INSTALLATION AND OPERATION MANUAL CENTRIFUGAL FANS · 2016-01-06 · INSTALLATION AND OPERATION...

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In force from 1 st of September 2012 - version 01 INSTALLATION AND OPERATION MANUAL CENTRIFUGAL FANS

Transcript of INSTALLATION AND OPERATION MANUAL CENTRIFUGAL FANS · 2016-01-06 · INSTALLATION AND OPERATION...

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In force from 1st of September 2012 - version 01

INSTALLATION AND OPERATION MANUAL

CENTRIFUGAL FANS

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CONTENTS CONTENTS .................................................................................................................................................................... 2 LIST OF FIGURES ..................................................................................................................................................... 3 LIST OF TABLES ........................................................................................................................................................ 3 LIST OF ANNEXES .................................................................................................................................................... 4 1. INTRODUCTION ............................................................................................................................................... 5 2. MODELS AVAILABLE AND APPLICATION .......................................................................................... 5

2.1 MODELS RSH (RSA) AND RNH + RNZM AND RSZM - SINGLE SUCTION FANS WITH DIRECT DRIVE 5 2.2 MODELS RSH AND RNH SINGLE SUCTION FANS WITH BELT DRIVE AND BASE FRAME ............................ 6 2.3 MODELS RSHJ AND RSBJ SINGLE SUCTION FANS WITH BELT DRIVE AND BASE FRAME ......................... 7 2.4 MODELS RSH/2 AND RNH/2(RNP/2) DOUBLE SUCTION FANS VK OR PR ............................................ 7 2.5 IMPORTANT INFORMATION APPLICABLE TO ALL FAN MODELS ...................................................................... 8 2.6 SYMBOLS AND SAFETY LABELING................................................................................................................... 9

3. SAFETY ................................................................................................................................................................ 10 4. DELIVERY, SHIPMENT, PACKAGING, RECEIVING STORAGE ............................................... 11

4.1 SHIPMENT ...................................................................................................................................................... 11 4.2 RECEIVING .................................................................................................................................................... 12 4.3 STORAGE ....................................................................................................................................................... 12

5. ASSEMBLY ......................................................................................................................................................... 12 5.1 STARTING ASSEMBLY .................................................................................................................................... 12 5.2 ASSEMBLY PROCEDURE ................................................................................................................................ 13

5.2.1 Mounting of fan - rubber isolators ............................................................................................... 13 5.2.2 Mounting of fan - plastic anti-vibration isolators with spring ............................................ 13 5.2.3 Important notice ................................................................................................................................. 17

6. OPERATION ...................................................................................................................................................... 17 6.1 PRIOR TO THE START-UP .............................................................................................................................. 17 6.2 INITIAL TESTING START-UP ......................................................................................................................... 18 6.3 INITIAL OPERATING PERIOD ......................................................................................................................... 18

7. CHECKS ............................................................................................................................................................... 18 7.1 CHECKS DURING NORMAL OPERATION ........................................................................................................ 18 7.2 CHECKS DURING SHUT-DOWN PERIOD ....................................................................................................... 19

8. MAINTENANCE ............................................................................................................................................... 19 8.1 BEARINGS AND BEARING MODULES ............................................................................................................. 19

8.1.1 RSH (RSA) and RNH with belt drive and base frame ........................................................... 19 8.1.2 RSHJ and RSBJ with belt drive and fan frame ........................................................................ 20 8.1.3 RSH/2 a RNH/2(RNP/2) ................................................................................................................... 27

8.2 ASSEMBLY AND DISASSEMBLY OF DIRECT DRIVE FANS ............................................................................. 29 8.3 V-BELT DRIVES ............................................................................................................................................. 29

8.3.1 Disassembly and assembly of V-belts ........................................................................................ 29 8.3.2 Disassembly a re-assembly of pulleys (system Taper-Lock®) .......................................... 29 8.3.3 Measuring of V-belt tension ........................................................................................................... 30

9. INSPECTION CHECKS AND REPAIRS ................................................................................................. 34 10. DISPOSAL ..................................................................................................................................................... 34 11. WARRANTY .................................................................................................................................................. 35 12. ANNEXES ....................................................................................................................................................... 36

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13. SUPPLEMENT .............................................................................................................................................. 41

LIST OF FIGURES Fig. 1 PM fan construction with motor fixed on isolator bracket ................................ 6 Fig. 2 Belt drive fan with base frame ................................................................................... 6 Fig 3 Production nameplate ................................................................................................... 10 Fig. 4 Details of rubber isolators ........................................................................................... 13 Fig. 5 Mean diameter ................................................................................................................. 21 Fig 6 Lubrication refill intervals ............................................................................................. 21 Fig. 7 Securing of fastening nuts .......................................................................................... 23 Fig 8 Securing of safety ring ................................................................................................... 23 Fig 9 Securing of safety ring with spanner ....................................................................... 24 Fig. 10 Securing of safety ring using hammer and puncher ...................................... 24 Fig. 11 Securing of adjustment bolt .................................................................................... 24 Fig. 12 Hexagonal spanner with torque moment gauge.............................................. 24 Fig. 13 Shaft cleaning ................................................................................................................ 25 Fig. 14 Oil application ................................................................................................................ 25 Fig. 15 Cleaning of housing base .......................................................................................... 25 Fig. 16 Pulling on the bearing module ................................................................................ 26 Fig. 17 Sequence of bolts tightening ................................................................................... 26 Fig. 18 Bolts tightening ............................................................................................................. 26 Fig. 19 Use of torque moment gauge ................................................................................. 26 Fig. 20 Aligning of pulleys in one plane .............................................................................. 30 Fig. 21 Checking abrasion of pulleys ................................................................................... 30 Fig. 22 Measuring of V-belt tension by Tension Tester ................................................ 31 Fig. 23 Approximate method of belt tension measuring ............................................. 32 Fig. 24 Assembly and disassembly of pulleys .................................................................. 34 Fig. 25 Measuring instrument for belt tension GATES – Tension Tester and SONIC .............................................................................................................................................. 40 Fig. 26 Laser ruler GATES ........................................................................................................ 40

LIST OF TABLES Table 1 Anti-vibration isolators .............................................................................................. 14 Table 2 Bearings for fans model RSH and RNH ............................................................... 20 Table 3 Identification of SY module according to the mean diameter ................... 21 Table 4 Bearing module type according to the fan’s size ............................................ 22 Table 5 Bearing module type according to fan size ....................................................... 27 Table 6 Bearing module type according to fan size ....................................................... 27 Table 7 Bearing type according to the fan size ............................................................... 28 Table 8 Bearing type according to the fan size ............................................................... 28 Table 9 Indicative values for temporary belt tension ................................................... 32 Table 10 Taper-Lock® bushings used for Janka fans ................................................... 33

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LIST OF ANNEXES Annex 1 Defects and troubleshooting ............................................................................... 36 Annex 2 Wiring diagram of electromotors - examples ............................................... 37 Annex 3 Transmission sheet – SAMPLE I ......................................................................... 37 Annex 4 Transmission sheet – SAMPLE II ....................................................................... 39 Annex 5 Material and dedicated tools needed for special installation and assembly works (not included in the fan package delivery) ........................................ 40

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1. INTRODUCTION Please read carefully this installation and operation manual before starting installation and commissioning of the fan. DO NOT IMPROVISE. If there is any question in the mind of user or operating / maintenance personnel please consult with the manufacturer or local sales representative.

