldor Authorized Service Centers, when convinced to their satisfaction that a Baldor motor developed defects in
material or workmanship within the warranty period, are authorized to proceed with the required repairs to fulfill
Baldors warranty when the cost of such repairs to be paid by Baldor does not exceed Baldors warranty repair
allowance. Baldor will not pay overtime premium repair charges without prior written authorization.
5. The cost of warranty repairs made by centers other than Baldor Authorized Service Centers WILL NOT be paid
unless first authorized in writing by Baldor.
6. Claims by a purchaser that a motor is defective even when a failure results within one hour after being placed into
service are not always justified. Therefore, Baldor Authorized Service Centers must determine from the condition
of the motor as delivered to the center whether or not the motor is defective. If in the opinion of a Baldor
Authorized Service Center, a motor did not fail as a result of defects in material or workmanship, the center is to
proceed with repairs only if the purchaser agrees to pay for such repairs. If the decision is in dispute, the
purchaser should still pay for the repairs and submit the paid invoice and the Authorized Service Centers signed
service report to Baldor for further consideration.
7. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
Note that Baldor SuperER Premium Efficiency electric motors are warranted for a period of three (3) years.
All other terms and conditions of the Limited Warranty statement apply.

MN400

General Information 1-1

Safety Notice:

This equipment contains high voltage! Electrical shock can cause serious or fatal injury.
Only qualified personnel should attempt installation, operation and maintenance of
electrical equipment.
Be sure that you are completely familiar with NEMA publication MG-2, safety standards
for construction and guide for selection, installation and use of electric motors and
generators, the National Electrical Code and local codes and practices. Unsafe
installation or use can cause conditions that lead to serious or fatal injury. Only qualified
personnel should attempt the installation, operation and maintenance of this equipment.

1-2 General Information

WARNING:

Do not touch electrical connections before you first ensure that

power has been disconnected. Electrical shock can cause serious
or fatal injury. Only qualified personnel should attempt the
installation, operation and maintenance of this equipment.

WARNING:

Be sure the system is properly grounded before applying power.

Do not apply AC power before you ensure that all grounding
instructions have been followed. Electrical shock can cause
serious or fatal injury. National Electrical Code and Local codes
must be carefully followed.

WARNING:

Avoid extended exposure to machinery with high noise levels. Be

sure to wear ear protective devices to reduce harmful effects to
your hearing.

WARNING:

This equipment may be connected to other machinery that has

rotating parts or parts that are driven by this equipment. Improper
use can cause serious or fatal injury. Only qualified personnel
should attempt to install operate or maintain this equipment.

WARNING:

Do not by-pass or disable protective devices or safety guards.

Safety features are designed to prevent damage to personnel or
equipment. These devices can only provide protection if they
remain operative.

WARNING:

Avoid the use of automatic reset devices if the automatic restarting

of equipment can be hazardous to personnel or equipment.

WARNING:

Be sure the load is properly coupled to the motor shaft before

applying power. The shaft key must be fully captive by the load
device. Improper coupling can cause harm to personnel or
equipment if the load decouples from the shaft during operation.

WARNING:

Use proper care and procedures that are safe during handling,
lifting, installing, operating and maintaining operations.
Improper methods may cause muscle strain or other harm.

WARNING:

Before performing any motor maintenance procedure, be sure that

the equipment connected to the motor shaft cannot cause shaft
rotation. If the load can cause shaft rotation, disconnect the load
from the motor shaft before maintenance is performed. Unexpected
mechanical rotation of the motor parts can cause injury or motor
damage.

WARNING:

Disconnect all electrical power from the motor windings and

accessory devices before disassembly of the motor. Electrical
shock can cause serious or fatal injury.

WARNING:

Do not use these motors in the presence of flammable or

combustible vapors or dust. These motors are not designed for
atmospheric conditions that require explosion proof operation.

MN400

Section 1
General Information
Safety Notice Continued
WARNING:

Motors that are to be used in flammable and/or explosive

atmospheres must display the UL label on the nameplate.
Specific service conditions for these motors are defined in
NEC 70-599.

WARNING:

UL rated motors must only be serviced by authorized Baldor

Service Centers if these motors are to be returned to a flammable
and/or explosive atmosphere.

Caution:

To prevent premature equipment failure or damage, only qualified

maintenance personnel should perform maintenance.

Caution:

Do not lift the motor and its driven load by the motor lifting
hardware. The motor lifting hardware is adequate for lifting only the
motor. Disconnect the load from the motor shaft before moving the
motor.

Caution:

If eye bolts are used for lifting a motor, be sure they are securely
tightened. The lifting direction should not exceed a 20 angle from
the shank of the eye bolt or lifting lug. Excessive lifting angles can
cause damage.

Caution:

To prevent equipment damage, be sure that the electrical service is

not capable of delivering more than the maximum motor rated amps
listed on the rating plate.

Caution:

If a HI POT test (High Potential Insulation test) must be performed,

follow the precautions and procedure in NEMA MG-1 and MG-2
standards to avoid equipment damage.

If you have any questions or are uncertain about any statement or procedure, or if you
require additional information please contact your Baldor distributor or an Authorized
Baldor Service Center.

MN400

General Information 1-3

Section 1
General Information
Receiving

Storage

Unpacking

Handling

Each Baldor Electric Motor is thoroughly tested at the factory and carefully packaged for
shipment. When you receive your motor, there are several things you should do
immediately.
1.

Observe the condition of the shipping container and report any damage
immediately to the commercial carrier that delivered your motor.

