Hudson Tuf-Lite II 1000 Series User manual

Installaon manual 1000H Page 1 of 10 May 2015
Tuf-Lite II® Fans
1000 Series
Auto-Variable® Hub
INSTALLATION MANUAL
Hudson Auto-Variable® Hubs and Tuf-Lite II® Fan Blades
Hudson Auto-Variable® (AV) hubs feature Timken tapered roller bearings and synthetic lubricants. All components are
suitable for high and low temperature operation and are interchangeable (except hub bodies) in 4, 5, or 6 blade configu-
rations. Hudson AV hubs are durable and designed for low maintenance and energy saving operation.
Hudson Tuf-Lite Il® (white, prev. blue) fan blades are made from fiberglass reinforced vinyl-ester resin having a very
high strength-to-weight ratio and superior ultra-violet and corrosion resistance. An elastomeric blade/holder joint cover
(not shown) prevents moisture from entering blade.
The individually balanced blades can be replaced independently—matched sets are not required.

Installaon manual 1000H Page 2 of 10 May 2015
RECOMMENDED TOOLS
 Long T-Handle Allen Wrench Set (3/16" to 3/8")
 Medium Size Flat Head Screw Driver
 Brass Ball Peen Hammer
 Flat Bastard File
 240 Grit Sand Paper
 Anti-Seize Lubricant
 WD-40
 12” Crescent Wrench
 Shop Towels
 Exact-A-Pitch® Digital Protractor (P/N 62375)
 25 ft. Measuring Tape
 Pencil or Marker
 Open/Box End Wrench Set (1/2" – 1-1/2")
 Socket Set for 1/2" Drive (1/2" – 1-1/2")
 Torque Wrench(s) Rated for 0-200 ft-lb
 Dial Indicator
INSTALLATION PROCEDURES
Clean all mating surfaces between fan shaft and coupling. All
grease and lubricant should be removed, leaving the mating
surfaces dry.
ASSEMBLY WITH BUSHING
Slide bushing and key onto straight fan shaft. Depending on
shaft size, an R-2 bushing or a Q-2 bushing will be supplied.
Tighten set screw in R-2 bushing flange to lock it on shaft. Q-2
bushings have no set screw. Set coupling squarely on bushing
and install the three (3) 3/8" cap screws. Using torque wrench
with 9/16" socket, tighten bolts evenly to recommended stand-
ard of 29 ft-lb (dry) (See Figure 1).
Figure 1
ASSEMBLY WITH TAPERED SHAFT
Align keyways and install coupling evenly on tapered shaft.
Install key in keyways, then install retainer plate. Install 3/4"
cap screw and lock washer through coupling into fan shaft.
Tighten with 1-1/4" socket torque wrench to 125 ft-lb
(lubricated), 130 ft-lb (dry) torque (See Figure 2).
INSTALLATION OF BOTH TAPERED
AND STRAIGHT SHAFTS
Clean mating surfaces of hub and coupling or flanged shaft, if
used, and apply a light coating of anti-seize and lubricating
compound.
Rigidly attach dial indicator and measure the run-out of top
face of coupling (See Figure 3). Rotate coupling and check for
alignment. Adjust coupling until run-out is less than 0.003".
Figure 2

Installaon manual 1000H Page 3 of 10 May 2015
MINIMUM VIBRATION -
THE FOLLOWING FOUR STEPS ARE
EXTREMELY CRITICAL
Figure 3
Install hub onto coupling and fasten in place with the four (4)
3/4" cap screws and lock washers used on the hub-shipping pallet
(See Figure 4). Make sure coupling is pulled down evenly. Tight-
en cap screws to recommended standard of 125 ft-lb (lubricated)
or 130 ft-lb torque.
Figure 4
Rigidly attach dial indicator to the air line support or other sta-
tionary object. Measure run-out of the rotary joint (See Figure 5).
Rotate hub 360° to locate point of minimum reading on the dial;
set indicator to read zero at this point.
Rotate coupling 360° while watching indicator at rotary
joint for misalignment reading. Total indicated run-out
should be 0.005". If run-out is over 0.005", mark low point
on face of coupling. Install shims under hub at low point
(See Figure 6).
Figure 6
Figure 5