• This installation and operation manual is intended for all users of the fan, in particular for operating and maintenance personnel. The manual includes technical information, health and safety cautions, instructions for taking over, shipping and handling, assembly and installation, operational information, maintenance information, repair suggestions, storage, list of components that are subject of wear and tear, decommissioning and disposal information and warranty information.

• It is imperative to adhere to the information presented in this manual to realize safe, reliable and efficient operation of the product. Non-compliance with stipulations provided in this manual will make the manufacturer not responsible for any damage caused.

• The user of the product is obliged to train, or organize training for the personnel appointed to operate and maintain the product. Furthermore, the user is responsible for making the personnel acquainted with this manual and all standards and regulations related to the product’s operation, in particular with applicable health and safety regulations.

• Special attention must be given to safety warnings and cautions. Failure to comply with any of these requirements could result in serious damage to the equipment and the property, in which it is situated, as well as severe personal injury to themselves and people at the site.

• Service, cleaning, maintenance and repairs of the product can only be performed by competent and trained personnel following instructions issued by an authorized operator.

2. MODELS AVAILABLE AND APPLICATION

2.1 Models RSH (RSA) and RNH + RNZM and RSZM - single suction fans with direct drive

• Centrifugal medium-pressure RSH fans and low-pressure RNH fans are of single suction, direct drive construction. They come with PM direct drive (Fig. 1) or PP socket-flange drive. The fans have been designed for ventilation of residential buildings, commercial buildings and industrial premises. Centrifugal low-pressure RNZM fans and medium-pressure RSZM fans are of single suction, direct drive construction with vertical rotation axes and are intended for connection of suction flange through a flexible sleeve direct to the equipment.

• The air temperature drawn through the fan must be within the limit values ranging from -20°C to +50°C for motors fixed on isolator bracket and from -20°C to +40°C for the socket-flange construction.

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Fig. 1 PM fan construction with motor fixed on isolator bracket

2.2 Models RSH and RNH single suction fans with belt drive and base frame

• Centrifugal medium-pressure RSH fans and low-pressure RNH fans are of single suction, belt-drive construction with a base frame (Fig. 2). The fans have been designed for ventilation of residential buildings, commercial buildings and industrial premises.

• The air temperature drawn through the fan must be within the limit values ranging from -20°C to +80°.

Fig. 2 Belt drive fan with base frame

Spiral casing

Impeller

Inlet cone

Fan frame

Base frame

Electromotor

Stool

Lifting lug

Spiral casing

V-belt guard Pulley

V-belts

Electromotor

Frame

Impeller

Intake cone

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2.3 Models RSHJ and RSBJ single suction fans with belt drive and base frame

• Centrifugal medium-pressure RSHJ and RSBJ fans are of singe suction, belt drive construction with base frame (Fig. 2). The fans have been designed for movement of air, which contains aggressive substances occurring in applications such as extraction and ventilation of industrial, production or storage facilities. Floating bearings fixed to isolator bracket are used on these fans.

• The air temperature drawn through the fan must be within the limit values ranging from -20°C to +80°.

2.4 Models RSH/2 and RNH/2(RNP/2) double suction fans VK or PR

• Centrifugal medium-pressure RSH/2 and low-pressure RNH/2 double suction fans with a free-end shaft or a belt drive and base frame (Fig. 3). The fans have been designed for ventilation of residential buildings, commercial buildings and industrial premises.

• The air temperature drawn through the fan must be within the limit values ranging from-20°C to +80°

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Fig. 3 Fan with free-end shaft (VK) and belt drive model with base frame (PR)

2.5 Important information applicable to all fan models • The fans are not airtight.

• The fans’ design is BNV, i.e. the fans are intended solely for use in a non-explosive environment.

• The fans are provided with nameplates - see chapter 2.6 Symbols and safety labeling.

• The air drawn through the fan must not contain any mechanical particles, fiber dust or foreign substances that might accumulate on the impeller or inside spiral box or cause their excessive corrosion. Solid substances or media containing solid particles must not be drawn through the fan.

• Ambient operating temperature of the fans must stay within the limit values ranging from -20°C to +40°C.

• Fans installed on plastic anti-vibration isolators are intended for sensitivity grades 2 and 3 according to the Czech code ČSN 33 2030. The plastic material of the anti-vibration isolator

Impeller

Intake cone

Shaft

Bearing seating

Fan frame

Lifting lugs 8x

Discharge

Suction

Fan Fan’s pulley

V-belts

Motor‘s pulley

Electromotor

Adjustment bolt

Frame

Slide rails

Latch

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has flammable class rating C3 according to the Czech code ČSN EN 13501-1+A1 and must not come to direct contact with acetone, toluene and chlorinated solvents and similar agents. The anti-vibration isolators come with nameplates provided by anti-vibration isolators’ manufacturer.

• Water and coarse impurities must not ingress into the anti-vibration isolators.

• The fans must not be exposed to direct action of weather. Electromotor and anti-vibration isolators must be protected from solar radiation, direct rain and snowing up for instance by a roofing applied over the whole fan housing.

• The protection roofing or similar protection shielding must not be fixed to the flexibly mounted fan or be in contact with any part of the fan.

• Basic performance specifications are indicated on the nameplate of the electromotor. Protection of the electromotor against dust and moist is recommended when installed in dusty and wet environment.

• The fan can be started only when in loaded conditions, i.e. either:

o When connected to ventilation ductwork it is intended for; or

o When suction end is closed; or

o When the discharge end is closed;

in order not to cause overloading of the electromotor leading to its damage. At the same time the electromotors must be provided with overloading protection in compliance with the Czech code ČSN 33 2000-1 ed.2. Check the isolation resistance of the electromotor prior to its first start-up following the procedure provided in the Czech code ČSN 35 0010 in order to avoid potential damage to the electromotor. Correct rotation direction of the impeller indicated by a guiding arrow on the spiral casing is to be checked at the start-up and the current drawn by the motor is to be checked.

• Ventilation ductwork may be connected to the fan solely through flexible vibration damping sleeves.

2.6 Symbols and safety labeling Symbols used on the product - warning and safety labels

Rotation direction of fan’s impeller

Open the door / remove the cover only when equipment at complete standstill

Lifting lug

Conformity certificate of the product

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Fig 3 Production nameplate

Explanation of important data provided on the production nameplate • TYPE – identification of fan’s type including nominal output of the electromotor

• Operating speed – speed of the fan at which the supply pressure and volumetric airflow values shown on the nameplate are achieved at air density of 1.2kg/m3.

• Maximum speed – maximum permissible speed of the actual fan’s impeller. THIS SPEED VALUE DOES NOT APPLY TO MAXIMUM PERMISSIBLE SPEED OF THE ELECTROMOTOR, which may be significantly lower!!!

• Guaranteed values of total pressure, volumetric airflow and speed are related to the density air drawn through the fan of 1.2kg/m3.

Protection of environment

Dispose of all the waste in a professional manner in such a way that no harm to the environment is caused.

Cartoon wrapping material is to be recycled by carrying to a collection point.

Faulty or disused electrical or electronic devices must be disposed of at relevant collection points.

3. SAFETY • Valid safety regulations and generally accepted technical rules must be complied with during

installation, electrical wiring works, commissioning, repairs and maintenance on the fans.

• Only authorized personnel or a licensed company holding valid authorization in compliance with Czech code ČSN 34 3205 and Regulation No. 50/78 Coll. is entitled to carry out installation of the fan including electrical wiring, commissioning, repair, maintenance and servicing. Further more the instructions given the Czech code ČSN 12 2002 must be adhered to.

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• The fan must always be isolated from electricity supply when being checked, cleaned or repaired.