2.

Verify that the part number of the motor you received is the same as the part
number listed on your purchase order.

If the motor is not put into service immediately, the motor must be stored in a clean, dry
and warm location. Several precautionary steps must be performed to avoid motor
damage during storage.
1.

Use a Megger periodically to ensure that the integrity of the winding insulation
has been maintained. Record the Megger readings. Immediately investigate
any significant drop in insulation resistance.

2.

Do not lubricate bearings during storage. Motor bearings are packed with
grease at the factory. Excessive grease can damage insulation quality.

3.

Rotate motor shaft at least 10 turns every two months during storage (more
frequently if possible). This will prevent bearing damage due to storage.

4.

If the storage location is damp or humid, the motor windings must be protected
from moisture. This can be done by applying power to the motors space
heater (if available) while the motor is in storage.

Each Baldor motor is packaged for ease of handling and to prevent entry of
contaminants.
1.

To avoid condensation inside the motor, do not unpack until the motor has
reached room temperature. (Room temperature is the temperature of the room
in which it will be installed). The packing provides insulation from temperature
changes during transportation.

2.

When the motor has reached room temperature, remove all protective wrapping
material from the motor.

The motor should be lifted using the lifting lugs or eye bolts provided.
1.

Use the lugs or eye bolts provided to lift the motor. Never attempt to lift the
motor and additional equipment connected to the motor by this method. The
lugs or eye bolts provided are designed to lift only the motor. Never lift the
motor by the motor shaft.

2.

If the motor must be mounted to a plate with the driven equipment such as
pump, compressor etc., it may not be possible to lift the motor alone. For this
case, the assembly should be lifted by a sling around the mounting base. The
entire assembly can be lifted as an assembly for installation. Do not lift using
the motor lugs or eye bolts provided.
If the load is unbalanced (as with couplings or additional attachments)
additional slings or other means must be used to prevent tipping. In any event,
the load must be secure before lifting.

1-4 General Information

MN400

Section 2
Installation & Operation
Overview

Installation should conform to the National Electrical Code as well as local codes and
practices. When other devices are coupled to the motor shaft, be sure to install
protective devices to prevent future accidents. Some protective devices include,
coupling, belt guard, chain guard, shaft covers etc. These protect against accidental
contact with moving parts. Machinery that is accessible to personnel should provide
further protection in the form of guard rails, screening, warning signs etc.

Location

The motor should be installed in an area that is protected from direct sunlight, corrosives,
harmful gases or liquids, dust, metallic particles, and vibration. Exposure to these can
reduce the operating life and degrade performance. Be sure to allow clearance for
ventilation and access for cleaning, repair, service and inspections. Ventilation is
extremely important. Be sure the area for ventilation is not obstructed. Obstructions will
limit the free passage of air. Motors get warm and the heat must be dissipated to prevent
damage.
These motors are not designed for atmospheric conditions that require explosion proof
operation. They must NOT be used in the presence of flammable or combustible vapors
or dust.

Mounting

1.

ODP motors are suitable only for indoor applications.

2.

TEFC motors are suitable for indoor or outdoor standard service applications.

The motor must be securely installed to a rigid foundation or mounting surface to

minimize vibration and maintain alignment between the motor and shaft load. Failure to
provide a proper mounting surface may cause vibration, misalignment and bearing
damage.
Foundation caps and sole plates are designed to act as spacers for the equipment they
support. If these devices are used, be sure that they are evenly supported by the
foundation or mounting surface.
After installation is complete and accurate alignment of the motor and load is
accomplished, the base should be grouted to the foundation to maintain this alignment.
The standard motor base is designed for horizontal or vertical mounting. Adjustable or
sliding rails are designed for horizontal mounting only. Consult your Baldor distributor or
authorized Baldor Service Center for further information.

Alignment

Accurate alignment of the motor with the driven equipment is extremely important.
1.

Direct Coupling
For direct drive, use flexible couplings if possible. Consult the drive or
equipment manufacturer for more information. Mechanical vibration and
roughness during operation may indicate poor alignment. Use dial indicators to
check alignment. The space between coupling hubs should be maintained as
recommended by the coupling manufacturer.

2.

End-Play Adjustment
The axial position of the motor frame with respect to its load is also extremely
important. The motor bearings are not designed for excessive external axial
thrust loads. Improper adjustment will cause failure.

3.

Pulley Ratio
The pulley ratio should not exceed 8:1.

4.

Belt Drive
Align sheaves carefully to minimize belt wear and axial bearing loads (see
End-Play Adjustment). Belt tension should be sufficient to prevent belt slippage
at rated speed and load. However, belt slippage may occur during starting.

Caution:

MN400

Do not over tension belts.

Installation & Operation 2-1

Section 1
General Information
Doweling & Bolting

Power Connection

After proper alignment is verified, dowel pins should be inserted through the motor feet
into the foundation. This will maintain the correct motor position should motor removal be
required. (Baldor motors are designed for doweling.)
1.

Drill dowel holes in diagonally opposite motor feet in the locations provided.

2.

Drill corresponding holes in the foundation.

3.

Ream all holes.

4.

Install proper fitting dowels.

5.

Mounting bolts must be carefully tightened to prevent changes in alignment.

Use a flat washer and lock washer under each nut or bolt head to hold the
motor feet secure. Flanged nuts or bolts may be used as an alternative to
washers.

Motor and control wiring, overload protection, disconnects, accessories and grounding
should conform to the National Electrical Code and local codes and practices.