Installaon manual 1000H Page 4 of 10 May 2015
INSTALL TUF-LITE II® BLADES
Remove blade clamp bolts, nuts, lock washers, and blade clamp
halves from hub. Assemble blade clamp halves over groove in
blade neck, and install into hub with thick leading edge to left and
thin trailing edge to right as you stand at end of blade. Install
clamp bolts through hub plates and blade clamp, putting bolt
heads on top side, lock washers and nuts on bottom (See Figure 7).
Tighten lightly.
Figure 7
SET PITCH AND TRACK
Use Hudson EXACT-A-PITCH® digital protractor (See Figure 8)
or a bubble protractor to set blade pitch. Mount protractor on a
flat bar as a base and place it approximately 1" from tip of blade.
Note pitch on protractor. Rotate fan 360°, noting high and low
pitch readings. Locate place where pitch reading is a mid-point
between high and low pitch readings, and set pitch at that point.
Figure 8
Rotate blade in socket until digital protractor shows specified
pitch angle to within ±0.2°. (Fan pitch angle is shown on fan
specification sheet for design duty.) For reverse acting hubs
(fails to minimum air flow on loss of instrument air pressure),
pitch angle should be set with 15 psi instrument signal and 55
psi supply air pressure applied (See "INSTALLING AIR
LINES").
After desired pitch angle is set, raise and lower end of fan
blade and find mid-point of blade travel. Hold blade at the
mid-point. Pull blade back so that it sits against blade clamp.
Push blade to the right to remove all slack.
Use torque wrench to tighten clamp bolts to recommended
standard of 65 ft-lb (lubricated) or 80 ft-lb (dry). Re-check
pitch setting. Blade must be set within ±0.2° of desired pitch
angle. Tighten clamp bolts evenly. DO NOT OVER-
TORQUE CLAMP BOLTS
When bolts are tightened, hold a pencil against top end of
blade and mark the level onto a fixed object, such as a pole or
the fan ring.
Install remaining blades at same place as first blade, following
procedures above. After tightening bolts, mark top end of
each blade in same place first blade was marked. If marks
differ by 1/2" or more, adjust blade.
CHECK TRACK
After fan is installed in fan ring, outline top end of each blade
onto fan ring with a marker. The difference between levels of
highest and lowest outlines should not be more than 1/2" (See
Figure 9).
Figure 9

Installaon manual 1000H Page 5 of 10 May 2015
Correct blade track by loosening clamp bolts and adjusting blade
to match track of other blades. Re-tighten bolts and re-check
track and pitch angle setting. Re-tighten blade clamp bolts to
recommended standard of 55 ft-lb (lubricated) or 60 ft-lb (dry)
torque.
INSTALL SEAL DISC
Making sure hole in seal disc is over oil filler assembly, fasten
seal disc to top of hub with six (6) 3/8" cap screws. Put flat
washer against seal disc and lock washer between flat washer
and cap screw. Tighten to recommended standard of 15 ft-lb
(lubricated) or 20 ft-lb (dry). Make sure seal disc is not inverted
and not touching blades (See Figure 10).
Figure 10
NOTE: The purpose of the seal disc is to prevent hot air from
recirculating back down through the hub, increasing efficiency.
CHECKING TIP CLEARANCE
Rotate fan in position inside fan ring to check tip clearance (See
Figure 11). Tip clearance recommendations for specific fan
diameters are noted in table.
Figure 11
Fan Size (ft) Minimum Maximum
5 through 9 1/4" 1/2"
10 through 11 1/4" 5/8"
12 through 14 1/4" 3/4"
Adjust fan ring for proper clearance at all points around its
circumference. To increase clearance, add spacers at fan ring
joints. Use a chisel to maintain correct distance until bolts on
ring are re-tightened (See Figure 12).
Figure 12
Figure 13
If a small adjustment is needed, tighten or loosen nut on fan
strut in area of incorrect clearance (See Figure 13). Make sure
to re-tighten inside jam nut.

Installaon manual 1000H Page 6 of 10 May 2015
INSTALLING AIR LINES
Remove protective shipping cover and install air line(s).
All 1000 series hubs are shipped completely pre-adjusted for
specified spring pre-load and pitch travel.
ROTARY JOINT
Hook up instrument line to connection on rotary joint (See Figure
14).
Figure 14
Rotary joint assembly used to deliver controlled pressure to hub
has mechanical seal with ball bearings to assure alignment. It is
very important that the air line is installed with some slack.
IMPORTANT: Do not pull air line to rotary air joint tight
when installing hub. Instrument air pressure should be 3-15 psi.
VALVE POSITIONER
Connect instrument line to connection marked INSTRU.
Connect supply line to connection marked SUPPLY (See
Figure 15). Instrument line hookup is all that is necessary
before operating. Instrument air pressure should be 3-15 psi.
Valve positioners are adjusted for 3 psi instrument starting
point. Supply air pressure should be set to level according to
table below.
Figure 15
BIAS RELAY
Connect both supply and instrument lines. Check instructions
included with bias relay. If problems are encountered, contact
Hudson fan engineer. Instrument air pressure should be 3-15 psi.
Bias relays are adjusted for 3 psi instrument starting point. Supply
air pressure should be set to level according to table below.
SUPPLY PRESSURE FOR VALVE POSITIONER OR BIAS RELAY
Hub Type Fan Diameter (ft) Blade Type Hub Spring
Supply Pressure (psi)
To Vary Pitch To Check Blade Pitch
Travel at Rest
Standard
Acting Hub
8B, C, D or H Yellow 35 45
9-14 B, C, D or H White 45 55
16-20 B or H Brown/Black 75 85
All Sizes W, HW Brown/Black 75 85
Reverse
Acting Hub All Sizes All White 45 55

