Compact GI Dust & Material Handling Fans - Installation, Operation & Maintenance Manual

COMPACT GI FANSWORD ABOUT SAFETYThe above WARNING decal appears on all nyb fans. Air movingequipment involves electrical wiring, moving parts, sound, and airvelocity or pressure which can create safety hazards if theequipment is not properly installed, operated and maintained. Tominimize this danger, follow these instructions as well as theadditional instructions and warnings on the equipment itself.All installers, operators and maintenance personnel should studyAMCA Publication 410, "Recommended Safety Practices for AirMoving Devices", which is included as part of every shipment.Additional copies can be obtained by writing to New York BlowerCompany, 7660 Quincy St., Willowbrook, IL 60527.ELECTRICAL DISCONNECTSEvery motor driven fan should have an independent disconnectswitch to isolate the unit from the electrical supply. It should benear the fan and must be capable of being locked by mainte-nance personnel while servicing the unit, in accordance withOSHA procedures.MOVING PARTSAll moving parts must have guards to protect personnel. Safetyrequirements vary, so the number and type of guards needed tomeet company, local and OSHA standards must be determinedand specified by the user. Never start a fan without having allsafety guards installed. Check regularly for damaged or missingguards and do not operate any fan with guards removed. Fans canalso become dangerous because of potential “windmilling”, eventhough all electrical power is disconnected. Always block therotating assembly before working on any moving parts.SOUNDSome fans can generate sound that could be hazardous toexposed personnel. It is the responsibility of the systemdesigner and user to determine sound levels of the system, thedegree of personnel exposure, and to comply with applicablesafety requirements to protect personnel from excessive noise.Consult nyb for fan sound power level ratings.AIR PRESSURE AND SUCTIONIn addition to the normal dangers of rotating machinery, fanspresent another hazard from the suction created at the fan inlet.This suction can draw materials into the fan where they becomehigh velocity projectiles at the outlet. It can also be extremelydangerous to persons in close proximity to the inlet, as theforces involved can overcome the strength of most individuals.Inlets and outlets that are not ducted should be screened toprevent entry and discharge of solid objects.RECEIVING AND INSPECTIONThe fan and accessories should be inspected on receipt for anyshipping damage. Turn the wheel by hand to see that it rotatesfreely and does not bind. If dampers or shutters are provided,check these accessories for free operation of all moving parts.F.O.B. factory shipping terms require that the receiver beresponsible for inspecting the equipment upon arrival. Notedamage or shortages on the Bill of Lading and file any claimsfor damage or loss in transit. nyb will assist the customer asmuch as possible; however, claims must be originated at thepoint of delivery.HANDLING AND STORAGEFans should be lifted by the base, mounting supports, or liftingeyes only. Never lift a fan by the wheel, shaft, motor, motorbracket, housing inlet, outlet, or any fan part not designed forlifting. A spreader should always be used to avoid damage.Whenever possible, fans and accessories should be stored in aclean, dry location to prevent rust and corrosion of steel com-ponents. If outdoor storage is necessary, protection should beprovided. Cover the inlet and outlet to prevent the accumulationof dirt and moisture in the housing. Cover motors with water-proof material. Refer to the bearing section for further storageinstructions.Check dampers for free operation and lubricate moving partsprior to storage. Inspect the stored unit periodically. Rotate thewheel by hand every two weeks to redistribute grease oninternal bearing parts.INSTALLATIONMAINTENANCE,OPERATINGINSTRUCTIONSIM-170Page 2FAN INSTALLATIONnyb wheels are dynamically balanced when fabricated. Completefans are test run at operating speeds to check the entireassembly for conformance to nyb vibration limits. Nevertheless,all units must be adequately supported for smooth operation.Ductwork or stacks should be independently supported asexcess weight may distort the fan housing and causecontact between moving parts. Where vibration isolators areused, consult the nyb certified drawing for proper location andadjustment.Slab-Mounted UnitsA correctly designed and level concrete foundation provides thebest means of installing floor-mounted fans. The mass of thebase must maintain the fan/driver alignment, absorb normalvibration, and resist lateral loads. The overall dimensions of theconcrete base should extend at least six inches beyond the baseof the fan. The weight of the slab should be two to three times theweight of the rotating assembly, including the motor. Thefoundation requires firmly anchored fasteners such as the anchorbolts shown in Figure 1. Hammer-drilled expansion fasteners canbe used in less demanding applicationsMove the fan to the mounting location and lower it over theanchor bolts. Shim and grout as required to level the fan. Fastenthe fan securely. When isolation is used, check the nyb