IM-150 General Purpose Fans - Installation, Operation & Maintenance Manual

GENERAL PURPOSE FANSA WORD ABOUT SAFETYThe above WARNING decal appears on all nyb fans. Airmoving equipment involves electrical wiring, moving parts,sound, and air velocity or pressure which can create safetyhazards if the equipment is not properly installed, operated andmaintained. To minimize this danger, follow these instructionsas well as the additional instructions and warnings on theequipment itself.All installers, operators and maintenance personnel shouldstudy AMCA Publication 410, "Recommended Safety Practicesfor Air Moving Devices", which is included as part of everyshipment. Additional copies can be obtained by writing to NewYork Blower Company, 7660 Quincy St., Willowbrook, IL60527.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. Fanscan also become dangerous because of potential “windmilling”,even though all electrical power is disconnected. Always blockthe rotating 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,the degree of personnel exposure, and to comply withapplicable safety requirements to protect personnel fromexcessive noise. Consult nyb for fan sound power levelratings.AIR PRESSURE AND SUCTIONIn addition to the normal dangers of rotating machinery, fanspresent another hazard from the suction created at the faninlet. This suction can draw materials into the fan where theybecome high velocity projectiles at the outlet. It can also beextremely dangerous to persons in close proximity to theinlet, as the forces involved can overcome the strength ofmost individuals. Inlets and outlets that are not ducted shouldbe screened to prevent entry and discharge of solid objects.ACCESS DOORSThe above DANGER decal is placed on all nyb cleanoutdoors. These doors, as well as access doors to the ductsystem, should never be opened while the fan is in operation.Serious injury could result from the effects of air pressure orsuction.Quick-opening doors must have the door handle nutssecurely tightened to prevent accidental or unauthorizedopening. Bolted doors must be tightened for the same reasonRECEIVING AND INSPECTIONThe fan and accessories should be inspected on receipt forany shipping damage. Turn the wheel by hand to see that itrotates freely and does not bind. If dampers or shutters areprovided, check these accessories for free operation of allmoving 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.INSTALLATIONMAINTENANCE,OPERATINGINSTRUCTIONSIM 150Page 2HANDLING 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.FAN INSTALLATIONnyb wheels are dynamically balanced when fabricated.Complete fans are test run at operating speeds to check theentire assembly for conformance to nyb vibration limits.Nevertheless, all units must be adequately supported forsmooth operation. Ductwork or stacks should be indepen-dently supported as excess weight may distort the fanhousing and cause contact between moving parts. Wherevibration isolators are used, consult the nyb certified drawingfor proper location and adjustment.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 out-line of the fan. The weight of the slab should be two to threetimes the weight of the rotating assembly, including the motor.The foundation requires firmly anchored fasteners such as theanchor bolts shown in Figure 1. Hammer-drilled expansion fas-teners can be 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.Fasten the fan securely.Elevated UnitsWhen an elevated or suspended structural steel platform isused, it must have sufficient bracing to support the unit load andprevent side sway. The platform should be of welded construc-tion to maintain permanent alignment of all members.V-BELT DRIVEInstallation1. Remove all foreign material from the fan and motorshafts. Coat shafts with machine oil for easier mounting.Mount the belt guard backplate at this time if partialinstallation is required prior to sheave mounting.Figure 12. Mount sheaves on shafts after checking sheave boresand bushings for nicks or burrs. Avoid using force. Ifresistance is encountered, lightly polish the shaft withemery cloth until the sheave slides on freely. Tightentapered bushing bolts sequentially so that equal torqueis applied to each.3. Adjust the motor on its base to a position closest to thefan shaft. Install belts by working each one over thesheave grooves until all are in position. Never pry thebelts into place. On nyb packaged fans, sufficient motoradjustment is provided for easy installation of the propersize belts.4. Adjust sheaves and the motor shaft angle so that thesheave faces are in the same plane. Check this byplacing a straightedge across the faces of the sheaves.Any gap between the edge and sheave faces indicatesmisalignment. Important: This method is only valid whenthe width of the surface between the belt edge and thesheave face is the same for both sheaves. When they arenot equal, or when using adjustable-pitch sheaves,adjust so that all belts have approximately equal tension.Both shafts should be at right angles to the center belt.Belt Tensioning1. Check belt tension with a tensioning gage and adjustusing the motor base. Excess tension shortens bearinglife while insufficient tension shortens belt life, canreduce fan performance and may cause vibration. Thelowest allowable tension is that which prevents slippageunder full load. Belts may slip during start-up, butslipping should stop as soon as the fan reaches fullspeed. For more precise tensioning methods, consultthe drive manufacturer’s literature.2. Recheck setscrews, rotate the drive by hand and checkfor rubbing, then complete the installation of the weathercover/belt guard.3. Belts tend to stretch somewhat after installation.Recheck tension after several days of operation. Checksheave alignment as well as setscrew and/or bushing bolttightnessPage 3Safe operation and maintenance includes the selection and use ofappropriate safety accessories for the specific installation. Thisis 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, verify withthe manufacturer that the starting torque is adequate for thespeed 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 fan ordislodged by the fan discharge. Check the interior of the fanas well. Turn the wheel by hand to check for binding.3. Check drive installation and belt tension.4. Check the tightness of all setscrews, nuts and bolts. Tightenhub setscrews with the wheel oriented so that the setscrewis 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 obtained without motor overload unless ductwork isattached. Check for correct fan speed and complete instal-lation. Ductwork and guards must be fully installed for safety.