Manual

ManualsBrandsAerovent ManualsFansES-2-06

INSTALLATION, OPERATION & MAINTENANCE MANUAL

Fans with CE Mark

ENGINEERING SUPPLEMENT

ES-2-06

Issue Date: 7-1-06

Rev. Date: NEW

Contents

Introduction .........................................................................1

Personal Protection ............................................................

Hazardous Materials ..........................................................

Installation

Shipping and Receiving ................................................

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

Unit Storage ...................................................................

Foundations and Supporting Structures

- Industrial Fans .......................................................

Fan Installation - Factory Assembled Units ...............

Fan Installation - Disassembled Units ........................

Bearing Installation ........................................................

Grouting ..........................................................................

Drive Mounting ..............................................................

Flexible Couplings .........................................................

Duct Connections ..........................................................

Guards and Enclosures ................................................

Electrical Supply and Controls ....................................

Maintenance

Motor Maintenance .......................................................

Drive Maintenance .......................................................

Bearing Maintenance ...................................................1 0

Wheel and Shaft Maintenance ...................................1 0

Structural Maintenance ............................................... 10

Fan Operation

Proper Use and Application ......................................

Sound ...........................................................................

Operation Checklist .....................................................

Optional Accessories ...................................................

Troubleshooting Guidelines .........................................

Disposal ........................................................................

Appendix A - Commercial Ventilator Installation

Instructions ...................................................................

Appendix B - Axial Fans ................................................

Introduction

This bulletin has been prepared to guide the users of

fans in the proper installation, operation and mainte

nance procedures to insure maximum equipment life

with trouble-free operation. Personnel operating or main

taining this equipment shall be trained in the proper

procedures for doing so.

Since many fans of this type have custom features or

components, please refer to the attached documentation

and appendices for additional information. When manu

facturers of components provide detailed installation and

operation manuals, they will be provided. Because of the

wide variety of equipment covered in this bulletin, the

instructions given here are general in nature.

For safe installation, startup and operational life of

this equipment, it is important that all involved with the

equipment be well versed in proper fan safety practices

and read this bulletin. Please review the safety section

before beginning any work. It is the user’s responsibil

ity to make sure that all requirements of good safety

practices and any applicable safety codes are strictly

adhered to. Only properly trained personnel should oper

ate and maintain this equipment.

Personal Protection

For safety reasons maintenance personnel should wear

personal protection equipment when attempting to main

tain fans. People with long hair are advised to tuck hair

back possibly into a cap.

Personal protection equipment should include the

following:

• Safety glasses or goggles approved by local safety

authority

• Protective shoes with steel toecaps and oil resis-

tant soles

• Heavy gloves that can cope with sharp edges or

exposure to hazardous chemicals. This is especially

important when hazardous residues are present in

fans.

• Breathing apparatus if toxic gases or vapors are

expected to be present.

• Close fitting clothing

Do not wear:

• Rings

• Bracelets

• Necklaces

• Loose items of clothing

It is the responsibility of the maintenance personnel

to determine that the lighting is sufficient for the work

being performed. Additional portable lighting may be

required as there are no lighting fixtures supplied with

the fans.

Hazardous Materials

Twin City Fan Companies, Ltd. is not always made

aware of the materials that may be handled with a fan

and therefore can not warn the user of these hazards.

Because of this, the end user must identify the mate

rial hazards present and indicate this on the fan with

a warning label. If there is risk of residual hazardous

material being left in a fan if the gas or vapor being

handled can accumulate as a deposit, all maintenance

and operation personnel must be trained to handle such

hazards before having access to the fan.

Lubricants used on fan components could be hazard

ous if they contact someone’s eyes or are consumed.

For additional general safety practices for air moving

equipment, see AMCA Bulletin 410.

Installation

Shipping and Receiving

All Twin City Fan Companies, Ltd. products are carefully

constructed and inspected before shipment to insure the

highest standards of quality and performance. Compare

all components with the bill of lading or packing list to

verify that the proper unit was received. Check each unit

for any damage that may have occurred in transit. Any

damage should be reported immediately to the carrier and

the necessary damage report filed.

Summary of content (16 pages)

