Fan 31

OPERATING and MAINTENANCE MANUAL
USER INFORMATION
FOR TRANSPORT INSTALLATION OPERATION MAINTENANCE and SAFETY of
I G W - F A N S and ACCESSORIES
Fan Systems Group Ltd. Rochdale Road, Greetland Halifax 4HX 8HB, United Kingdom Tel: +44 (1422) 37 81 31 Fax: +44 (14 22) 37 86 72 e-mail: sales @fansystems.co.uk
11/04
Fan Systems Group Ltd

Rochdale Road, Halifax 4HX 8HB, United Kingdom certified acc. to DIN EN ISO 9001:2000
Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
LIST OF CONTENTS
PAGE
3 4 4 5 5 5 6 7 7 7 7 8
Commonly used designs of Axial Fans and Centrifugal Fans .................................................................................... Preface......................................................................................................................................................................... 1. 2. 2.1 3. 4. 5. 5.1 5.2 5.3 5.4 5.4.1 5.4.2 5.4.3 5.5 5.5.1 5.6 5.7 5.8 5.9 6. 7. 7.1 8. 8.1 8.2 8.3 8.4 8.5 9. Transport and Transport advice ............................................................................................................................... Installation of Axial and Centrifugal Fans General...................................................................................... Special installation instructions (Centrifugal fans, design 5 and similar designs with motor-coupling-shaft)............... Dismounting Refitting ............................................................................................................................................ Start-up ....................................................................................................................................................................... Maintenance ............................................................................................................................................................... Vibration monitoring ..................................................................................................................................................... V-Belt Drive.................................................................................................................................................................. - Checking intervals ..................................................................................................................................................... Flat belt drives .............................................................................................................................................................
Bearings Monitoring of bearings ................................................................................................................................................. 8 Additional instructions for various fan bearing types .................................................................................................. 9 Grease quality and lubrication intervals ....................................................................................................................... 10 Shaft seals for gases and fluids (see also section 8.2)................................................................................................ Shaft seals ................................................................................................................................................................... WDK-Seals .................................................................................................................................................................. Mechanical Starting Couplings .................................................................................................................................... Impeller inspection....................................................................................................................................................... Dismounting - Refitting of impellers see section 11. + 12............................................................................................ Additinal requirements at extended warranty (> 12 months). ...................................................................................... 10 11 12 13 13 13 13
Electric Motors ........................................................................................................................................................... 13 + 14 Instructions for storage and prolonged standstill (see also section 1. Transport) ................................................ 14 Precautions against unintentional start-up................................................................................................................... 14 Special instructions................................................................................................................................................... Operation at higher temperatures (> 70C) / Smoke proof design .............................................................................. Gastight fans................................................................................................................................................................ Explosion protection (see also section 4. explosion-proof fans).................................................................................. Frequency converter .................................................................................................................................................... Thermal safety ............................................................................................................................................................. 14 14 15 15 15 15
Down-time limitation.................................................................................................................................................. 15 Detailed diagram Axial fan ......................................................................................................................................... Detailed diagram Centrifugal fan Design 1 (direct drive) ........................................................................................... Detailed diagram Centrifugal fan Design 2 (drive through V-belt).............................................................................. Detailed diagram Centrifugal fan Design 5 (drive through coupling).......................................................................... 16 17 18 19
10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 19.1 19.2 20. 21.
Tunnel-Fans................................................................................................................................................................ 20 Dismantling and refitting of impellers having an extraction device...................................................................... 22 Dismantling and refitting of impellers and pulleys having taperlock bushes...................................................... 23 Installation and fitting instructions for flexible connections................................................................................. 24 Vane control with manual and remote control........................................................................................................ 25 Fire dampers .............................................................................................................................................................. 26 Storage instructions for spare parts........................................................................................................................ 27 Cabin vents................................................................................................................................................................. 27 Booster blowers for combustible gases.................................................................................................................. 27 Fan cowls non watertight.......................................................................................................................................... 28 Watertight fan cowls..................................................................................................................................................... 28 Fan cowls with fan ....................................................................................................................................................... 28 Maintenance Protocol................................................................................................................................................ 29 Fundamental safety instructions for products and components of Fan Systems .............................................. 30 + 31

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
Commonly used designs of Axial Fans
Commonly used designs of Centrifugal Fans
Long casing Flange motor Guide vanes Terminal box Service access (G = without service access)
Direct drive Impeller access from inlet side
Long casing Large door Flange motor Guide vanes Terminal box
Belt drive with base frame Impeller access from inlet side Motor mounted on rails Belt protection
Short casing Flange motor Guide vanes Terminal box
Belt drive Impeller access from inlet side Motor mounted on rails on the bearing support
Casing with bellmouth Flange motor Guide vanes Terminal box
Drive through coupling Impeller access from inlet side Common support for bearings and motor Safety guard
Long casing with bellmouth (R) =fully reversible with bellmouth at both ends
Drive through coupling Impeller access from inlet side Common support for bearings and motor Safety guard
Double inlet Belt drive on base frame Rotor to be dismounted from both sides Shaft supported with two bearings Motor mounted on rails Belt protection

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
PREFACE
This is an operating and maintenance manual, not a system design guide. When designing systems using fans a multitude of factors must be considered which exceeds the possibilities of this publication. We must point to the relevant specialist literature, standards, guidelines, directives and courses as they are offered by universities, technical collages and associations such as AMCA, BS, VDI, VDE and VDMA. If desired we can offer suggestions for required studies. We have carefully manufactured a solid and reliable fan for you which corresponds to the state of the art. However, during operation fans are often exposed to large - often unexpected - stress. Even improbable accidents must be avoided, even in the case of two different failures occuring simultaneously. Fans must be regularly inspected and maintained by qualified staff in order to avoid damage and accidents. Material damage and personal injuries can result from improper service. Damaged bearings and too high vibration levels can lead to failures and subsequent damage. Fans include movable parts which are exposed to wear and tear. Special attention must be paid to the bearings. In spite of high safety standards and their normally long life expectancy, in the end every bearing wears out. Slight damage to the bearings may for example quickly worsen. Regular inspections must be carried out taking operating conditions into consideration. Destroyed bearings can lead to shaft failures and a total loss of the fan. Also V-belt drives and couplings are equipped with wearable parts and must be inspected regularly. Vibrations are an enemy of all rotating machines, which - as is known - can lead to unpredictable fatigue failures. The best protection consists in minimizing the vibration energy. At the time of delivery from our works the fan has a high vibration quality. But because of bad inlet conditions, material build-up, wear, transport damage, fitting faults, bearing damage, overheating and other reasons, heavy vibrations can occur. Therefore, together with the inspection of the bearings, the vibration levels must be checked regularly. Fans should not be installed near working or common areas. The fan must always be installed in such a way that no rotating parts can be touched. In case of free inlets or outlets protecting guards must be fitted. If the fan is connected to ducts, these must be supplied with protecting guards on the inlet and outlet side. Parts which can come loose from the impeller and foreign bodies must be contained safely inside the protection. Before beginning any work on the fan, the electrical connections must be interrupted. The switching device must be marked and secured so that unintended operation cannot occur. The impeller must be mechanically blocked.
We refer to the Fundamental Safety Instructions of Fan Systems, which are an integral part of this Operating and Maintenance Manual and which must be strictly adhered to (see sect. 21.)
The DIN EN 292 Parts 1 and 2 "Safety of machines" is the basis of all safety aspects. Please, carefully follow the instructions set out below. 1. TRANSPORT
see also section 7.
For lifting with cranes, attach hooks only to the lifting eyes provided for this purpose. Complete fans should only be lifted by means of the lifting eyes at the foundation, not at the lifting eyes of components such as the casing or motor. When using fork-lifts the fork is to be only applied to the base frame. Lowering is to be done with the lowest possible speed onto a soft support. Shocks, shaking and dropping might lead to imbalances and deformation or even destruction, especially of the bearings. During every transport and during storage ensure that no water (e.g. by rain) can get into the motor, the bearings or other sensitive components. Axial fans (including jet fans) must, in case of short transport and temporary storage in the open, be stored in a horizontal position, if possible under a canvas cover so that no water can penetrate along the shaft into the motor. We would recommend only closed transport and storage in closed rooms without large temperature variations. Safety advice: Inspect safe connection between fan and hoisting device, pay attention to the centre of gravity, do not cant or tilt, do not step under the load!
TRANSPORT ADVICE
Lifting eyes A only for single components of the fan In case of complete fan only use lifting eyes B Do not use hoist askew, use a traverse beam to achieve vertical loads. Lift and lower load slowly, use a soft support, e.g. wooden girders!

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
2.
INSTALLATION OF AXIAL AND CENTRIFUGAL FANS - GENERAL
When installing fans the instructions according to DIN 4024 (machine foundations.) parts 1 and 2 must be observed. Fans are only to be installed in the mounting position for which they were ordered and supplied (horizontal/vertical). Installation must be done on a level foundation. Care must be taken that the fans are not mechanically deformed or submitted to unwanted forces in order to prevent jamming or grinding of the impeller. When using vibration isolators, they must be placed so that a uniform compression is obtained. It may be necessary to insert shims. When the fan is installed the isolators must not be canted, dragged over the floor or stressed on one side only. In that case the rubber or the springs could be damaged. Flexible connections must be installed to allow some fan movement, especially during the start-up. Equally, they must not be collapsed too far or misaligned so there are folds which could unduly impede the air flow, see also 13. Installation instructions for flexible connections. In case of high pressure and danger of abrasion, guide rings (ducts) must be provided. The connection of the fan to the motor must be done according to the connection diagram in the terminal box and according to the instructions of the motor maker. All motors are to be protected by means of motor protection devices. The connection must be carried out by licensed expert staff taking into consideration the protection and safety instructions.
2.1
Special installation instructions
Centrifugal fans, design 5 and similar designs with motor-coupling-shaft

The careful alignment with respect to height, lateral displacement and angle between shafts carried out during production may be disrupted during installation. The coupling can compensate large misalignments, but large forces on the shafts and the bearings may result, which will lead to increased vibrations, especially for fans with large shaft power and/or high speed. The frequency of these vibrations corresponds to the 2nd harmonic of the rotation frequency and can thus easily be distinguished from an imbalance. The base frame of the fans can be deformed during transport or installation, e.g. because of uneven floor conditions. Therefore, the alignment usually must be corrected. For high demands concerning silent running and bearing life, we urgently recommend the alignment of the shafts by means of optical laser devices, especially in the case of high loads and speeds. This should be done before the start-up and, if necessary, should be repeated periodically. The driving motor and/or the bearings position must be corrected with shims until the vibrations of the 2nd harmonic remain below the permissible values. Speed [1/min] 750 1500 3000 6000 n Per 100 mm coupling diameter [1/100 mm] Parallel offset Air gap differences (angle faults) 9 6 3 2 9 5 2,5 1,5 2950 n0,88 Couplings recommended alignment tolerances, if not indicated differently.
1340 n0,75
3.
DISMOUNTING - REFITTING
Under certain circumstances, large fans must be dismounted into separate components, in order to enable transport through narrow access doors. Pages 16 - 19 show detailed diagrams of standard fans to ease dismounting-refitting. This work should only be carried out by expert staff. Installation support devices should be available. All parts fitting together must be marked before being dismounted. Special attention must be paid to the relationship between the parts. The interchange of parts can cause installation difficulties. The dismounting and installation of the impeller can either be done by the use of an extraction disc or a clamping bush (see section 11.+12.). Attention: Under no circumstances should one dismount the hub from the impeller backplate; imbalance would surely arise. The bearings must not be canted. Shims must be re-used for adjustment if they were used before. The bearing casing and foundation must be bolted carefully. During the remounting of the impeller on the shaft, the use of graphite grease may be advantagous. Attention! Taper-lock bushes may not be greased! Attention must be paid to the following additional instructions: The pulleys must be in alignment. The tension of the belt must be adjusted. Too high tension can cause bearing damage, too low tension increased belt wear, see section 5.2. In case of divided casings, the casing parts must be joined using a long-life elastic sealing. The flange corners and the connection between casing and inlet nozzle are of special importance. In case of flexible couplings, both shaft parts must be aligned, see table above. Starting couplings usually can be removed from the motor shaft ends and refitted in the same way as impellers. But, in case of fluid couplings, we recommend the assistance of special expert staff.

