CENTRIFUGAL FANS INSTALLATION AND MAINTENANCE INSTRUCTIONS EQLR CENTRIFUGAL FAN

Transcription

1 CENTRIFUGAL FANS INSTALLATION AND MAINTENANCE INSTRUCTIONS EQLR CENTRIFUGAL FAN Size CONTENTS PAGE STORAGE BEFORE INSTALLATION...2 INSTALLATION...3 INSTALLATION ALTERNATIVES...3 CONNECTION TO FAN OUTLET...4 ELECTRICAL CONNECTIONS...5 SAFETY ISOLATING SWITCH...5 SAFETY GUARDS...6 TO ADJUST THE V-BELT TENSION...6 TO CHANGE THE V-BELTS...6 TO INSTALL HABASIT FLAT-BELT DRIVES...7 TO HANDLE THE MOTOR FOR BELT TENSION ADJUSTMENT...8 TO REMOVE THE BELT GUARD EQLR (PRINCIPLE)...8 BELT PULLEYS...9 AIRFLOW MEASUREMENT...10 TEMPERATURE CORRECTIONS...10 INSTALLATION OF FREQUENCY INVERTERS...11 CLEANING...12 BEARINGS

2 2 Installation and Maintenance Instructions STORAGE BEFORE INSTALLATION The storage space for fans must not be exposed to vibrations from the surroundings that can give rise to bearing damage. If the fans are stored for more than 3 months, you should relieve the tension on the drive belts and rotate the fan impellers at regular intervals by hand. Important! If the fans are idle for more than 3 months before or after installation you should relieve the tension on the drive belts and rotate the fan impellers at regular intervals by hand. If this is not done, the ball bearings could become damaged as shown in the illustration below. Important! When commissioning a new unit, check the drive belt tension and adjust if necessary after approx. 30 min. of operation, if required. ACTIONS TO TAKE BEFORE STARTING The fan must not be started with the damper on the suction or the delivery side closed. Prior to starting the fan, check that the impeller rotates freely and that there are no objects which can be drawn in and damage the fan. Load damage Belastnings When commissioning the air handling unit, check the drive belt tension and adjust the belt tension after approx. 30 min. of operation, if required. See below. If the fan is equipped with steel spring anti-vibration mountings, you must remove the transport safety devices before starting. CHECKS TO BE MADE PRIOR TO COMMISSIONING Check that the fan section is connected to the ducting or equipped with the necessary EQAZ-28 protective screen, both on the fan inlet and fan outlet. Check that an authorized electrician has given approval for commissioning the unit. Check that the impeller rotates freely and that there are no objects which can be drawn in and damage the fan. COMMISSIONING The fan must not be started with the damper on the suction or the delivery side closed. However the motor can be briefly energized with the inspection panel open for checking the direction of rotation. MAINTENANCE The fan must be inspected and cleaned every 6 12 months. The intervals between service are based on the assumption that the unit is in operation for about 2000 hours per 12-month period in a normal comfort ventilation installation. If the supply and/or extract air has a high dust content, the unit should be serviced more frequently. Check the belt tension every 6 months. The fan is accessible from the inspection panel. Important! Isolate the power supply before carrying out any inspection and service work.

3 Installation and Maintenance Instructions 3 INSTALLATION INLET: Protective screen EQAZ-28 Counterflange EQAZ-27 Flexible connection EQAZ-25 Connection piece EQAZ-26 OUTLET: Damper EQAZ-12 Connection piece EQAZ-26 Flexible connection EQAZ-25 Counterflange EQAZ-27 Protective screen EQAZ-28 Fig. 1 INSTALLATION ALTERNATIVES The fan can be installed to discharge air into a duct or into some other unit section. Alternative directions of air discharge and locations of the discharge opening are shown in Fig. 2 and 3. HORIZONTAL INSTALLATION VERTICAL INSTALLATION (SIZES ) Top 1) inlet Outlet upwards Outlet forward (Outlet downwards) Outlet Forward (Inlet, left-hand side) Outlet upwards (Outlet downwards) Normal inlet (end wall) Top 1) inlet Fig. 2 (Inlet bottom 2) ) (Utlopp nedåt) 1) Upward outlet not possible. 2) Downward outlet not possible. Fig. 3 Normal inlet (end wall)