Installaon manual 1000H Page 7 of 10 May 2015
OPERATING INSTRUCTIONS
Start fan and check rotation. Viewed from top (discharge), fan
blades should rotate clockwise.
Hudson recommends to re-verify the blade clamp torque after
the initial 10-15 minutes of cold operation (i.e., the fan
doesn’t need to be exposed to the working temperature of the
process). This will ensure that the blades are settled within the
clamps after the centrifugal forces have acted.
Check motor power consumption to make sure fan is pulling
desired load. CAUTION: If positive pitch is set in summer to
use all available motor amps (nameplate rating), motor
could be overloaded in winter. Design pitch angles usually do
not use all available horsepower; therefore, motors will not be
overloaded at lowest winter temperatures if preset pitch re-
mains unaltered.
For the fans that have remained idle (such as a shut-down or
turn-around), it is highly recommended to re-verify the torque
on the blade clamps before putting it back into operation.
HUB MAINTENANCE
Hub is designed for oil lubrication and is filled with Summit
Syngear 7150 or Shell Omala RL 150 synthetic oil for mini-
mum oxidation and very low evaporation over wide tempera-
ture ranges. For minimum maintenance, Hudson strongly rec-
ommends using only synthetic oil. Under normal conditions
oil level should be checked on a yearly basis.

