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TCF MPQN, MPQS Installation, Operation & Maintenance Manual

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Page 1
MPQN/MPQS Modular
Plenum Fans
INSTALLATION, OPERATION & MAINTENANCE MANUAL
Throughout this manual, there are a number of HAZARD WARNINGS that must be read and adhered to in order to prevent possible personal injury and/or damage to equipment. Two signal words "WARNING" and "CAUTION" are used to indicate the severity of a hazard and are preceded by the safety alert symbol.
WARNING Used when serious injury or death MAY result from misuse or failure to follow specific instructions.
CAUTION Used when minor or moderate injury or product / equipment damage MAY result from misuse or failure to follow specific instructions.
NOTICE
Indicates information considered important, but not hazard-related.
It is the responsibility of all personnel involved in installation, operation and maintenance to fully understand the Warning and Caution procedures by which hazards are to be avoided.
ES-110
February 2012
Contents
Introduction .........................................................................1
Shipping and Receiving .....................................................1
Handling .............................................................................. 1
Short Term Storage ...........................................................1
Long Term Storage............................................................1
Foundations and Supporting Structures .......................... 2
Fan Installation ...................................................................3
Assembly of Fans and Sealing/Isolation Strips ..............3
Fan Operation – Safety .....................................................3
Operation Checklist ............................................................ 4
Maintenance of Fans ......................................................... 4
General Motor Maintenance ......................................... 4
Wheel and Shaft Maintenance ..................................... 5
Structural Maintenance ................................................. 5
Troubleshooting Guidelines................................................ 5
Troubleshooting Performance Problems
Air Capacity Problems ..................................................5
Noise Problems .............................................................5
Vibration Problems ........................................................ 5
Motor Problems ............................................................. 5
Limitation of Warranties and Claims ............................... 6
Introduction
The purpose of this manual is to provide instructions that complement good general practices when installing or operating fans manufactured by Twin City Fan & Blower. It is the responsibility of the purchaser to provide qualified personnel experienced in the installation, operation, and maintenance of air moving equipment. Instructions given in the body of this manual are general in nature and apply to a variety of models manufactured by Twin City Fan & Blower. Most units can be installed and maintained with the instructions given. Special applications may require additional information. These instructions are supplied in the form of attached appendices. Use the instructions in the appendix if the directions in this manual differ from instructions in the appendix.
As always, follow good safety practices when installing, maintaining and operating your air moving equipment. A variety of safety devices are available. It is the user’s responsibility to determine adequate safety measures and to obtain the required safety equipment.
Shipping and Receiving
All Twin City Fan & Blower products are carefully constructed and inspected before shipment to insure the highest standards of quality and performance. Compare all components with the bill of lading or packing list to verify that the proper unit was received. Check each unit for any damage that may have occurred in transit. Any damage should be reported immediately to the carrier and the necessary damage report filed.
Handling
Handling of all air moving equipment should be conducted by trained personnel and be consistent with safe handling practices. Verify the lift capacity and operating condition of handling equipment.
CAUTION
Maintain handling equipment to avoid serious personal injury.
Units shipped completely assembled may be lifted with slings and spreader bars. Use well-padded chains, cables or nylon straps. On most units, lifting lugs are provided for attaching chains (see Figure 1). Lift the fan in a fashion that protects the fan and fan coating from damage. Never lift a fan by the inlet or discharge flange, shafting or drives, wheel or impeller, motor or motor base, or in any other manner that may bend or distort parts.
©2010 – 2018 Twin City Fan Companies, Ltd.
Page 2
Figure 1. Lifting Lug Locations
SWIVEL EYE HOOK (By Customer)
A
DETAIL A
NOTE: When lifting, the straps/chains should be at a minimum angle of 45
Partial or disassembled units require special handling. All parts should be handled in a fashion which protects the coatings and parts from damage. Components should be handled such that forces are not concentrated and bending or distortion cannot occur. Housing should be lifted using straps and spreaders. Do not distort housing or side plates when lifting.
o
Short Term Storage
If fan installation is to be delayed, store the unit in a protected area. Protect the fan and motor bearings from moisture and vibration (or shock loading).
Long Term Storage
Prior to Storage – Motor bearings are to be greased at
the time of going into extended storage per the motor manufacturer’s specifications.