4 4 Installation and Maintenance Instructions CONNECTION TO THE FAN OUTLET Installation principle: All connections should be fitted edge-to-edge with the back plate of the fan. N.B! Not all connection facilities are shown. See Fig. 5 and 6. Fig. 5 Connection piece Flexible connection Counterflange Duct EQAZ-26 EQAZ-25 EQAZ-27 Fig. 6

5 Installation and Maintenance Instructions 5 ELECTRICAL CONNECTIONS Double-storey air handling unit The electrical connections must be wired by a qualified electrician. Use a rubber-insulated cable, but do not run the cable through the inspection panel/door. Allow about 1.2 m of extra cable on the inside of the casing of the EQLR-005 to 032, to enable the fan to be withdrawn for service. See Fig. 9. approx. 1.2 m Fig. 9b Use a trepanning drill, for instance, for drilling a hole for the cable gland at a suitable point on the casing. The cable gland can be arranged as shown in Fig. 8. Fig. 9c. Fan in upper storey, size Fig. 7 Fig. 8 SAFETY ISOLATING SWITCH The fan should be equipped with a safety isolating switch such as the APAC. Always switch off the air handling unit and set the safety isolating switch in the OFF or 0 position, before beginning work on the fans. Locate the safety isolating switch so that the fan unit can be withdrawn without the need for disconnecting any electrical connections. Fig. 9d. Fan in bottom storey, size Do not use the safety isolating switch for switching the unit on and off. Important! Be careful not to damage the filter bags while removing/installing the filter cassettes! Fig. 9e. Fan with side panel, size Single-storey air handling unit Fig. 9f. Vertical unit, size Fig. 9a = Suitable area where the cable gland can be locating without preventing fan withdrawal. See Fig. 9a f.

6 6 Installation and Maintenance Instructions SAFETY GUARDS Observe the provisions of the EU Machinery Directive concerning safety guards, which stipulate that the fan must be equipped with a drive belt guard and a fan inlet protective screen or protective screen (removable by means of tools) fitted to the inside of the casing behind the inspection panel or a door lock. TO ADJUST THE TENSION OF V-BELTS The belts must operate with a certain initial tension to ensure correct contact with the pulleys. If insufficiently tensioned, the drive belts may slip, and if excessively tensioned, the bearings in the motor and fan may be overloaded. When correctly tensioned, the belt deflection will be 15 m per metre of distance between the centres (c/c) when a force P (N) is applied. TO CHANGE THE V-BELTS To change the belts, first move the motor towards the fan by a sufficient amount to allow the old belts to be easily prised off the pulleys and the new belts to be prised on. Change all the belts at the same time. Use belts with the same production number (matched belts), i.e. belts of exactly the same length. Tension the belts in accordance with the instructions on this page and align them as shown in Fig. 12. NB! Retension the belts after the fans have been in operation for 30 minutes. The deflection should preferably be measured by means of a tensiometer. See Fig. 10 and 11. The force P is dependent on the belt type as shown in the table below. c/c L P Fig. 10 EUL(B,F) cm N Fig. 12 Fig. 11 Belt profile Pitch diameter of smaller pulley P i N / belt Normal Max. 1) SPZ SPZ SPA SPA SPB SPB SPC SPC ) New belt

