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Web : www.flaktwoods.com

INSTRUCTION MANUAL

Page 2 of 41

UID NO.:FAN MANUAL/Flakt2003

CONTENTS INTRODUCTION GL SERIES

4 - 5

FUNCTIONAL DESCRIPTION & DESIGN GL

6

SAFETY PRECAUTIONS

7

CONDITION ON DELIVERY

8

ERECTION ASSEMBLED FAN ASSEMBLY PROCEDURE OF BEARINGS IMPELLER LOCKING ARRANGEMENT SOME IMPORTANT NOTES FANS ON VIBRATION ISOLATOR ACCESSORIES

9 10 - 14 15 16 17 18 - 20

COMMISSIONING PROCEDURE ASSEMBLY & START UP CHECK LIST PRECAUTIONS BEFORE STARTING CHECK UP DURING RUNNING

21 22 23

INSTRUCTION MANUAL

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UID NO.:FAN MANUAL/Flakt2003

CONTENTS MAINTENANCE RUNNING MAINTENANCE SHUTDOWN MAINTENANCE LUBRICATION VIBRATION ACCEPTANCE NORMS LOCATION FIXED & FREE BEARINGS AFTER MOUNTING CLEARANCE OF BEARINGS INLET DIMENSION GF LIST OF SPARE

24 24 25 - 27 28 - 29 30 31 32 33

ANNEX DATA RECORDED DURING TRIAL RUNNING OF FAN DOS & DON'T'S BRIEF DESCRIPTION OF FAN COMPONENTS TROUBLE SHOOTING CAN HELP WHEN YOU SUSPECT A PROBLEM

34 35 36 37 - 39

HOW TO ORDER

40

ADDRESS & CONTACT NO.

41

YOUR FANS.. .. DESCRIPTION AND IDENTIFICATION

INSTRUCTION MANUAL

Page 4 of 41

UID NO.:FAN MANUAL/Flakt2003

INTRODUCTION

GL FAN

GL series is a centrifugal fan suitable for application such as ventilation, air conditioning, air handling units and also industrial purpose. It is belt driven and available in single and double inlet versions. The side plates of the casing are rectangular and this facilitates the installation of the fans in plants and air handing units. It eases transportation problems for large sized fans which may be dispatched in a dismantled condition if required.

GF is available in the following arrangements : Arrangement 3 : In this arrangement, the impeller is single inlet single width (SISW) and simply supported design, i.e. the impeller is placed between bearings. The fan is belt driven Arrangement 5 : In this arrangement, the impeller is double inlet double width (DIDW) with simply supported design and is belt driven.

INSTRUCTION MANUAL UID NO.:FAN MANUAL/Flakt2003

Arrangement 3 :

Arrangement 5 :

Page 5 of 41

INSTRUCTION MANUAL

Page 6 of 41

UID NO.:FAN MANUAL/Flakt2003

FUNCTIONAL DESCRIPTION AND DESIGN

GF FAN STANDARD CONSTRUCTIONAL FEATURES Mechanical Design (Fig 10) The static parts of the fan consist of the following: 1. Casing (either single piece or of bolted design) including inlet cone and bearing pedestal. 2. Motor bracket (optional accessory). 3. Inbuilt fan guide vane (optional accessory). The rotor of the fan consist of the following parts: 4. Impeller 5. Shaft with bearing and bearing housing. 6. V-belt drive with guard.

Additional Accessories and Features In case flow control is needed by means of damper an in-built guide vane alongwith driving lever is provided. A standard design of motor bracket is also available. The fan is also suitable to be mounted on vibration isolators with a common base frame.

INSTRUCTION MANUAL

Page 7 of 41

UID NO.:FAN MANUAL/Flakt2003

SAFETY PRECAUTIONS

The operation and maintenance of machinery of any kind requires a person to be cautions and aware of the damages that exist. In order to avoid injuries to personal and damage to machinery, the following precautions are very important. 1.

Never apply power to the fan motor for any reason until the fan has been completely installed in its system, and the system inspected to be sure that no debris has been left in the fan & ducts, and it is known that the inspection doors at the inlet and outlet of the air passages are shut. The usual procedure is to remove the fuses from the disconnect switch and open its safety isolation switch until the installation is completed and inspected.

2.

Start the fan momentarily and disconnect it. Observe rotation of the wheel or the drive rotation is correct. Do not allow the fan to run backward, except momentarily.

3.

Do not open or access inspection doors while the fan is running.

4.

Always open the disconnect switch and lock it in the open position with a padlock before doing any service or maintenance work on the fan.

5.

After service of any kind make certain that all adjustment have been properly made and tightened ,inspection doors closed, there is no debris in the air passages and all tools have been removed before unlocking the disconnect switch to place the fan in operation.

6.

Make a periodic inspection of the fan wheel, bearings and coupling to be sure that corrosion has not set in to weaken them. Where there are signs of corrosion there is danger of mechanical failure. Corroded parts should be replaced.

7.

Always use caution in every maintenance or operational procedure.

INSTRUCTION MANUAL

Page 8 of 41

UID NO.:FAN MANUAL/Flakt2003

CONDITION ON DELIVERY A. Transport : The fans are dispatched in dismantled condition with proper packing. Handle all fan parts with care. Use lifting lugs and good rigging techniques. Slings and timbers should never be passed through the casing and impeller in order to assist in rigging. Pay particular attention to rotor assembly consisting impeller, hub, shaft, bearing housings and bearings. Avoid any shocks that could damage the parts and their coatings or alter the impeller balance. If the impeller is damaged slightly, it will have to be repaired and balanced again.

B.

Check for Transportation Damages : When packages are received at site, check all parts with the help of the packing list and drawing. If necessary ,make a list of the missing parts ( in case of shortage) and initiate action for replacement, insurance etc. Check the condition of the parts that may have been damaged during transport. In case of damages, take steps to repair the damages in consultation with manufacturer

C.

Storage : General :As soon as received ,the different parts of the fan should be placed in clean and dry covered premises.