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 qualitymaterials and components. Proper maintenance will ensure along and 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.Clean or 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. During any routine maintenance, all setscrews and boltsshould be checked for tightness. See the table forcorrect torques.5. When installing a new wheel, the proper wheel-to-inletclearance must be maintained (see Figure 2 ).WARNING: Do not remove or loosen the fan hub from thefan wheel. Removing or loosening the fan hub from the fanwheel will cause imbalance and void the warranty.Table 1 - WHEEL SETSCREW TORQUESSetscrew Size Carbon Steel Setscrew Torque*Diameter (in.) lb.-in. lb.-ft.3/8 252 217/16 396 331/2 600 505/8 1164 97* Stainless Steel setscrews are not hardened and shouldnot be tightened to more than 1/2 the values shown.Table 2 - BEARING SETSCREW TORQUE, NlMSetscrew ManufacturerDiameter Link-Belt Sealmaster SKF McGill Dodge#10 40 -- 35 35 --1/4 90 65 50 85 --5/16 185 125 165 165 1603/8 325 230 290 290 2757/16 460 350 350 -- --1/2 680 500 620 -- 600WHEEL-CONE CLEARANCESFigure 2WHEEL 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. Be sure to ground the welder directly to thefan wheel. Otherwise, the welding current could pass throughthe fan bearings and damage them.BEARINGSStorageAny stored bearing can be damaged by condensation causedby temperature variations. Therefore, nyb fan bearings arefilled with grease at the factory to exclude air and moisture.Such protection is adequate for shipment and subsequentimmediate installation.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 cau-tion when purging, as excessive pressure can damage theseals. 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 noattempt should be made to replace lost grease. Bearing surfacetemperatures will decrease when the internal grease quantityreaches a normal operating level. Relubrication should followthe recommended schedule.LubricationUse the table for relubrication scheduling according to operat-ing speed and shaft diameter. Bearings should be lubricatedwith a premium quality lithium-based grease conforming toNLGI Grade 2. Examples are:Mobil - Mobilgrease XHP Chevron - Amolith #2Texaco - Premium RB Shell - Alvania #2These greases are for bearing surface temperatures of 40°F. to180°F. For surface temperatures of 181°F. to 230°F. useMobilith SHC220.Do not use “high temperature” greases, as many are not for-mulated to be compatible 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. Except on split pillowblocks.Completely filled bearings will run hotter until a sufficientamount of grease is purged out of the seals.Split pillowblock bearings (Link-Belt P-LB6800 & P-LB6900,SKF SAF 22500, Dodge SAF-XT) should be cleaned andrepacked at approximately every eighth lubrication interval.This requires removal of the bearing cap. Clean out old greaseand repack the bearing with fresh grease. Pack the bearing fullyand fill the housing reservoir to the bottom of the shaft on bothsides of the bearing. Replace the bearing cap, being careful notto mix caps as they are not interchangeable from one bearingto another. Do not over lubricate.BEARING LUBRICATION INTERVAL [months]NOTE: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. will shortenbearing life.c. Under extremely dirty conditions, lubricate morefrequently.3. Assumes horizontal mounting configuration. For verticallymounted applications, lubricate twice as frequently.Fan Size “A” Dimension Fan Size “A” Dimension12 41/2 27 101/815 51/2 30 111/418 7 33 121/422 81/4 36 133/824 91/4Page 4The New York Blower Company – 7660 Quincy Street – Willowbrook, Illinois 60527-5530Page 5COMMON 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 orbearings.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 dueto closed 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. Damaged or incorrectly installed cut off sheet or diverter.6. Poor system design, closed dampers, air leaks, cloggedfilters, or coils.7. Obstructions or sharp elbows near inlets.8. 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.REPLACEMENT 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 yourlocal nyb representative or visit: http://www.nyb.com.Example: Part required: WheelShop/control number: B-10106-100Fan description: Size 27 General Purpose Fan Rotation:ClockwiseArrangement: 10Suggested replacement parts include:Wheel Component parts: DamperShaft MotorBearings Sheaves V-BeltsShaft SealLIMITED 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 nybof any 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 equip-ment sold to the buyer shall carry the original manufacturer’swarranty only. All transportation charges and any and all salesand use taxes, duties, imports or excises for such part or partsshall be paid for by the buyer. nyb shall have the sole right todetermine whether defective parts shall be repaired orreplaced.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 inadvance, 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 not manufacturedor supplied by nyb for use in any of its products shall have beensubstituted and used in place of a part manufactured 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 remedy,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.SPECIFY ROTATION AS VIEWED FROM DRIVE SIDEParts ListInlet Hanger PanelInlet CollarInlet Cone*Wheel*ShaftHousing*PedestalDrive Side Hanger BraceMotorMotor PlatformBearingsSheavesBelt1.2.3.4.5.6.7.8.9.10.11.12.13.* Orders for parts must specify rotation.For assistance in selecting replacementparts, contact your local nyb representa-tive or visit: http://www.nyb.com.Form 810 MJN