7 Installation and Maintenance Instructions 7 INSTALLATION OF HABASIT FLAT-BELT DRIVE Important! Never install an ice-cold or a stiff drive belt. Allow the belt to thaw, become soft and flexible before you install it. The elasticity of the material is affected by cold, which both makes installation difficult and may cause the belt to rupture (where it is jointed together) in the future. 1. Fit the motor and fan pulleys to their corresponding shafts but do not tighten the bushes. 2. Fit the belt around the pulleys and push the motor by hand so that the belt is stretched. 3. Align the pulleys by means of a straight edge and tighten the pulley bushes. 4. Tighten the motor mounting bolts only so hard that the motor will still be able to slide on the guide rails. DISTANCE BETWEEN THE MARKS Before tensioning (mm) Type: F 0, F 1 2,8% Tension the belt until the elongation tabulated above has been achieved. After tensioning (mm) Type: F 14, A 2, A 3, A 4 2,5% ,8 102, ,6 205, ,4 307, ,2 410, ,0 512, ,8 615, ,6 717, ,4 820, ,2 922, ,0 1025,0 5. Measure the longest free measurement distance on the belt to the nearest 100 mm. The belt must not be in contact with the pulleys along the measurement distance. 6. Remove the belt, place it on a flat surface and mark off the above measurement distance to the nearest 100 mm. Measurement distance Use a straight edge to check that the pulleys are in line. 7. Refit the belt to the pulleys and tension the belt by means of the tensioning screws on the motor guide rails. Keep the shafts of the motor and fan as parallel as possible. 8. Conclude the tensioning when the belt has achieved the elongation specified in the table. If the belt moves sideways, adjust by means of the tensioning screws on the motor guide rails or motor bracket. 9. Rotate the drive belt by hand in both directions of rotation. If the belt tends to move axially in one direction or the other, this is because the shafts are not parallel. Adjust by means of the tensioning screws of the slide rails until the belt remains in the centre of the pulleys while the pulleys are rotating. 10. When tensioning has been completed and the belt remains in position when the drive is rotating, securely tighten the motor mounting bolts. Start by tightening the bolts nearest to the pulley.

8 8 Installation and Maintenance Instructions HANDLING THE MOTOR FOR ADJUSTING THE TENSION OF THE BELT Adjust the belt tension by moving the motor. The images below show the adjustment when the motor is placed in-ternally. When the motor is placed externally, the adjustment is made in the same way. 1. Remove the belt guard, if used. 2. Back off slightly the 4 mounting bolts. 3. Change the belt tension by means of the tensioning screws. 4. Check the alignment of the drive. Change with the adjusting screws. 5. Retighten the mounting bolts. 6. Refit the belt guard, if used. WHEEL DIAMETER GREATER THAN 800 CM Tensioning pad Tensioning screw N.B. If the motor is equipped with an EQLZ-28 motor enclosure, you will have to remove the upper part of the enclosure to make the motor mounting bolts accessible for adjusting the belt tension. Mounting bolt WHEEL DIAMETER UP TO 710 CM Slide rail Tensioning screw Mounting bolt Adjusting screw Mounting bolt Fig. 14 TO REMOVE THE BELT GUARD, (PRINCIPLE) Adjusting screw Movable cover plate for motor shaft Fig. 13 Fig. 15

9 Installation and Maintenance Instructions 9 BELT PULLEYS To remove and refit the belt pulley Never hammer the belt pulley onto or off the shaft, since even light blows and shocks may damage the bearings, which will give rise to noise and an abnormally high rate of wear. To remove: 1. Remove the screws, oil them sparingly and screw one of them into the extractor hole, i.e. the tapped hole in the bush. See Fig. 16 and Tighten the screw until the bush is free of the hub and the unit is free of the shaft. 3. Remove the pulley and bush from the shaft as one unit. EUL(B,F) 15 To fit: 1. Clean the bore of the pulley and the inside and outside of the bush to remove any anti-corrosion agent, and make certain that the surfaces are completely free from oil and dirt. Fit the bush into the pulley. 2. Oil the screws sparingly and screw them loosely into the tapped holes in the pulley. See Fig Clean the shaft and fit the pulley and bush onto the shaft as one unit. 4. Tighten the screws alternately until they are all securely tightened. Extractor hole Screw Screw Fig. 17 Fig. 16