Conduit Box

For ease of making connections, an oversize conduit box is provided. The box can be
rotated 360 in 90 increments. Auxiliary conduit boxes are provided on some motors for
accessories such as space heaters, RTDs etc.

AC Power

Connect the motor leads as shown on the connection diagram located on the name plate
or inside the cover on the conduit box. Be sure the following guidelines are met:
1.

AC power is within 10% of rated voltage with rated frequency. (See motor
name plate for ratings).
OR

2.

AC power is within 5% of rated frequency with rated voltage.

OR

3.

A combined variation in voltage and frequency of 10% (sum of absolute

values) of rated values, provided the frequency variation does not exceed 5%
of rated frequency.

Performance within these voltage and frequency variations are shown in Figure 2-1.

2-2 Installation & Operation

MN400

Section 1
General Information
Figure 2-1 Motor Performance VS Voltage Variations
+20

Maximum
Torque

Full -Load
Current

Changes in Motor Performance (%)

+15

+10

+5

Full -Load
Current

Power
Factor

Efficiency

Efficiency

10

15

20

Power
Factor

Maximum
Torque
15

10

+5

+10

+15

Voltage Variations (%)

MN400

Installation & Operation 2-3

Section 1
General Information
First Time Start Up

Be sure that all power to motor and accessories is off. Be sure the motor shaft is
disconnected from the load and will not cause mechanical rotation of the motor shaft.
1.

Make sure that the mechanical installation is secure. All bolts and nuts are
tightened etc.

2.

If motor has been in storage or idle for some time, check winding insulation
integrity with a Megger.

3.

Inspect all electrical connections for proper termination, clearance, mechanical

strength and electrical continuity.

4.

Be sure all shipping materials and braces (if used) are removed from motor
shaft.

5.

Manually rotate the motor shaft to ensure that it rotates freely.

6.

Replace all panels and covers that were removed during installation.

7.

Momentarily apply power and check the direction of rotation of the motor shaft.

8.

If motor rotation is wrong, be sure power is off and change the motor lead
connections. Verify rotation direction before you continue.

9.

Start the motor and ensure operation is smooth without excessive vibration or
noise. If so, run the motor for 1 hour with no load connected.

10. After 1 hour of operation, disconnect power and connect the load to the motor
shaft. Verify all coupling guards and protective devices are installed. Ensure
motor is properly ventilated.

Coupled Start Up

This procedure assumes a coupled start up. Also, that the first time start up procedure
was successful.
1.

Check the coupling and ensure that all guards and protective devices are
installed.

2.

Check that the coupling is properly aligned and not binding.

3.

The first coupled start up should be with no load. Apply power and verify that
the load is not transmitting excessive vibration back to the motor though the
coupling or the foundation. Vibration should be at an acceptable level.

4.

Run for approximately 1 hour with the driven equipment in an unloaded

condition.

The equipment can now be loaded and operated within specified limits. Do not exceed
the name plate ratings for amperes for steady continuous loads.

Jogging and Repeated Starts Repeated starts and/or jogs of induction motors generally reduce the life of the motor
winding insulation. A much greater amount of heat is produced by each acceleration or
jog than than by the same motor under full load. If it is necessary to to repeatedly start or
jog the motor, it is advisable to check the application with your local Baldor distributor or
Baldor Service Center.
Heating - Duty rating and maximum ambient temperature are stated on the motor name
plate. Do not exceed these values. If there is any question regarding safe operation,
contact your local Baldor distributor or Baldor Service Center.

2-4 Installation & Operation

MN400

Section 3
Maintenance & Troubleshooting
WARNING:

General Inspection

Inspect the motor at regular intervals, approximately every 500 hours of operation or
every 3 months, whichever occurs first. Keep the motor clean and the ventilation
openings clear. The following steps should be performed at each inspection:
WARNING:

Lubrication & Bearings

Type of Grease

UL rated motors must only be serviced by authorized Baldor

Service Centers if these motors are to be returned to a flammable
and/or explosive atmosphere.

Do not touch electrical connections before you first ensure that

power has been disconnected. Electrical shock can cause serious
or fatal injury. Only qualified personnel should attempt the
installation, operation and maintenance of this equipment.

1.

Check that the motor is clean. Check that the interior and exterior of the motor
is free of dirt, oil, grease, water, etc. Oily vapor, paper pulp, textile lint, etc. can
accumulate and block motor ventilation. If the motor is not properly ventilated,
overheating can occur and cause early motor failure.

2.

Use a Megger periodically to ensure that the integrity of the winding insulation
has been maintained. Record the Megger readings. Immediately investigate
any significant drop in insulation resistance.

3.

Check all electrical connectors to be sure that they are tight.

Bearing grease will lose its lubricating ability over time, not suddenly. The lubricating
ability of a grease (over time) depends primarily on the type of grease, the size of the
bearing, the speed at which the bearing operates and the severity of the operating
conditions. Good results can be obtained if the following recommendations are used in
your maintenance program.
A high grade ball or roller bearing grease should be used. Recommended grease for
standard service conditions is Polyrex EM (Exxon Mobil).
Equivalent and compatible greases include:
Texaco Polystar, Rykon Premium #2, Pennzoil Pen 2 Lube and Chevron SRI.
Maximum operating temperature for standard motors = 110 C.
Shutdown temperature in case of a malfunction = 115 C.

Lubrication Intervals

Recommended lubrication intervals are shown in Table 3-1. It is important to realize that
the recommended intervals of Table 3-1 are based on average use.
Refer to additional information contained in Tables 3-2 and 3-3.