Long term storage

Storage for a period of more than three months must be ensured in the best possible condition, basically protected from dampness so as to avoid oxidisation of the different parts of the fan unit. The mechanical parts with machined surfaces are coated with anti-corrosion varnish. In the case of prolonged storage, before putting in to service, the equipment will be inspected periodically and the machined parts will be protected from time to time using protective coating in case of need. They will be stored in sufficiently large premises, thus providing space for inspection and easy maintenance of the equipment stored. Moreover , the storage premises will protect the equipment from sudden changes in temperature, dust, foreign matter, etc. The impeller and bearing assembly should be rotated at a very low speed ( rotation by hand) for about thirty minutes, once a week.

Storage of bearing As a general rule, the bearings are given a rust prevention treatment in the works before being packed. They can be preserved for several years, in their original packing , on a condition that the relative humidity in the storage premises is not over 60 % A higher degree of relative humidity, up to 75% is however permissible for short term storage.

INSTRUCTION MANUAL UID NO.:FAN MANUAL/Flakt2003

Page 9 of 41

ERECTION ASSEMBLED FANS

1.

Ensure that the concrete foundation has been made at site as per general assembly drawing.

2. Check foundation for evenness, and its different levels. 3. Mark centre lines of fan and foundation pockets on the foundation. NOTE: REFER ENCLOSED GENERAL ASSEMBLY DRAWING. ♦

FOUNDATION BOLTS, FAN ON BASE FRAME: -

4. Place the foundation bolts in all foundation pockets as required and hook up with the common holding rods provided in the foundation. 5. Clean the threaded portion of the bolt. 6. Generally the concrete block foundation provided to support the fan unit should be at a level lower than the final installation level by about 50mm. This clearance allows correction of the civil engineering false level. It is therefore necessary to maintain the center of the fan and the level of installation. 7. Place the steel packers in between the foundation bolts to the required height. 8. Place the base frame on the packers and bolt together at four corners. 9. Fasten the foundation bolts with base frame. 10. Adjust the horizontal level of the base frame by adjusting steel packers by using dumpy level. The dimensions to be maintained as per the GA drawing. Check up the diagonal dimensions for assuring the squareness of the base frame. 11. Place the Fan on Base Frame ; ensure that the fastening bolts are tightened with taper washer.

INSTRUCTION MANUAL

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UID NO.:FAN MANUAL/Flakt2003

ASSEMBLY PROCEDURE FOR BEARING AND BEARING HOUSING The following procedure will be applicable rotor, loose bearings and bearing housings, if and when used.

1. PRE -ASSEMBLY CHECKING : As the bearings are finished to high precision, thorough inspection and checking on the following points are essential prior to assembly : a) On opening the packing of bearings, the same shall be thoroughly checked for dirt or other foreign matter and if found, same shall be carefully washed unless and until it is necessary. b) The shaft shall be checked for damage due to transport and handling. Particularly the surfaces where the bearings are to be mounted should be checked for rusting, scoring etc. Rust, if found, should be removed by rust remover. Heavy pitting on bearing surfaces of shaft is not acceptable. Localized scorings could be removed using oil stone. If the shaft is found to have a bend, the same should not be used for assembly. c) Bearing housings although made by precision machining to the given specifications, a thorough checking is essential to make sure against any defects in the bearing seating surfaces or dirt inclusion which can possibly result from handling, transportation etc. The flaw, if any, is to be carefully corrected with the use of an oil stone or fine emery paper and the dirt to be thoroughly washed off and cleaned. d) Bearing to be mounted shall be taken out of the original protective packing only immediately before mounting. e) The mounting and dismounting tools and necessary jigs must be of proper dimension and simple design so that they do not cause any mechanical damage to the bearings.

INSTRUCTION MANUAL

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UID NO.:FAN MANUAL/Flakt2003

2)

GENERAL INSTRUCTIONS :With tapered bore: A bearing with tapered bore, which is seated direct on a shaft, or which is mounted with an adapter sleeve, ordinarily requires a somewhat tighter fit than a bearing with cylindrical bore. This fit is achieved by pressing on the inner ring by means of a nut or by driving in the sleeve. In both cases, the inner bearing is expanded and this results in a reduction of radial bearing clearance. If a double row self aligning ball bearing is mounted on an adapter sleeve, the sleeve nut might be tightened but not so much as to prevent the outer bearing from turning easily and it must be possible to swing the outer race easily from one side to the other side. Double row spherical roller bearings which are used mostly in heavy load applications are mounted with greater interference. The radial clearance is adapted to this fit and its reduction can be measured while mounting by means of a feeler gauge. For checking the correct fit of the inner ring, both the reduction of radial clearance and the distance of the inner ring is driven axially on the tapered seating or on the adapter sleeve and is measured. For solid shafts, the axial displacement is approximately fifteen times as large as the desired clearance reduction.

ASSEMBLY PROCEDURE a)

Keep the bottom half of bearing housings on the bearing pedestal.

b)

Clean the shaft with the use of white sprit.

c)

Insert the brass seal on to the shaft at impeller end.

d)

Insert the M.S cover plate on to the shaft at impeller end.

e)

Keep the rotor assembly in position but slightly elevated position on supports above the bearing housing bottom halves.

f)

Insert the double - lip seal on to the shaft at impeller end if applicable.

g)

Insert the taper sleeve on to the shaft to the location with thread portion outside.

h)

Locate the bearing position and assemble the lock washer and nut with the taper sleeve. (no locating ring for this bearing as this is free bearing).

INSTRUCTION MANUAL

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UID NO.:FAN MANUAL/Flakt2003

i)

Keep the gap between bearing to bearing housing to accommodate the expansion of shaft as shown in our drawings.

j)

Tighten the lock nut on the taper sleeve. For tightening the nut, do not use steel chisel or rod but use either brass or copper rod for taking the force of hammer. The necessary tightness is achieved when the brass or copper rod flares at the load transfer end. Check for the clearance between roller and outer race as mentioned in SKF catalogue.

k)

Insert the another double-lip seal on to the shaft if applicable.

l)

Now start assembly of drive side (coupling side) bearing by inserting the double lip seal on to the shaft if applicable.

m)

Insert the lock nut and lock washer on to the shaft.

n)

Arrange the locating ring on one side or either side of bearing , as the case may be.

o)

Insert the bearing with large dia of bore facing outside.

p)

Insert the taper sleeve on to the shaft.

q)

Locate the bearing position and assemble the lock washer and nut with the taper sleeve.

r)

Tighten the lock nut as explained in point no.

s)

Now keep the lock washer teeth locked to the lock nut groove by bending.

t)

Insert the another seal on to the shaft.

u)

Rest the rotor on the bottom half of bearing housing.

v)

Lubricate the bearings with recommended grease from one side of the bearing with pressure, so that the grease comes at the other side of the bearing through roller gapes. Check that the bearing is greased uniformly on both sides all around. Fill the bottom half of the bearing housing with grease.

w)

Place the top half bearing housing without applying any grease. Check for free rotation of the rotor assembly.

x)

Tighten the parting off bolts to the correct tightness.