10 10 Installation and Maintenance Instructions AIRFLOW MEASUREMENT If the air handling unit is supplied with a control system, the flow can be read directly in the control panel display. NB! In the case of air handling units supplied with a control system, the pressure tappings in the end connection panels of the unit are not connected to the airflow sensor of the fan. If you still want to read the manometer pressure with an external manometer, you can connect the tubes from the airflow sensor of the fan across T-nipples to the pressure tappings in the end connection panel of the air handling unit. The EQLR has equipment for airflow measurement. The airflow q can be calculated by applying a manometer reading Δp (Pa), and a constant k in the following formula: q = 1 Δp m 3 /s k The manometer reading, Δp, which is the difference between the pressure in the empty section at the fan inlet and the pressure inside the inlet cone can be read with a manometer (pressure range up to 6000 Pa) which is connected to 2 externally located nipples. The value of the constant k is specified in the table below. Important! For EQLZ-42 U-tube manometers, use only the blue manometer fluid supplied with the instrument. Never use any other type of fluid. Precision-adjust the zero point with the zero adjustment screw. A flow indicator with built-in pressure transducer (available as an accessory) connected by means of hoses to the external nipples, converters the manometer pressure reading to a flow (m 3 /s) which is shown on a display and transmits a 0 10V output signal, linear with the flow. If this external means of measuring flow will not be permanent, the tubes must be restored to their original condition. Size EQLR, aaa-b Fan GXLB-aaa COP 008-3, , , , , , , 018-2, , ,020-3,023-2, , , 027-3, 032-2, , , 036-3, 041-2, , , 045-3, 050-2, , , 054-3, 063-2, 072-2, , , 068-3, 072-3, 079-3, , ,89 TEMPERATURE CORRECTION The flow scale on the direct reading instrument and the flow formula above apply to air with a temperature of +20 C. For other temperatures, the flow must be corrected using the following formula: q = q 20 (273 + t) 293, m 3 /s where q = the actual flow through the fan, q 20 = the flow reading and t = the current temperature in C.

11 Installation and Maintenance Instructions 11 INSTALLATION OF FREQUENCY INVERTERS Warning! Improper installation of frequency inverters may damage the bearings inside the motor. TO CONNECT THE SHIELD CONDUCTOR Should it be necessary to connect the shield conductor to an earth screw in the motor or frequency inverter, this must be done so that the impedance will be as low as possible. In these cases, the length of the conductor should be restricted to 5 times its width. For example, if the shield conductor is 1 cm wide, it must not be longer than 5 cm in length. The motor and frequency inverter should be supplied and installed by FläktGroup. FläktGroup will not accept guarantee liability for motor damage if the motor has been wired to a frequency inverter that has not been installed by a fitter who is not from or been chosen by FläktGroup. The frequency inverter and the motor must be installed by a qualified electrician possessing the right knowledge of installations with a speed-controlled drive system (frequency inverters) and EMC safety. The following recommendations should be regarded as a complement to the installation instructions of the supplier. If you encounter any differences between these instructions and those of the supplier, the supplier s instructions shall have priority over those given below. This is due to the guarantee liability/commitment of the manufacturer. Shield MOTOR The cable gland fitted to the terminal box of the motor must be of an EMC approved type, for example: Miltronic SKINTOPMS-SC. The shield conductor shall only be connected via the EMC-approved cable gland, not to the earth screw. The shield must have 360º contact with the casing. Casing Shield GENERAL A shielded, continuous 4-wire cable designed for EMC installations for motor drives must be used in the electrical installation between the motor and the frequency inverter. The shield must have at least 80% optical tightness, for example Nexans NCY or Ölflex Classic. The shield must have 360 º contact with the casing both in the motor and in the frequency inverter for achieving maximum area of contact. Safety isolating switch or junction boxes installed between the frequency inverter and the motor are not advisable. FREQUENCY INVERTER The shield conductor must be connected either via an EMC-approved cable gland in the frequency inverter casing or through a sleeve designed for this purpose. The shield conductor must not be connected to an earth screw. OTHER PARTICULARS In addition to the above, the following should be observed: type of mains power supply local rules and regulations the manufacturer s installation instructions for the frequency inverter. OUTPUTS HIGHER THAN 22 KW If the output is higher than 22 kw, a symmetric shielded cable with concentric or in another way symmetrically designed protective earth conductor should be used. For recommendations for these installations, refer to the installation instructions for the frequency inverter. The shield must have 360º contact with the casing. Shield