Table 3-1 Lubrication Intervals *

NEMA / (IEC) Frame Size
Up to 210 incl. (132)
Over 210 to 280 incl. (180)
Over 280 to 360 incl. (225)
Over 360 to 5800 incl. (300)

10000
**

6000
2700 Hrs.

Rated Speed - RPM

3600
1800
5500 Hrs.
12000 Hrs.
3600 Hrs.
9500 Hrs.
* 2200 Hrs. 7400 Hrs.
*2200 Hrs.
3500 Hrs.

1200
18000 Hrs.
15000 Hrs.
12000 Hrs.
7400 Hrs.

Lubrication intervals are for ball bearings. For roller bearings, divide the listed lubrication interval by 2.

**

For 6205 and 6806 bearings. For 6807 bearings, consult oil mist lubrication (MN401).
Relubrication interval for 6205 bearing bearing is 1550Hrs. (using grease lubrication).
Relubrication interval for 6806 bearing bearing is 720Hrs. (using grease lubrication).

MN400

900
22000 Hrs.
18000 Hrs.
15000 Hrs.
10500 Hrs.

Maintenance & Troubleshooting 3-1

Table 3-2 Service Conditions

Severity of Service
Standard
Severe
Extreme
Low Temperature

Ambient Temperature
Maximum
40 C
50 C
>50 C* or
Class H Insulation
<30 C **

Atmospheric
Contamination
Clean, Little Corrosion
Moderate dirt, Corrosion
Severe dirt, Abrasive dust,
Corrosion

Type of Bearing
Deep Groove Ball Bearing
Ball Thrust, Roller
All Bearings

Special high temperature grease is recommended (Dow Corning DC44). Note that Dow Corning DC44 grease does
not mix with other grease types. Thoroughly clean bearing & cavity before adding grease.

**

Special low temperature grease is recommended (Aeroshell 7).

Table 3-3 Lubrication Interval Multiplier

Severity of Service
Standard
Severe
Extreme
Low Temperature

Multiplier
1.0
0.5
0.1
1.0

Table 3-4 Bearings Sizes and Types

Frame Size
NEMA (IEC)

Up to 210 incl. (132)

Over 210 to 280 incl. (180)
Over 280 to 360 incl. (225)
Over 360 to 449 incl. (280)
Over 5000 to 5800 incl. (355)
Spindle Motors
76 Frame
77 Frame
80 Frame
*

Bearing Description
(These are the Large bearings (Shaft End) in each frame size)
Bearing
OD
Width
Weight of
Volume of grease
D mm
B mm
Grease to
to be added
add *
in3
teaoz (Grams)
spoon
6307
80
21
0.30 (8.4 )
0.6
2.0
6311
120
29
0.61 (17 )
1.2
3.9
6313
140
33
0.81 (23 )
1.5
5.2
NU319
200
45
2.12 (60)
4.1
13.4
NU328
300
62
4.70 (130)
9.2
30.0
6207
6210
6213

72
90
120

17
20
23

0.22 (6.1)
0.32 (9.0)
0.49 (14.0)

0.44
0.64
0.99

1.4
2.1
3.3

Weight in grams = .005 DB

3-2 Maintenance & Troubleshooting

MN400

Lubrication Procedure

Be sure that the grease you are adding to the motor is compatible with the grease already
in the motor. Consult your Baldor distributor or an authorized service center if a grease
other than the recommended type is to be used.
Caution: To avoid damage to motor bearings, grease must be kept free of dirt.
For an extremely dirty environment, contact your Baldor distributor or
an authorized Baldor Service Center for additional information.
With Grease Outlet Plug
1.

Clean all grease fittings.

2.

Remove grease outlet plug.

3.

If motor is stopped, add the recommended amount of grease.

If motor is to be greased while running, a slightly greater quantity of grease will
have to be added. Add grease slowly until new grease appears at shaft hole in
the endplate or purge outlet plug.

4.

Re-install grease outlet plug.

Without Grease Outlet Plug

1.

Disassemble motor.

2.

Add recommended amount of grease to bearing and bearing cavity. (Bearing

should be about 1/3 full of grease and outboard bearing cavity should be about
1/2 full of grease.)

Note: Bearing is 1/3 full when only one side of bearing is completely full of grease.
3.

Assemble motor.

Sample Lubrication Determination

Assume - NEMA 286T (IEC 180), 1750 RPM motor driving an exhaust fan in an ambient
temperature of 43 C and the atmosphere is moderately corrosive.
1.

Table 3-1 list 9500 hours for standard conditions.

2.

Table 3-2 classifies severity of service as Severe.

3.

Table 3-3 lists a multiplier value of 0.5 for Severe conditions.

4.

Table 3-4 shows that 1.2 in3 or 3.9 teaspoon of grease is to be added.

Note: Smaller bearings in size category may require reduced amounts of grease.

MN400

Maintenance & Troubleshooting 3-3

Section 1
General Information
Accessories

The following is a partial list of accessories available from Baldor.