• If there is no ductwork connected to the suction or discharge side of the fan, a protecting grill must be applied on the open side of the fan in order to avoid risk of personnel injury by rotating blades of the impeller and to avoid intrusion of any foreign subject into the spiral casing. The protecting grill can be ordered at the manufacturer on request.

• Keep the nameplate on the fan clean and in good condition.

• Do not remove the plastic anti-vibration isolators before field installation of the fan due the hazard of personnel injury. There are pre-stressed springs inside the plastic anti-vibration isolators, therefore the isolators must not be removed nor disassembled. Handle the isolators with care during shipping and storage, as they are prone to damage by a shock or stroke.

• Allow for required safety clearance around the fan in compliance with Czech code ČSN 73 5105 when installing.

• The fans must not be used under different operating conditions than those for which they have been designed. The manufacturer cannot be hold responsible for any damage caused by improper use of the equipment and the user bear all risks.

• During shipping and handling the lifting of fans is allowed only with lifting lugs labeled with lifting symbols.

• Changes, amendments and modifications to the fan that may have any influence on its safe operating must not be performed without the manufacturer’s permission.

• Maximum operating speed of the fan’s impeller must not be exceeded in any manner.

4. DELIVERY, SHIPMENT, PACKAGING, RECEIVING STORAGE • The fan’s delivery scope includes complete product complying with the specification given in

the order form and accompanying technical documentation supplied together with the fan.

• The accompanying technical documentation contains:

o Warranty certificate - quality certificate and factory testing certificate;

o Manual for use and operation;

o Declaration of conformity.

4.1 Shipment • The fans form together with the electromotors a shipment and assembly unit. They are not

provided with any packaging for shipment.

• The anti-vibration isolators are delivered along with leveling&adjusting bolts and anchoring material. The anti-vibration isolators are shipped separate from the fans due to safety reasons.

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4.2 Receiving Immediately upon receipt of a shipment, carefully inspect for damage and compliance with the ordered specification and scope including the accompanying technical documentation.

The receiving procedure and way of shipment and further agreements related to shipment and receiving are to be stipulated in the Contract of Purchase.

4.3 Storage The fans must be stored in dry, dust-free spaces with ambient temperature not dropping under +5°C. The fans must be protected against mechanical damage, soiling and intrusion of foreign subjects. The fan must not be exposed to direct action of weather effects.

The impeller must be rotated by hand at least every 14 days during the storage period in order to o re-coat all lubricated bearings with grease avoiding their corrosion.

5. ASSEMBLY

5.1 Starting assembly • Only authorized personnel or a licensed company holding valid authorization certificate may

perform the fan’s assembly.

• The wiring and grounding of the electrical equipment, motors and the entire electrical installation must comply with the valid electrical standards, especially ČSN 33 2000-4–41 ed.2, ČSN 33 2000-5-51 ed.3, ČSN 33 2000-5-54 ed. 2. Furthermore, the wiring and grounding set-up has to be adequate to comply with the ambient conditions with regards to the safe equipment operation. Only authorized personnel or a licensed company holding valid authorization in compliance with Czech code ČSN 34 3205 and ČÚBP and ČBÚ Regulation No. 50/78 Coll. can perform works on electrical installations

• Check that the fan was stored in compliance with the conditions specified in chapter 4.4. Storage. Give special attention to checking there is no foreign subject inside the spiral casing.

• Check for good condition of the fan before starting assembly, smooth operation of the electromotor and fan’s impeller, whipping of the pulleys, alignment of the pulleys applying a ruler on worked sides of the pulleys’ crown, cleanliness of pulleys grooves, good condition of paint coat, good condition and tension of the V-belt according to the Czech code ČSN 02 3109.

• When handling, transporting or shipping the fan may be lifted only with lifting lugs marked with lifting symbol labels. Overhead lifting is prohibited.

• The lifting lug on the electromotor is designed to support only the electromotor weight, it is not designed for lifting of the entire fan assembly.

• Allow for sufficient clearance for assembly works and manipulation during installation. A clear safety passage around the fan must be ensured in compliance with the Czech code ČSN 73 5105.

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5.2 Assembly procedure 5.2.1 Mounting of fan - rubber isolators • This is a fan version comprising base frame with the rubber isolators located between the

fan’s frame and the base frame - see Fig. 5 right hand side. The base frame has pre-drilled holes for fastening to the floor structure.

Fig. 4 Details of rubber isolators

5.2.2 Mounting of fan - plastic anti-vibration isolators with spring

• The plastic isolators with spring are to be attached to the fan’s frame and fastened directly to the floor structure that can alternatively be made from concrete, timber or steel - see Fig. 5 left hand side. Make sure the fans furnished with plastic isolators have all parts assembled on them prior to putting the whole fan assembly onto the plastic isolators in order the total assembly weight takes effect on the plastic isolators’ springs.

• The floor must be structurally adequate, flat and level, dry and free of any dirt.

• Put structurally adequate timber balks on the floor. Make sure the height of the timber balks exceeds by at least 5mm the installation height of the plastic isolators. Let the fan sit on the timber balks.

• Place the plastic isolators under the fan’s frame right under the pre-drilled holes in the frame. Drift lubricated leveling&adjustment bolts with a nut and spring washer into the holes in the fan’s frame. Tight them freely into the isolators’ joints and secure the isolators to the fan’s frame with the nuts.

• Screw the anchoring bolts into anchoring tubes and set bolts into anchoring slots provided in the isolators and anchoring holes or slots in concrete floor. Do not tighten the bolts yet. Potential unevenness of the floor surface may be eliminated with metal sheets of various thickness inserted between the seating areas of the isolators and the floor.

Lift up the fan, remove washers and let the fan carefully down on the isolators. Plastic isolators P41-P48 and P61-P67 cannot be leveled using the adjusting bolts as the plastic casing is not strong enough to cope with the stress induced!!! When plastic isolators P8x are applied, smaller level unevenness up to 1mm can be rectified with the leveling&adjustment bolts.

Plastic anti-vibration isolators with spring Rubber anti-vibration isolators Fan frame

FAN FRAME BASE FRAME RUBBER ANTI-VIBRATION ISOLATOR

Detail of flexible mounting on rubber anti-vibration isolators

Adjusting bolt and securing nut

Understructure

Anti-vibration isolator

Anchoring bolt

Anchoring tube Concre floor Slot for anchoring tubes

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• After leveling the adjustment bolts are to be secured by nuts, the anchoring tubes are to be filled up with grout and after grout hardening the anchoring bolts will be fastened.