Storage Procedure – Fans should be stored indoors whenever possible where control over temperature, shock and dust is reasonably maintained. If units are to be stored outside in the elements, they should be covered with a water-resistant material. Stored equipment should be stored on a clean, dry floor or blocked up off the ground on blocks to prevent unit from setting in any water or directly on the ground. If shock or vibration will be present during storage, the unit may need to be placed on some type of vibration dampening material to aid in preventing brinelling of the bearing surfaces.
Start-Up – When the unit is removed from storage, all bearing grease should be purged and replenished with fresh grease as per the lubrication decal. The motor should be measured to verify that the resistance is still at a satisfactory level compared to the value recorded prior to storage.
Foundations and Supporting Structures
Floor mounted fans should be installed on a flat, level surface with sufficient structure support. Support shall be suitable for static and dynamic loads and foundation frequencies be separated at least 20% from the rotational speed/speed ranges. If the fans are mounted on a sub-structure, an inertia base with spring isolator system should be considered. Fans mounted to or within a structure should be placed as close as possible to a rigid member such as a wall or column. The structure must be designed for rotating equipment; static design for strength is not sufficient to insure proper operation. Supports for suspended fans must be cross-braced to prevent side sway. Structural resonance should be at least 20% from fan operating speed. Any ducting and/or dampers with sleeves should have independent support; do not use the fan for support. Isolating the fan from ductwork with flex connections eliminates transmission of vibration.
1. Sufficient structure must be provided to support weight of fan assembly.
2. Sufficient restraint must be provided to resist the pressure force against the fans. Typically fans are assembled in an application in a modular fashion with multiple fans working in parallel. The cumulative thrust force must be restrained to prevent the fan assemblies from leaning or tipping forward. The force acting on the fan assemblies is calculated as shown below.
Thrust force (lb
27.68 Where P
s = Maximum operating static pressure (in. w.g.)
W = Width of each individual fan (in.) H = Height of each individual fan (in.) N = Quantity of fans in system
27.68 = conversion factor for in. w.g. to PSI
Example Parallel fan system employing nine (9) – Size 182 fans
in a 3 x 3 configuration. (3 fans high x 3 fans wide) System pressure is 5 inches of water column. Outside dimension of fan housing = approx. 32 in. by
32 in.
Thrust force (lb
27.68
Thrust force (lb
27.68
Note: The thrust force is distributed evenly across the front
surface of the parallel fan system.
H x W x N x P
f) =
H x W x N x P
f) =
32 x 32 x 9 x 5
f) =
s
s
= 1665 (lbf)
2
Twin City Engineering Supplement ES-110
Page 3
Figure 2.
RUBBER GASKET
NOTE 5
RUBBER GASKET
OUTER SHELL
RUBBER GASKET
NOTES
D
B
A
RUBBER GASKET
RUBBER GASKET
C
NOTES:
1. On the horizontal between fans, one strip of gasket material is needed on inlet side & two on drive end on 222 & above, 200 and below get one strip on each end.
2. Gaskets need to connect in all corners to ensure proper sealing.
3. Rubber gasket is to be placed directly next to the mounting holes on the inlet and drive side.
4. Rubber gasket is 1/2 in. x 2 in. x cut-to-fit.
5. Rubber gasket is to be held in place be double-stick foam tape during assembly.
3. Recommend attachments to the sides and top of the parallel fan system incorporating some form of spring support, i.e. rubber snubbers/isolators or springs. Such devices should be attached to prevent significant point loading on an individual fan. They should be located on the side of the parallel fan system at the top corner and along the top every 2 fans or less.
a. When the fans are rigidly mounted to the base,
an assumption can be made that half of the thrust load will be supported at the base, and the supports added at the top of the fan need to carry a minimum of one half of the thrust load.
b. When the fans are supported on an isolation base
or isolators, it will be necessary to add thrust restraints around the periphery of the fan assembly to support the entire thrust load. Flex connections are required when using isolators or isolation base.
c. Attachments to the fan can be made utilizing the
factory mounting holes. Recommend that the gage of the materials be checked for tear out strength in thrust applications. If necessary utilize multiple mounting hole locations to distribute the load.
Fan Installation – Factory Assembled Units
Follow proper handling instructions given earlier.