Contact your Baldor distributor for availability and pricing information.
Note: Space heaters and RTDs are standard on some motors.
Bearing RTD
RTD (Resistance Temperature Detector) devices are used to measure or
monitor the temperature of the motor bearing during operation.
Bearing Thermocouples
Used to measure or monitor bearing temperatures.
Bearing Thermostat
Temperature device that activates when bearing temperatures are excessive.
Used with an external circuit to warn of excessive bearing temperature or to
shut down a motor.
Conduit Boxes
Optional conduit boxes are available in various sizes to accommodate
accessory devices.
Cord & Plug Assembly
Adds a line cord and plug for portable applications.
Drains and Breathers
Stainless steel drains with separate breathers are available.
Drip Covers
Designed for use when motor is mounted in a vertical position. Contact your
Baldor distributor to confirm that the motor is designed for vertical mounting.
Fan Cover & Lint Screen
To prevent build-up of debris on the cooling fan.
Nameplate
Additional stainless steel nameplates are available.
Roller Bearings
Recommended for belt drive applications with a speed of 1800 RPM or less.
Rotation Arrow Labels
Rotation arrows are supplied on motors designed to operate in one direction
only. Additional rotation arrows are available.
Space Heater
Added to prevent condensation of moisture within the motor enclosure during
periods of shut down or storage.
Stainless Hardware
Stainless steel hardware is available. Standard hardware is corrosion resistant
zinc plated steel.
Winding RTD
RTD (Resistance Temperature Detector) devices are used to measure or
monitor the temperature of the motor winding during operation.
Winding Thermocouples
Used to measure or monitor winding temperatures.
Winding Thermostat
Temperature device that activates when winding temperatures are excessive.
Used with an external circuit to warn of excessive winding temperature or to
shut down a motor.
Note: On some motors, leads for accessory devices are brought out to a separate
conduit box located on the side of the motor housing (unless otherwise
specified).

3-4 Maintenance & Troubleshooting

MN400

Section 1
General Information
Table 3-5 Troubleshooting Chart
Symptom
Motor will not start
Excessive humming
Motor Over Heating

Possible Causes
Usually caused by line trouble, such
as, single phasing at the starter.
High Voltage.
Eccentric air gap.
Overload. Compare actual amps
(measured) with nameplate rating.
Single Phasing.
Improper ventilation.

Unbalanced voltage.
Rotor rubbing on stator.
Over voltage or under voltage.
Open stator winding.
Grounded winding.
Improper connections.

Bearing Over Heating

Misalignment.
Excessive belt tension.
Excessive end thrust.
Excessive grease in bearing.
Insufficient grease in bearing.
Dirt in bearing.

Vibration

Misalignment.
Rubbing between rotating parts and
stationary parts.
Rotor out of balance.
Resonance.

Noise
Growling or whining

MN400

Foreign material in air gap or

ventilation openings.
Bad bearing.

Possible Solutions
Check source of power. Check overloads, fuses,
controls, etc.
Check input line connections.
Have motor serviced at local Baldor service center.
Locate and remove source of excessive friction in
motor or load.
Reduce load or replace with motor of greater capacity.
Check current at all phases (should be approximately
equal) to isolate and correct the problem.
Check external cooling fan to be sure air is moving
properly across cooling fins.
Excessive dirt build-up on motor. Clean motor.
Check voltage at all phases (should be approximately
equal) to isolate and correct the problem.
Check air gap clearance and bearings.
Tighten Thru Bolts.
Check input voltage at each phase to motor.
Check stator resistance at all three phases for balance.
Perform dielectric test and repair as required.
Inspect all electrical connections for proper
termination, clearance, mechanical strength and
electrical continuity. Refer to motor lead connection
diagram.
Check and align motor and driven equipment.
Reduce belt tension to proper point for load.
Reduce the end thrust from driven machine.
Remove grease until cavity is approximately 3/4 filled.
Add grease until cavity is approximately 3/4 filled.
Clean bearing cavity and bearing. Repack with correct
grease until cavity is approximately 3/4 filled.
Check and align motor and driven equipment.
Isolate and eliminate cause of rubbing.
Have rotor balance checked are repaired at your
Baldor Service Center.
Tune system or contact your Baldor Service Center for
assistance.
Remove rotor and foreign material. Reinstall rotor.
Check insulation integrity. Clean ventilation openings.
Replace bearing. Clean all grease from cavity and new
bearing. Repack with correct grease until cavity is
approximately 3/4 filled.

Maintenance & Troubleshooting 3-5

3-6 Maintenance & Troubleshooting

MN400

BALDOR ELECTRIC COMPANY

P.O. Box 2400
Ft. Smith, AR 729022400
(501) 6464711
Fax (501) 6485792
Baldor Electric Company
MN400

Printed in USA
7/01 C&J10000

Installation Instructions
PowerFlo

Fans

Amarillo Chittom AirFlo

728 S. Wheeling
Tulsa, OK 74104
(918) 585-5638
FAX (918) 587-3577
e-mail info@amarillochittom.com
web site http://www.amarillochittom.com
IM-PowerFlo01

December 2003

A NOTE ABOUT YOUR NEW FAN AND THIS MANUAL ...........

Thank you for purchasing a PowerFlo fan from Amarillo Chittom AirFlo. Your new fan
includes features and quality construction that is the result of years of research using the best
equipment and manufacturing practices available. Amarillo Chittom AirFlo is as interested as
you are in the fan exceeding your expectations of performance and life. This manual has been
developed to make installing and maintaining your new fan a simple and trouble free
experience.
PowerFlo fans represent the best performing and most cost effective aluminum fan on
the market today. As with any investment in precision equipment, proper care and some
precautions will help protect your investment for years of trouble free operation while obtaining
maximum performance. If you have any questions concerning the installation, operation or
maintenance of your new PowerFlo fan, please contact us for assistance.