certifieddrawing for installation instructions.Elevated UnitsWhen an elevated or suspended structural steel platform is used,it must have sufficient bracing to support the unit load and preventside sway. The platform should be of welded construction tomaintain permanent alignment of all members.V-BELT DRIVEInstallation1. Remove all foreign material from the fan and motor shafts.Coat shafts with machine oil for easier mounting. Mountthe belt guard backplate at this time if partial installation isrequired prior to sheave mounting.2. Mount sheaves on shafts after checking sheave bores andbushings for nicks or burrs. Avoid using force. If resistanceis encountered, lightly polish the shaft with emery clothuntil the sheave slides on freely.3. Adjust the motor on its base to a position closest to the fanshaft. Install belts by working each one over the sheavegrooves until all are in position. Never pry the belts intoplace. On nyb packaged fans, sufficient motor adjustmentis provided for easy installation of the proper size belts.4. Adjust sheaves and the motor shaft angle so that thesheave faces are in the same plane. Check this by placinga straightedge across the faces of the sheaves. Any gapbetween the edge and sheave faces indicates misalign-ment. Important: This method is only valid when the widthof the surface between the belt edge and the sheave faceis the same for both sheaves. When they are not equal, orwhen using adjustable-pitch sheaves, adjust so that allbelts have approximately equal tension. Both shafts shouldbe at right angles to the center belt.Belt Tensioning1. Check belt tension with a tensioning gage and adjust usingthe motor slide base. Excess tension shortens bearing lifewhile insufficient tension shortens belt life, can reduce fanperformance and vay cause vibration. The lowest allow-able tension is that which prevents slippage under full load.Belts may slip during start-up, but slipping should stop assoon as the fan reaches full speed. For more precisetensioning methods, consult the drive manufacturer’sliterature.2. Recheck setscrews, rotate the drive by hand and check forrubbing, then complete the installation of the belt guard.3. Belts tend to stretch somewhat after installation. Rechecktension after several days of operation. Check sheavealignment as well as setscrew and/or bushing bolt tightness.START-UPSafe operation and maintenance includes the selection and useof appropriate safety accessories for the specific installation.This is the responsibility of the system designer and requiresconsideration of equipment location and accessibility as well asadjacent components. All safety accessories must be installedproperly prior to start-up.Safe operating speed is a function of system temperature andwheel design. Do not under any circumstances exceed themaximum safe fan speed published in the nyb bulletin, which isavailable from your nyb field sales representative.Procedure1. If the drive components are not supplied by nyb, verifywith the manufacturer that the starting torque is adequatefor the speed and inertia of the fan.2. Inspect the installation prior to starting the fan. Check forany loose items or debris that could be drawn into the fanor dislodged by the fan discharge. Check the interior of thefan as well. Turn the wheel by hand to check for binding.Figure 1Page 33. Check drive installation and belt tension.4. Check the tightness of all setscrews, nuts and bolts. Whenfinished, tighten hub setscrews with the wheel oriented suchthat the setscrew is positioned underneath the shaft.5. Install all remaining safety devices and guards. Verify thatthe supply voltage is correct and wire the motor. “Bump” thestarter to check for proper wheel rotation.6. Use extreme caution when testing the fan with ducting dis-connected. Apply power and check for unusual sounds orexcessive vibration. If either exists, see the section onCommon Fan Problems. To avoid motor overload, do notrun the fan for more than a few seconds if ductwork is notfully installed. On larger fans, normal operating speed maynot be attained without motor overload unless ductwork isattached. Check for correct fan speed and complete instal-lation. Ductwork and guards must be fully installed forsafety.7. Setscrews should be rechecked after a few minutes, eighthours and two weeks of operation (see Tables 1 & 2 forcorrect tightening torques).NOTE: Shut the fan down immediately if there is any suddenincrease in fan vibration.FAN MAINTENANCEnyb fans are manufactured to high standards with quality mate-rials and components. Proper maintenance will ensure a longand trouble-free service life.Do not attempt any maintenance on a fan unless the elec-trical supply has been completely disconnected andlocked. In many cases, a fan can windmill despite removal ofall electrical power. The rotating assembly should be blockedsecurely before attempting maintenance of any kind.The key to good fan maintenance is regular and systematicinspection of all fan parts. Inspection frequency is determinedby the severity of the application and local conditions. Strictadherence to an inspection schedule is essential.Regular fan maintenance should include the following:1. Check the fan wheel for any wear or corrosion, as eithercan cause catastrophic