1. Move the fan to the final mounting position.
2. Remove skid, crates, and packing materials carefully.
3. If supplied, place vibration pads or isolation base on mounting bolts. Line up holes in fan base with bolts.
4. Place fan on mounting structure. Carefully level unit using shims as required at all mounting hole locations. Bolt down the unit.
DETAIL A
DETAIL C
FRAME
PERF. PLATE
OUTER SHELL
MOUNTING HOLE
OUTER SHELL
RUBBER GASKET
RUBBER GASKET
OUTLET ONLY
222 & ABOVE
FRAME
RUBBER GASKET
RUBBER GASKET
DETAIL B
DETAIL D
RUBBER GASKET
OUTER SHELL
MOUNTING HOLE
RUBBER GASKET
RUBBER GASKET
Assembly of Fans and Sealing/Isolation Strips
1. Fans must be securely bolted to a base either directly through the factory mounting holes or with a properly designed clip. Final bolting of layer of fans to the support structure or base should be done after the individual fans are bolted together as a row.
2. During installation rubber strips need to be installed between each fan. Use double-sided foam tape to hold strips in place during installation. Two (2) to three (3) pieces of tape can be used as needed for this purpose (each end and middle of rubber strip). Location of these strips is documented in Figure 2.
3. The first fan on the bottom row will have the 2 vertical strips placed next to the mounting holes. Note: Strips should be cut to ensure an airtight seal between fans.
4. The bolts to be snugged up on vertical sections for the first row. Once all strips are in place, the bolts shall be tightened to torque values in table. See Table 1.
5. The bolts holding the fan to the supporting structure can now be torqued.
6. Rubber strips are then placed on the top of the fan to support the fan above it according to the pattern shown. Note: On larger fan assemblies 2 strips are used in the back to support the weight of the motor.
7. The second row and succeeding rows can be installed using the same assembly steps as the first row.
8. Rubber strips are not normally needed on the outside or top of the parallel fan system.
9. Sealing around the perimeter should be accomplished using a flexible material.
Table 1. Torque Values MPQN/MPQS Fasteners
Size
3/8 – 16 UNC
Net Type
Nylock 16 – 17
Twin City Engineering Supplement ES-110 3
Torque Values
(ft lbs)
Page 4
Fan Operation - Safety
For general safety practices for air moving equipment, see AMCA Bulletin 410. Twin City Fan & Blower has many safety accessories available. These safety devices include (but are not limited to) inlet and discharge screens. The use, abuse, or non-use of safety devices is the responsibility of the purchaser. Facility-related safety conditions include fan accessibility and location. How easily can non-service personnel access the unit? Is the fan in a hazardous duty environment? Was the unit ordered for this duty? Other concerns must also be addressed. All fans should be powered through switches which are easily accessible to service personnel from the fan. Every switch should have the ability to be “locked-off” by the service person and the key to be retained by this person to prevent accidental power of the fan while service is in process.
Operation Checklist
WARNING
Verify that proper safety precautions have been followed. Electrical power must be locked off.
□
Correct any problems which may have been found. (Follow safety guidelines - shut power off.) Perform checklist again until unit is operating properly.
□
Run unit up to speed. Verify fastener tightness. These may have loosened during shipment or installation.
□
Setscrews attaching wheel hub to shaft.
□
Nuts on inlet funnel.
□
Nuts and bolts holding motor.
□
Nuts holding housing frame to base and base to ground.
□
Bolts in taper-lock bushings.
□
Grease line connections.
After one week of operation, check all nuts, bolts and setscrews and tighten if necessary.
Figure 4. Proper Wheel Rotation
a
t
i
t
o
o
n
R
BAF, BAE, EPF, EPQ, MPQN, MPQS, APF & APQ Wheels
Check fan mechanism components:
□
System connections are properly made and tightened.
□
Bearings are properly lubricated.
□
Wheel, drives and fan surfaces are clean and free
of debris.
□
Rotate the impeller by hand to verify it has not shifted
in transit.
□
Check fan/wheel overlap. (See Figure 3.)