INSTRUCTION MANUAL

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UID NO.:FAN MANUAL/Flakt2003

WITH CYLINDRICAL BORE: The force needed to mount a bearing increases rapidly with bearing size. Larger bearing can not easily be pressed on to a shaft or in to a housing because of the mounting force required. Therefore, the bearing or one bearing ring is heated before mounting. The temperature difference between the bearing and its seating depends on the magnitude of the interference fit and the bearing size. Normally a bearing temperature of 80 to 90ºC (175ºF to 195ºF).

ing to a temperature greater than 125°C(255 °F), however, because the material may change metallurgically and produce alternations in diameter or hardness. Local overheating must be avoided. When using a heating device, use a thermometer to check the bearing's temperature. Wear clean protective gloves when mounting a hot bearing. Lifting (hoisting) gear can facilitate mounting. Push the bearing along the shaft to its abutment and hold the bearing in position, pressing until a tight fit is obtained. SKF can supply heating tools, such as oil baths, induction heaters, heating cabinets and electric and electric plates with adjustable thermostat and cover, for all common mounting needs. When a bearing requires an interference fit in the housing, a moderate inctrease in the housing temperature, from 20 to 50°C (70 to 120°F) is normally sufficient, since the amount of interference is seldom large. A heater or oil bath can be used for the job.

INSTRUCTION MANUAL

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UID NO.:FAN MANUAL/Flakt2003

Bearings with shields or seats should not be heated.

Lifting gear (housing) To facilitate future dismounting equip shafts with ducts and distribution grooves for pressurized oil SKF heaters are generally equipped with adjustable thermostats Nevertheless it is advisable to use a separate thermometer to check bearing temperature immediately before mounting. The thermometer is also useful during test runs and for monitoring bearings during operation

Use clean protective gloves to hold the hot bearing press it hard against the abutment face so that the inner ring fits snugly on the

A cabinet equipped wiyh an adjustable thermostat and a fan is a versatile tool suitable for many heating operations. Bearings of different sizes or a large number of bearings can e heated together in a cabinet. Small bearing housings can also be heated. Keep the cabinet clean to reduce the risk of bearing contamination. Bearings can also be stored hot, ready to mount. In addition to bearings, couplings, sleeves and other components can also be heated in a cabinet.

Oil baths ensure even heating. They also make it possible to heat and maintain a bearing at a certain temperature. Keep the oil in a clean bath to prevent bearing contamination.

Never place a bearing directly in contact with the sides

Bearing rings, or even complete bearings, can be suspended in an oil bath.

INSTRUCTION MANUAL

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UID NO.:FAN MANUAL/Flakt2003

IMPELLER LOCKING ARRANGEMENT SIMPLE SUPPORTED FAN

Fitting of impeller on shaft

OVERHUNG FAN

INSTRUCTION MANUAL

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UID NO.:FAN MANUAL/Flakt2003

Some important notes ! Direction of discharge The fans are supplied in discharge direction as specified in order . This can be altered at site .

! Connection of duct Duct connection of the fan casing must not exert any load directly on the fan as the casing may be deformed and the inlet cone may come in contact with impeller . ! Direction of impeller The direction of rotation is indicated in fan casing .

INSTRUCTION MANUAL

Page 17 of 41

UID NO.:FAN MANUAL/Flakt2003

Erection on vibration isolator ! ! ! ! ! ! ! !

Ensure of grouting pocket positions in civil foundation are as per GA drg. Bolt the isolators with base frame . Insert the grouting bolts in mounting holes of isolators. Place the base frame in position and at it's required elevation , level it in X- Y axis ; provide temporary support under base frame . While positioning the base frame , ensure the grouting bolts are positioned at center in their respective pockets . Grout the isolator pockets Use non shrinkable cement . Remove temporary support only after curing is complete . The isolators are loaded now. Check level of shaft . If required , place shims between base frame and isolator .

Important point to be noted ! The main idea of providing vibration isolator is to avoid transmission of undue vibration from the equipment to the surrounding structure and not to reduce equipment vibration , in fact equipment vibration may be on higher side due to soft foundation and vibration value 10 mm/s ( Peak Value ) is acceptable for Fans. ! We do not normally recommend to use vibration isolator when fans are installed at ground level.

INSTRUCTION MANUAL

Page 18 of 41

UID NO.:FAN MANUAL/Flakt2003

ACCESSORIES ( REFER ASSEMBLY DRAWING FOR ITEMS APPLICABLE) 1.

Fix the evase with fan outlet.

2. Fix the inlet damper with inlet box (wherever applicable) /inlet Ensure correct damper orientation; the close to open direction of damper will be same with that of impeller rotation. 3. Fix the inlet and outlet flexible connection. Ensure flexibility after installation ; For dust application flexible connection are provided with sleeve . Follow the air flow mark for correct installation. 4. Fix the actuator bracket on the casing/foundation 5. Fix the actuator with actuator bracket. 6. Fix the linkage between actuator and damper. The operating lever on the actuator and the lever on the damper should be in parallel and of equal length , for proper operation of the damper. 7. Fix the sealing arrangement on inlet box as shown in fig. 20 8. Bolt the cooling disc halves together on the shaft.