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
Single inlet centrifugal fans

For fans with access at the drive side of the casing: the impeller can be drawn out of the casing together with motor/bearing support after removing the bolts of the access opening and of the motor/bearing support. The impeller can be pulled out of the casing and the motor can be dismounted from the pedestal. For fans with access at the inlet side: first the inlet cone has to be removed by taking off the screws. Then the impeller has to be taken off the shaft by either loosening the taperlock bush or using the extraction disc, depending on how the bush is mounted on the shaft. Now the motor or shaft with bearing can be removed on the drive side.
Fan with split casing

For fans with mounting opening at the inlet side: first the inlet cone has to be removed by taking off the screws. The upper part of the fan casing can be lifted off after removing the flange screws. The impeller has to be supported by wooden bars, or by a crane, but is not to be lifted yet. Remove the fixing screws of the motor (directly driven impeller) or fan bearing (belt drive or coupling). Loosen the extraction disc or taper-lock-bush, respectively, and pull the shaft out of the hub using an extraction device. Afterwards the impeller can be lifted out of the lower part of the fan casing.
Double inlet centrifugal fans

The impeller must be supported inside of the casing (wooden wedges, but not under the impeller blades) so that the bearings are relieved. Then the screws at the foot of the bearing casing are removed and inlet grill, inlet bellmouth and bearing support at the opposite side of the drive are taken off. Now the impeller with shaft and bearing casing can be drawn out horizontally. Then the casings of the bearing are dismounted and the bearings are drawn off.
In case of a divided casing, remove screws of inlet grill and inlet bellmouth, take off the belt drive, and take off the upper part of the casing after having removed the flange screws. Fix impeller at crane by means of fixing devices, but do not yet lift. Remove fixing screws from bearings of the casing. Fix lifting devices at both ends of the shaft and connect to the crane. Carefully hoist the complete unit of impeller, shaft, bearing, inlet bellmouth out of the lower part of the casing. Further dismounting of the parts can be done after setting down the complete unit. Axial Fans
A difference must be made between fans with a large access door and all other designs. At first, the power supply must be visibly and safely interrupted. For design B with a large bolted access, the bolts and the access door are removed. Then the impeller can either be loosened by means of the extraction disc or the taper-lock bush (see section 11. and 12.). Then the motor bolts can be removed. Lifting devices are to be used. For all other designs the fan must be separated from all connecting parts such as for example protective grills, silencers and, ducts, and must be placed on the floor with the impeller up. Then the impeller can be detached either with an extraction disc or taperlock bush. After that the motor can be unbolted. Lifting devices are to be used.
4.
START-UP
General Safety Instructions:

Before engaging the fan, the casing and duct pipes must be investigated for foreign particles. Loose parts can be carried by the air flow and can lead to injuries. Attention must be paid to the installation of protection grills, belt protection and other safety features. No one may ever stand in the air flow! The air pressure might be so strong that a human body and even heavy objects could be sucked into the fan or blown away. The safety instructions for electrical equipment and of the electricity supply company must be observed at all times. The rotational direction of the fan is indicated by an arrow on the fan casing, the fan protection or the motor. This should be checked by briefly starting the motor and observing the rotating parts. If it is wrong, the electrical leads must be reconnected. The amperage must be measured and compared to the nominal current of the motor. Centrifugal fans must be throttled appropriately, otherwise the motor can be overloaded. The reverse is true for axial fans. With free outlet they absorb less power than when throttled. Before the rotational direction is reversed, the impeller must come to a complete standstill. The high moment of inertia can otherwise lead to damage.
Mechanical Safety
Safety features must be installed to prevent moving parts being touched. If not an integral part of the fan they must be provided by the installation company. This is especially the case for inlets, outlet and access doors which must be secured on site.
Fan with belt drive

The correct running of the belts must be checked (refer to chapter 5.2). The bearing temperature must be monitored. The temperature on the bearing housing will normally rise to 50 - 60C (handwarm), rarely to 70C or more. Be careful when touching. If the temperature rises to higher values, the start-up must be repeated after a cooling down period. If normal values are not achieved the fault must be found and eliminated.
Systems with dampers

Dampers that can interrupt the airflow completely must be connected in such a manner that the fan is automatically stopped immediately after closing of the damper. Otherwise an excessive heating of the fan and excessive vibrations can occur.
Fans operating in parallel

When fans are operating in parallel ensure that the non-operating fans are not rotating in the opposite direction of their intended rotational direction. The start-up of a fan rotating in the wrong direction can otherwise lead to overloading of the power supply and motor. Damage to the impeller can also occur. Special care must be taken when carrying out maintenance work. The impeller has to be mechanically blocked before starting the maintenance work.

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
Maximum Speed, different speeds and speed control.

The fan may not be operated at higher speeds than stated in the data sheet. A speed reduction is only permissible after checking with Fan Systems. This is to ensure that the fan is not going to operate at a resonance frequency which can damage the fan or associated components. When using variable speed control, resonance frequencies of the various fan components may be reached. At the corresponding speeds no permanent operation may occur. When starting up the system the variable speed control must be programmed so that these resonance speeds are bypassed quickly. Please note section 8.4
Motor protection Fans have a relatively high moment of inertia. In most cases relays for heavy start are necessary. When selecting and setting the relays the whole operating range must be considered. For example a fan motor will draw 16 % current when the air or gas going through the fan is -20C instead of 20C just because of the difference in the density.
Starting couplings
To avoid excessive heating and overloading of the coupling, a maximum 4 starts per hour is permissible. Between any 2 starts a cooling period of at least 10 minutes is required.
Explosion-proof fans (please also refer to section 8.3)

Very special care must be taken. In addition to other instructions the following must be noted: The build-up of electrostatic charges must be avoided by grounding all relevant parts. Special care must be taken to ensure adequate distance between rotating and non-rotating parts. The motor may at no point become overloaded or overheated.
5.
MAINTENANCE
The safety instructions for initial operation of the fans are also valid for maintenance. The maintenance frequency depends largely on the operating conditions, surrounding conditions and required availability. The frequency must be set by the system designer taking into consideration the instructions of the fan supplier. Sufficient spare parts must be available. All impellers have been carefully balanced prior to leaving the factory. Imbalance can occur due to dust, wear, abrasion and accumulation of material on the impeller, leading to vibrations and damage of bearings. Low levels of vibrations must always be maintained.
5.1
Vibration monitoring
Increased vibrations always constitute a danger signal (VDI 2056 and ISO 2372). Changes in the vibration level can best be monitored by measuring the mechanical vibrations on the bearings and/or the motor. By comparison over a prolonged period changes can best be detected. If significant changes are observed the cause must be established, for example dirt accumulation or wear on the impeller. Cleaning and/or rebalancing of the impeller may be necessary.
5.2
V-Belt Drive
Belts will be stretched in the course of time, especially during the first operating hours. Several checks and re-tightenings of the belts are necessary. The belt tension must be checked from time to time. The values given in the table below must be observed. Too high tension increases the bearing load (risk of bearing damage), a too low tension leads to belt slip, creaking and additional wear. Re-tightening is possible by parallel movement of the motor in its rails or lifting of the motor pivot. Care has to be taken that the pulleys remain strictly parallel to each other (use a ruler or a piece of string). The correct belt tension can be determined by measuring the deflection Ea using a spring balance. If belts are to be replaced, this should always be done for a complete set in order to assure equal length. Replacing a single belt is strictly inadvisable. The fitting of new belts should be carried out carefully in order to avoid overstretching. For new belts the initial tension should be set higher, so that the deflection is 0,75 x the tabular value. If re-tightening is required the tabular value or the value from the special documentation should be used. We recommend the following checking intervals: 1. Check: 2 to 3 hours after start-up 2. Check: 8 to 12 hours after start-up 3. Check: 1 week after start-up Further checks acc. to requirements and operating conditions.
Pretension of V-belts
The centre distance L between the pulleys is measured and a defined force f (see table) is applied to the middle of the belts. The deflection Ea is measured and the tension adjusted until the Ea value from the table is reached. Example: A belt drive has 180 as smallest pulley diameter dk a SPB profile and L = 1000 mm. For a force of 75 N/belt the deflection at re-tightening should be 3,32 1000 Ea = = 33,2 mm 100 For the initial set up with new belts Ea should be Ea = 0,75 x 33,2 = 24,9 mm.
Impression depth per belt Test force per belt Centric distance
Ea in mm f in N L in mm

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
Profile
Test Force f per V-belt
Diameter of the smallest pulley
f (N)
SPZ
25
SPA
50
SPB
75
(dk mm) 56 71 > 71 90 > 90 125 > 125 71 100 > 100 140 > 140 200 > 200 112 160 > 160 224 > 224 355 > 355
Deflection depth Ea per 100 mm center distance Ea (mm) Standard 3,19 2,86 2,67 2,47 4,16 3.58 3,33 3,19 3,90 3.32 2,89 2,73
Belt tension for standard V-belt types
In case of other types, e. g. larger drives, see separate documentation (Label)
5.3
Flat belt drives
The flat belt tension is adjusted at our works and normally needs no re-tightening or maintenance. When a new belt is installed, it is important to stretch it exactly as instructed. The given values must be observed. A too high tension increases the bearing load (risk of bearing damage), a too low tension leads to belt slip, creaking and additional wear. Please note the special instructions of the Flat Belt manufacturer. The correct stretching is obtained as follows: Put the belt on a plane surface and mark two points e. g. spaced 1000 mm apart. Mount the belt on the pulleys and stretch it by moving the motor parallel on its rails. The stretching is correct when the distance has increased by the prescribed amount. In order to stretch the complete belt evenly, the belt drive has to be turned manually several times. Example: Stretching 2 % Distance before tensioning: 1000 mm Distance afterwards: 1020 mm
5.4
BEARINGS
5.4.1 Monitoring of bearings

Every bearing has to be checked regularly. Dirt particles or humidity must not enter the bearing as they may cause premature failure. When relubricating or replacing bearings, utmost cleanliness must be observed. When monitoring bearings it is a great advantage to use shock pulse monitoring (SPM-method). Measurement should be made directly at the bearing unit. The separate instructions of the test equipment manufacturer must be adhered to. Not only the momentary values are of importance, but also the comparison of the data over a prolonged period since this best allows changes to become apparent. In rare cases SPM measurements can lead to wrong conclusions. Bearing noise and temperature development should also be recorded, especially for essential fans. Increasing values are always a sign of danger. The relubrication intervals are valid for stationary machines under normal conditions for non-ageing lithium soap lubricants as prescribed in section 5.4.3, as long as the temperature on the external bearing ring remains below 70C. For temperatures exceeding 70C every increase by 15C will halve the greasing interval. The maximum temperature limit of the grease is not to be exceeded. The life expectancy of bearings is largely dependent on the operating conditions and the conditions at site. We strongly recommend regular bearing checks The intervals depends on the importance of the fan. For machines of essential importance we recommend annual bearing replacement even in the absence of increased vibrations, after relatively fan running hours. Bearings for less important machines should be replaced less often or when a breakdown is imminent.