CONTENTS
1.0

Getting Ready For Installation

1.1

Parts Identification and Inspection

1.2

Pre-Installation Planning

2.0

Hub Installation

3.0

Blade Installation

4.0

Initial Operation Procedures

5.0

Periodic Maintenance

6.0

Warranty

Service, Quality and Dependability For Over 40 years

Page 2

1.0

Getting Ready For Installation ...

1.1

Parts Identification and Inspection

Every fan has been carefully manufactured and packaged for shipment.
Please inspect the materials to ensure that you have received all of your
shipment and that no damage has occurred during shipping. If any damage is
evident, either before or after unpacking, please notify the delivering carrier
immediately to file a damage claim.

1
2
5

3
11
10
6

4
9

1
2
3
4
5
6
7
8
9
10
11

Fan Blade
Quantity as specified on order
Fan Hub
1 Per Fan
Air Intake Side Blade Clamp
1 Per Blade
Discharge Side Blade Clamp
1 Per Blade
Checo Split Taper Bushing
1 Per Fan
Bushing Attachment Bolts
3 Per Fan
Bushing Bolt Lock Washer
3 Per Fan
Blade Clamp Bolt
2 Per Blade
Blade Clamp Bolt Flat Washer
4 Per Blade
Blade Clamp Self-Locking Nut
2 Per Blade
Key (Generally Provided By Others)
1 Per Fan

Service, Quality and Dependability For Over 40 years

Page 3

1.2

Pre-Installation Planning

The installation of your new PowerFlo fan is simple and with a little planning
can be accomplished very quickly. One person can perform the installation
provided a means of lifting the hub into position is available.
For most installations, the fan shaft key is provided with the shaft. Check to
make sure the key is available and that the shaft is clean and in good
condition. This is a good time to double check that the correct size bore has
been ordered for the fan bushing.
A list of tools is provided below for your reference. The digital protractor as
shown is the easiest and generally the most accurate for setting blade pitch. If
one is not available, you can order one through Amarillo Chittom AirFlo or you
may use a bubble protractor with 1/2 degree or finer increments that is
available through better local tool distributors. A smaller torque wrench is
shown and may be desirable for tightening the split taper bushing bolts since
excessive torque on these bolts may cause damage.

A
B

E
Tools Required:
A
B
C
D
E
F
G
H

Torque Wrench
Box End Wrench
1 1/8 for 3/4 Bolts
3/4 for 1/2 Bolts
Socket (Bshg Hdwe) 9/16 for 3/8 Bolts
3/4 for 1/2 Bolts
Socket (Blade Hdwe) 1 1/16 for 3/4 Nuts
3/4 for 1/2 Nuts
Allen Wrench
1/8 Hex for 1/4 Set Screw
Plain Blade Screw Driver
Precision Protractor (For blade pitch adjustment)
Straight Edge (For blade pitch adjustment)

Service, Quality and Dependability For Over 40 years

Page 4

2.0 Hub Installation ...

Drive a screwdriver into the flange of the
split taper bushing to enlarge the bore
enough to slide onto the fan shaft.
Caution - Do not drive the screw driver
into the tapered surface or damage to
this critical mating surface may occur.
The fan hub may be installed either with
the bushing away from the end of the
shaft or with the bushing towards the
end of the shaft. If the bushing goes
towards the end of the shaft, slide the
fan hub on the shaft prior to installing
the split taper bushing.
When lifting the fan hub, bolts may be
inserted into the blade clamp mounting
holes to use as a handle.
DO NOT APPLY ANTI-SIEZE
COMPOUND TO THE SHAFT OR TO
THE BUSHING BOLTS.
Slide the split taper bushing and key
onto the fan shaft until it is in the desired
location on the shaft. Remove the
screw driver from the flange allowing the
bushing to clamp down on the shaft.
Use an allen wrench to tighten the set
screw over the key just enough that the
bushing and key will not move during
mounting of the fan hub.
Slide the tapered bore of the fan hub
over the split taper bushing. Insert the
bushing bolt through the split lock
washer and drilled holes in the bushing
flange. Finger start the bolts in the hub.
Service, Quality and Dependability For Over 40 years

Page 5

Using a torque wrench, tighten the three

split taper bushing bolts. The bolts
should each be tightened a little at a
time and move to the next bolt
sequentially, working up to the specified
torque for the bolt. After the bolt
reaches the specified torque, keep
going around the bolts in order checking
the torque until no further tightening is
required to remain at the specified
torque value.

Torque 3/8 bolts to 35 ft. lbs.

Torque 1/2 bolts to 45 ft. lbs.

3.0

Do not over torque the bushing bolts or

damage may occur.
Tighten the set screw over the key in the
split taper bushing completely so the
screw point locks into the key surface.

Blade Installation ...

The blade clamps are different for the air
intake side of the fan and the air
discharge side. The two parts can be
identified by the depth of the cut for the
blade shank shoulder. The cut is
deeper on the air discharge side to
produce a droop in the installed fan
blade.
Place one of each clamp around the
shank of the blade as shown.
Hold the blade so that the clamp with
the deeper shoulder cut is to the
discharge side of the fan and tip of the
fan blade is angled slightly towards the
air intake side of the fan.
The clamps should easily slide between
the two plates of the fan hub.