Guard for cooling disc

A Assembly of disc halves

Shaft Dia. D

Tightening torque A

kpm kgfm

Nm Nm

ft lb

25-65

0

3

29.4

21.7

5

49

36.1

80

10

90-100

15

110

25

INSTRUCTION MANUAL

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UID NO.:FAN MANUAL/Flakt2003

9. Weld the cooling disc guard fixing angle on the bearing pedestal as shown in fig. 21. 10. Weld the coupling guard fixing angle on the bearing pedestal. 11. After completing all erection and alignment work, full grouting of the foundation bolts shall be carried out. NOTE : Whenever welding is carried out on the fan parts during erection at site condition, direct earthing to be given, to avoid current passing through the bearings. 52.

Installation of belt pulley. 12

13 11

11) TENSIONING SCREW 12) TENSIONING PAD 13) SLIDE RAILS

V-Belt Section

Force required to deflect V-Belt 16 mm per metre of centre distance Kilogramforce (Kgf) P

Newton (N)

A

1.0 to 1.5

10 to 15

B

2.0 to 3.1

20 to30

C

4.1 to 6.1

D

7.1 to 10.7

70 to 105

E

12.2 to 18.3

120 to 180

40 to 60

C/C

INSTRUCTION MANUAL

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UID NO.:FAN MANUAL/Flakt2003

Never hammer the belt pulley on to or off the shaft, since even light blows and shock may damage the pulley and this will give rise to noise and an abnormally high temperature at bearings. To remove : a)

Remove the screws marked 14, oil them sparingly and screw one of them into the extractor holes marked 15 i.e., the tapped holes in the shaft .

b)

Tighten the screw until the bush is free of the hub and the unit can be removed from the shaft.

c)

Remove the pulley and bush from the shaft as one unit.

To fit : a)

Clean the bottom of the pulley and the inside and outside of the bush to remove any dirt corners or region and make certain that the surfaces are completely free from oil and dirt. Now fit the bush into the pulley.

b)

Oil the screws sparingly and screw them loosely into the tapped holes in the pulley.

c)

Clean the shaft and fit the pulley and bush as one unit on to the shaft.

d)

Tighten the screw alternately until they are all securely tight.

15

14

14

14) SCREW 15) EXTRACTOR HOLE

INSTRUCTION MANUAL

Page 21 of 41

UID NO.:FAN MANUAL/Flakt2003

COMMISSIONING PROCEDURE ASSEMBLY AND STARTING UP CHECK LIST. DESCRIPTION

Tightening of foundation bolts

REMARKS & MEASURED VALUES

:

STATIC PARTS: Positioning of the inlet cone

:

Tightening of fixing bolts on the ducts

:

Tightening of the fixing bolts of static parts

:

Closing of the inspection door

:

ROTOR PARTS: Shaft alignment

:

Tightening of fixing bolts impeller / hub

:

Expansion clearance on the free bearing

:

Alignment of the coupling LUBRICATION: Fan bearings lubrication

:

Inlet damper lubrication

:

UTILITIES: Connection to the electric circuit

:

Connection to the control system

:

INSTRUCTION MANUAL

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UID NO.:FAN MANUAL/Flakt2003

PRECAUTIONS BEFORE FIRST STARTING OR BEFORE STARTING AFTER DISMANTLING 1.

Check the mounting of the bearing housings and electric motor.

2.

Check that the coupling is tightened properly.

3.

Check that the foundation bolts are properly tightened.

4.

Check that the connecting flanges between the fan and ducting are good, and proper packing is provided.

5.

Check that the different components of the control system are correctly connected.

6.

Check that the Inlet damper is fully closed.

7.

Check that no foreign object has been left anywhere in side the fan.

8.

Check that no water stays in the bottom of the casing and inlet box.

9.

Check that the specified guards have been fitted.

10.

Check that the inspection door on the casing and inlet box are correctly shut.

11.

Check that the rotor can turn freely without rubbing with any static parts.

12.

Check that the bearings have been correctly filled with bearing lubricant as it is noted in the section `LUBRICATION”.

FIRST START AFTER ASSEMBLY 1. People responsible for the starting must always stay nearest as possible to the emergency stop switch. 2. The fan is rotating in correct direction

B IMPELLER

P IMPELLER

T IMPELLER

INSTRUCTION MANUAL

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UID NO.:FAN MANUAL/Flakt2003

3. 4. 5.

The fan inlet must be shut. During the acceleration phase, that there is no abnormal noise. Once the fan has reached full speed, open the damper. Check bearing vibration level. The vibration levels indicated in below are in full accordance with the standard VDI 2056. VELOCITY IN mm/sec (RMS) FAN HEALTH CONDITION

FAN ON CONCRETE FOUNDATION

FANS ON VIBRATION ISOLATOR

ADMISSIBLE

4.5

7

STILL ADMISSIBLE

11

18

ALARM LEVEL TRIP LEVEL

12.0 13.0

19 20

Check that the bearing temperature is good. Normally this temperature first raises and then decreases and stabilizes at particular temperature. SET THE ALARM POINT AT 100 ° C. SET THE TRIPPING POINT AT 110 ° C. If the bearing temperature is too high, this generally indicates:

♦ Improper assembly ♦ Inner clearance is too small ♦ Jamming of bearings ♦ Excessive friction of seal Improper lubrication in quantity or quality.

Check up the noise of the bearing housings : ♦ Grinding noise

:

♦ Whistling Clear noise at regular intervals ♦ Intermittent noise ♦ Cracking noise

: :

Inadequate lubrication (Surface rubbing directly against one another Improper lubrication (Grade or quantity) Imprints in race of outer ring because of abnormal vibration.

:

Rolling part deteriorated or damaged

:

Presence of foreign particles

♦ Whining or high pitch noise

:

Axial thrust from motor.

INSTRUCTION MANUAL

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UID NO.:FAN MANUAL/Flakt2003

MAINTENANCE RUNNING MAINTENANCE 1. Fill bearing lubricant of recommended specification and quantity at the specified intervals for bearing housings. The interval should be determined based on local condition like working environment etc. 2. Check periodically vibration levels of the fan at both bearings. 3. Check periodically the proper seating of fan on the foundation and for abnormal vibration at any location. 4. Check for looseness of any bolts in the fan pedestals, casing, etc.