12 12 Installation and Maintenance Instructions CLEANING Wipe the fan clean with a piece of cloth. It is particularly important to keep the impeller clean to avoid unbalance and vibrations. Important! Make sure that the fan outlet engages in the rear holder of the frame of the outlet connection. Important! Don t use liquids, since these may seep in between the sheet-metal joints and will be absorbed by the casing insulation. TO WITHDRAW THE FAN OUT OF THE UNIT CASING, SIZE EQLR The fan can be withdrawn out of the unit casing as follows: 1. Remove the panel frame including the panel and the fixed panel by removing the screws under the plugs that cover them. 2. Disconnect the motor/ control cable leading to the frequency inverter and pull the cables out through the rotor wall/filter wall. 3. If a shear absorber is fitted: Remove the screws (2 screws) to the shear absorber brackets. You do not need to back off the screws on the backside. If a pressure absorber and steel spring anti-vibration mountings are fitted: Remove the screws of the fan beam in the floor at both ends. 4. If steel spring anti-vibration mountings are fitted: Remove the screws that hold the fan connection against the fan outlet. 5. Withdraw the fan unit. Be careful to avoid damaging the packing at the fan inlet (applies to a rubber vibration absorber). The fan may be withdrawn so far that half of the fan motor (without the support of the guide rails) extends outside the unit, but no further. 6. After completed maintenance, push the fan back into the casing and follow the above procedure in the reverse order.

13 Installation and Maintenance Instructions 13 BEARINGS SPHERICAL ROLLER BEARINGS, BEARING BLOCKS FITTED WITH GREASE NIPPLES To refit: 1. Inspect the seals and replace them if they are defective. Fit the seals, taper sleeve and bearing onto the shaft. Fit the bottom half of the bearing block in the appropriate position as marked earlier. Fit the bolts and nuts, but don t tighten them. 2. Rotate the outer race of the bearing through a few revolutions to ensure that the rollers are in the correct position. Fit the tab washer and the nut onto the sleeve and tighten the nut by hand, so that the shaft, sleeve and bearing are firmly in contact with one another. Lower the shaft with the bearing into the bottom half of the bearing block. 3. Mark one of the tab washer tabs which is in line with a slot in the nut. Then tighten the nut so that the slot is displaced five tab pitches from the marked tab, and then fold one of the washer tabs into a suitable slot in the nut. Lubrication: The SKF type 222(00) CCK bearings are mounted on H3(00) taper sleeves in the type SKF SNA5(00)TAV bearing block. These self-aligning spherical roller bearings are equipped with grease nipples and should be lubricated once a year if they are run 8 hours a day and twice a year if they run around the clock. Lubricate with about 100 grams of grease per bearing. Appropriate grease is SKFALFALUBE LGMT2 or the equivalent. To dismantle: 1. Remove the top half of the bearing block. 2. Fold back the tabs of the tab washer and back off the nut a few turns. 3. Mark the position of the bearing block and then release the bottom half from the support arm. Tab pitches 4. Pack the bearing block and the spaces between the rollers with SKF ALFA LUBE LG MT2 or equivalent grease. 5. Fit the top half of the bearing block and bolt it in position. 6. Secure the bearing block to the support arm by tightening the bolts. 4. Raise the shaft with the bearing block about one millimetre. Use a drift or a piece of pipe applied to the nut to tap the taper sleeve out of the bearing. Remove the bearing together with the bottom half of the bearing block from the shaft.