Service, Quality and Dependability For Over 40 years

Page 6

Line up one of the holes in the plates

and blade clamps. Place a blade clamp
bolt through a flat washer and insert the
bolt through the hole that is lined up in
the clamps and plates. Place another
flat washer on the blade clamp bolt and
start the self-locking nut on the bolt
finger tight.
Caution - If the clamps do not
slide freely between the plates,
check to see that you do not
have either two intake side
clamps or two discharge side
clamps.
Recommended practice for
tightening bolted joints is to
hold the bolt head still while
turning the nut. Therefore, it is
a good idea to make sure the
nuts are on the side of the hub
easiest to access with the
torque wrench. If not, remove
them one at a time and switch
them before all the blades are
installed.
Installing spacer rings to
reduce the fan diameter for
proper tip clearance will
decrease fan performance
slightly. Better fan
performance will be achieved if
the fan ring can be increased
in size instead of reducing the
fan diameter.

Swing the blade around until the second

set of holes lines up between the plates
and clamps. Install the second blade
clamp bolt finger tight with a flat washer
under both the bolt head and the nut.
Slide the blade shoulder firmly against
the clamps and tighten the blade clamp
bolts just enough that the blade does not
slide in the clamps while working the
blade up and down in the clamps
from the blade tip.
Rotate the blade around the
circumference of the fan ring to make
sure there is proper tip clearance all the
way around. Recomended minimum tip
clearance is 3/8 inch at any point.
If necessary because of interference
with the fan ring, spacer rings have
been shipped with your fan assembly to
reduce the fan diameter. Determine
how much the blade must be moved in
to provide proper tip clearance. Each
spacer ring will reduce the fan radius
(i.e. increase tip clearance) by 1/8 inch.
A maximum of three spacer rings may
be installed on each fan blade.
To install spacer rings, loosen the single
blade installed in the hub. Slide the
blade towards the center of the hub and
snap the required number of spacer
rings over the blade shank.

Service, Quality and Dependability For Over 40 years

Page 7

Pull the blade out radially so the spacer

rings are firmly sandwiched between
the blade shank shoulder and the back
side of the blade clamp. Tighten the
bolts enough to keep the blade in
position while rocking the blade up
and down in the clamps from the
blade tip. Rotate the blade again to
verify proper tip clearance all the way
around.
Install the rest of the fan blades in the
hub repeating the procedure used for
the first blade.
Install the same number of spacer rings
on every fan blade. Failure to maintain
consistency in the number of spacer
rings on each blade will result in
increased vibration and stress.
For vertical applications, it might be
easier to install blades in opposite
sockets so that the weight remains
balanced as much as possible during
installation.
Mark a location on the fan ring where
each blade will be pitched. For vertical
applications this will either be at the
three oclock or nine oclock position,
depending on direction of rotation.
Loosen the blade clamp hardware just
enough that the blade can be rotated in
the blade clamps. Line up the trailing
edge with your reference mark you just
made on the fan ring.
At a position one inch from the blade tip,
lay a straight edge across the trailing
edge of the fan blade and the high point
of the blade airfoil. Rotate the blade in
the clamps until you get the right pitch.
Service, Quality and Dependability For Over 40 years

Page 8

Caution - The blades should

be adjusted in pitch until the
target value is achieved plus or
minus 1/4 degree. Failure to
rotate each blade to the same
position for adjustment of the
blade pitch can result in
excessive variation between
blades. Excessive pitch
variation may result in vibration
and high stress levels in the
fan or surrounding equipment.

Torque the blade clamp hardware to 50

ft. lbs for 1/2 bolts or 90 ft. lbs. for 3/4
inch bolts. Tighten one nut a turn or
two and move over to the other bolt for a
turn or two, switching back and forth
until the proper torque is reached and
maintained on both nuts.
Recheck the blade pitch at the position
one inch in from the tip to make sure it
has not changed during tightening of the
blade clamp hardware.
Repeat this process for each fan blade,
rotating them one at a time to the same
position in the fan ring and setting the
pitch on the blade.
Locate a convenient place in the fan ring
to check the tip track of the fan blades.
Place a mark in the fan ring at the
trailing edge of the fan blade parallel to
the rotation of the fan blade in the ring.
Rotate each blade to the same position
in the fan ring, mark and number the
location of the trailing edge for each
blade.

Caution - Excessive tip track

may lead to high vibration
levels in the fan or surrounding
equipment. Stress in the fan
blade and hub will increase
with excessive tip track.

If the distance between the two outer

marks is greater than 1/2 inch, identify
the blade that is different. Loosen that
blade and move the blade in the desired
direction. Retorque the blade clamp
hardware.
Recheck the pitch of the blade that tip
track adjustment was made to and
recheck the tip track of all blades.
Repeat the process as necessary.

Service, Quality and Dependability For Over 40 years

Page 9

4.0

Initial Operation Procedures ...

Check to see that all hardware is tight and the fan rotates freely by hand before
starting the fan.
Make sure all guards are in place and that proper procedures are followed for
removing any lock out devices.
Bump the fan motor and verify the direction of fan rotation is correct.
Start the fan and watch both the fan and the fan ring as the fan comes up to
speed. If any contact or excessive movement of the fan ring is observed, shut
the fan off immediately and correct the cause of the problem. Allow the fan to
operate several minutes so the fan drive system stabilizes.
Check the fan speed and the fan motor power consumption. When checking
the power on an electric fan motor, be sure to measure the voltage and the
motor current. Checking the motor amperage only may give a false power
indication since high or low voltage affects the amperage of the motor at a
constant load condition.
Caution - Obtaining amperage and voltage readings on an electric motor may
require defeating the safety features of electrical enclosures. Please seek the
assistance of a qualified electrician and follow all applicable safety precautions.
The HP value provided in the fan specifications is the HP required at the fan
shaft to meet the specified air flow and static pressure requirements. The
motor output HP required will be higher than the specified fan HP because of
losses in the gear drive or belt drive. The actual fan HP may increase at
temperatures lower than those used for the selection and rating of the fan due
to changes in the density of the air moving through the fan.
Consult the factory if the difference between the measured HP of the motor
and the specified fan HP seems excessive. Minor adjustments in pitch to
achieve the desired fan HP are normal due to variations in equipment, fan ring
geometry and tip clearances.
Warning - Do not increase the fan operating speed above the RPM listed in the
fan specifications without first consulting the factory. Operating the fan at
excessive speeds may shorten the life of the fan significantly.
Service, Quality and Dependability For Over 40 years

Page 10

5.0

Periodic Maintenance ...