PAGE 1
ENGINEERING SUPPLEMENT INSTALLATION, OPERATION & MAINTENANCE MANUAL Fans with CE Mark ES-2-06 Issue Date: 7-1-06 Rev. Date: NEW Contents Personal Protection Introduction ......................................................................... 1 Personal Protection ............................................................ 1 Hazardous Materials .......................................................... 1 Installation Shipping and Receiving ................................................
PAGE 2
Handling Handling of all air moving equipment should be conducted by trained personnel and be consistent with safe handling practices. Verify the lift capacity and operating condition of handling equipment. Maintain handling equipment to avoid serious personal injury. On most units, lifting lugs are fashioned to protect the fan and fan housing from damage. Secure lifting equipment to all provided lifting lugs to avoid instability while moving the equipment.
PAGE 3
sleeve with a diameter of 2 to 21⁄2 times the anchor bolt diameter should be provided around the anchor bolt for final adjustment (see Figure 2). The mounting surface of the foundation should be smooth for good shim contact. When deciding the thickness of the foundation, approximately 25 to 40mm height should be allowed for shimming, grouting, leveling, washers, nuts, etc. The foundation plan on the customer submittal drawing indicates the mounting hole size and locations on the fan. Figure 2.
PAGE 4
11. Check that bearings are fully lubricated and check the oil level in the static oil lube systems (if supplied). bore hubs), or for bushing bore hubs, progressively tighten the bushing bolts per Table 3. Record the measured torque value. 12. Install any accessories shipped loose from the factory. c. Insert shaft through opening in drive side. (If splithoused unit, lower into position.) Fan Installation - Disassembled Units d. Install bearings onto shaft. Do not tighten bearing setscrews at this time.
PAGE 5
10. Mount drives as follows: a. Slip (do not pound) proper sheave onto corresponding shaft. CAUTION: PLACING FAN SHEAVE ON MOTOR CAN OVERSPEED WHEEL AND CAUSE STRUCTURAL FAILURE. b. Align sheaves with a straight- Figure 5. edge extended along the Sheave Alignment perimeters of both sheaves, just making contact in two places on outside perimeters of both sheaves (see Figure 5). Parallel alignment should be within 5mm per meter of center distance. Angular Misalignment should be less than 1 degree. c.
PAGE 6
Twin City Fan Companies Engineering Supplement 2-06 522 - - 526 - - - 528 - 532 534 536 538 3.938" 105mm 110mm 4.438" 115mm 120mm 125mm 4.938" 135mm 5.438" 140mm 150mm 5.938" 160mm 6.438" 170mm 6.
PAGE 7
Table 2c.
PAGE 8
Grouting Grouting is the final installation step. Check all shims before grouting to make sure that the fan is resting evenly on all points with anchor bolts secured to hold the shim. Use forms with sufficient space allowed for working the grout. The concrete foundation should be clean and well moistened before pouring grout. Use a commercial grade non-shrinking grout and be especially sure when pouring grout that the anchor bolt sleeves are filled.
PAGE 9
• Plug and Plenum fans. These fans are intended for installation in a user supplied enclosure. Twin City Fan Companies, Ltd. rarely knows the details of the enclosure and therefore can not provide guarding based on the needs of the final installation for these types of fans. The user must verify that the enclosure a plug or plenum fan is located in is compliant with EN 953 and EN 294 and EN 811. Guards shall not be removed during fan operation as this could cause severe injury.
PAGE 10
Drive Maintenance V-belt drives need periodic inspection, re-tensioning, and occasional belt replacement. Follow Table 5 on page 11 for drive inspections and maintenance. Proper belt tension can be found on the included datasheet specific to each fan. A log should be kept with belt tension and replacement information. Bearing Maintenance Proper lubrication of the fan drive bearings helps assure maximum bearing life.
PAGE 11
Table 5. Drive Maintenance and Inspection TYPE OF MAINTENANCE WHEN TO DO WHAT TO DO Check for sheave groove wear Initial inspection: 8 hours. Second inspection: 24 hours. Third inspection: 100 hours. Periodically thereafter. Check for belt ride in the groove. In multiple groove drives, belt ride should be uniform, not more than 1/16" above or below top of sheave groove. Check groove wear area for wear. Side wall of groove should be straight, not dished out.
PAGE 12
Operation Checklist M Verify that proper safety precautions have been followed. M Electrical power must be locked off. Check fan mechanism components: M Nuts, bolts, setscrews are tight per Tables 1 - 4. M Mounting connections are properly made and tightened. M Bearings are properly lubricated. M Wheel, drives and fan surfaces are clean and tightened. M Rotating assembly turns freely and does not rub. M Drives on correct shafts, properly aligned, and properly tensioned.
PAGE 13
Air Capacity Problems 1. Resistance of the system is not at design rating. If resistance is lower than expected, both airflow and horsepower may be up. If resistance is higher than anticipated, air volume will be down. 4. Damaged rotating components (bearings, shaft, fan, wheel, sheaves). 2. Fan speed is not at design speed. 7. Vibration transmitted by another source. 3. Air density is not at the design value. Also check air performance measurement techniques/procedures. 8.
PAGE 14
Appendix A – Commercial Ventilator Installation instructions (cont'd) Figure 9. Hooded Ventilators Hooded units sizes 12 to 42 use a one-piece hinged hood. To lift the hood, remove the two bolts located under the mushroom cap and prop the hood up with the supplied safety rods. Push and lock into place. A screw is installed at the end of the pin side of the hinge in the hood angle to prevent accidental removal of the hood. To close the hood, replace the bolts to lock in place.
PAGE 15
Figure 10. TCVX Blade Angle Adjustment Blade Leading Edge 3. Twist each blade to the desired blade angle. 4. Re-tighten the blade retaining bolts to the torque shown in Table 7. Work in a star pattern, working your way up to the desired torque in steps. Tightening one bolt to the full torque before moving on to the next can crack the hub. Hub 5 4 5.0" 3 " 25.0 Detail "X" Figure 12. "E" Prop Blade Angle Indicating Marks 5 4 Blade 2.
PAGE 16
4. Repeat steps 1 through 3 for all blades. Make sure all blades are set at the same mark. 4. Tighten elastic stop nuts evenly and torque to the following foot-pounds: 5. After all blades are set at a new angle, run the fan for a few minutes and then re-torque all blade bolts. Table 8. U-Bolt Torque for Aerovent Blades Blade Adjustment on Aerovent Reversible Adjustable Pitch Propeller Assembly Procedures 1. Lay hub on a horizontal surface with openings of shank sockets (Figure 15) facing up.