Table 1 Anti-vibration isolators

Anti-vibration isolators for PM model direct drive fans

Velikost

ventilátoru RSH kW OV Typ Počet Šířka (mm)

Hloubka(mm) Typ Počet

250 0,75 80 P41 4 215791 4315 1,5 90 P42 4 215784 4400 1,1 90 P42 4 215784 4500 2,2 100 P43 4 - -630 5,5 132 P62 4 - -630 7,5 132 P62 4 - -

Velikost

ventilátoru RNH kW OV/počet pólů Typ Počet Šířka (mm)

Hloubka (mm) Typ Počet

250 all 80 P42 4 215791 4315 all 80-90 P42 4 215784 4400 0,37-1,1 90 P42 4 215784 4400 1,5 100 P45 4 215784 4500 1,5 112 P43 4 - -500 2,2 112/8 P43 4 - -500 3 132/8 P46 4 - -500 4 132/6 P46 4 - -500 5,5 132 P46 4 - -630 4 160 P62 4 - -630 5,5 160 P63 4 - -630 7,5 160 P63 4 - -630 11 180 P63 4 - -

215791215784

40 100

PRUŽINA_PRYŽ_345 25_M6_45.12_(50 ShA)PRUŽINA_PRYŽ_644 35_M8_G_116.12_(40 ShA)

Drážka v podkladu Pryžové isolátory

40 100

Motor Plastové isolátory Drážka v podkladu Pryžové isolátory

Motor Plastové isolátory

Size of Plastic isolators

fan type No. No. type

Plastic isolators Groove in floor

width

depth

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Anti-vibration isolators for fan models RSHJ and RSBJ

Velikost

ventilátoru RSHJ a RSBJ OV Typ Počet Šířka (mm)

Hloubka (mm)

250 71-90 P42 6315 71-100 P42 6400 80-132 P45 6500 90-160 P46 6630 100 P44 6630 112-160 P47 6800 100-132 P62 10800 160-180 P63 10

1000 160 P65 101000 180 P66 101000 200 P64 10

Motor Plastové isolátory Drážka v podkladu

40 100

Anti-vibration isolators for fan models RNH/2

Velikost

ventilátoru RNH/2 kW OV Typ Počet Šířka (mm)

Hloubka (mm)

500 2,2-7,5 112-132 P43 8500 11 160 P46 8630 3-11 132-160 P62 8630 15 180 P63 8630 18,5 200 P63 8800 4 160 P820D 8800 5,5 160 P820D 10800 7,5 160 P820D 10800 11 180 P820D 10800 15 200 P63 10800 18,5 200 P820D 10800 22 200 P65 10800 30 225 P820C 10

1000 7,5 160 P820C 91000 11 180 P820C 101000 15 200 P820B 91000 18,5 225 P820B 101000 22 225 P820B 101000 30 250 P820B 101000 40 280 P820A 101000 55 280 P821D 101250 30 250 P821C 111250 40 280 P821C 121250 55 280 P821B 11

Motor Plastové isolátory Drážka v podkladu

40 100

Anti-vibration isolators for fan models RSH and RNH with belt drive and base frame

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Velikost

ventilátoru RSH kW OV Typ Počet Šířka (mm)

Hloubka(mm)

200 all all P41 5250 all all P42 4315 all all P42 5400 1,1-3 80-100 P42 6400 4-5,5 112-132 P45 6500 1,5-3 90-100 P43 5500 4-7,5 112-132 P46 5630 2,2-15 100-160 P47 5800 3.4 100-112 P44 9800 5,5-22 132-180 P47 9

1000 7,5-15 160 P65 91000 22 180 P66 91000 30 200 P66 9

Velikost

ventilátoru RNH kW OV Typ Počet Šířka (mm)

Hloubka (mm)

250 all all P42 4315 all all P42 5400 0,55-3 80-100 P42 6400 4 112 P45 6500 0,75-4 90-112 P43 5500 5,5-7,5 132 P46 5630 1,5 112 P62 5630 2,2 112 P62 5630 3 132 P62 5630 4 160 P44 5630 5,5 160 P63 5630 5,5 132 P44 5630 7,5 160 P63 5630 11 160 P65 5800 2,2 - 7,5 112 - 160 P820C 5800 11 160 P820B 5800 15 180 P820B 5

1000 3 132 P820A 51000 4 160 P820A 71000 5,5-15 160 - 180 P820B 71000 18,5 200 P820A 71250 5,5-15 160-200 P820A 91250 18,5-22 225 P821A 51250 30 250 P821B 71250 40 280 P821C 9

Motor Plastové isolátory Drážka v podkladu

40 100

40 100

Motor Plastové isolátory Drážka v podkladu

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Accessories of each plastic anti-vibration isolator: • One adjustment bolt with nut and washer intended for fastening of the isolators to fan’s frame. • Two anchoring bolts with washers and anchoring tubes intended for fastening of the isolators to the

structural floor.

5.2.3 Important notice Be sure the flexible sleeves attached to the fan, electrical wires of the electromotor and grounding wires are clear and do not interfere with free, unobstructed vibration movements of the fan sitting on anti-vibration spring isolators, i.e. there is no point of rigid contact between the isolated frame and the surrounding structures. Ensure electrical wires include loops and drainage of the spiral casing is provided by means of a flexible hose.

6. OPERATION • The fan may be commissioned only by properly briefed and trained personnel complying with

all applicable safety codes and regulations.

• Maximum permitted speed of the fan’s impeller must not be exceeded in any manner.

• Electromotors with rated output above 4kW (including) are recommended to be equipped with Y - ∆ switching-over or soft-start device or frequency modulator, otherwise the V-belts suffer from excessive wear and tear.

6.1 Prior to the start-up • Make sure the isolation resistance of the electromotor is measured in accordance with the

Czech code ČSN 35 0010 to prevent potential damage to the electromotor.

• Be sure the following items are checked:

o No foreign object intruded inside the spiral casing;

o Electromotor and fan’s impeller move freely;

o Good condition of anti-vibration isolators;

o Good condition of paint coat.

o Tensioning of V belts in compliance with Czech code ČSN 02 3109

o Proper tightening of bolts securing the electromotor to the base

o Instructions issued by manufacturer of the electromotor for commissioning have been adhered to.

o Tightness and correct working position of the flexible sleeves (be careful the flexible sleeves are not overly tight or the distance between flanges is too small)

• The fan can be started only when under loaded conditions, i.e. either:

o When connected to ventilation ductwork it is intended for; or

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o When suction end is closed; or

o When the discharge end is closed;

in order not to cause overloading of the electromotor leading to its damage. At the same time the electromotors must be provided with overloading protection in compliance with the Czech code ČSN 33 2000-1 ed.2. Check the isolation resistance of the electromotor prior to its first start-up following the procedure listed in the Czech code ČSN 35 0010 in order to avoid potential damage to the electromotor.

6.2 Initial testing start-up • Check for correct rotation direction of the impeller indicated by a guiding arrow on the spiral

casing at the initial start-up. At this time also check for the current drawn by the electromotor.

6.3 Initial operating period • Belts’ tensioning must checked after the initial 24 hours of operation. Ensure the belts are re-

tensioned to comply with the tensioning values required as shown in the belt drive transmission sheet.

• The operating staff must pay special attention to the bearings at least during the first 72 hours of operating (preferably longer), especially to their temperature.

7. CHECKS

7.1 Checks during normal operation • Ensure regular checks of fan’s smooth run, electromotors’ smooth run, smooth run and

temperature of bearings, occurrence of vibrations and shaking and excessive noise are carried out.

• Bearings’ temperature can be measured with a contact thermometer or with another suitable device.

• Measuring of mechanical vibrations, choice of measuring places and measuring procedures are ruled by codes ISO 14694:2003 and ISO 14695:2003 – Velocity of vibrations, see Table 2.

Table 2 Velocity of vibrations vef

Output < 3,7kW > 3,7kW Isolator tuhé pružné tuhé pružné Vibration velocity mm/s mm/s mm/s mm/s Operating values < 9 < 14 < 7,1 < 11,8 Alarming values 9 - 12,7 14 - 19,1 7,1 - 9 11,8 - 12,5 Emergency values > 12,7 > 19,1 > 9 > 12,5

Operating values: Acceptable values suitable for long-tem operation.

Alarming values: Increased attention by the servicing personnel to be paid and more frequent vibration measuring, a repair action necessary.

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Emergency values: Dangerous values, which may lead to damage of the fan, immediate shut-down of the fan is necessary.