Most fan failures are not sudden catastrophic degradation of the equipment
and can be prevented by regular inspection and maintenance of the fan and
fan drive system. Correcting problems before fan failures occur is more cost
effective than replacing equipment after a fan failure.
PowerFlo fans should be inspected for damage and correct hardware torque
after the first full week of operation and at intervals not greater than six
months thereafter. Be sure to follow all safety precautions including proper
lock out and tag out procedures when inspecting and performing maintenance
on your equipment.
Clean any accumulated scale or foreign matter from the fan assembly when
you perform the regular maintenance on the fan. The build up of foreign matter
on the fan increases operating stresses and may affect the life of the fan in
addition to reducing fan efficiency.
Check the fan for any cracks, dents or corrosion. Black streaks originating
from rivets are a good indicator that wear is occuring in the connections. Pay
particular attention to any areas exhibiting black streaks for cracks and
looseness of the mechanical joints. Sudden or frequent appearance of these
black oxide trails may be an indication of excessive vibration in the operating
unit or very high aerodynamically induced loads in the fan blades. Blades with
wear or damage may be replaced individually without adversely affecting fan
balance. Please consult the factory for details concerning blade replacement.
The 5052-H38 aluminum used for construction of the fan blades is a marine
alloy offering good resistance to corrosion and minor dents. Special coatings
and hardware options are available for fans operating in more aggressive
environments. Please contact the factory for information concerning suitability
of the fan and recommended options for fans operating in corrosive
environments.
Check the fan blade tips and the fan rings for any signs of wear or contact.
Check all hardware for proper torque.

Service, Quality and Dependability For Over 40 years

Page 11

6.0

Warranty ...

Amarillo Chittom AirFlo warrants to the original purchaser only the material and workmanship
of its products for 24 months after delivery or 12 months after equipment is put into use,
whichever occurs first.
Amarillo Chittom AirFlo will repair or replace, at its option, and without charge, the equipment
or any part or parts thereof which shall fail due to defective material or workmanship within
said period, provided and on condition that:
1.
The equipment is promptly delivered with all handling and freight charges prepaid to
Amarillo Chittom AirFlo, 728 South Wheeling, Tulsa, Oklahoma, 74104 or contact Amarillo
Chittom AirFlo at (918) 585-5638, for its inspection, repair or replacement.
2.
Equipment is accompanied by a proof of purchase document when returned to Amarillo
Chittom AirFlo.
3.
All replacement parts are F.O.B., Tulsa, Oklahoma, and will be shipped freight
collect.
This warranty is limited to defects in material and workmanship, and it does not apply to
loss or damage which is the result of accident, misuse, mis-application (including operation
at critical speeds), resonance, improper installation, negligence, acts of god or any cause
occurring after delivery to the original purchaser.
All other warranties, expressed, implied or statutory, including warranties of fitness for a
particular purpose and of merchantability, are limited to the above period of this warranty
and are otherwise excluded from this warranty.
Amarillo Chittom AirFlo continually strives to improve the design and mechanical quality of its
products. We are not, however, obligated to install these improvements on products previously
manufactured.
The foregoing shall be the sole and exclusive remedy of any person, whether in contract,
tort or otherwise, and Amarillo Chittom AirFlo shall not be liable for incidental or consequential
damage or commercial loss, nor for any other loss or damage except as set forth above.
This warranty may not be extended or modified.
This warranty gives you specific legal rights and you may have other rights which vary from
state to state.
Rev. 5-28-03

Service, Quality and Dependability For Over 40 years

Page12

Hayden Part
Number
029908
729376-0001
029917
029924
029418
036544
035306-154
037292
039152
029892
035306-48
035133-5VX670
039157
029929-01
029929-02

3 Hayden Model TT540

2 Build to Assembly Drawing 037910-3

NOTES:
1 Hayden Part Number 037910-3

Item Quantity
#
1
4
2
2
3
4
4
2
5
2
6
1
7
1
8
1
9
1
10
1
11
1
12
2
13
1
14
2
15
2
Leg
Fan Ring Assembly
Fan Guard
Core Guard
Pillow Block
Shaft
Sheave
Prop
Motor Mount
Core Assembly
Sheave
V-Belt
Electric Motor
Lift Support
Lift Support

Part
Name
TT540
73
TT540
TT540 #14 GA. Galvanized
1-15/16
1-15/16 Diameter X 34 SSTL
2B5V154
72 (Chittom)
TT540 Belt Drive
IC54093XX-12RB8-CALXB-0
2BK48
Browning BX82
15 HP 460/3/60 1750 RPM (Baldor)
TT540
TT540

Material
Description

Replacement Parts List for

Solar PN-1063795-3, -7

(This page intentionally left blank)