failures. Check also for the build-up of material which can cause unbalance resulting invibration, bearing wear and serious safety hazards. Cleanor replace the wheel as required.2. Check the V-belt drive for proper alignment and tension(see section on V-belt drives). If belts are worn, replacethem as a set, matched to within manufacturer’s toler-ances.3. Lubricate the bearings, but do not over lubricate (see thebearing section for detailed specifications).4. Ceramic-felt shaft seals require no maintenance, althoughworn seals should be replaced. When lip-type shaft sealsare provided, lubricate them with “NEVER-SEEZ” or otheranti-seize compound.5. During any routine maintenance, all setscrews and boltsshould be checked for tightness. See the table for correcttorques.6. When installing a new wheel, the wheel should becentered in the housing between the inlet and drive sides.WHEEL BALANCEAirstreams containing particulate or chemicals can cause abra-sion or corrosion of the fan parts. This wear is often uneven andcan lead to significant wheel imbalance over time. When suchwear is discovered, a decision must be made as to whether torebalance or replace the wheel.The soundness of all parts should be determined if the originalthickness of components is reduced. Be sure there is no hiddenstructural damage. The airstream components should also becleaned to remove any build-up of foreign material. Specializedequipment can be used to rebalance a cleaned wheel that isconsidered structurally sound.Balance weights should be rigidly attached at a point that willnot interfere with the housing nor disrupt airflow. Rememberthat centrifugal forces can be extremely high at the outer radiusof a fan wheel. Welding is the preferred method of balanceweight attachment. Weld material for standard Compact GIwheels should be a nickel, aluminum bronze alloy. Be sure toground the welder directly to the fan wheel. Otherwise, thewelding current could pass through the fan bearings and dam-age them.Table 1 - WHEEL SETSCREW TORQUESSetscrew SizeDiameter (in.)Carbon Steel Setscrew Torque*lb.-in. lb.-ft.1/45/163/8751442526.21221* Stainless Steel setscrews are not hardened and shouldnot be tightened to more than 1/2 the values shown.Table 2 - BEARING SETSCREW TORQUE, lb.-in.SetscrewDiameterManufacturerLink-Belt Sealmaster SKF McGill Dodge1/45/1690185651255016585165--160WHEEL – INLET CLEARANCESWheel is centered in housing.Page 4BEARINGSStorageAny stored bearing can be damaged by condensation caused bytemperature variations. Therefore, nyb fan bearings are filledwith grease at the factory to exclude air and moisture. Suchprotection is adequate for shipment and subsequent immediateinstallation.For long term or outdoor storage, mounted bearings should beregreased and wrapped with plastic for protection. Rotate thefan wheel by hand at least every two weeks to redistributegrease on internal bearing parts. Each month the bearingsshould be purged with new grease to remove condensation,since even a filled bearing can accumulate moisture. Use cautionwhen purging, as excessive pressure can damage the seals.Rotate the shaft while slowly adding grease.OperationCheck the setscrew torque before start-up (see table for correctvalues). Since bearings are completely filled with grease at thefactory, they may run at an elevated temperature during initialoperation. Surface temperatures may reach 180°F. and greasemay bleed from the bearing seals. This is normal and no attemptshould be made to replace lost grease. Bearing surfacetemperatures will decrease when the internal grease quantityreaches a normal operating level. Relubrication should follow therecommended schedule.LubricationUse the following table for bearing lubrication interval, accordingto operating speed. Bearings should be lubricated with apremium quality lithium-based grease conforming to NLGI Grade2. Examples are:Mobil - Mobilgrease XHPTexaco - Premium RBChevron - Amolith #2Shell - Alvania #2Do not use “high temperature” greases, as many are not for-mulated for the high speeds associated with fan bearings.Add grease to the bearing while running the fan or rotating theshaft by hand. Be sure all guards are in place if lubrication isperformed while the fan is operating. Add just enough grease tocause a slight purging at the seals. Do not over lubricate.BEARING LUBRICATION INTERVAL [months]Sealmaster, McGill, Link-Belt, and SKFNOTE:1. These are general recommendations only; specificmanufacturer’s recommendations may vary slightly.2. Assumes clean environment, -20°F. to 120°F.a. Consult The New York Blower Company foroperation below -20°F. ambient.b. Ambient temperatures greater than 120°F. willshorten bearing life.c. Under extremely dirty conditions, lubricate morefrequently.3. Assumes horizontal mounting configuration. Forvertically mounted applications, lubricate twice asfrequently.COMMON FAN PROBLEMSExcessive VibrationA common complaint regarding industrial fans is “excessivevibration”. nyb is careful to ensure that each unit is preciselybalanced prior to shipment; however, there are many othercauses of vibration including:1. Loose mounting bolts, setscrews, bearings or couplings.2. Misalignment or excessive wear of couplings or bearings.3. Misaligned or unbalanced motor.4. Bent shaft