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
5.4.2 Additional instructions for various fan bearing types

The grease types and re-greasing intervals to be used are specified in 5.4.3. Necessary re-greasing should if possible be done while the machine is running, while taking the necessary safety precautions. If this is not possible, turn the shaft by hand. It is important that the inside of the bearings remains absolutely free from humidity, dirt and dust, even after service. Therefore bearings that are located in the air stream are provided with double-lip seals. High performance grease acc. to 5.4.3 must be used. At our factory the bearings are greased with a heavy duty long life grease.
Bearings with permanent lubrication

Bearings with permanent lubrication, recognised by the absence of grease nipples, do not need re-greasing.
Cartridge bearing with re-greasing device and grease control disc

A control disc removes old grease during relubrication, pressing it out into the casing. During relubrication the temperature may temporarily increase due to the presence of too much grease. After this is ejected by the control disc, temperature will fall to its normal steady state level. The grease can be removed at infrequent intervals e. g. in connection with the replacement of bearings.
Cartridge bearing unit
Plummer block bearing with re-greasing device and grease control disc
A control disc removes old grease during relubrication, pressing it out through slots in the casing. During relubrication the temperature may temporarily increase due to the presence of too much grease. After this is ejected by the control disc, temperature will fall to its normal steady state level. Re-greasing is best done taking the necessary precautions not to come close to moving parts while the machine is running so that surplus old grease can be removed immediately and is not carried away by the air stream (for fans where the bearing are in the airstream, e. g. axial flow fans or double inlet fans).
Plummer block bearing with re-greasing device and without grease control disc
The bearing is initially filled up to 2/3 with grease. Relubrication has to be made at regular intervals. The correct quantity of grease should be applied, because overgreasing may lead to an increase of temperature. The installed overpressure valve serves for pressure relief. After several relubrications the housing is filled with grease and must be cleaned. The upper part of bearing housing must then be taken off to remove the old grease without damaging the bearing. New grease has to be squeezed by hand into the bearing. Please use clean grease and take care that no impurities come into the grease.
Plummer block bearing with permanent lubrication and without grease nipple
When the grease must be renewed dismount the top of the bearing housing and remove the old grease, without damaging the balls/rollers. Press the new grease (absolutely clean!) by hand into the spaces between the balls/rollers. It is of paramount importance that only absolutely clean grease is used and that no particles of any kind get into the bearing during regreasing. The space between the double-lips must also be filled with grease so that the friction between lips and shaft are reduced.
Plummer block bearing The relubrication intervals can be seen from the following curve, or are informed in separate directions.

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
5.4.3. Grease quality and lubrication intervals

Except for special cases - where this is clearly indicated - the motor bearings are greased with lithium soap grease. The different brands are mutually compatible. The brand is selected by the motor supplier, see name plate. Current Lithium soap grease brands: SKF - LGMT 2/3 Shell - Alvania R3 Mobil Oil - Mobilux 3 FAG - Arcanol L 71 Esso - Beacon 3 Aral - Aral HL3 Blaser - Blasolube 462
Fan bearings are normally greased with the same grease as the motor bearings. The grease data are given on a label.
Lubrication intervals at normal conditions acc. to DIN 51 825 -10 bis +70C room temperature with the above mentioned grease types Bearing type kf
_______ Deep-groove ball bearing single-row ----------- Cylindrical roller bearing single row
1.1 3.5
n = speed l min1 d = size of bore (refer to bearing catalogue)
dm = average bearing diameter [mm] = (d+D)/2 D = outer diameter (refer to bearing catalogue)
In two cases other grease types are used. For bearings with exceptionally heavy loads Optimol Longtime PD2 made by Optimol lwerke Munich is used, which gives longer bearing life. Please note the label regarding special grease type. If bearings have to operate at high temperatures, we use Staburags N12MF made by Klber, Munich. This grease type is suitable for 20 to 160C continous operation, short term for up to 180C. Please note the label regarding special grease type. Oil lubrication When using oil lubrication, special instructions must be noted. In the manufacturers works the correct oil quantity is put into the casing. Before re-starting after prolonged stoppage the maximum oil supply has to be re-established. It is recommended to change the oil after a couple of hours after the initial commissioning. All further oil changes must be done according to the operating conditions, but at least annually. The oil change must be done while the equipment is not running.
If during commissioning no leakage of oil is observed, an ongoing oil check - for example monthly - is sufficient. During operation the oil level can reach the minimum marking. When refilling during operation, the oil quantity added should not exceed 5 mm below the maximum marking to avoid excess oil being added including the oil in circulation.
5.5
Shaft seals for gases and fluids
(see also section 8.2)
We use a number of different sealing methods, please refer to the below table. The selected method should always be checked whether it is adequate for the toxidity of the medium. A regular relubrication is necessary and at the same time a leak test must be carried out, since often the real operating conditions are not known at the time of design and installation. The test is carried out either with the use of gas detecting equipment, the human nose or by pressure testing. The critical parts are sprayed with a lathering fluid to detect the leaks by means of bubbles. The tightness of the total fan can also be tested by sealing the whole unit, applying a defined pressure and then measuring the rate of pressure decrease. We recommend to change seal rings at least once per year. The seals type 3 + 4 must be greased regularly in order to avoid excessive wear and temperature rise. Type 5 is designed to operate without grease, but a grease filling reduces the leakage. The grease must be suitable for the temperature, see 5.4.3 and agree with the medium. The relubrication intervals depend on the operating conditions and must be checked every 6 months. The grease chambers are then refilled with the impeller turning slowly. The necessary amount of grease is reached when the resistance to the filling noticeably increases (only use manual lubrication presses). Under no circumstances should the grease be pressed into the seals using force, because the sealing rings can be pressed apart. Additional greasing should only be carried out if the seal is leaking. If special oiling or cooling equipment has been installed, special instructions in the documentation must be adhered to. For gases with particles inert gas seals should be used.
10

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
SHAFT SEALS
Type 1
Hub lining
Tightness Class Ia No requirements
Standard design, gap between casing and hub about 1 to 2 mm.
Type 2
Tightness Class Ib Hub lining, impeller with fuming bars. No requirements
The negative pressure reduces the leakage rate.
produced
Type 3 Tightness Class II Design WD1 acc. to DIN V 24 194 part 2; test pressure 1000 Pa
With one sealing ring. combined with fuming bars.
Can
be
m3 Leakage rate max.: 2,4 10 3 2 s m m = inner surface of fan casing
Type 4
A) Tightness Class III = Standard acc. to DIN V 24 194 part 2; test pressure 1000 Pa: Design WD2 m3 Leakage rate max.: 0,8 10 3 2 A) With two sealing rings and s m lubrication nipples. Can be combined B) Tightness Class IV (grease filling) with impeller fuming bars. Nuclear Standard acc. to DIN 25 414: 3 B) As A) but the space between the Leakage rate max. 10 dm (bei 1 bar + 20 C) rings is carefully filled with grease. h m2
Test pressure p= 20 mbar = 2000 Pa

Type 5 A) Tightness Class III without inert gas: Design WDK acc. to DIN V 24 194 part 2; test pressure 1000 Pa: m3 With two or more sealing rings, grease Leakage rate max.: 0,8 10 3 2 chamber and lubrication nipples. s m Vacuum suction or sealing gas is required for applications with special B) Tightness Class IV with inert gas: requirements as to tightness, acc. to DIN V 24 194 part 2; test pressure 1000 Pa: temperature and tip speed. m3 Leakage rate max.: 0,27 10 3 2 For temperatures up to 500C. s m
Casing Materials for all designs: Standard Mild Steel Options: Stainless steel, aluminium. Sealing rings: Standard: FKM (Viton ) -30/+200C, lubrication required. Optional: PTFE (Teflon) -80/+200C, self lubricating. Running speed v 14 m/s Running speed v 18 m/s
11

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
5.5.1 WDK-Seals
When assembling WDK-seals special care has to be taken.
Carefully draw shaft sleeve with 0-ring over the shaft and insert flat or round sealing against the casing. The lower part of the casing (with thread for partition bolts) should be placed from below onto the shaft and attached with fastening screws, so that the partition is approximately horizontal. Remove the looped coil spring from the first sealing ring.Open the hooked spring lock and insert the spring from one end into the (seen from the pressure side) first chamber of the seal casing until it can be gripped from the other side. Slightly grease sealing element 1 on both lateral sides, place with bore on the shaft and insert locked spring into the spring groove of the sealing ring. Align sealing ring segment in axial direction of first chamber and push into the chamber. Slightly grease sealing ring segment 2 on both sides, place with bore onto the shaft and draw spring into spring groove. Push sealing segment 2 so far into the chamber, until sealing ring segment 1 shows on the other side. Slightly grease sealing segment 3 (with locking groove) on both sides, place with bore onto the shaft, and draw spring into spring groove. Ensure that the securing plates properly grip the securing groove of the sealing ring. The individual sealing ring segments are marked with the same numbers and must enclose the shaft in the same arrangement. Turn assembled sealing ring on the shaft until the locating plate grips into the locating notch of the divided casing. The other rings can be inserted in the same way as ring No.1, whereby the sealing rings must be greased slightly on both sides. After installation of the last sealing ring align all exposed segments so that the second half of the casing can be put on top without difficulties. While doing this check once again the correct position of the locating plate. Slightly grease the second half of the casing in its partition and draw it carefully over the sealing rings and bolt it together with the lower part of the casing. Detach the fastening below the shaft seal and turn shaft seal so far onto the shaft until the connection for the grease re-lubrification has reached the correct position. Place flat or round sealing on the sealing surface of the fan casing, align shaft sealing to shaft and screw onto the back side of the fan.
12