Figure 3. Wheel-Funnel Overlap
A
DIA
B
Size
122 150 165 182 200
222
245
MPQN/MPQS
A B Size A B
13.00 0.25
14.13 0.25
16.16 0.25
19.00 0.38
20.82 0.41
23.16 0.45
25.51 0.50
270 300 330 365 402 445 490
28.11 0.55
31.23 0.61
34.36 0.67
38.00 0.75
41.90 0.82
46.33 0.91
51.01 1.00
Maintenance of Fans
This section contains general maintenance instructions for your Twin City Fan & Blower unit. For specific information about maintenance of components, particularly for special application fans, see the attached documents.
General Motor Maintenance
The three basic rules of motor maintenance are keep the motor clean, dry and properly lubricated. Keeping motors and windings clean is important because dirt and dust serve as thermal insulators. Heat normally dissipated by the motor is trapped causing overheating and/or premature failure. Blow dust and dirt out of windings and off the motor periodically. Use low pressure (50 psig) airstream so that winding damage does not occur. Keep the area surrounding the motor open so the air can circulate through the motor cooling fan. Follow normal maintenance schedule given to the right. Motors should be kept dry to avoid electrical short circuits. Motors kept in storage for long periods of time can have moisture condense on the windings. Be certain the motor is dry before using.
Check fan electrical components:
□
Motor is wired for proper supply voltage.
□
Motor was properly sized for power and rotational
inertia of rotating assembly.
□
Motor is properly grounded.
□
All leads are properly insulated.
Trial “bump”:
□
Turn on power just long enough to start assembly
rotating.
□
Check rotation for agreement with rotation arrow. Does the assembly make any unusual noise? (See Figure 4.)
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Twin City Engineering Supplement ES-110
Page 5
Some smaller motors are lubricated for life. Motor bearing lubrication, if required, must follow a rigorous schedule. Motors less than 10 hp running about eight hours a day in a clean environment should be lubricated once every five years; motors 15 to 50 hp, every 3 years; and motors 50 to 150 hp, yearly. For motors in a dusty or dirty environment or running 24 hours a day, divide the service interval by 2. If the environment is very dirty or high temperatures exist, divide the service interval by 4. Lubrication requirements are normally attached to the motor. Do not overlubricate.
Wheel and Shaft Maintenance
Periodically inspect the shaft and wheel for dirt buildup, corrosion, and signs of excess stress or fatigue. Clean the components and, when appropriate, apply new coatings. (Any addition of coatings or weld can create an imbalance.) Check the balance of the assembly.
Structural Maintenance
All structural components or devices used to support or attach the fan to a structure should be checked at regular intervals. Vibration isolators, bolts, foundations, etc., are subject to failure from corrosion, erosion, and other causes. Improper mounting can lead to poor operation characteristics or fan fatigue and failure. Check metallic components for corrosion, cracks, or other signs of stress. Concrete should be checked to ensure the structural integrity of the foundation.
Noise Problems:
1. Air performance is incorrect and fan is not at design point of operation. Fan forced to operate in an unstable flow region.
2. Bearing failure. Check bearings (lubrication).
3. Supply voltage high or inconsistent supply frequency. Adjustable frequency controllers can generate motor noise.
4. Objects which are installed in a high velocity airstream can generate noise. This includes flow sensors, turning vanes, etc.
5. Poor fan inlet conditions.
6. Acoustics or sound measurement procedure incorrect.
Vibration Problems:
1. Misalignment of drive components.
2. Poor foundations or mounting structure (resonances).
3. Foreign material attached to rotating components.
4. Damaged rotating components (bearings, shaft, fan, wheel).
5. Broken, loose or missing setscrews.
6. Loose bolts.
7. Vibration transmitted by another source.
8. Water accumulating in airfoil blades.
9. Fan is operating in stall or unstable flow region.
Troubleshooting Guidelines
Use current safety practices when investigating fan or system performance problems. General safe practices and performance troubleshooting guidelines can be found in AMCA Publications 410 and 202, respectively. Fan application and field measurement procedures can be found in AMCA Publications 201 and 203.
Troubleshooting Performance Problems
The lists below indicate possible areas to check when air or sound values do not match expectations. Most fan problems can be pinpointed to one of these common causes.
Air Capacity Problems:
2. Fan speed is not at design speed.
3. Air density not at design values. Also check air performance measurement techniques/procedures.
4. Devices for air modulation are closed or plugged. Also check filters.
5. Wheel mounted improperly or is rotating in reverse.
6. Parts of system or fan have been damaged or need cleaning.
NOTICE
All fans manufactured by Twin City Fan & Blower are factory balanced prior to shipment. Handling and movement of the fan during shipment may cause the rotating assembly to shift. Balance should be checked once the fan is installed. If a final trim balance is required, it is the end user's responsibility to bring the fan back to factory specifications. Final trim balancing is not the responsibility of Twin City Fan & Blower.