SHUT DOWN MAINTENANCE: 1. Open inspection door in casing. Clean the impeller blades and internals. 2. Check for erosion of the impeller. 3. Check the overlap and radial clearance between impeller shroud and inlet cone. If found disturbed adjust the same. 4. Remove used bearing lubricant from bearing housing. 5. Check the bearing condition like roller clearance and the rolling surfaces of races. 6. Fill new lubricant in the bearing housing. 7. Check alignment of fan and motor. If necessary correct the same. 8. Check the Inlet damper flaps movement. 9. Apply grease for Inlet damper bearing housings. 10. Check the tightness of all fixing bolts.

INSTRUCTION MANUAL

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UID NO.:FAN MANUAL/Flakt2003

LUBRICATION FAN BEARINGS (GREASE LUBRICATION) Requirement : Consistency class : NLGI 2 (National Lubrication Grease Institute scale) COMPANY IOCL

BRAND NAME SERVO Grease WR 2

Quantity : Press grease from one side of the bearing till it comes out through the opposite end. Continue the process and rotate the impeller slowly by hand till the bearing is completely filled with grease. Put some extra grease (not more than 1/3 rd of inside volume of Plummer block) inside the Plummer block. Before Commissioning Existing Grease to be taken out from the Bearing Housing and SERVO Grease WR 2 to be filled as per the above mentioned procedure. Note : Over greasing will cause overheating of bearing . FAN BEARINGS (Oil LUBRICATION) Requirement : Viscosity Grade 68 Type of Lubrication: Oil bath and circulation ring. Lubrication : Mineral oil with anti foam, corrosion and anti oxidation additives. Suggested lubricants : BHARAT HYDROL 68 , SERVO SYSTEM 68 or Equivalent. Filling per bearing housing: As per maximum and minimum mark given on the Oil level indicator.(revert to us in case of any doubt) Note : Do not exceed the maximum mark , since excess oil would result overheating And oil leakage thru’ the shaft passage. INLET DAMPER According to the installation conditions and the operating frequency of the inlet damper following should be lubricated. VANE BEARINGS : Make sure when topping up that the spent grease is discharged normally. LINK ROD PINS : Apply grease after cleaning if required. Lubrication interval : Normally three months, to be changed as and when required.

INSTRUCTION MANUAL

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UID NO.:FAN MANUAL/Flakt2003

Lubrication interval and amount Grease For fans provided with spherical roller bearing, the bearings housing are fitted with grease nipples and are fitted with the correct amount of grease when requested. The lubrication intervals and the amount of grease necessary for relubrication The chart is based on a temperature of 70°C. For every 15°C increase in temperature the lubrication interval should be reduced to 50% of the value obtained from the chart. (Example : For a fan fitted with spherical roller bearings with the bearing bore diameter of 120mm and running at 1000RPM the relubrication interval will be 800 operating hours if the bearing's temperature does not exceed 70°C).

Oil

When inspecting the oil level of a bearing, check to ensure that the right type of oil is in use and that the oil level gauge's air vent is unobstructed. Take a small sample of the oil and compare it with fresh oil. If the sample look's cloudy, then it is mixed with water and should be replaced. Dark or thick oil is a sign of dirt or indicates that the oil has started to carbonize. Change the oil completely and, if possible, clean the bearing by flushing it with fresh oil . When changing the oil, be sure that you are using the same type of oil , and that you refill to the required level . A more reliable method for determining the oil condition is to analyze a sample . If the oil is contaminated it may be worthwhile to change the seals or consider filtration . Oil in oil bath circulation systems requires change only once each year, providing that the operating temperatures does not exceed 50 to 60 º C and the oil does not become contaminated . Change the oil four times each year for operating temperatures of 100 º C ; monthly for operating temperature of 100 º C.

INSTRUCTION MANUAL

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UID NO.:FAN MANUAL/Flakt2003

RELUBRICATION INTERVALS IN OPERATING HOUR

d= m m 10

20 40

60 80 100 120

1.5

3

5 103 4.5 9 4 8 3.5 7 6 2.5 5 2 4 1.5 3

2 1.5

2 10 7.5 1.5

10 9 8 7 6 5 4

360

7.5

160 200 240 280

3

500

1.5

D = DIAMETER OF BEARING

420

c b a 2.5 2.5 3 4 2 2.5 10 2 6 1.5 1.5 4 4 10 4 2 8 10 3 6 9 10 87 4 8 3 6 6 5 2.5 5 4 2 4 3 1.5 3 2.5 2.5 2 10 2

t = operating hours

2

2

10

2

10 2 10

2

3

4 5 6 789 103

2

3 4 5 6 7 89 104

2

N = RPM

a : radial ball bearings b : cylindrical roller bearings c : spherical roller bearings, taper roller bearings, thrust ball bearings; full complement cylindrical roller bearing (0.2 t); crossed cylindrical roller bearings with cage (0.3 t); cylindrical roller thrust bearings, needle roller thrust bearings, spherical roller thrust bearings (0.5 t). General formula for

relubrication amount : G = 0.005 DB G = Grease qty. in gm D = Bearing OD in mm B = Bearing width in mm AT MOUNTING AT RE-LUBRICATION

SHAFT DIAMETER - mm 160

65

80

90

100

110

125

135

140

150

gm

240

310

340

380

470

680

850

1000

1800 2200

gm

24

40

55

70

80

110

130

150

130

150

INSTRUCTION MANUAL

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UID NO.:FAN MANUAL/Flakt2003

VIBRATION ACCEPTANCE NORMS AS PER VDI2056/ISO2372 FOR RIGIDLY MOUNTED FANS

400

µ 315

160

IN

125

RM Sva lue

100 80

A

D

M

IS

S

s

Displacement amplitude s

200

Displacement s

250

IB

LE of S T vib IL ra tio L nv A D elo M cit IS y S v A I D B = LE M rm 11 IS s mm S /s IB LE G O O D

63 50 40 31.5 25 20

v rm

=

s

16

v rm

s m/ 5m 4.

12.5

=

s

10

/s mm 1.8

6.3 5 4 3.15 2.5 2.0 1.6

Vi br at ion lev el v of rm hu s= ma 0. np 11 mm er ce /s pt ion

1.25 1.0 315

400

500

630

800

1000

1250

1600

2000 2500 3150

4000 5000 6300 8000 10000 12500 16000 20000 25000

Fig. 13 Example of Vibration Severily for Machine Class III.