• Two times a year the integrity of springs and casings of anti-vibration isolators has to be checked. In addition, in a dusty environment check that foreign subjects and impurities do not ingress into the anti-vibration isolators. In moist and aggressive environment check that metal parts of the anti-vibration isolators do not corrode, restore paint coat if needed.

7.2 Checks during shut-down period Check for cleanliness of fan’s internal surfaces, mainly the impeller. Regular checks must be carried out followed by removal of dust deposits in order to avoid imbalanced weight on the impeller. Cleaning frequency depends on the extent of impeller soiling. Further, the checks include tightening of bolted connections, corrosion, and smooth rotation of impeller. It is understood all checks are carried out following the instructions provided in chapter 6.1 “Prior to the start-up”.

8. MAINTENANCE Maintenance and servicing of electrical equipment may be carried out only by authorized personnel or a licensed company holding valid authorization in compliance with Czech code ČSN 34 3205 and Regulation No. 50/78 Coll.

8.1 Bearings and bearing modules 8.1.1 RSH (RSA) and RNH with belt drive and base frame Fan size 200 to 800 • The lubricant used in 2RS bearings which are furnished with rubber sealing gasket ensures

lubrication of the bearings throughout the whole service life of the bearings as the re-lubrication period exceeds the anticipated service life of the bearings. The maximum storage period of the lubricant is 4 years though. Should the fan be stored for a longer period of time, the bearings must be replaced after the maximum storage period expires.

Fan size 1000 to 1250 • Refill the lubricant of the bearings after approximately 50 hours of operation. Pay special

attention to the bearings during the first couple of days of operation. Bearings’ temperature must not exceed +80°C.

• Use plastic lubricant LV 2-3 for re-lubrication.

• Regular re-lubrication period is approximately 8,000 operating hours. The re-lubrication period may be adjusted depending on the actual operating routine, however must not exceed service life of the lubricant, which is approximately 2 years.

• Use 20g of lubricant for re-lubrication of a bearing for fan size 1000 and 26g for fan size 1250.

• Remove the old lubricant carefully from the housing when replacing the bearings due to a damage or wear and tear. Fill the bearing and the bottom half of housing caps with new lubricant.

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• Check for technical condition of bearings’ felt sealing at fan size 1000. Saturate the felt sealing with a solution of cylinder oil before assembling the bearing.

Table 2 Bearings for fans model RSH and RNH

Fan size Bearing Fan size Bearing 200 6203-2RS P636 500 6307-2RS P636 250 6203-2RS P636 630 6309-2RS P636 315 6304-2RS P636 800 6310-2RS P636 400 6305-2RS P636 1000 6312 P6

Use bearing 6314 for fan model RNH 1250

8.1.1.1 Disassembly • Remove the ductwork connected.

Fan size 630 to 1250 • After removal of inlet cone and bolt from the shaft end, the impeller can be removed by a

puller and taken out from the housing through the inlet cone opening.

• Remove the belt drive guard. Unscrew the nuts holding seating plates to the spiral casing. Pull the seating plates along with the pulley towards the pulley. Remove the pulley using a puller. At this time the bearings can be replaced.

Fan size 200 to 500 • Do not remove the inlet cone. The impeller can be removed along with the seating and pulley

by pulling towards the pulley.

8.1.1.2 Assembly • Proceed reversely compared to the disassembly procedure.

8.1.2 RSHJ and RSBJ with belt drive and fan frame Bearing supplied in the SY bearing modules come with high quality filling consisting of lithic-calcic plastic lubricant with long service life, consistence grade 2 according to NLGI. This plastic lubricant is extremely water resistant and provides long service life even if exposed to high loads. Therefore it is generally not necessary to re-lubricate the bearings. However, if the bearings are exposed to high soiling and contamination, carry high loads or work at higher temperatures it is necessary to re-lubricate the bearings in order to achieve their full projected service life.

8.1.2.1 Maintenance of SY bearing modules SY Recommended lubricant • If there is a need to re-lubricate the bearings, plastic lubricant LGWA 2 manufactured by SKF is

recommended. This lubricant is fully compatible with the original lubricant charge. Also the universal plastic lubricants LGMT 2 and LGMT 3 by SFK are compatible with the original charge and can be used for re-lubrication.

Lubricant refill intervals • The lubricant refill interval tf can be determined as a function of the speed n, mean bearing’s

diameter dm (see Table 24, Fig. 6) and operating temperature (°C); see Fig. 6. The recommended lubricant refill intervals match the point of time, when 90% of the bearings are still reliably lubricated.

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Fig. 5 Mean diameter

Table 3 Identification of SY module according to the mean diameter

Identification/size of SY module

Mean diameter dm

17 28,5 20 33,5 25 38,5 35 53,5 40 60 55 77,5 60 85

Fig 6 Lubrication refill intervals

• The lubricant refill intervals determined in the diagram are applicable for bearings and bearing modules operating at temperatures ranging from +40 to +55°C. If the operating temperature is lower than +40°C for a prolonged period of time, the service life of plastic lubricant is decreasing due to worsened oil separation. If the bearings’ operating temperature is supposed to exceed +70°C for a prolonged period of time, more frequent lubricant refill is advisable. In very demanding, very polluted or moist working environment the refill lubricant interval has to be shortened by up to 90%. For high loads imposed on the bearing the refill lubricant interval has to be shortened by approximately 50%. Also vibration may affect service life of the plastic lubricant. The vibration affect cannot be exactly specified, however it obviously takes more impact with the increasing operating temperature.

Lubricant refill interval tf (hours)

Operating temperature

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Refill of lubricant • Slowly refill the plastic lubricant while the fan is operating until the new lubricant starts

leaking around the sealing gasket. Do not apply excessive pressure when refilling the lubricant as it could lead to damage of bearing’s sealing gasket.

8.1.2.2 Disassembly and assembly of SY bearing module Disassembly • Remove the ductwork connected to the fan.

• Remove the belt drive guard and shaft guard.

• Remove pulley following the procedure specified in chapter „8.3.2 Pulley disassembly“.

• Remove the intake cone (remember to drill off the securing rivets).

• Loosen the bolt at the shaft end and pull down the impeller using puller (consider big weight of the impeller at bigger fans after removed from the shaft). Take out the impeller through the intake cone opening.

• At this time determine the type of bearing module according to the fan’s size - see. Table 4 Table 4 Bearing module type according to the fan’s size

Fan’s size Bearing module by SKF 250 SY 17 FM 315 SY 20 FM 400 SY 25 FM 500 SY 35 LF 630 SY 40 LF 800 SY 55 LF

1000 SY 60 LF

Following information applies to SY _ _ FM bearing modules: • Loosen adjustment bolt in the centering safety ring and loosen fastening bolts.

• At this time you may pull down the bearing module from the shaft.

Following information applies to SY _ _ LF bearing modules: • It may be necessary to remove corrosion from shaft ends with abrasive strip or to repair

damaged surface of the shaft.

• Loosen the bolts in the assembly ring of the first bearing module.

• Unscrew fastening bolts in the second bearing module.

• Loosen the stepped bushing sitting on the shaft with light tapping on side of the assembly ring of the first bearing module.

• Remove fastening bolts of the first bearing module.

• Pull down first bearing module from the shaft.

• Fasten the fastening bolts on the second bearing module again.

• Loosen thoroughly bolts of the assembly ring on the second bearing module.

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• Loosen the stepped bushing sitting on the shaft with light tapping on side of the assembly ring of the second bearing module.

• Remove fastening bolts of the second bearing module.

• Pull down second bearing module from the shaft.