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
5.6
Mechanical Starting Couplings
The maintenance mostly depends on the operating conditions. Usually a regular control is not necessary as a dynamic stress of the internal roller bearings only occurs during the starting phase until the nominal speed has been reached. The bearings are fully enclosed and do not have any re-greasing devices. In case of heavier loads, and if frequent starts are done (more than four times a day), in case of temperatures higher than 50C or with dust loads, we recommend to check the roller bearings, the sealing rings and the abrasion of the coupling after approximately 8000 hours of operation.
5.7
Impeller inspection
If abrasion, corrosion or dirt deposits on the impeller are likely, regular inspections, cleaning and repeated balancing must be carried out at least once a year, in extreme cases even at intervals of one or two weeks. Wearing plates on the impellers should only be installed by a qualified workshop. Buying a second impeller is recommended for alternate maintenance. Frequent impeller inspections using the penetrant paint method are recommended for fans operated with speed control, to check against starting fatigue.
5.8 5.9
DISMOUNTING - REFITTING of impellers see section 11. and 12. Additional requirements at extended warranty (> 12 months)
If an extended warranty has been agreed, the following requirements have to be fulfilled absolutely (if not, the warranty is lost) : - This Operation and Maintenance Manual has to be folowed exactly - We must be informed about each maintenance/repair within 15 working days. - Among other yearly checks according to the maintenance plan in chapter 20 the insulation system of the warm motor has to be checked (resistance in between widing and earth at 500V DC).
6.
ELECTRIC MOTORS
The guidelines and safety instructions of the motor manufacturer must be strictly adhered to. By nature the fan is a machine with a high inertia. This is especially the case for large impellers with low speed, i. e. a motor with a relatively low power and a small torque. Therefore the time should be checked at least for all fans having a lower number of rotations than the motor and
The cooling air of the motor must not be obstructed and the exhaust air - also from other machines must not be reused.
for all motors above 10 kW. The short relay times generally in use today will in many cases make it necessary to use relays for extra heavy starts of centrifugal couplings. Special attention is necessary when single phase motors are employed, as these motors generally have an extremely unfavourable torque curve.
Electrical connections All work may only be carried out by qualified personnel on stopped machines with the power supply cut off and visibly secured against restart. This also applies to auxiliary power supplies ( e. g. space heaters). Check that the voltage is switched off! Surpassing the tolerance laid down in EN 60034-1/DIN VDE 0530, part 1, i. e. voltage 5 %, frequency 2 %, correct curve shape and lack of symmetry increase the heating up of the motor and affect the electro magnetic compatibility. Please note the performance data on the motor plate and the connecting diagram in the motor terminal box.
The electrical connection must be permanently secured (no dangling leads); prepared cable ends must be used. Make safe earth connections. The minimum air gap between non-isolated, voltage carrying parts and the grounding may not be less than: 8 mm for UN 550 V, 10 mm for UN 725 V, 14 mm for UN 1000 V. The terminal box must be free of foreign matter such as dirt, humidity etc. Cable gland holes not in use and the terminal box itself must be closed to ensure they are free from dust and humidity. For testing without a load on the shaft the shaft key must be secured. For machines with brakes, the correct operation of the brakes must be tested before starting the motor.
Operation Normally vibration levels of veff 3,5 mm/s (PN 15 kW) and 4,5 mm/s (PN > 15 kW) respectively are safe, but in some cases higher levels must be accepted, see ISO 14 694 (Draft). If changes occur compared to the normal operation - e. g. increased temperature, noise or vibration levels - the cause must be established, if necessary after referring to the motor manufacturer. Safety protection devices must not be disconnected even during trial operation. When in doubt turn off the fan. In dirty locations the motor must be cleaned regularly. Bearings with relubrication should be greased while the motor is running. Use the correct grease type. In case of overflow, grease valves with stop caps (IP 54 shaft side; IP 23 shaft and cooling side), remove these before operating the motor and close again afterwards. Bearings should be exchanged after approx. 10.000 h for bearings with permanent lubrication (1Z-bearings) for 2 pole motors, and approximately 20.000 hours for motors having higher pole numbers, unless otherwise stated by the manufacturer. General All electrical machines have dangerous parts that are under electrical tension, are rotating and which may have hot surfaces. All work transporting, connecting, operating and maintaining is only to be carried out by qualified and reliable personnel (prEN50110-1/VDE 0105, IEC 364 should be adhered to). Inexpert handling can lead to serious damage to people and property.
13

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
Appropriate use Low voltage machines are made according to the standards EN 60034 (VDE 0530). The use in explosion areas is strictly prohibited, unless specifically designed for this purpose (see marking on the name plate). Protection classes less than IP 23 should not be used outside. Machines with air cooling are designed for an at site temperature of -20C to +40C and a height above sea level of less than 1000 m. Different instructions on the name plates have to be strictly followed. The conditions at site must match all instructions on the name plate.
Low voltage motors are components for installation into end products according to the machine directive 89/392/EWG. Start-up is not permissible until the conformity of the end product with the machine directive has been established (note e. g. EN 60204-1).
Transport and storage Damages to the motor that are noticed must immediately be repaired. Start-up may have to be delayed. Tighten the inserted transport bolts before lifting. The bolts are designed for carrying the weight of the motor, not any additional loads. Remove transportation securing devices before putting into operation. Reuse for renewed transport. If storing low voltage machines ensure a dust free, dry and vibration free (Veff 0,2 mm/s) site. Measure the insulation resistance before putting the motor into operation. If the measured values are 1k for every Volt of the measuring voltage, the windings must be dried out. Follow the "storage instructions" from the motor manufacturer. Mounting Ensure an even support with good flange and/or foot connection and exact alignment if directly coupled. Avoid resonance frequencies in surrounding equipment. Turn the rotor by hand and listen to unusual grinding noises. Control the direction of rotation. Pulleys and couplings are only to be mounted/dismounted using appropriate tools (heated). Safety guards etc. are to be fitted. Avoid unsuitable belt tension (chapter 5.2). The balancing condition of the low voltage machine is marked on the name plate (H = half shaft key, F = full shaft key). If the motor has a half shaft key (H), the corresponding coupling must also be balanced with a half shaft key. Protruding parts of the shaft key must be removed. If required a special protective screen is to be mounted at site to avoid foreign bodies falling into the fan.
Under certain operating conditions the motor casing can be subject to condensation. This can be avoided by the use of a space heater or applying a low voltage to the windings. Drainage openings on the motor must be regularly opened and checked. The end user must protect the motor against overload under special conditions, e. g. when the fan handles hot gases or if the motor cannot operate under standard temperature and pressure at site. For start-up of centrifugal fans sometimes the absorbed power must be reduced, e. g. by partial closing of dampers in the duct, reduction of rotational speed or partial closing of an inlet vane. The normally used asynchronous motors with squirrel cage rotor conform, when used properly and operated at a power supply according to EN 50 160, with the requirements of the EU-directive concerning electromagnetic compatibility. When being fed by a frequency converter, electromagnetic disturbances may be emitted depending on the design of the converter. To avoid surpassing the limits set in EN 50 081-1 for the converter/motor system, the EMV-instructions of the converter manufacturer must be adhered to. For motors with built-in sensors (e. g. thermistors) the sensor leads can cause interference. The requirements to the motor acc. to EN 50 082-2 are generally complied with. For motors with built-in sensors (e. g. thermistors) the end user must ensure the appropriate selection of the sensor leads and the measuring instruments to ensure proper operation.
7.
INSTRUCTIONS FOR STORAGE AND PROLONGED STANDSTILL (refer also to section 1. TRANSPORT)
Care must be taken that the fan and the motor are protected against humidity and dust. Large temperature changes should be avoided. Otherwise damage to electric motors, cable boxes, bearings, painted surfaces and seals might result. It is to be considered that not all paints are weather resistant, corrosion might occur for example under a primer. Prolonged standstill may reduce the lubrication properties of grease or oil. Corrosion can occur on the bearings and they might fall dry and belts might become brittle. Ball bearings can develop pits. In order to avoid this, the fan should be operated for about 10 minutes every month. If this is impossible at least the impeller should be turned by hand. The grease is to be exchanged every 3 years.
7.1
Precautions against unintentional start-up
The user must take appropriate measures and provide appropriate equipment to avoid unwanted power supply to the fan and associated equipment. This has special relevance during service and maintenance operations. Beside the electrical power supply also other potential energy sources such as hydraulic, pneumatic, potential energy, spring loads and draft in the duct system must be considered. Separation, switching, grounding and interlocking gear must be installed by the user. Safety devices against unwanted switching must be clearly visible. The user must comply with EN 1037 Safety of machines - Avoidance of unwanted start-up".
8. 8.1
SPECIAL INSTRUCTIONS Operation at higher temperatures (> 70C) / Smoke proof design
For fans designed for operation at higher temperatures, precautions against the touching of hot surfaces (e. g. safety guards, warning signs) must be taken. In the case of cold starts, the power consumption could possibly exceed the design value and the current consumption could increase to inadmissibly high values. This is especially the case when centrifugal fans are not started against closed dampers. Careful observation of the start-up is required. The user has to secure that the cable that he inserts into the terminal is free movement during operation. Usually fans are installed with antivibration mounts, here the cables have to be fixed near the terminal box to the fan casing. According to the temperature requirements the wires inside the terminal box have to be isolated with additional glas fibre tubes.
14

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
Before the fan is switched off, it shall be operated for some time at low gas temperatures (<100C), until impeller, shaft and housing have cooled off. This is to prevent heat from the fan impairing the bearings or grease at standstill. Also, the shaft shall be turned until it has cooled off, to prevent warping of the warm shaft. When using cooling discs for higher temperatures, it should be noted, that adequate cooling is only achieved when the speed of rotation is sufficient. At high impeller temperatures and low speeds (e. g. when running on a frequency converter) or when stopped (e. g. due to emergency stoppage or power failure) the user must ensure that the cooling disc is externally cooled, e. g. with a separate fan with a special power supply. Additional measures according to local or legal regulations, standards, directions or instructions must be observed. In case of imbalance and abnormal vibrations as well as after dismounting and remounting of the impeller, the fan must be inspected.
8.2
Gastight fans
(refer also section 5.5)
Gastight fans must be regularly checked for any leakage. If the permissible limit values are exceeded and the health of humans is endangered, the system must be shut down and safety measures for standstill must be carried out. A general room ventilation should be provided so an unobserved leakage will not lead to poisonous or explosive gas concentrations. In case of mounting and maintenance work, the shaft seals must not be damaged. They are not to be dragged over sharp edges. The sealing rings must be centred exactly on the shaft. The sum of shaft eccentricity and offset must not exceed 0.3 mm. The transport instructions must be carefully observed. Scratches, pressure marks, rust or other damage to the shaft surface at the sealing ring position cause leaks. The sealing lips must never be dry. After remounting, a gastightness check must again be carried out. Additional measures according to local or legal standards, directions or instructions must be observed. In the case of imbalance and abnormal vibrations as well as after dismounting and remounting of the impeller, a check is necessary.
8.3
Explosion protection (refer also section 4. explosion-proof fans)
The regulations under VDMA 24 169 parts 1 and 2 as well as DIN EN 1127 are to be complied with. They should constitute the basis for the operation of all equipment in systems which have explosion risk. Systems that have been designed to operate within a explosion risk zone must be equipped with safety netting on all inlet and outlet openings with a maximum mesh of 12 x 12 mm to keep unwanted particles out. To avoid unwanted objects dropping into the system some type of cover must be provided by the user. Openings must be located in accessible and easily controllable areas. All conductive parts must be earthed. To reduce the explosion risk when aluminium is present the possibility of rust and/or airborne rust must be excluded. Also, no iron oxide or metal based paints may be used. All additional local or regulatory standards, laws and regulations must be investigated and adhered to. The prescribed distance between the rotating and fixed parts has been adhered to while manufacturing the fan. Before starting the fan e. g. after installation or maintenance, ensure that the distance has not been altered e. g. due to wear on the bearing, transport damage, incorrect installation etc. If imbalance and/or abnormal vibrations occur the fan must be stopped immediately and the fault repaired. After maintenance work, such as dismounting and remounting of the impeller, the fan and the distances between rotating and static parts must be checked before restarting.
8.4
Frequency converter
The frequency converter must be set so that unnecessary loads on the fan due to high acceleration or deceleration are avoided. In general the start-up time for an impeller with the diameter of 1000 mm should be at least 30 seconds, between 1000 and 2000 mm at least 60 seconds and for larger diameters 120 seconds. To avoid frequently repeated accelerations and decelerations which can lead to material fatigue, the process control should be made as slow as feasible. The accelerations coming from the process control should not be larger than 0,45 rad/s, except when passing through resonance frequencies. Material fatigue in the impeller and other parts of the fan is reported to have occurred in the past due to frequent speed changes. In order to avoid the impeller should be replaced after, at the most, 0,5 million speed changes (equal to 2 years at 4000 operating hours/year and one speed change per minute). If resonance frequencies are passed through while doing the speed changes an even lower life expectancy may result.
Warning: After disconnecting the power supply to the frequency converter at least 10 minutes must pass before the leads or other components of the converter can be touched. There is serious risk of injury from stored energy in the capacitors. Also control boards can be at the voltage of the power supply. Before touching any components they should be grounded.
Before mounting and starting operation the special instructions from the manufacturer of the frequency converter must be noted and adhered to. Some general comments on the use of frequency converters: To minimise magnetic fields the motor and converter should be placed as closely together as possible. The leads must have a mechanical protection and not be longer than specified by the manufacturer. Cable, cable shields, the frequency converter and the motor must be grounded. To avoid radio interference additional filters may be necessary.
8.5
Thermal safety
Fans of components that can become less than -10C cold or more than 70C warm must be protected on site, be provided with insulation and have warming signs (EN 563). It should be noted that bearings can become very hot, but should not be insulated, since heat accumulation could damage the bearings.
9.
DOWN-TIME LIMITATION
Proper mode of operation, checks, regular maintenance and the availability of wear and spare parts are necessary for avoiding fan down-time. Wear parts are among others: Roller bearings - V/flat belts and pulleys - elastic sleeves - vibration attenuators - sealings - sealing rings - couplings - impeller in the case of abrasive operation. In order to monitor the fan status a written record is recommended which must be signed and dated by the inspector (see also section 20.)
15