Frequency in cpm

INSTRUCTION MANUAL

Page 29 of 41

UID NO.:FAN MANUAL/Flakt2003

VIBRATION ACCEPTANCE NORMS AS PER VDI2056/ISO2372 FANS ON VIBRATION ISOLATOR MACHINE CLASS IV 400

µ 315

Displacement amplitude s

200 160

I N RM A D SM va I lu S e S of S T I vib I B L r L a L E tio A n D ve M lo ci I ty S S A I D v B M L I E S S I B L E

125 100 80 63 50 40 31.5 25

v rm

O

O

=

s

D

v rm

12.5

18 mm /s

s m/ 7m

G

16

=

=

s

20

s

Displacement s

250

s m/ 8m 2.

10 8 6.3 5

Vi br at io n

4 3.15

v

rm s

2.5 2.0 1.6 1.25

le ve lo f hu = ma 0. 11 mm n pe rc /s ep tio n

1.0 315

400

500

630

800

1000 1250 1600 2000 2500 3150

4000 5000 6300 8000 10000 12500 16000 20000 25000

Fig. 14 Example of Vibration Severily for Machine Class IV.

Frequency in cpm

NSTRUCTION MANUAL

Page 30 of 41

UID NO.:FAN MANUAL/Flakt2003

LOCATION OF FIXED AND FREE BEARING

FREE BRG.

FIXED BRG.

INSTRUCTION MANUAL

Page 31 of 41

UID NO.:FAN MANUAL/Flakt2003

AFTER MOUNTING CLEARANCE OF BEARING WITH TAPERED BORE

NUT ADEPTER SLEEVE

Bearing bore diameter d

Reduction in radial internal clearence

Over incl.

min

mm

mm

30 40 50 65 80 100 120 140 160 180 200 225 250 280 315 355 400 450 500 560 630 710 800 900 1000 1120

40 50 65 80 100 120 140 160 180 200 225 250 280 315 355 400 450 500 560 630 710 800 900 1000 1120 1250

BEARING LOCKING WASHER

0.020 0.025 0.030 0.040 0.045 0.050 0.065 0.075 0.080 0.090 0.100 0.110 0.120 0.130 0.150 0.170 0.200 0.210 0.240 0.260 0.300 0.340 0.370 0.410 0.450 0.490

max

Axial drive-up Taper 1:12 on diameter min

max

Taper 1:30 on diameter

min

max

mm 0.025 0.030 0.040 0.050 0.060 0.070 0.090 0.100 0.110 0.130 0.140 0.150 0.170 0.190 0.210 0.230 0.260 0.280 0.320 0.350 0.400 0.450 0.500 0.550 0.600 0.650

0.35 0.4 0.45 0.6 0.7 0.75 1.1 1.2 1.3 1.4 1.6 1.7 1.9 2.0 2.4 2.6 3.1 3.3 3.7 4.0 4.6 5.3 5.7 6.3 6.8 7.4

Minimum permissible residual clearance after mounting bearings with initial clearance Normal

C

3

C

4

mm 0.4 0.45 0.6 0.75 0.9 1.1 1.4 1.6 1.7 2.0 2.2 2.4 2.7 3.0 3.3 3.6 4.0 4.4 5.0 5.4 6.2 7.0 7.8 8.5 9.0 9.8

1.75 1.9 2.75 3.0 3.25 3.5 4.0 4.25 4.75 5.0 6.0 6.5 7.75 8.25 9.25 10 11.5 13.3 14.3 15.8 17 18.5

2.25 2.75 3.5 4.0 4.25 5.0 5.5 6.0 6.75 7.5 8.25 9.0 10 11 12.5 13.5 15.5 17.5 19.5 21 23 25

0.015 0.020 0.025 0.025 0.035 0.050 0.055 0.055 0.060 0.070 0.080 0.090 0.100 0.110 0.120 0.130 0.130 0.160 0.170 0.200 0.210 0.230 0.270 0.300 0.320 0.340

0.025 0.030 0.035 0.040 0.050 0.065 0.080 0.090 0.100 0.100 0.120 0.130 0.140 0.150 0.170 0.190 0.200 0.230 0.250 0.290 0.310 0.350 0.390 0.430 0.480 0.540

0.040 0.050 0.055 0.070 0.080 0.100 0.110 0.130 0.150 0.160 0.180 0.300 0.220 0.240 0.250 0.290 0.310 0.350 0.360 0.410 0.450. 0.510 0.570 0.640 0.700 0.770

INSTRUCTION MANUAL

Page 32 of 41

UID NO.:FAN MANUAL/Flakt2003

Inlet dimension - GF FAN S IZ E

FA N T YPE G F ( A ,B ) B G (M M )

GFAF

H (M M ) M IN

m

S (M M )

MAX

m

M IN

m

MAX

025

3 to 6

2

5

4

6

031

3 to 6

2

5

5

9 ,3

040

3 to 6

2

8

6

10

050

3 to 6

2 ,5

9 ,5

6

10

063

3 to 6

4

11

6

15

071

3 to 6

9

+- 4

6

15

080

3 to 6

10

+- 4

090

3 to 6

11

+- 4

10 0

3 to 6

1 2 ,5

+- 4

112

3 to 6

16

+- 4

12 5

3 to 6

16

+- 4

14 0

3 to 6

18

+- 4

16 0

3 to 6

20

-

IMPELLER

+ 5

S

G

H

m

INLET

INLET

INSTRUCTION MANUAL

Page 33 of 41

UID NO.:FAN MANUAL/Flakt2003

LIST OF SPARES The following spare parts are recommended to be kept as stand by for two years normal operating condition. Quantity of replacement depends on individual application. 1. 2. 3. 4. 5.

Impeller with shaft and hub. Fixed bearing . Refer drg. for brg. No. Free bearing . . Refer drg. for brg. No. Brass sealing plates(if applicable) Coupling : - . Refer drg. for type and size.