Assembly Keep the bearing module in its original wrapping until the assembly start. This prevents the bearing and bearing module from unnecessary soiling.

Proceed reversely compared to the disassembly procedure. Choose correct type of bearing module depending on fan’s size as specified in Table 4.

Following information applies to SY _ _ FM bearing modules: • Pull the bearing module on the opposite side of the shaft than the securing gadget is located.

• Put the bearing module on the seating area. Tighten the fastening bolts. It is recommended that washers (for instance DIN 125) and lock washers (according to DIN 128) are applied to secure nuts on the bolts or the bolts themselves. See Fig.7.

Fig. 7 Securing of fastening nuts

• Set axial position of the shaft in the bearing and rotate the shaft several times.

• Move the centric safety ring to its operating position on the extended section of the inner ring and tighten the safety ring by forceful movement in the main rotation direction of the shaft. See Fig. 8.

Fig 8 Securing of safety ring

• Tighten the safety ring in its operating position

o Using a spanner DIN 1810, shape type B.See Fig. 9, or

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Fig 9 Securing of safety ring with spanner

o Using a hammer and punche. See Fig. 10.

Fig. 10 Securing of safety ring using hammer and puncher

• Thoroughly secure the adjustment bolt on the centric safety ring. See Fig. 11.

Fig. 11 Securing of adjustment bolt

Following information applies to SY _ _ LF: A spanner provided with torque moment gauge or another instrument indicating the torque moment applied is necessary to ensure neither insufficient or excessive torque moment is applied on the adjustment bolts. See Fig. 12.

Fig. 12 Hexagonal spanner with torque moment gauge

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• Remove burrs from the shaft with abrasive cloth or smooth file; see Fig. 13. Wipe the shaft with a clean threads-free cloth.

Fig. 13 Shaft cleaning

• Spread shaft surface smoothly with thin oil. See Fig. 14.

Fig. 14 Oil application

• Clean the bearing module base and seating area; see Fig. 15. Check for evenness of the seating area. If the bearing module base needs underlay apply spacers in a form of thin metal sheets in such a way they support the entire base area of the bearing module.

Fig. 15 Cleaning of housing base

• Pull the bearing module on the shaft and set it in correct position. The assembly side of the bearing module must face outwards in order to be easily accessible for further assembly works. See Fig. 16. Secure the bearing module safely to the seating area.

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Fig. 16 Pulling on the bearing module

• Set the assembly ring so that the adjustment bolt matches exactly the groove in the clamping bush.

• Take shorter end of Allen wrench and tighten the bolts by half revolution following the bolts tightening sequence shown on Fig. 17. Apply only decent torque moment on the bolts so that they can still be loosen by hand. See Fig. 18.

Fig. 17 Sequence of bolts tightening

Fig. 18 Bolts tightening

• Turn the Allen wrench and tighten the adjustment bolts with its longer arm. Turn the bolts gradually one after the other by ¼ revolution following the sequence of bolts’ tightening until the Allen wrench starts springing.

• Put the red torque moment gauge on the shorter arm of Allen wrench and keep tightening the bolts until the Allen wrench touches the torque moment gauge. See Fig. 19. If you use a different torque moment wrench, apply the recommend torque moment of 7.4Nm on the bolts.

Fig. 19 Use of torque moment gauge

• Pull the bearing module on the other side of the shaft and follow the whole above outlined procedure again.

Note

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Do not use tools such as hammer or tube for tightening the adjustment bolts.

8.1.3 RSH/2 a RNH/2(RNP/2) 8.1.3.1 Fan size RSH/2 and RNH/2 - 200 to 400 The lubricant used in 2RS bearings which are furnished with rubber sealing gasket ensures lubrication of the bearing throughout the whole service life of the bearing as the re-lubrication period exceeds the anticipated service life of the bearing. The maximum storage period of the lubricant is 4 years though. Should the fan be stored for a longer period of time, the bearings must be replaced after the maximum storage period expires.

Table 5 Bearing module type according to fan size

Fan size Bearing module by SKF 250 6304 2RS P636 315 6305 2RS P636 400 6306 2RS P636

Disassembly Loosen bolts connecting the bearing seating (spider) and the spiral casing. Disassemble the bearing seating and pull down the bushing from the bearing. Now the bearing can be removed from the shaft.

Assembly Proceed reversely compared to the disassembly procedure. 8.1.3.2 Fan size RSH/2 and RNH/2 - 500 to 800 • Bearings supplied in the SY bearing modules come with high quality filling consisting of lithic-

calcic plastic lubricant with long service life, consistence grade 2 according to NLGI. This plastic lubricant is extremely water resistant and provides long service life even if exposed to high loads. Therefore it is generally not necessary to re-lubricate the bearings. However, if the bearings are exposed to high fouling and contamination, carry high loads or work at higher temperatures it is necessary to re-lubricate the bearing in order to achieve their full projected service life.

Table 6 Bearing module type according to fan size

Fan size Bearing module by SKF 500 SY 35 FM 630 SY 40 FM 800 SY 55 FM

NOTES:

• For recommended lubricant type, lubricant refill intervals and lubricant refill procedure please refer to the chapter „8.1.2.1 Maintenance of SY bearing modules SY“.

• For disassembly and assembly of the bearing module please refer to the chapter „8.1.2.2 Disassembly and assembly of SY bearing module“ – sections concerning type SY__FM.

8.1.3.3 Fan size RSH/2 and RNH/2 - 1000 to 1250 Refill the lubricant of the bearings after approximately 50 hours of operation. Pay special attention to the bearings during the first couple of days of operation. Bearings’ temperature must not exceed +80°C.

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Use plastic lubricant LV 2-3 for lubricant refill.

Regular lubrication refill period is approximately 8,000 operating hours. The refill period may be adjusted depending on the actual operating routine, however must not exceed service life of the lubricant, which is approximately 2 years

Apply 20g of lubricant for re-lubrication of a bearing for fan size 1000 and 26g for fan size 1250.

Remove the old lubricant carefully from the housing when replacing the bearings due to a damage or wear and tear. Fill the bearings and bottom half of housing caps with new lubricant.

Check for technical condition of bearings’ felt sealing at fan size 1000. Saturate the felt sealing with a solution of cylinder oil before assembling the bearing.

Table 7 Bearing type according to the fan size

Fan size Bearing module by SKF RNH/2 1000 2315 K + casing S615 RSH/2 1000 2318 K + casing S618 RNH/2 1250 22222 K + casing S522

Disassembly At first provide suitable support to the rotor shaft. Then unscrew the bolts connecting fan frame and bearing housing. At this time unscrew the split housing and remove its upper part. Straighten the curved bit of locking washer and loosen safety nut by 2 or 3mm. Tap towards the fan inlet and unscrew the bolt securing the fan frame with bearing housing. Now the bearing housing can be taken out.

Assembly Proceed reversely compared to the disassembly procedure. 8.1.3.4 Fans RNP/2

Table 8 Bearing type according to the fan size

Fan size Bearing module by SKF 160 KH204 AE ASAHI 180 KH204 AE ASAHI 250 KH204 AE ASAHI 280 KH205 AE ASAHI 315 KH205 AE ASAHI 355 KH206 AE ASAHI 400 KH206 AE ASAHI 450 KH207 AE ASAHI

Disassembly Loosen and remove the eccentric ring. Unscrew bolts connecting the bearing seating and the spiral casing and remove the whole bearing seating (spider). Now the bearing can be removed from the seating. The impeller can be removed through the inlet opening after dismantling the latch and removal of shaft through the inlet opening. It is advisable to mark the impeller position on the shaft. This will facilitate the consequent assembly works.