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
AXIAL FAN
Part Description 1 Casing
Part Description 6 Impeller hub
2 3 4 5
Service access
OPT
7 8 9
Taperlock bush
Part Description Part Description 11 Terminal box 15 Motor fixation bolt IP54 (IP55) with cover and sealing w.u. 12 Cable gland 16 Key
Part Description 20 Puller plate
w.u.
Bolt for service access OPT Anti spark lining OPT Impeller
Bolt for taperlock 12.1 Cable duct bush w.u. Bolt for impeller hub 13 Ground wire 14 Motor
17 Cable OPT 18 Name plate + direction arrow 19 Mounting brackets OPT
21 Bolt for puller plate w. u. 22 Bolt for puller plate w.u. 23 Plastic cap w.u. 24 Distance ring w.u.
10 Guide vane w.u. = when used
OPT = Optional
16

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
CENTRIFUGAL FAN
Design 1 (direct drive)
2 3 4 5
Motor pedestal Inlet cone Base frame Impeller compl.
OPT = Optional
Part Description 11 Flex. connection inlet OPT 7 Taperlock bush w.u. 12 Counter flange inlet for flex. connection OPT 8 Motor 13 Hexag. bolt for motor foot 9 Flex. connection 14 Hexag. nut + washer outlet OPT for motor foot 10 Counter flange 15 Hexag. bolt + washer outlet for for impeller hub flex. connection OPT w.u. = when used
Part Description 6 Impeller hub
Part Description 16 Hexag. bolt + washer
17 Name plate Fan Systems 18 Screw for Taperlock bush w.u. 19 Hexag. nut + washer OPT 20 Hexag. bolt + washer OPT
Part Description 21 Hexag. nut + washer OPT 22 Cooling disc with guard OPT 23 Shaft lining w.u.
24 Resilient mount OPT 25 Hexag. nut or bolt (depends on resilient OPT mount)
17

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
CENTRIFUGAL FAN
Design 2 (drive through V-belt)
Part Description 1 Casing 2 3 4 5 6 7 Bearing pedestal Inlet cone Base frame Impeller comp. Impeller hub Taperlock bush w.u.
Part Description 8 Motor 9 10 11 12 13 14 Flex. connection outlet OPT Counter flange outlet for flex. connection OPT Flex. connection inlet OPT Counter flange inlet for flex. connection OPT Stretching rail Hexag. nut + washer for motor foot
Part Description 15 Hexag. bolt + washer for impeller hub 16 Hexag. bolt + washer 17 18 19 20 21 Name plate Fan Systems Screw for Taperlock bush w.u. Hexag. nut + washer OPT Hexag. bolt + washer OPT Hexag. nut + washer OPT
Part Description 22 Cooling disc with guard 23 Shaft lining 24 25 26 27 Bearing
OPT w.u.
Part Description 27.2 Puller disc bearing side 27.3 V-belt 27.4 V-belt protection 28 29 30 31 Hexag. bolt + washer for motor rail Hexag. nut + washer for motor rail Vibration attenuator OPT Hexag. nut or bolt (depends on vibration attenuator) OPT
Hexag. bolt for bearing foot Hexag. nut + washer for bearing foot V-belt drive
27.1 Puller disc motor side
OPT = Optional
w.u. = when used
18

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
CENTRIFUGAL FAN
Design 5 (drive through coupling)
2 3 4 5
Motor/bearing pedestal Inlet cone Base frame Impeller compl.
Part Description Part Description 7 Taperlock bush w.u. 13 Hexag. bolt for motor foot 8 Motor 14 Hexag. nut + washer for motor foot 9 Flex. connection 15 Hexag. bolt + washer outlet OPT for impeller hub 10 Counter flange outlet 16 Hexag. bolt + washer for flex. connection OPT 11 Flex. connection 17 Name plate inlet OPT (Fan Systems)
Part Description Part Description 19 Hexag. nut + washer 25 Hexag. bolt for OPT bearing foot 20 Hexag. bolt + washer 26 Hexag. nut + washer OPT for bearing foot 21 Hexag. nut + washer 27 Coupling with OPT protection 22 Cooling disc 28 Vibration attenuator with guard OPT OPT
23 Shaft lining
w.u.
29 Hexag. nut or bolt (depends on vibration attenuator) OPT
Impeller hub
OPT = Optional
12 Counter flange inlet for flex. connection OPT w.u. = when used
18 Screw for Taperlock bush w.u.
24 Bearing
19

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
10.
DESCRIPTION
TUNNEL-FANS
A jet fan consists of the following parts:
1 Mounting structure 2 Anti-swing device (optional / for silencer length > 1500mm) 3 Saftety wire / safety chain (depending on the fan size 2, 4, 6 or 8 units) 4 Mounting bracket for safety wire / safty chain 5 Tear-off monitor (electrical switch) 6 Jet fan housing 7 Guide vane 8 Impeller 9 Pre-guide vane (if required) 10 Motor 11 Bellmouth or silencer (inlet side or both sides) 12 Protection grille (inlet side or both sides) 13 Terminal box 14 Auxillary terminal box (if required) (Optional parts: 1/2/3/4/5/9/11/13/14)
MOUNTING 1. 2. 3. 4. 5. Type, number and size of anchor bolts depends on the roof construction. If the bolts are not shown in our drawings, please ask the civil engineer. The holes on the tunnel roof are to be marked using a template and drilled according to the maker's instructions (expansion / cleaning etc.). Fasten anchor bolts, load test according to the makers specification (by load device / torque or similar) Lift the mounting structure to the ceiling / adjust all loose bolt connections and tighten them (torques see enclosed table). Mount the complete jet fans to the tunnel roof and check that the fans are horizontal if required re-adjust the bolt connections at the mounting structure. Mount the anti-swing device (if part of the design.) Install the tearoff control, adjust the elctrical switch Mount the safety wires / chains at the tunnel roof with the appropriate mounting brackets , thibles and rope grips (for details see sketch to the right). A slack of around 10 mm must be maintained. Establish the electrical connections. Inspect the surface protection. If necessary repair with the paint supplied with the fan.
6. 7. 8.
9. 10.
Bolts size M6 M8 M10 M12 M16 M20 M24
Steel galvanised stiffness 8.8 10 Nm 25 Nm 49 Nm 85 Nm 210 Nm 425 Nm 710 Nm
Torque Stainless steel A4 (ISO) stiffness 70 7,5 Nm 18 Nm 36 Nm 62 Nm 150 Nm 303 Nm -
Stinless steel 1.4571/ 1.4529 stiffness 50 3,8 Nm 9 Nm 18 Nm 31 Nm 75 Nm 150 Nm 250 Nm
20

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
COMMON MOUNTING MISTAKES
NAMEPLATES
All jet fans are equipped with a nameplate near the terminal box, which shows the machine number (important for future spare part inquiries) and the technical data. Also shown are the rated power of the electrical motor and the rated current. With these two values the electrician at site is able to connect the jet fan to the switchboard with the correct electrical protection.
All jet fans have a main airflow direction. This is the lowest power consumption and sound pressure operation mode compared to the reverse mode. To aid the correct mounting inside a tunnel this main airflow direction is marked with an arrow.
OPERATION: START, STOP / REVERSAL START Jet fans have, depending of their type, size, the background velocity and the volatage drop during start-up an run-up time shorter than 10 seconds. After this period the jet fan must have reached its rated rotational speed if this is not the case, it has to be switched off and the reason for the longer run-up time has to be investiged. STOP / REVERSAL Here we have to distinguish between the normal operation and operation in an emergency situation: At normal operation the period in between stop and restarting into the oposite direction (only allowed for reversible jet fans!) should be minium 2 minutes. Only in a emergency situation can it be restarted in the reverse direction already after 20 seconds
SAFTETY IN OPERATION (In addition to the already mentioned General Instrustions the following directives are valid) NECESSARY SAFETY CHECKS (At least every 6 months, in the beginning more often)
As the fans operate close to persons and are liable to damages and collisions, the fan must be inspected for external damage at least every 6 months . All damaged parts must be exchanged immediately. The vibration level acc. to VDI 2056 / ISO 2372 in horizontal radial, horizontal axial and vertical radial direction must be checked at measuring points which are marked during the first measurement. By comparing the measured values over a longer time period, changes become apparent. If the values eare subject to major changes, the causes must be investigated, e.g. dirt on the impeller. Perhaps a rebalancing is necessary. Increased vibration values can lead to destruction of the fan, represents an acute risk and lead to the loss of the maker's warranty. For example, vibrations can lead to the loosening of suspension bolts in the tunnel roof. If there is an increased risk of the fan getting dirty, inspection and cleaning must be done more often than described below.
RECOMMENDED SAFETY CHECKS VISUAL INSPECTION (At least every 6 months, in the beginning more often)
Conduct thorough inspection for damage and corrosion of silencers, impeller, inlet cone, motor, cable, connections, mounting frame and vibration attenuators. Damages, especially damage to the surface protection, must be repaired before they became worse. NOISE CONTROL (At least every 6 months, in the beginning more often) The proper operation can be ascertained by checking the noise and temperature levels generated. For this purpose the noise at start and stop can be compared with that of similar fans. INSPECTION OF MOUNTING (every 6 months, in the beginning more often) Carry out careful inspection of all supporting parts and screw connections. All nuts must be secured against loosening and fixed with the correct torque. Damaged surface protection at the screw connections should be remedied.
21