INSTRUCTION MANUAL UID NO.:FAN MANUAL/Flakt2003

Page 34 of 41

ANNEX

DATA RECORDED DURING TRIAL RUNNING OF FAN CUSTOMER:

FAN TYPE:

ORDER REF. No.: DATE

APPLICATION: :

STARTED AT :

RUNNING

DURATION : AMBIENT TEMP:

ACCEL.TIME :

STOPPED AT

MEDIUM TEMP.:

NO LOAD CURRENT :

:

VIBRATION LEVEL RECORD: DISPLACEMENT IN MICRONS (PEAK TO PEAK) -VELOCITY IN mm / sec.(RMS). H - Horizontal, V - Vertical, A - Axial MEASUREMENT LOCATION

H Dis. / Vel.

V Dis. / Vel.

A Dis. / Vel.

FAN SPEED & DAMPER POSITION

FAN DE. BEARING FAN NDE. BEARING MOTOR DE. BEARING MOTOR NDE. BEARING

SL.NO.

TIME

FAN BRG.TEMP °C DE

NDE

MOTOR BRG.TEMP °C DE

NDE

1 2 3 4 5 6 7 CHECKED BY:

WITNESSED BY :

MOTOR POWER kW

INSTRUCTION MANUAL

Page 35 of 41

UID NO.:FAN MANUAL/Flakt2003

ANNEX DO‛S & DONT‛S DO‛S : 1.

FILL

BEARING

LUBRICANT

OF

RECOMMENDED

SPECIFICATION

AND

QUANTITY AT THE SPECIFIED INTERVALS FOR BEARING HOUSING. 2. CHECK PERIODICALLY THE VIBRATION LEVELS ON BOTH THE BEARINGS OF THE FAN. 3. CHECK PERIODICALLY THE PROPER SEATING OF THE FAN FOUNDATION AND FOR ABNORMAL VIBRATION AT ANY LOCATION. 4. CHECK FOR LOOSENESS OF ANY BOLTS IN THE FAN PEDESTALS AND CASING ETC. 5. AT THE TIME OF ERECTION / COMMISSIONING, OPEN THE BEARING HOUSING AND CHANGE THE OLD OIL. CHECK IF ANY DIRT OR DUST IS SETTLED

INSIDE

THE

HOUSING

AND

CLEAN

THOROUGHLY

BEFORE

POURING NEW OIL. 6. ENSURE THE DAMPER IS IN CLOSED CONDITION WHILE STARTING THE FAN. 7. PROVIDE INSULATION OVER THE ENTIRE AREA OF FAN COMPONENTS FOR HIGH TEMPERATURE FAN.

DONT‛S : 1.

DON‛T REMOVE THE INSPECTION DOOR WHEN THE FAN IS IN RUNNING CONDITION.

2. WHILE SHUT DOWN, ENSURE THE MOTOR POWER CONNECTION IS REMOVED BEFORE ANYBODY ENTERS IN TO THE FAN FOR ANY VERIFICATION.

INSTRUCTION MANUAL

Page 36 of 41

UID NO.:FAN MANUAL/Flakt2003

ANNEX BRIEF DESCRIPTION OF FAN COMPONENTS

1. CASING WITH INLET BOX

"

IT HOUSES ROTOR & INLET CONE.

2. BASE FRAME

"

IT SUPPORTS CASING, INLETBOX, BEARING PEDESTAL & MOTOR.

3. BEARING PEDESTALS

"

THIS IS FOR MOUNTING OF BEARING HOUSING.

4. BEARING & BEARING HOUSING

"

THIS HAS BEEN BRIEFED IN OUR O&M MANUAL UNDER THE HEADING “ASSEMBLY PROCEDURE FOR BEARING & BEARING HOUSING”

5. INLET CONE

"

IT GUIDES THE ENTRY OF FLOW MEDIA TOWARDS THE IMPELLER.

6. DAMPER/IVC

"

TO GUIDE AND CONTROL THE FLOW AT THE INLET SIDE.

7. INLET/OUTLET FLEXIBLE CONNECTIONS

"

THIS IS TO TAKE CARE OF THE CONNECTION DUCT MOVEMENTS WHEN THE FAN IS IN OPERATION.

8. ROTOR ASSEMBLY

"

THIS IS COMPRISING OF IMPELLER,SHAFT,HUB, BEARING & BEARING HOUSING. IMPELLER BLADES ARE BACKWARD CURVED DESIGN.

INSTRUCTION MANUAL UID NO.:FAN MANUAL/Flakt2003

Page 37 of 41

ANNEX

Troubleshooting can help when you suspect a problem TYPICAL PROBLEM

POSSIBLE CAUSE Mounting of Fan Misalignment during installation Impeller Unbalance during operation

VIBRATION

SOLUTION

Inadequate mass or stiffness of supporting structure Shaft, coupling between shaft and drive, belt pulley , shaft got bent Material build-up, corrosion, wear

Stiffen /Increase weight Correct alignment

Looseness

In the mounting, Between shaft and impeller, coupling / pulley or bearing

Aerodynamics

Inlet condition non-uniform, pre-rotation of the air, system effect, pulsation due to fan operating at surge zone

Vibration

Impeller unbalance during operation Inadequate mass or stiffness of supporting structure Wrong type, overlubrication

Mounting PREMATURE BEARING FAILURE

AREA TO CHECK

Lubrication

Environment

Contaminants in lubricant, Ambient temperature high .

Install vibration monitor to check the trend ; Clean the impeller periodically ; Take preventive action for corrosion and wear; In-situ balancing of impeller Tighten fastening bolts ; Replace coupling .pulley; tighten bearing adapter sleeve as per tolerance given in SKF catalogue. Duct layout to be modified; baffle plate /straighteners may be used to achieve uniform flow; Selection of fan to be reviewed. In-situ balancing Stiffen /Increase weight Check recommended lubrication , quantity and interval Change lubricant immediately; Review selection of lubricant .