Motor Problems:
1. Incorrect wiring.
2. Speed of fan too high.
3. Parts improperly installed - binding.
4. Bearings improperly lubricated.
2
5. WR
capability of motor too low for application.
6. Protection devices may be improperly sized.
Motor Lubrication – The major cause of motor bearing failure is contamination of grease, insufficient grease, or incompatibility of grease. If a fan is to be stored for any length of time at the job site and the bearings are regreasable, the motor bearings should immediately be filled with grease while rotating the fan and then the bearings should be regreased and rotated monthly. This will prevent moisture, which condenses within the bearing, from corroding the raceways. Most greases used on motor bearings are lithium base. Use the greases shown in the motor information. Do not mix the bases without completely purging out the initial grease.
Twin City Engineering Supplement ES-110 5
Page 6
Initially, follow the lubrication instruction in the motor information. The frequency of lubrication should be adjusted depending on the condition of the old grease being purged. This is the responsibility of the user. If the grease is dirty, the lubrication frequency should be more often.
a. Noise – If a bearing is increasing in noise intensity
and/or vibration, it will probably result in failure.
b. Temperature – If a bearing temperature begins to
gradually rise, it will generally result in failure. A bearing can operate up to 200 degrees and operate satisfactorily if the temperature remains constant and the bearing receives adequate lubrication. Remember that a roller bearing under the same load and speed will be somewhat more noisy and run warmer than a ball bearing. This is normal.
Rough handling and/or dropping a fan can result in brinelling the bearing. This appears as a clicking noise at first, then gradually worsens until failure.
Limitation of Warranties and Claims
Seller warrants to the original purchaser that the goods sold hereunder shall be free from defects in workmanship and material under normal use and service (except in those cases where the materials are supplied by the buyer) for a period of one year from the date of original installation or eighteen (18) months from the date of shipment, whichever occurs first. The liability of seller under this warranty is limited to replacing, repairing, or issuing credit (at cost, F.O.B. factory and at seller’s discretion) for any part or parts which are returned by buyer during such period provided that:
a. seller is notified in writing within ten (10) days
following discovery of such defects by buyer, or within ten (10) days after such defects should reasonably have been discovered, whichever is less;
b. the defective unit is returned to seller, transportation
charges prepaid by buyer.
c. payment in full has been received by seller or said
products; and
d. seller’s examination of such unit shall disclose to its
satisfaction that such defects have not been caused by misuse, neglect, improper installation, repair, alteration, act of God, or accident.
dBA.
No warranty made hereunder shall extend to any seller product whose serial number is altered, effaced or removed. Seller makes no warranty, express or implied, with respect to motors, switches, controls, or other components of seller’s product, where such components are warranted separately by their respective manufacturers. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, WHETHER STATUTORY OR OTHERWISE, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. In no event shall seller be liable to buyer for indirect, incidental collateral, or consequential damages of any kind. (BUYER’S FAILURE TO PAY THE FULL AMOUNT DUE WITHIN SIXTY (60) DAYS OF DATE OF INVOICE SHALL OPERATE TO RELEASE SELLER FROM ANY AND ALL LIABILITY OR OBLIGATION ARISING PURSUANT TO ANY WARRANTY, EXPRESS OR IMPLIED, WHETHER STATUTORY OR OTHERWISE, INCLUDING ANY IMPLIED WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, MADE IN CONNECTION WITH ANY CONTRACT FORMED HEREUNDER. BUYER AGREES THAT SUCH FAILURE TO PAY SHALL CONSTITUTE A VOLUNTARY WAIVER OF ANY AND ALL SUCH WARRANTIES ARISING PURSUANT TO SUCH CONTACT.)
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Twin City Engineering Supplement ES-110
Page 7
Twin City Engineering Supplement ES-110 7
Page 8
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TWIN CITY FAN & BLOWER | WWW.TCF.COM
5959 Trenton Lane N | Minneapolis, MN 55442 | Phone: 763-551-7600 | Fax: 763-551-7601
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