Assembly Proceed reversely compared to the disassembly procedure.

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8.2 Assembly and disassembly of direct drive fans Disassembly • Remove the ductwork connected and proceed further depending on the inlet cone type.

Molded inlet cone in the side of spiral casing • Unscrew the bolts on motor seating plate on the spiral casing. Move the spiral casing away

from the motor over the impeller. Now unscrew the bolt at end of shaft and pull down the impeller using puller.

Inlet cone attached to the side of spiral casing • Remove the inlet cone, unscrew the bolt at the shaft end and pull down the impeller using

puller.

Assembly Proceed reversely compared to the disassembly procedure depending on the inlet cone type.

8.3 V-belt drives When replacing the V-belts the complete set of V-belts is to be replaced at a time on multiple groove drives. To tighten the V-belts proceed according to the code ČSN 02 3109.

8.3.1 Disassembly and assembly of V-belts • Unscrew the securing bolts and the bolts on the motor slide rails. Move the electromotor

towards the fan shaft. The V-belts get loose and can be lifted off the pulleys.

• Proceed in the opposite way when assembling the V-belts. Before final tensioning of the V-belts, the pulleys must be aligned in one plane. Fasten the bolts on motor’s slide rails and the securing bolts. Tensioning of the V-belts is ruled by Czech code ČSN 02 3109.

8.3.2 Disassembly a re-assembly of pulleys (system Taper-Lock®)

Pulley disassembly • Unscrew the screws on the hub, pull them out from the holes, and screw one or two of them

fully into the withdrawal hole with internal thread. Slightly tap the pulley. Tighten the withdrawal screws; the hub and the pulley will separate from each other. Remove the pulley by hand and pull the hub off the shaft

Pulley re-assembly (system Taper-Lock®): • Clean and remove any grease from the hub and conical pulley surface.

• Lubricate the screws and put on the hub and pulley so that the threaded holes match the holes without thread.

• Insert the screws into the holes and screw them uniformly by hand.

• Place the pulley on the cleaned shaft and shift it into the required position and tighten the screws with torque moment as required.

• Check alignment of pulleys’ fronts at one plane using a ruler or laser ruler GATES.

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• Grasp the pulley by both hands and pull it hard to be sure that everything is firmly fitted and connected.

• Be careful when tightening hexagonal head screw. The wrench must not spring off the screw head when tightening to avoid damage to the hexagonal head.

• Check tightening of the securing screws after the first 50 operating hours.

• Make sure the tightening of the securing screws is checked on regular basis as a part of regular maintenance works on the equipment.

Fig. 20 Aligning of pulleys in one plane

Fig. 21 Checking abrasion of pulleys

• The maximum permitted abrasion of the pulley’s V-groove is 0.4mm. Checking of pulley groove sides proceeds with a dedicated gauge as shown on the Fig. 21.

8.3.3 Measuring of V-belt tension • Measuring of the V-belts tension can be acomplished either manually using a Tension tester or

by using a sound Sonic Tension Meter.

• Under no circumstances estimate the tension of V-belts "by experience". This may lead to insufficient tension of the belts and their subsequent destruction.

• The required measuring values are given in the transmission data sheet, which is part of the technical documentation. An example is provided in the Annex.

Measuring procedure (Pen type tension tester) • Set the deflection of the belt by using the ring at the bottom of the scale.

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• Keep the upper ring on the zero value.

• Put a straight ruler across the pulleys.

• Place the Tension Tester perpendicularly to the center of the belt and keep pushing the tester until the lower edge of the lower ring is aligned with the axis of the ruler’s plane.

• Use the upper ring to read the deflection force F (N).

• Compare the result with the values of min/max tightening force.

• Note:

o If the measured F is less than the "Minimum force for the deflection (N)”, it is necessary to tighten the belt.

o If the measured F is higher than the "Maximum power for the deflection (N)”, it is necessary to loosen the belt.

o Observe the value of the tension forces in the transmission data sheet for tension and tightening (after 24 hours of operation).).

• Check for the alignment of pulleys front ends being in one plane (Fig. 21) using a ruler or laser ruler GATES.

Fig. 22 Measuring of V-belt tension by Tension Tester

Note:

• If the transmission data sheet is not available, an approximate method can be used for measuring of the belt tension (only suitable for temporary fan operation such as fan start-up):

o Set the value "f" = 1.5 mm for every 100 mm "T" by the ring at the bottom of the scale see “.

o Keep the upper ring on the zero value.

o Put a straight ruler across the pulleys.

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o Place the Tension Tester perpendicularly to the center of the belt and keep pushing the tester until the lower edge of the lower ring is aligned with the axis of the ruler’s plane.

o Use the upper ring to read the deflection force F (N).

o Compare the results with the values of F´ and F´´ (see Table 9).

o Note:

a) If the measured F is less than F´´, it is necessary to tighten the belt

b) If the measured F is greater than F´´, it is necessary to loosen the belt.

The belt tension must be checked regularly in compliance with the transmission data sheet (see Annex 3 and Annex 4) and always after the first 24 hours of operation.

Fig. 23 Approximate method of belt tension measuring

Table 9 Indicative values for temporary belt tension

Belt tension measuring using acoustic tension meter (Sonic Tension Meter) The required values of measuring are given in the transmission data sheet, which is part of the technical documentation. An example is given in the Annex.

Measuring procedure (Sonic Tension Meter – acoustic)

• Enter the values of:

o Specific mass of the belt – MASS;

o Width of the belt – WIDTH;

o Length of the belt‘s span – SPAN.

• Hold the sensor about 10 cm away from the belt and hit slightly with finger into the belt.

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• Compare the measured value f (frequency [Hz]) with the values of min/max tightening frequency (an example - Annex).

• Note:

o If the measured f is less than the "Minimum frequency Hz (Sonic)”, it is necessary to tighten the belt

o If the measured F is higher than the "Maximum frequency Hz (Sonic)”, it is necessary to loosen the belt.

o Note the values of tightening frequency Hz in the transmission data sheet (see Annex 3 and Annex 4) for tension and tightening (after 24 hours of operation) and observe them.

Important warning • Problems resulting from insufficient tension of the belt

o Excessive abrasion due to the diffraction of the belt from pulley‘s groove.

o Excessive operation noise.

o Excessive vibration of the belt.

• Problems resulting from excessive tension of the belt

o Excessive load imposed on the bearings, shaft and motor consequently leading to shortening of their service life. .

o Increasing loads on all other components.

o Increased vibration and noise. Table 10 Taper-Lock® bushings used for Janka fans

Taper-Lock

bushing Tightening torque

of bolts (Mn)

Number of fastening bolts

(pcs)

Bolts with internal hexagon (“)

Spanner (mm)

1108 5,6 2 1/4“ 3 1210 20 2 3/8“ 5 1610 20 2 3/8“ 5 1615 20 2 3/8“ 5 2012 30 2 7/6“ 6 2517 50 2 1/2“ 6 3020 90 2 5/8“ 8 3535 115 3 1/2“ 10 4030 170 3 5/8“ 12

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Fig. 24 Assembly and disassembly of pulleys

9. INSPECTION CHECKS AND REPAIRS • Regular inspection checks of the fan are to be carryout out once every six months. In particular

the following items are subject of the inspection checks :

o Technical conditions of bearings;

o Cleanliness of internal surfaces, mainly the impeller;

o Technical conditions of the impeller - imbalanced movements;

o Vibrations and shaking vef of the entire fan assembly - Table 2;

o Proper fastening of belts holding down the electromotor to its seating plate

o Technical condition and tension of V-belts according to the Czech code ČSN 02 3109;

o Technical condition of isolators;

• If the inspection check is followed by a repair action involving a major change of loads it is necessary to implement measures preventing the base frame changing is altitude by using equalizing metal sheets or to ensure compression of the isolators by bolt nuts. After the inspection check each isolator is to be put into its original condition (equalizing metal sheets or loosening of bolt nuts).