Installaon manual 1000H Page 8 of 10 May 2015
PARTS LIST
Tuf-Lite® Fans - Auto-Variable® Hubs
1000H Series
ITEM
NO. P/N DESCRIPTION
QTY.
BLDS PER HUB
4 5 6
1Specify
Bore
Q2 Bushing (up to 2 5/8 bore)
R2 Bushing (2 11/16 to 3/5 bore) 111
265450
65455
Coupling for Q2 Bushing
Coupling for R2 Bushing
(Specify Bushing)
111
372424 Cap Screw, 3/4 NC x 2 1/2 444
473738 3/4” Lock Washer 444
565425 Seal Plate 111
670505 Bolt, Stove, Rnd H, 1/4 x 1/2 long 444
7
65128
65129
65130
Hub Body, 4 Blades
Hub Body, 5 Blades
Hub Body, 6 Blades
1
1
1
871405 1/4 NPT Pipe Plug 222
965272 Lower Piston 111
10 65270 Upper Piston 111
11 74423 Roll Pin 3/16 x 1/2 333
12 K2030
62210
65175
73331
Actuator Bearing Assembly Consisting of:
1 – Actuator Stud
1 – Actuator Bearing
1 – Retainer Ring
456
13 73114 Oil Seal Silicone O-Ring #2-258 111
14 62703 Bearing Housing Gasket 456
15 65200 Bearing Housing 456
16 65216 Bearing Spacer 456
17 70180
70181
Roller Bearing Cup
Roller Bearing Cone 810 12
18 73332 Retainer Ring 456
19 65217 Support Washer 456
20 62369 Bearing Shim (as required) 456
21 65240 Blade Shaft 456
22 73475 Bearing Housing Oil Seal 456
23 74432 Roll Pin 3/16 x 1 1/2 456
24 72126 Blade Shaft Nut 456
25 72376 Cap Screw, Self Locking 16 20 24
26 72610 Drive Screw 444
27 62750 Name Plate 111
28 73250 Silicone O-Ring #2-253 111
29 72110 Low Pitch Stop Nut 222
30 65150 Spring Housing 111
31
63115
63116
63117
63101
Spring (To Suit Fan Dia.)
W- White
HH Inner – Black
HH outer – Brown
H - Yellow
111
32 63126 Spring Washer 111
33 72110 Spring Pre-load Nut 3/4 111
34 K2080 Spring Rod Assembly 111
35 73213 Silicone O-Ring #2-227 111
36 72312 Cap Screw 1/4 NC x 1 666
37 64100 2702D Rotary Joint Assembly 111
38 64530 Copper Flare Gasket 111
39 62215 Air Hose 111
40 64535 Male Connector 111
41 64300 Rotary Joint Adapter 111
42 74423 Roll Pin 3/16 x 1/2 111
43
44 65177 Blade Clamp Adapter 456
45 65009 Clamp Plate 810 12
46 72360 Cap Screw, 1/2 NC x 1 16 20 24
47 73726 Lock Washer, 1/2 NC 16 20 24
48 70701 Blade Clamp Bolt 5/8 NC x 7 w/ Nut 810 12
49 73730 Lock Washer, 5/8 NC 810 12
50
ITEM
NO. P/N DESCRIPTION
QTY.
BLDS PER HUB
4 5 6
51 65003
65016
Blade Clamp Half (Aluminum) Std.
Blade Clamp Half (Gray or Ductile
Iron) Opt.
810 12
52
71066
71064
71065
Oil Filler Assembly
1 – 3/8 NPT Nipple
1 – 3/8 NPT Elbow
1 – 3/8 NPT Plug
111
53 62599 Silicone Diaphragm 111
54 72332 Cap Screw, Self Locking 20 20 20
55 65320 Lower Diaphragm Cover 111
56 72522 F.H. Cap Screw, Self Locking 666
57 65300 Upper Diaphragm Cover 111
58 74430 Roll Pin 3/16 x 1 111
59 65290 Bottom Diaphragm Plate 111
60 65276 Top Diaphragm Plate 111
61 73495 Air Seal Washer 3/4 111
62 72342 Cap Screw 3/8 NC x 1 1/4, SS 444
63 73722 Lock Washer, 3/8 444
64 72330 Cap Screw 3/8 NC x 5/8, SS 666
65 73623 Flat Washer 3/8, SS 666
66 73722 Lock Washer 3/8, SS 666
OPTIONAL EXTRA VALVE POSI-
TIONER ASSEMBLY INCLUDES:
39 62215 Air Hose 111
67 64535 Male Connector 111
68
64510 Model 73N12F Positioner
(Low Temp/High Temp Diaphragms
and O-rings)
111
69 M2040 Range Spring Holder Sub Assembly 111
70
64251
64252
64253
64255
Range Spring (as required)
15 Deg. Travel B-W-B
20 Deg. Travel P-W-P
25 Deg. Travel Y-W-Y
30 Deg. Travel R-W-R
111
71 64540 Male Elbow, 5/16 Tube 111
72 65515 Range Spring Guide 111
73 73307 Retainer Ring 111
54406 Supply Pressure Regulator
0-100 psi, 1/4 NPT (Not Shown)
111
74 65525 Base Plate 111
75 64580 Torque Sleeve 111
76 64565 Spring Pin (1/8 x 1 1/8) 111
77 65500 Feedback Rod (5 7/8) 111
78 73213 Silicone O-Ring Seal #2-227
(Furnished when Rotary Joint
Spacer is required)
111
79 65535 Rotary Joint Spacer
4 Blades: Required when Yellow Hub
Spring is used. (1104W, 1204W)
6 Blades: Required when Yellow Hub
Spring is used. (1106W, 1206W)
111
80 72315 Cap Screw, 1/4 NC x 1 1/4
(When Rotary Joint Spacer is
required)
666
81 64525 Bearing Seat 111
82
81107
81112
Seal Disc
38” Dia for 7’ – 10’ AV Fans
42” Dia for 11’ – 14’ AV Fans
111
83 70325 Eye Bolt, 3/8-16 x 1 1/4, A489 333
84 72050 Nut, Hex, 3/8-16, SS 333
85 64529 Gasket, 5/8 Tube Size 666
Note:
1. Items 83 & 84 for shop handling only, remove after paint.

Installaon manual 1000H Page 9 of 10 May 2015
HUDSON PRODUCTS CORPORATION
Auto-Variable® Hub
Series 1000H

Installaon manual 1000H Page 10 of 10 May 2015
Hudson, Auto-Variable, Combin-Aire, Exact-A-Pitch, Fin-Fan, Heatflo, Hy-Fin, Split-Flo, Solo Aire, Stac-Flo, Steamflo, Thermflo, Tuf-Edge, Tuf-Lite, Tuf-Lite II, and Tuf-Lite III are registered trademarks of Hudson Products
Corporation.
©2012 Hudson Products Corp. All Rights Reserved.
9660 Grunwald Rd.
Beasley, Texas 77417-8600
Phone: [phone]
Fax: [phone]
1-800-634-9160 (24 Hours)
EMAIL: [e-mail]
http://www.hudsonproducts.com