INSTRUCTION MANUAL UID NO.:FAN MANUAL/Flakt2003

Page 38 of 41

ANNEX

Troubleshooting can help when you suspect a problem TYPICAL PROBLEM

PREMATURE BEARING FAILURE

AREA TO CHECK

SOLUTION

Alignment

Shaft alignment, overtightened bearings

Loading

Radial and/or thrust

Load

Overload from belt drive or coupling Malfunctioning controls, sudden operational change System pulsation, looseness

Correct alignment ;dismantle the bearing refit with specified tolerance Review bearing selection Review bearing selection Check controls and system Check system ; check fastening of bolts . Ensure fan inlet dust concentration within specified limit. Review selection of impeller material for aggressive condition . System correction required

POSSIBLE CAUSE

Thermal Shock Vibration PREMATURE MATERIAL FAILURE

PERFORMANCE DEFICIENCY IN VOLUME OR PRESSURE

Abrasion/corrosion

Excessive dust from system .Fans running with bypassed dust arrestor. Water/acid fume ingress in fan

System Effect

Clearances

Turbulent Inlet condition, nonuniform flow, deviation of actual system resistance from predicted one , pre-rotation or swirl at inlet Impeller and inlet

Driver

Belt slippage

Environmental Problems

Problems Material build-up in casing , inlet or ductwork blockage Incorrect motor connection, improper Impeller rotation

Rotation

Check for deviation from drawing/manual; correction . Belt tightness to be adjusted. Check and clean periodically. System correction required Follow the indicated direction of rotation given on casing by arrow mark

INSTRUCTION MANUAL UID NO.:FAN MANUAL/Flakt2003

Page 39 of 41

ANNEX

Troubleshooting can help when you suspect a problem TYPICAL PROBLEM

AREA TO CHECK

SOLUTION

Mechanical Interference

Touching between impeller and inlet cone due to external forces on casing or Impeller /shaft movement or thermal expansion and distortions

Bearings

Inadequate lubrication, pitted bearing worn balls, races, seal failure, alignment improper, High velocities Buildup on fan Impeller, casing

Adjust inlet gap taking care of expansion in hot condition , check for expansion provision in casing foot ; fixed and expansion joint wherever provided are in place ; remove duct load from fan casing by providing flexible connection piece. Replace bearing ; correct alignment

POSSIBLE CAUSE

NOISE

Airborne Foreign Material in Fan Casing Drive Too much grease in bearing

OVER HEATED BEARING

Belts too loose and squealing

Poor alignment Bent shaft Abnormal end thrust Dirt in bearing Pinching effect on bearing outer race Bearing outer race in rotating in housing

Interference fit of bearing outer race in housing Loose housing fit

Install Attunuator Check and clean preiodically , system correction required Adjust belt tension Consult manual for lubrication amount and interval Correct Replace Check antithrust blade in impeller Clean Repalce housing with correct tolerance Repalce housing with correct tolerance

INSTRUCTION MANUAL

Page 40 of 41

UID NO.:FAN MANUAL/Flakt2003

HOW TO ORDER ….

YOUR DATA ABOUT THE : Installation process details and position of the fan site elevation

m

electrical frequency

Hz

Inlet conditions Pressure flow

:

TOTAL or

STATIC +

mm W C

m 3/s

:

°C

temperature :

%

relative humidity

Outlet conditions Pressure

:

TOTAL or

STATIC

mm W C

Gas g/m 3

dust concentration Possibility of:

BUILD UP

CORROSION

EROSION

Fan design temperature flow regulation with :

°C IN LET DAM PER

IN LET VAN E CONTROL

VARIABLE SPEED

general arrangement :SINGLE INLET DOUBLE INLET OVER HUNG IM PELLER

COUPLING

IMPELLER BETW EEN BEARINGS BELT DRIVE

M ATERIAL or SEALS impositions

INSTRUCTION MANUAL

Page 41 of 41

UID NO.:FAN MANUAL/Flakt2003

ADDRESS AND CONTACT NOS. WORKS ADDRESS

TEL. NO

FAX NO

KOLKATA Budge Budge Trunk Road, Maheshtala, Kolkata – 700 141

+91 33 24901811

+91 33 24902411 / 1643

CHENNAI 147, Poonamallee High Road, Village : Numbal Chennai – 600 077

+91 44 26272023

+91 44 26272606

MARKETING OFFICES DELHI 1st Floor, Front Position, Plot No. 28, Okhla Industrial Estate, Phase – 3, New Delhi – 110 020

+91 11 41814600

+91 11 26920112

KOLKATA 1E & 1, “ Sristi ” 12, Ho Chi Minh Sarani, Kolkata – 700 071

+91 33 22820207

+91 33 22810208

MUMBAI 301 – 303, Chintamani Plaza, 3rd Floor, Andheri Kurla Road, Chakala, Andheri East, Mumbai – 400 099

+91 22 67830200

+91 22 66978944

CHENNAI 147, Poonamallee High Road, Village : Numbal Chennai – 600 077

+91 44 26272023

+91 44 26272606

+91 20 25539079 / 4402

+91 20 25530874

PUNE Master Executive Centre, ‘Sneha Leela’ 1237 Apte road, Deccan Gymkhana, Pune – 411 004 BANGALORE “Shreyas” 157, 9th Cross, Indiranagar, 1st Stage, Bangalore – 560 038

+91 80 41635050

INSTRUCTION MANUAL UID NO.:FAN MANUAL/Flakt2003

DESCRIPTION

IDENTIFICATION SHEET FLAKT REFERENCE REF. DRG. NO. APPLICATION CUSTOMER

FAN DESCRIPTION :-

MAIN CHARACTERISTICS DEFINITION RATED GAS FLOW DIFFERENTIAL STATIC PRESSURE TOTAL EFFICIENCY RATED OPERATING TEMPERATURE MECHANICAL DESIGN TEMPERATURE FAN SPEED DENSITY AT 180 ° C CRITICAL SPEED RATED FAN POWER MOTOR POWER FAN WEIGHT FAN ACESSORIES WEIGHT MOTOR WEIGHT DYNAMIC LOAD DUE TO ROTOR GD² VALUE IMPELLER DIA IMPELLER WEIGHT DAMPER OPERATING FORCE ACTUATOR STROKE LENGTH BEARING LUBRICATION INSULATION AREA (M2) SHAFT DIA AT BRG.

UNIT KG/S (mmWC)/Pa % °C °C RPM Kg/AM³ RPM KW KW KG KG KG. KGF. kg.M² mm KG. N mm

mm

RATED LOAD

Goto that URL

Click on “Customer Care”

Click on “Customer Complain Entry”

Please fill up the Form, after Submission you will get a Complain No. Keep the Complain No. with you for future reference