• Important warning: Damaged or worn V-belts must be replaced. Always replace all V-belts applied in the transmission drive at a time on multiple groove drives (whole V-belt kit).

• Record identified and repaired defects in the “Repair and inspection checks log”, which the user is obliged to maintain.

• To facilitated repair of some defects, a troubleshooter guide indicating possible causes of defects and presenting repair suggestions is provided in Annex 1.

10. DISPOSAL • The expected service life of the fans operated in compliance with the terms and conditions set

forth for operation and maintenance is 10 years. Service life of fans with a special surface

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treatment is determined on a case-by-case basis depending on the actual environment the fan is exposed to and depending on composition, temperature and humidity of the air drawn through the fan.

• The product disposal (at the end of its service life) should be carried out in accordance with the Czech Act No185/2001 Coll.

• Iron and non-iron metals have to be scrapped. Electromotors, bearings, vibration isolators and V-belts have to be disposed of in accordance with the instructions issued by their manufacturers.

11. WARRANTY The manufacturer warrants this product against defects under normal use and if the terms and condition stipulated in this manual are adhered to for a period of one year. The warranty period starts on the day the product is shipped off the production facility.

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12. ANNEXES Annex 1 Defects and troubleshooting

Only authorized personnel - trained electrician is entitled to remove causes of other defects on the electromotor or electrical wiring.

Defect Possible cause Remedy

Fan’s performance parameters do not comply with the projected values

Closed damper in ventilation ductwork. Open dampers.

Incorrectly balanced louvers or diffusers in the ventilation system

Balance elements.

Clogged or dirty ductwork, heating coil, filter, impeller or similar.

Clean ductwork, heating coil, filters, impeller etc.

Squeezed ventilation ductwork. Repair and align ductwork

Ductwork joints sealing untight. Seal ductwork joints

Incorrect direction of impeller rotation. Change phases on electromotor

Measured ventilation parameters do no comply with the projected values.

Follow instruction of the ventilation designer or fan manufacturer

Excessive vibrations of fan

Unbalanced impeller, clogged impeller, dirt deposit on impeller.

Balance the impeller or replace with a new balanced impeller, clean impeller.

Damaged bearing of shaft. Replace bearing or shaft.

At fans sitting on anti-vibration isolators - Incorrect adjustment of anti-vibration isolators by adjustment bolt, unbalanced impeller.

Adjust anti-vibration isolators, balance the impeller or replace with a new balanced impeller

Excessive temperature of fan’s or electromotor’s bearings

Overlubricated bearing *) Remove excessive lubricant, if need be clean bearing, lubricate *)

Underlubricated bearing *) Refill lubricant *)

Faulty or unsuitable lubricant *) Replace lubricant *)

Impurities inside bearing Clean bearing and apply new lubricant

Faulty bearing Replace bearing

Bearing damaged during assembly

Overtensioned V-belts Slide electromotor

Excessive ambient temperature Decrease ambient temperature

Bearing rustles Impurities in bearing or lubricant Clean and apply new lubricant

Faulty bearing Replace bearing

Bearing whistles Underlubricated bearing *) Refill lubricant *)

Burnt fuse or circuit breaker tripping

Overheated winding and electromotor surface

Higher current drawn by motor, measured ventilation parameters do not comply with projected values

Adjust the fan parameters to comply with the nameplate values according to the instruction issued by fan manufacturer. Lower temperature or higher specific weight of

air that the nameplate values Faulty electromotor or fuses As per next point

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Annex 2 Wiring diagram of electromotors - examples

!!!WHEN ACOMPLISHING WIRING OF POWER SUPPLY TO THE ELECTROMOTOR ALWAYS PROCEED

ACCORDING TO INSTRUCTIONS AND RECOMMENDATIONS ISSUED BY ELECTROMOTOR’S MANUFACTURER!!

Annex 3 Transmission sheet – SAMPLE I

Basic wiring Wiring with thermistors

Wiring with thermocontacts Three-phase double-speed motors DAHLANDER: (D/YY) (Y/YY) Motors: 4/2 and 8/4

Three-phase double-speed motors Double wiring: (Y/Y) Connection for two separated wirings 6/4

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Transmission sheet of fan belt drive - applicable for tensioning using GATES pen

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Annex 4 Transmission sheet – SAMPLE II

Transmission sheet of fan belt drive – applicable for tensioning using sonic belt tension meter GATES SONIC TENSION METER model 507C.

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Annex 5 Material and dedicated tools needed for special installation and assembly works (not included in the fan package delivery) • Puller (for impeller pulling off the shaft).

• Mechanical measuring instrument for belt tension measuring GATES Tension Tester (pen type).

• Acoustic measuring instrument for belt tension measuring GATES SONIC TENSION METER model 507C.

• Ruler or laser ruler GATES (alignment of front faces of pulleys into one plane)

• Gauge - for measuring of abrasion of pulley grooves sides.

Fig. 25 Measuring instrument for belt tension GATES – Tension Tester and SONIC

Fig. 26 Laser ruler GATES

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13. SUPPLEMENT Associated codes, directives and regulations ČSN EN ISO 4017 Bolts with hexagonal head with thread up to the head - production

class A and B

ČSN EN ISO 4032 Hexagonal nut, type 1 - production class A and B

ČSN EN ISO 7089 Flat circular washers - ordinary type - production class A

ČSN 02 1739 Washers for I, U, IE, UE sections

ČSN 02 3109 V-belts of standard cross-section shape

ČSN 12 2002 Fans. General safety requirements.

ISO 14694:2003 Industrial fans -- Specifications for balance quality and vibration levels

ISO 14695:2003 Industrial fans -- Method of measurement of fan vibration

ČSN 33 2000-4-41 ed. 2 Low voltage electrical installations - part 4-41: Protection measures ensuring safety - Electrical shock protection.

ČSN 33 2000-5-51 ed. 3 Low voltage electrical installations - part 5-51: Choice and construction of electrical equipment - General directives.

ČSN 33 2000-5-54 ed. 2 Low voltage electrical installations - part 5-54: Choice and construction of electrical equipment - grounding, protection wires a wires for protection cross-bonding

ČSN 33 2030 Electrostatic - regulations for avoiding static electricity hazard

ČSN 33 2190 Electrical regulations. Connecting electrical machines and electromotor drives to power supply

ČSN 34 3205 Servicing and operating electrical machines with rotating parts

ČSN 35 0010 Electrical machines with rotating parts. Testing.

ČSN EN 13501-1+A1 Fire rating of products for buildings and constructions - part 1: Rating according to results of test of reaction to fire

ČSN 73 5105 Production industrial buildings

ČSN 33 2000-1 ed. 2 Low voltage electrical installations - part 1: basic criteria, determining basic characteristics, definitions

Act No.185/2001 Coll. Act on waste and changes of some other acts

Regulation No. 50/1978 Coll. Regulation on competency required for working on electrical installations

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Prepared by: JANKA ENGINEERING, s. r. o.

JANKA ENGINEERING, s. r. o. Vrážská 143,

153 01 Prague 5, Radotín

tel.: + 420 251 088 777

e-mail: [email protected]

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