14 14 Installation and Maintenance Instructions GROOVED BALL BEARINGS WITH TAPER SLEEVE; THE BEARING BLOCK HAS NO GREASE NIPPLES The SKF type 62(00) 2RS1K+H2(00) bearings are main-tenance-free and should not be greased. The bearing is secured to the shaft by means of a taper sleeve. To remove: 1. Fold back the tab of the tab-washer and back off the nut a few turns. 2. Apply a slight blow to tap the taper sleeve out of the bearing. Use a hammer and a drift. 3. Remove the bearing from the shaft. Y-BEARING WITH ECCENTRIC LOCK RING, THE BEARING BLOCK HAS NO GREASE NIPPLES The, type SKFYET bearings are maintenance-free and should not be greased. The bearing is secured on the shaft by means of an eccentric lock ring. The bearing is glued to the shaft. To remove: 1. Back off the stop screw by means of an Allen key. 2. Unscrew the eccentric lock ring (usually in a direction opposite the fan s direction of rotation). Mark the position of the bearing on the shaft. Remove the support arm. 3. The bearing is glued to the shaft. Use an extractor tool to extract the bearing from the shaft. Fasten the claws of the extractor tool against the inner bearing race. The bearing can also be removed by tapping on the inner bearing ring with a hammer. To refit: 1. Fit the bearing taper sleeve tab washer and nut assembly onto the shaft. Fit the tab washer so that the tabs slope outwards, and fit the nut with the bevelled side towards the bearing. 2. Fit the bearing assembly onto the shaft. 3. Tighten the nut by hand, so that the shaft, bearing and taper sleeve are firmly in contact with one another. 4. Mark one of the tab washer tabs which is in line with a slot in the nut. Then tighten the nut so that the slot is displaced by the number of tab pitches (from the marked tab) specified in the table below and then fold one of the washer tabs into a suitable slot in the nut. Bearing type SKF RS1K SKF RS1K SKF RS1K SKF RS1K SKF RS1K SKF RS1K Quantity Tab pitches 1,5 1,5 1,5 2 2,5 3 To refit: 1. Wipe off the inner surface of the bearing to remove the protective film. Place the bearing in the bearing vibration absorber. 2. Fit the support arm on the bearing and bearing vibration absorber. 3. Carefully clean the shaft. Apply glue (Loctite 603) onto the shaft. Mount the support arm with bearing to the marked position on the shaft. Secure the support arm to the fan casing. 4. Fit the eccentric lock ring against the inner race of the bearing and turn it by hand in the direction of fan rotation until the lock ring locks in its position. 5. Use the Allen key to tighten the stop screw. If you can measure the tightening torque, do not exceed the value tabulated below. Too much tightening torque involves risk of cracks forming in the inner bearing race. Fan size M (Nm)

15 Installation and Maintenance Instructions 15 TO REMOVE A LUBRICATED Y-BEARING Step 1 Support the shaft carefully with lifting slings before you begin work. Fasten the one end onto the shaft between the bearing holder and the impeller. Keep in mind that the impeller weighs kg depending on its size. See the exact weight specified in the list of spare parts Step 4 Remove the mounting bolts of the bearing block and allow the shaft be supported by the lifting sling, if necessary, so that the fan impeller will not touch the inlet cone. The bearing is glued onto the shaft. Therefore use an extractor tool to extract the bearing from the shaft. Fasten the claws of the extractor tool against the inner bearing race. The bearing can also be removed by tapping on the inner bearing ring with a hammer. Step 2. Unscrew the stop screw using an Allen key. Step 5 Replace the bearing block. Step 3 Open the eccentric lock ring by screwing it against the direction of rotation. Measure and mark the position of the bearing on the shaft, x = mm X 1. Bearing block 2. Grease nipple 3. Eccentric lock ring 4. Stop screw

16 16 Installation and Maintenance Instructions TO REFIT AN Y-BEARING Step 1 Wipe off the inner surface of the bearing to remove the protective film. Apply and spread glue (Loctite 603) on the shaft. The glue seals the joint and prevents corrosion. Push the bearing on the shaft to the marked position. Step 4 Tighten the stop screw of the lock ring using an Allen key. If you can measure the tightening torque, do not exceed the value given below. Too much tightening torque involves risk of cracks forming in the inner bearing race. NB! The tightening torque M for the Stop screw is 27 Nm Lim Step 2 Tighten the mounting bolts of the bearing block. Step 5 The refitting of the bearing is now completed. Check that the impeller rotates as is should and carry out a final inspection. Step 3 Fit the eccentric lock ring at its position in the inner race and screw it forcefully by hand in the direction of the shaft rotation to lock the ring in position.