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
11.
DISMANTLING AND REFITTING OF IMPELLERS HAVING AN EXTRACTION DEVICE
Accessibility: At first the impeller must be made accessible. In the case of radial fans this includes:
1. 2. 3. 4.
Take off duct system at inlet side of the fan. Remove screws at the inlet cone of the casing (includes inlet spigot, protection grill, inlet cone and/or inlet duct). Carefully take off inlet cone Attention: Do not damage the sealing. ATTENTION: Measure the distance between impeller back disc and inlet cone and maintain it when refitting. Differences in the distance lead to capacity reduction!
For axial fans the fan in general must be dismounted and placed on a level surface with the impeller pointing upwards. Exceptions are swing out type axial fans where the impeller is accessible after opening the door and fans inside jet cowls.
DESCRIPTION OF FUNCTION
For impellers fitted directly on the shaft, the screw (7) is screwed into the fan shaft (6), so that the disc (3) presses against the shaft end. The impeller hub (5) is connected to the disc (3) by means of 2 screws (2).
DISMANTLING OF IMPELLER
No
Part Indication
Quantity
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
washer dismounting screw shaft journal impeller hub forcing screw extraction disc fixing screw, extraction disc set bolt
1 1 1 1 1 1 2 1
a) b) c) d) e) f) g) A B C D
In case of corrosion a rust dissolving oil must be employed. The use of hammers, crowbars, or other violent methods is not allowed. Remove the three screws (7) and (2) and lift off disc (3). Put on screw (4) or small plate into fan shaft bore. Fit disc (3) again with the screws (2). Put screw (1) into the thread of the disc (3), as can be seen from above diagrams. Turn to the right until the impeller comes loose. Then lift out the impeller. Remove screw (4) or plate. Fit the disc (3) by means of the two bolts (2) to the impeller hub (5). Clean and grease shaft and impeller bore. Lift impeller onto the fan shaft and press slightly. Put screw (7) with washer into the bore of the disc (3) and screw it as deeply as possible into the motor shaft.
FITTING OF IMPELLER
Tightening torque for draw-up screw (7) and fixing screw(2)

Screw Starting torque [Nm] 10 25 49 86 210 410 710
M6 M8 M10 M12 M16 M20 M24
Fan assembly
Carry out points 1 - 3 in reverse order. Check distances measured under 4. Turn the impeller by hand and check that it is turning freely.
22

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
12.
1. 2. 3. 4.
DISMANTLING and REFITTING of IMPELLERS and PULLEYS HAVING TAPERLOCK BUSHES
Accessibility: At first the impeller must be made accessible. In the case of radial fans this includes:
Take off duct system at inlet side of the fan. Remove screws at the inlet cone of the casing (includes inlet spigot, protection grill, inlet cone and/or inlet duct). Carefully take off inlet cone Attention: Do not damage the sealing. Attention: Measure the distance between impeller back disc and inlet cone and maintain it when refitting. Differences in the distance lead to capacity reduction!
For axial fans the fan in general must be dismounted and placed on a level surface with the impeller pointing upwards. Exceptions are swing out type axial fans where the impeller is accessible after opening the door and fans inside jet cowls.
Description of function: The hub has a conical inner bore. A conical bush, which is cylindrical inside is inserted. When tightening the fixing screws, the bush between shaft and hub is expanded and locked in place.
DISMOUNTING OF IMPELLER
a) b) c) d) If corroded use rust dissolving oil. Do not use hammers, crowbars or other use of force. Detach all screws. Depending on size of the bush, unscrew one or two screws, oil them and screw them into the set bores. Tighten screw(s) uniformly, until the bush comes out of the hub, so that the bush can move freely on the shaft. Remove impeller with the bush from the shaft.
REMOUNTING OF THE IMPELLER

1. Clean and degrease all uncovered surfaces, such as the bore and the conical surface of the taperlock bush as well as the conical bore of the hub. Insert the taperlock bush into the hub and superimpose all connection bores (half-thread bores must always have half-plain bores on the opposite side). Slightly oil and screw in threaded stud (Gr. 1008 - 3030) and/or cylindrical screws (Gr. 3535 - 5050). Don t fix screws tightly. Clean and grease shaft. Push disc with taperlock bush onto the shaft until desired place is found. When using a slot key, place it first into the slot. Between slot key and bore slot there must be a small gap. Tighten thread studs and/or cylinder screws uniformly by using a screw driver, DIN 911, with the torques indicated in the table. After a short time of operation (1/2 or 1 hour) check torque of the screws and correct if necessary.
2. 3. 4. 5. 6.
fixing bore pull-off bore small hub

Bush Torque
large hub
Screws Bush TorqueScrews Bush Torque Screws
[Nm] 1008 1108 1310 1315 1210 1215 1610 1615
Nb. Size 1/4" BSW 3/8" BSW 3/8" BSW 3/8" BSW 3020 3030 3535 2517 2012
[Nm] 31 48
Nb. Size 2 2 7/16" BSW 1/2" BSW 5/8" BSW 1/2" BSW 4545 5050 4040
[Nm] 170 192 271
Nb. Size 3 3 3 5/8" BSW 3/4" BSW 7/8" BSW
5,6 20 20 20
2 2 2 2
90 112
2 3
Fan assembly
Carry out points 1 - 3 in reverse order. Check distances measured under 4. Turn the impeller by hand and check that it is turning freely.
23

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
13.
INSTALLATION AND FITTING INSTRUCTIONS FOR FLEXIBLE CONNECTIONS
Flexible connections in ventilation plants are used to assure the flexibility between the duct (stationary) and the fan (on resilient mount). The possibilities and the limits of the elastic materials must be respected. Normally the length of fabrication is 150 mm.
Measurements, Tolerances Design A Design B
Fitting
At the site (fitting instructions), ensure that the connection is not twisted and that the screw holes at the flanges of fan and duct are in line. The screw ends of the fixing must point away from the connection, so that the fabric is not damaged by the screws. Screws with flat round heads, e.g. cylinder screws with a slit (DIN EN ISO 1207) or flat head screws with a cross slit (DIN EN ISO 7045) are recommended. Threaded stay bolts should be protected with cap nuts acc. to DIN 1587, or similar. The flexible connections must be protected against damage, from welding, stepping-on, sharp objects, chemicals, paint etc. A cover or insulation should only be installed if agreed upon (heat accumulation). Surface treatment is not permissible.
Transport, Storage
Flexible connections design A should only be transported and stored in a stretched condition. For design B connections and backing flanges will be supplied separately. In case of longer storing times when not installed, the connections must be stored safely.
Pay attention to correct air direction! Air must blow into the cone, otherwise additional flow loss will arise.
24

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
14. OPERATING INSTRUCTIONS - User Information VANE CONTROL WITH MANUAL AND REMOTE CONTROL
SPECIAL SAFETY ASPECTS FOR RADIAL VANE CONTROLS We have carefully built a solid and reliable component, which corresponds to the state of the art.
Material damages and personal injuries can result from insufficient maintenance. Increased vibrations may lead to breakage and subsequent damages. Caution is necessary near moving parts. This applies to the guide vane blades and the driving and/or actuating mechanisms. When fixing the vanes in position the locking mechanism must be checked so that unwanted movement is avoided.
TRANSPORT During transport by cranes the supporting devices must only be attached to the lifting eyes provided for this purpose.
When using a fork lift no movable parts may be touched nor damaged. Positioning on the floor should be done with the slowest lowering speed. Shocks, shakes and dropping might lead to deformations.
INSTALLATION Ensure that the casing is not mechanically deformed or twisted in order to prevent jamming of the vane blades or damage to other parts. Guide vane controls may only be fitted so that they conform to the airflow direction for which they were ordered and designed. Please check that the guide vane control gives the air flow a rotational component in the same rotating direction as the rotation of the impeller. All moving parts must be protected against corrosion, dirt and icing.
The centrifugal vane control must be installed in the inlet of the fan. If a duct or flexible connection is not connected to the inlet, an inlet screen or protection grill must be installed. When using a flexible connection the fan and the pedestal should be placed on vibration attenuators. Ducts in front of the inlet should not have bends at a length of at least 2.5 times the inlet diameter in order to avoid uneven flow and turbulence. Obstructions to the airflow in front of or behind the vane control should be avoided. If this is not possible, the manufacturer must be notified in writing when ordering.
START-UP Before starting the fan, fan casing and ducts must be inspected for foreign particles. The turning direction is indicated on the fan casing by an arrow. The correct turning direction can be checked by shortly switching on the fan and observing the direction of rotation. The absorbed current must be measured and compared with the nominal value of the motor.
During the starting phase the angle of the vane blades should be changed slowly in order to find the natural resonance frequencies of the guide vane control. Vane angles where the vibration speed exceeds 7 mm/s must be passed through quickly during operation, if they can not
& be blocked. Longterm throttling, 10 min, should be avoided with blade angles of more than 75 ( V min 0,25
& V nominal).
FUNCTION The guide vane control is designed for the flow indicated on the data sheet of the fan +max.20 %. By means of the guide vane control, operating points below the characteristic curve of the fan can be reached. The control range is dependent on the characteristic curve of the fan, the operating point of the system and the fan.
The power consumption for each working point changes with the setting angle of the guide vane. It is always smaller than the power consumption of the characteristic curve of the fan. The guide vane can be operated manually or through remote control drives. By means of a guide vane control up to 35% of energy loss can be saved. The guide vane control changes the characteristic curve of the fan, while a throttling control creates additional resistances and thus changes the resistance curve of the system.
Attention: Vane control always causes considerable turbulence - except with fully open vanes. When the turbulence hits the impeller, this may cause very high vibrations. In order to limit these, especially when the motor power is high, the control range should be fine as possible adjusted. MAINTENANCE The smooth movement of the various parts of the guide vane control and the device for locking the manual lever must be checked. This should be done at least every six months. The bearing has self-lubricating sleeves so that no additional lubrication is required. During painting care must be taken that the paint does not impair the mobility of the blades and the control devices. For all other bearings the indicated lubrication intervals must be observed. Note that every bearing only has a limited life expectancy.
Ensure the smooth movement of ball leads and tie rods and check for damage or deformations. Defective blade bearings, tie rods or roller bearings of the control ring may lead to increased vibrations and thus to fatigue. Mechanical, electrical or pneumatic control drives must also be checked.
25

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
15.
15.1 SAFETY ASPECTS
FIRE DAMPERS
We have carefully manufactured a solid and reliable product according to the state of the art. Product damage and personal harm can result from insufficient maintenance. Excessive vibration may cause fractures leading to serious damage. Caution is necessary near moving parts. This applies to the damper blades and the driving and/or actuating mechanisms. A malfunction of the damper blade lock might cause the blade to move unexpectedly due to its own weight, wind or air flow.
15.2
TRANSPORT
During transport only the specially provided lifting eyes are to be used as attachment points. When using forklift trucks the forks must not be allowed to damage the product. The lowering of the product should be carried out at the minimum lowering speed. Impact shocks, jerking and dropping can lead to deformations.
15.3
MOUNTING
Ensure that the casing is not mechanically deformed or distorted in order to prevent a jamming of the damper blade or damage to other components. Fire dampers can only be used in the installation position for which they were ordered and designed (horizontal or vertical). All movable parts and all control and operating levers must be protected from corrosion, dirt and icing.
15.4
INITIAL OPERATION
In case of fire the damper is closed mechanically either manually by a spring mounted fusible link, by disconnecting the pressurized air supply or the power supply. The purpose is to avoid the spreading of smoke and/or fire along the ducts. Normally the triggering temperature is set to 70C. Before the initial operation the casing is to be checked for foreign particles. The rotational direction is shown on the casing. The correct direction can be verified through observation of the rotating parts.
15.5
MAINTENANCE - General
Fire dampers fulfil an essential function and must therefore be inspected and serviced regularly. The bearings are made of a stainless steel shaft (DIN 1.4571), with a loose fit inside a bushing of the same material. Lubrication is not required. However, every 6 months an operational check should be done, during which the release mechanism should be tested a number of times so that a quick and faultless closing can be verified. The bearings must be inspected and cleaned if dirt or salt deposits from sea water spray are observed, e. g. using pressurised air or clean water. When painting, care must be taken to avoid paint restricting the free movement of the damper blade(s) and actuator(s). After a fire the functional capability of all parts must be inspected. Ensure that deformations due to heat have not impaired the tightness or the free movement of the damper. The release mechanism needs special attention during the inspection to ensure its operability.
15.6
MAINTENANCE - Special instructions
15.6.1 Manually operated fire damper