due to mishandling or material impact.5. Accumulation of foreign material on the wheel.6. Excessive wear or erosion of the wheel.7. Excessive system pressure or restriction of airflow due toclosed dampers.8. Inadequate structural support, mounting procedures ormaterials.9. Externally transmitted vibration.Inadequate Performance1. Incorrect testing procedures or calculations.2. Fan running too slowly.3. Fan wheel rotating in wrong direction or installed back-wards on shaft.4. Wheel not properly centered relative to inlet cone.5. Poor system design, closed dampers, air leaks, cloggedfilters, or coils.6. Obstructions or sharp elbows near inlets.7. Sharp deflection of airstream at fan outlet.Excessive Noise1. Fan operating near “stall” due to incorrect system designor installation.2. Vibration originating elsewhere in the system.3. System resonance or pulsation.4. Improper location or orientation of fan intake and dis-charge.5. Inadequate or faulty design of supporting structures.6. Nearby sound reflecting surfaces.7. Loose accessories or components.8. Loose drive belts.9. Worn bearings.Premature Component Failure1. Prolonged or major vibration.2. Inadequate or improper maintenance.3. Abrasive or corrosive elements in the airstream or sur-rounding environment.4. Misalignment or physical damage to rotating componentsor bearings.5. Bearing failure from incorrect or contaminated lubricant orgrounding through the bearings while arc welding.6. Excessive fan speed.7. Extreme ambient or airstream temperatures.8. Improper belt tension.9. Improper tightening of wheel setscrews.RPM1- 1001- 2001- 3001- 4001-Shaft 1000 2000 3000 4000 50001” 6 5-6 4-6 3-4 2Page 5* Order for parts must specify rotation.LIMITED PRODUCT WARRANTYAll products are warranted by nyb to be free from defects inmaterials and workmanship for a period of one (1) year aftershipment from its plant, provided buyer demonstrates to satis-faction of nyb that the product was properly installed and main-tained in accordance with nyb's instructions and recommenda-tions and that it was used under normal operating conditions.This warranty is limited to the replacing and/or repairing by nyb ofany part or parts which have been returned to nyb with nyb'swritten authorization and which in nyb's opinion are defective.Parts not manufactured by nyb but installed by nyb in equipmentsold to the buyer shall carry the original manufacturer’s warrantyonly. All transportation charges and any and all sales and usetaxes, duties, imports or excises for such part or parts shall bepaid for by the buyer. nyb shall have the sole right to determinewhether defective parts shall be repaired or replaced.This warranty does not cover any customer labor charges forreplacement of parts, adjustments or repairs, or any other workunless such charges shall be assumed or authorized in advance,in writing, by nyb.This warranty does not cover any product which, in the judge-ment of nyb, has been subject to misuse or neglect, or whichhas been repaired or altered outside nyb's plant in any waywhich may have impaired its safety, operation or efficiency, orany product which has been subject to accident.This warranty shall be null and void if any part notmanufactured or supplied by nyb for use in any of its productsshall have been substituted and used in place of a partmanufactured or sup-plied by nyb for such use.There are no warranties, other than those appearing on theacknowledgement form INCLUDING NO WARRANTY OFMERCHANTABILITY OR FITNESS FOR A PARTICULARPURPOSE, given in connection with the sale of the goods soldhereunder. The buyer agrees that his sole and exclusive reme-dy, and the limit of nyb's liability for loss from any cause what-soever, shall be the purchase price of the goods sold hereun-der for which a claim is made.The New York Blower Company – 7660 Quincy Street – Willowbrook, Illinois 60527-5530DIRECT DRIVE COMPACT GI FANSParts List1. Inlet Plate2. Wheel3. Housing*4. Drive Side Hanger/Pedestal5. MotorPage 6REPLACEMENT PARTSIt is recommended that only factory-supplied replacement partsbe used. nyb fan parts are built to be fully compatible with theoriginal fan, using specific alloys and tolerances. These partscarry a standard nyb warranty.When ordering replacement parts, specify the part name, nybshop and control number, fan size, type, rotation (viewed fromdrive end), arrangement and bearing size or bore. Most of thisinformation is on the metal nameplate attached to the fan base.For assistance in selecting replacement parts, contact your localnyb representative or visit: http://www.nyb.com.Example: Part required: WheelShop/control number: B-10106-100Fan description: Size 125 Compact GI FanRotation: ClockwiseArrangement: 9Suggested replacement parts include:Wheel Component parts: DamperShaft MotorBearings SheavesShaft Seal V-BeltsParts List1. Inlet Plate2. Wheel3. Shaft4. Housing*5. Drive Side Hanger/Pedestal6. Motor7. Bearings8. Belt9. Sheaves10. Arr. 9 Motor Mounting Base11. Arr. 9X Motor Mounting Base* Orders for parts must specify rotation.For assistance in selecting replacementparts, contact your local nyb representativeor visit: http://www.nyb.com.Form 210 MJNARROW INDICATES CLOCKWISE ROTATIONBELT DRIVE COMPACT GI FANSSPECIFY ROTATION AS VIEWED FROM DRIVE SIDE