Check the ease of movement of the damper blade and the pin used to lock the manual lever. The manual operation can be a stand alone feature or an addition to an automatic release mechanism. In the second case the manual lever has a special shape allowing the manual closing of the damper irrespective of the automatic release mechanism.
15.6.2 Fire damper with fusible link / thermo switch

In the event of a fire, when the temperature rises above approx. 70 degrees C, the soft solder melts and the fire damper releases automatically. The plunger pin of the catch on the adjusting element is freed, the damper blade falls in the closing direction and is locked into the "CLOSED" position by the locking pin. A check is carried out by pushing the red button which simulates a thermal release. To check the soft solder melting piece, the inspection flap must be removed and the soft solder melting piece taken out of the release device. Ensure that no outer damage is visible, then reload the spring and replace the soft solder melting piece. If the fire damper is to be put into service again after a release, a new soft solder melting piece must first be installed into the air shaft. Subsequently one must pull the locking pin out and move the hand lever to the "OPEN" position. To lock it into this position the plunger pin is again pushed into the catch.
15.6.3 Fire dampers with pneumatic cylinder

The fire damper is closed in the pressureless condition by a spring which is built into the compressed air cylinder. The closing procedure can be triggered by one of the following actions: 1. The temperature in the air shaft reaches the pre-set temperature and the temperature valve is actuated. 2. Actuation of the hand valve on the fire damper. 3. Interruption of the power supply to the solenoid valve i. e.: through the electrical temperature switch on the fire damper, halon release, emergency stop switch or failure in the electrical supply. 4. Actuation of the main valve on the control system. 5. Leak in the compressed air supply. The damper is closed by a spring built into the pneumatic cylinder. The system pressure should be checked. It should be between 2 and 10 bar. The pneumatic cylinder rod must be cleaned regularly and be lubricated with a thin film of acid free lubrication oil. The seals in the pneumatic cylinder are self lubricating. The filter in the pneumatic air system should be checked and if necessary renewed. The filter housing should be cleaned and the accumulated water drained.
15.6.4 Fire damper with electric motor

Check whether the spring built into the electric positioning motor closes if the power supply is interrupted. This can occur if: 1. The temperature in the duct reaches the pre-set temperature 2. The power supply is switched off 3. There is a fault in the power supply
26

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
16. STORAGE INSTRUCTIONS for SPARE PARTS

All parts should be stored in a room at 15 - 25C with a relative humidity of maximum 70 %. Variation in the temperature should be limited to maximum 1C per hour. Roller bearings are delivered in the original packing. The maximum storage time is two years. After one year the bearings have to be exchanged. A renewed conservation would be too expensive. Rubber or rubber coated spare parts such as radial packing rings, O-ring seals, flexible connectors, dampers and V-belts have to be protected against light and have to sealed in plastic wrapping. The parts should be checked as to their elasticity and brittleness every year. The maximum storage is five years or less according to the manufacturers instructions. Parts made of metal such as impellers, shafts, bushes, pulleys and bearing housings have to be checked every year. Surface protecting coats have to be preserved, if necessary. Bright finished metal treated parts have to be greased.
17. C A B I N V E N T S
SPECIAL SAFETY ASPECTS FOR CABIN FANS
We have carefully manufactured a solid and reliable component for you which corresponds to the technical state of the art. Property damage and injuries could result from insufficient maintenance.
INSTALLATION and INITIAL OPERATION

Installation has to be done on a level surface. Take care that the fans are not mechanically stressed or deformed during direct mounting of fans on ducts or walls.
MAINTENANCE
The frequency of maintenance depends on the operating mode, the environmental conditions and the required reliability. Check that the vent operates smoothly. This has to be done at least every 6 months. All movable parts have to be protected from corrosion and icing. The spindle and the bearings have to be kept well greased with "Molycote". Check sealing rubber for brittleness. During paint work ensure that the easy rotation of the cowl is not impaired.
18. BOOSTER BLOWERS FOR COMBUSTIBLE GASES

Please note the special instructions by the Swiss Association for Gases and Water Treatment (SVGW): "Guide lines for the construction, maintenance and operation of gas compression systems with an operating pressure up to 1 bar - G6". All blowers are tested before despatch as to their operation and gas tightness (24 h, 250 mbar). In spite of this, before commissioning, the following controls are necessary (transport and storage damage): 1. 2. 3. 4. 5. 6. 7. Before connecting the ducts, it must be checked that no foreign objects are in the fan casing/ducts. Tightness control: Protect the casing against excess test pressure. Attention!! Maximum test pressure: 250 mbar. Higher pressures can lead to damage to the fan or seals. Check the air gap on the impeller inlet: min. 2 mm. Turn the impeller by hand and listen for abnormal noises. Grinding noise can come from the airgap, the seals or the bearings. Check the bolts. Check protection equipment. Direction of rotation: The first start of the motor should be brief to allow for checking the direction of rotation. For direct drive fans the direction can be checked on the cooling blower of the motor. Compare the direction with the directional arrow on the casing. If the direction is incorrect, review the wiring of the motor.
If the fan is used after prolonged storage, the seals and bearings must be carefully checked. Necessary repairs can only be done by the manufacturer or his representative. During operation the tightness must be checked with appropriate methods.
Maintenance/revisions: To ensure the safe operation of the blower, it must be checked and maintained. After 20.000 operating hours, but no later than every 36 months. If the ambient temperature exceeds 30C for prolonged periods or the bearing temperature exceeds 70C, the time intervals must be reduced. The ambient temperature must not exceed 40C. Maintenance may only be carried out by the supplier or his representative. A label (red) must be attached to the blower showing the date (month/year) of the last revision.
27

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
19. FAN COWLS NON WATERTIGHT

These cowls have no moveable parts and need no special maintenance. The normally installed protection guard should be checked regularly and replaced if necessary.
19.1 WATERTIGHT FAN COWLS

Protection guards should be inspected regularly and replaced if necessary. Watertight fan cowls have moveable parts whose proper function can become impaired due to dirt, salt deposits and/or corrosion. This should be checked regularly by operating the parts. There are two basic types of spindles: In the simple design the spindle is turned by turning the cowl head. The cowl head closes the cowl by pressing against a rubber ring on the casing. The other design has a spindle that is rotated by a handle acting on an angle gear. The angle gear is lubricated for life. The handle runs in a nylon bushing that does not require lubrication. The spindle is greased by the manufacturer using "Molycote". If at all, it needs greasing only after prolonged service. The spindle is accessible after dismounting the protective guard. The locking mechanism may only be used when in vertical position and the cowl can be turned freely. Check that the closing works smoothly. This has to be done at least every 6 months. All movable parts have to be protected from corrosion and icing. The spindle and the bearings have to be kept operational by greasing with "Molycote". Check the rubber ring for brittleness. During paint work ensure that the smooth operation of the cowl is not impaired.
19.2 FAN COWLS WITH FAN SPECIAL SAFETY ASPECTS FOR COWLS
We have carefully manufactured a solid and reliable component for you which corresponds to the technical state of the art. Property damages and injuries could result from insufficient maintenance. Damaged bearings and increased vibrations could lead to failures and serious damage.
TRANSPORT
To hoist the fan in a crane, attach hooks only to the lifting eyes provided for this purpose. Lowering is to be done at the lowest possible speed. Shocks and vibrations might lead to imbalance and deformations. When using fork-lifts, the fork is only to be applied very carefully.
INSTALLATION
Installation has to be done on a level basis. Care has to be taken that the casings are not mechanically stressed or deformed. Follow the wiring diagram in the cable box when connecting electric motors. All motors are to be protected by proper relays. Furthermore, pay attention to section 6 (electric motors) and if necessary 8.3 (Explosion protection).
INITIAL OPERATION
Before initial operation, casings and ducts are to be checked for the absence of foreign matter. The direction of rotation is indicated by an arrow on the fan casing. Check that it is correct by briefly engaging the starter and observing the rotation. If this is incorrect, two electric conductors are to be changed. The motor current is measured and to be compared with the nominal current. If the cowls with fan and motor are built for an operation with potentially hazardous gases, no rust nor rust-film may be present together with the aluminium impellers and paint must be free of iron oxide and light alloy in order to avoid risk of ignition. Additional measures prescribed by local or legal rules, guide-lines or regulations must be observed. The required gaps between rotating and fixed parts have been observed during construction of the fans. In the case of unbalanced or abnormal vibrations, and after dismantling and reassembly of the fan, a careful check is required.
MAINTENANCE PROCEDURES FOR STORAGE, INSTALLATION and STANDSTILL INTERVALS

Care must be taken that the fan and motor are protected against humidity and dust. Large temperature changes should be avoided. Damage to electric motors, cable boxes, bearings, painted surfaces and seals might otherwise result. Prolonged standstill may reduce the lubrication properties of grease or oil. In addition corrosion might occur in bearings. In order to avoid these potential problems, the fan should be operated for about 10 minutes every month. If this is not possible at least the impeller should be turned by hand.
MAINTENANCE
The frequency of the necessary maintenance depends largely on the operating conditions, the conditions at site and the required reliability. It must be determined during the design of the system taking into account our instructions.
28

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
20.
MAINTENANCE PROTOCOL
FANTYPE
AXIAL JET X X CENTR. X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
MEASURE
First Inspection inspection for transport damage inspection of completeness flex. connection not damaged vibration attenuator correctly adjusted alignment of belt disks correct alignment of coupling correct safe installation garanteed safe mounting garanteed all bolts of the mounting structure are thightened with the correct load safety wires / chains mounted with a maximum slack of about 10 mm damaged paint repaired all safety measures verified all safety measures verified tension of belt drive checked function of bearing analyser checked function of vibration monitor checked function of tear-off control checked direction of rotation checked vibration level at the bearing / motor measured horizontal / vertical / axial ................mm/s / ................mm/s / ................mm/s sound pressure level measured (3m / 45 from the inlet) ............................................................dB(A) frequency converter drive (yes / no / type) ............................................................ electrical values recorded voltage / frequency ......................V /.......................Hz current phase U / V / W ..............A / ..............A / ..............A Maintenance bearing checked / relubricated shaft sealing checked / relubricated belt tension checked flexible connection checked vibration attenuators checked Starting-up coupling checked Coupling checked (alignment / rubber elements) Radial vane - mobilty of blades checked vibration level at the bearing / motor measured horizontal / vertical / axial ................mm/s / ................mm/s / ................mm/s sound pressure level measured (3m / 45 from the inlet) ............................................................dB(A) electrical values recorded voltage / frequency ......................V /.......................Hz current phase U / V / W ..............A / ..............A / ..............A visual check for corrosion visual check for other damages check of all bolt connections at mounting structure insulation check at the warm motor (resistance in between winding and earth at 500V DC) ..................................dB(A)
AUDITOR
DATE
X X X X
Inspection after installation
Inspection at taking into operation
X X
X X
X X
X X X
X X X
X X X X
X X X
X X
X X X
X X X X X
X X X
29

Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
21.
FUNDAMENTAL SAFETY INSTRUCTIONS for products and components of Fan Systems
21.1
Principle; designated use
21.3
The machine/installation has been built acc. to the technical state of the art and the recognized technical regulations. Nevertheless, its use may constitute a risk to life and limb of the user or third parties or cause damage to the machine and other material property. Use machine only in technically faultless conditions as well as according to its designation, adhere to safety regulations and pay attention to dangers, strictly observing the working instructions! Attend to defects impairing safety immediately. Pay careful attention to the operating instructions as well as the instructions concerning inspection and maintenance.
Selection and qualification of staff: Basic responsibilities
Any work on and with the machine/installation must be executed by reliable persons only. Statutory minimum age limits must be observed. Only employ trained or instructed staff and set out clearly the responsibilities of the personnel for set-up, operation, maintenance and repair! Make sure that only authorized personnel work on or with the machine! Work on the electrical system and equipment of the machine must be carried out only by a skilled electrician or by instructed persons under the supervision and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations! Work on hydraulic systems must be carried out only by personnel with special knowledge and experience of hydraulc equipment!
21.2
Organizational Measures
In addition to working instructions, note general legal and other binding directions concerning prevention of accidents and environmental protectionl! Operating instructions are to be complemented by duties regarding operating particulars such as: organization of work, sequence of work, employed staff. The staff involved with a particular machine must have read the operating instructions before starting work, especially the chapter "Safety Instructions. Doing this during any work is too late. This especially applies to persons working only occasionally on a machine, e.g. during set-up up or maintenance. Check - at least from time to time - whether the staff is carrying out the work in compliance with the operating instructions and paying attention to risks and safety factors. For reasons of security, long hair must be tied back or otherwise secured, garments must be closely fitting and no jewellery - such as rings - may be worn. Injury may result from being caught up on the machinery or from rings catching on moving parts. Use protective equipment wherever required by the circumstances or by law! Observe all safety instructions and warnings attached to the machine. See to it that safety instructions and warnings attached to the machine are always complete and perfectly legible. In the event of safety-relevant modifications or changes in the behaviour of the machine during operation, stop the machine immediately and report the malfunction to the relevant authority! Never make any modifications, additions or conversions which might affect safety without the suppliers approval. This also applies to the installation and adjustment of safety devices and valves as well as to welding work on load-bearing elements. Spare parts must comply with the technical requirements specified by the manufacturer. Spare parts from original equipment manufacturers can be relied upon to do so. Never modify the software of programmable control systems! Replace hydraulic hoses within stipulated and appropriate intervals even if no safety-relevant defects have been detected! Adhere to prescribed intervals or those specified in the operating instructions for routine checks and inspections! Specially adapted tools and workshop equipment are indispensible for maintenance work.
21.4
Safety instructions governing specific operational phases
21.4.1 Standard operation

Avoid any operational mode that might be prejudicial to safety. Take the necessary precautions to ensure that the machine is used only when in a safe and reliable state! Operate machine only when all protective and safety devices, such as removable safety devices, emergency shut-off equipment, sound protections, exhaust installations are in place and fully functional! Check the machine at least once per working shift for obvious damage and defects. Report any changes (incl. changes in the machines working behaviour) to the relevant organization/person immediately. If necessary, stop the machine immediately and lock it. In the event of malfunction, stop the machine immediately and lock it. Have any defects rectified immediately. During start-up and shut-down procedures always watch the indicators in accordance with the operating instructions. Before starting-up or setting the machine in motion, make sure that nobody is at risk! Never switch off or remove suction and ventilation devices when the machine is in operation.
21.5
Special work in conjunction with utilization of the machine/installation and maintenance and repairs during operation; disposal of parts.
Observe the adjusting, maintenance and inspection activities and intervals set out in the operating instructions, including information on the replacement of parts and equipment. These activities may be executed by skilled personnel only. Brief operating personnel before beginning special operations and maintenance work, and appoint a person to supervise the activities. In any work concerning the operation, conversion or adjustment of the machine and its safety devices or any work related to maintenance, inspection and repair, always observe the start-up and shut-down procedures set out in the operating instructions and the information on maintenance work. Ensure that the maintenance area is adequately secured! If the machine is completely shut down for maintenance and repair work, it must be secured against inadvertent start-up by:
30

- locking the principle control elements and removing the ignition key and/or - attaching a warning sign to the main switch.
Tel: +44 (14 22 378 131 Fax: +44 (14 22) 371 672
21.6.2 Gas, dust, steam and smoke

Carry out welding, flame-cutting and grinding work on the machine only if this has been expressly authorized, as there may be a risk of explosion and fire. Before carrying out welding, flame-cutting and grinding operations, clean the machine and its surroundings from dust and other inflammable substances and make sure that the premises are adequately ventilated (risk of explosion). Observe any existing national regulations if work is to be carried out in narrow rooms.
To avoid the risk of accidents, individual parts and large assembled units being moved for replacement purposes, should be carefully attached to lifting tackle and secured. Use only suitable and technically faultless lifting gear and suspension systems with adequate lifting capacity. Never work or stand under suspended loads. The fastening of loads and the supervision of crane operators should be entrusted to experienced persons only. The supervisor giving the instructions must be within sight or sound of the operator. Always use specially designed or other safety ladders and working platforms for carrying out overhead assembly work. Never use machine parts as a climbing aid. Wear a safety harness when carrying out maintenance work at greater heights. Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow and ice. Before cleaning the machine with water, steam jet (high-pressure cleaning) or detergents, cover or tape up all openings which - for safety and functional reasons - must be protected against water, steam or detergent penetration. Special care must be taken with electric motors and switchgear cabinets. Ensure during cleaning of the machine that the temperature sensors of the fire-warning and fire-fighting systems do not come into contact with hot cleaning agents as this might activate the firefighting system. After cleaning, remove all covers and tapes applied for that purpose! After cleaning, examine all fuel, lubricant and hydraulic fluid lines for leaks, loose connections, chafe marks and damage. Any defects found must be rectified without delay! Always tighten any screwed connections that have been loosened during maintenance and repair. Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immediately upon completion of the maintenance and repair work. Ensure that all used materials and parts are disposed of safely and with minimum environmental impact.
21.6.3 Hydraulic and pneumatic equipment

Work on hydraulic equipment may be carried out only by persons having special knowledge and experience in hydraulic systems. Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair damage immediately. Splashed oil may cause injury and fire. Depressurize all applicable system sections and pressure pipes (hydraulic system, compressed air system) before carrying out any repair work. Hydraulic and compressed air lines must be laid and fitted properly. Ensure that no connections are interchanged. The fittings, lengths and quality of the hoses must comply with the technical requirements.
21.6.4 Noise
All sound protecting provisions of the machine must be closed during operation. Always wear the prescribed ear protectors.
21.6.5 Oil, grease and other chemical substances

When handling oil, grease and other chemical substances, observe the product-related safety regulations! Be careful when handling hot materials (risk of burning or scalding)!
21.7
Mobile machinery and equipment
(Machinery and equipment used at various sites) For loading use only lifting gear and tackle of sufficient capacity! Appoint a competent supervisor to assist in the lifting operations. Lift machinery and equipment properly with suitable lifting gear and only in accordance with the operating instructions (fixing points for lifting tackle, etc.). Only use suitable means of transport with adequate carrying capacity.! Fasten the loads safely using the suitable fixing points! Before or immediately after completion of the loading operations the machine must be secured by means of recommended/supplied devices against inadvertent shifting. A warning sign must be attached to the machine. Before restarting the machine these devices must be properly removed. Carefully refit and fasten all parts removed for transport purposes before restarting the machine. Cut off the external power supply of the machine even if only minor changes of place are planned. Properly reconnect the machine to the supply mains before restarting. Proceed in accordance with the operating instructions when restarting the machine.
21.6 Warning of special dangers 21.6.1 Electrical energy

Only use original fuses with the specified current rating. Switch off the machine immediately if trouble occurs in the electrical system. Work on the electrical system or equipment may only be carried out by a skilled electrician or by specially instructed personnel under his/her control and supervision and in accordance with the applicable electrical engineering rules. Disconnect the power supply, where applicable, to machines or parts thereof on which inspection, maintenance or repair work is to be carried out. Before starting any work, check the de-energized parts for the presence of power and ground or short-circuit them in addition to insulating adjacent live parts and elements. The electrical equipment is to be inspected and checked at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately. Necessary work on live parts and elements must be carried out only in the presence of a second person who can cut off the power supply in case of danger by actuating the emergency shut-off or main power switch. Secure the working area with a red-and-white safety chain and a warning sign. Use insulated tools only. Before starting work on high-voltage assemblies and after cutting off the power supply, the feeder cable must be grounded and components such as capacitors, short-circuited with a grounding rod.
31

Fan 31

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Fan 31

Uploaded by

Copyright:

Available Formats

OPERATING and MAINTENANCE MANUAL

Fan Systems Group Ltd

Fan Systems Group Ltd

Commonly used designs of Axial Fans

Commonly used designs of Centrifugal Fans

Direct drive Impeller access from inlet side

Short casing Flange motor Guide vanes Terminal box

Casing with bellmouth Flange motor Guide vanes Terminal box

Fan Systems Group Ltd

Fan Systems Group Ltd

INSTALLATION OF AXIAL AND CENTRIFUGAL FANS - GENERAL

Special installation instructions

Centrifugal fans, design 5 and similar designs with motor-coupling-shaft

Fan Systems Group Ltd

Single inlet centrifugal fans

Fan with split casing

Double inlet centrifugal fans

General Safety Instructions:

Fan with belt drive

Systems with dampers

Fans operating in parallel

Fan Systems Group Ltd

Maximum Speed, different speeds and speed control.

Explosion-proof fans (please also refer to section 8.3)

Fan Systems Group Ltd

Test Force f per V-belt

Diameter of the smallest pulley

Belt tension for standard V-belt types

In case of other types, e. g. larger drives, see separate documentation (Label)

Flat belt drives

5.4.1 Monitoring of bearings

Fan Systems Group Ltd

5.4.2 Additional instructions for various fan bearing types

Bearings with permanent lubrication

Cartridge bearing with re-greasing device and grease control disc

Cartridge bearing unit

Fan Systems Group Ltd

5.4.3. Grease quality and lubrication intervals

n = speed l min1 d = size of bore (refer to bearing catalogue)

Shaft seals for gases and fluids

(see also section 8.2)

Fan Systems Group Ltd

Tightness Class Ia No requirements

Standard design, gap between casing and hub about 1 to 2 mm.

Tightness Class Ib Hub lining, impeller with fuming bars. No requirements

The negative pressure reduces the leakage rate.

With one sealing ring. combined with fuming bars.

m3 Leakage rate max.: 2,4 10 3 2 s m m = inner surface of fan casing

Test pressure p= 20 mbar = 2000 Pa

Fan Systems Group Ltd

Fan Systems Group Ltd

Mechanical Starting Couplings

Fan Systems Group Ltd

Precautions against unintentional start-up

Fan Systems Group Ltd

(refer also section 5.5)

Explosion protection (refer also section 4. explosion-proof fans)

Fan Systems Group Ltd

Part Description 1 Casing

Part Description 6 Impeller hub

Part Description 20 Puller plate

17 Cable OPT 18 Name plate + direction arrow 19 Mounting brackets OPT

10 Guide vane w.u. = when used

Fan Systems Group Ltd