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IM-1080
User Manual
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Twin City IM-1080 User Manual

Inline Fume Exhaust Fans
INSTALLATION, OPERATION & MAINTENANCE MANUAL
IM-1080
August 2014
INTRODUCTION
This manual has been prepared to guide the users of TFE, QFE, QIFE, and TVIFE Fume Exhaust Fans in the proper installation, operation and maintenance procedures to insure maximum equipment life with trouble-free operation.
TFE and QFE QIFE TVIFE
CONTENTS
Inspection and Receiving ...........................................................................................................................................................2
Handling and Rigging .................................................................................................................................................................2
Storage .........................................................................................................................................................................................2
Installation
Operation Checklist .....................................................................................................................................................................5
Maintenance
Jib Crane Operation ....................................................................................................................................................................6
Troubleshooting ...........................................................................................................................................................................7
Caution:
Fan systems include rotating components and electrical devices. Proper care must be taken during installation and maintenance of all fan system components to protect personnel. This includes, but is not limited to the use of protective enclosures, guards, locking devices to stop rotating parts, and electrical disconnect lock-outs. Refer to applicable local codes to ensure compliance for all protective devices.
Fans create a suction at the inlet. Care should be taken around the inlet of the fan, whether it is in operation or not. Make sure the inlet area is clear prior to energizing the system. This includes all personnel and loose, foreign objects.
©2012 Twin City Fan Companies, Ltd.
INSPECTION 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.
UNIT STORAGE
If fan installation is to be delayed, store the unit in an environmentally stable and protected area. During storage, the fan should not be subjected to vibration from external sources or bearing damage may occur. The unit should be reasonably protected from any accidental impacts. Cover the fan to protect coatings and to prevent any foreign material or moisture from entering the inlet or discharge. Take care to protect the motor, drives and bearings.
HANDLING AND RIGGING
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. Maintain handling equipment to avoid serious personal injury.
Units shipped may be lifted with slings and spreader bars. Use well-padded chains, cables or nylon straps (see Figure
1). On most units, lifting lugs are fashioned to protect the fan and fan housing from damage. Never lift a fan by the inlet or discharge flange, shafting or drives, wheel, motor or motor base, or in any other manner that may bend or distort parts.
Mixing plenum boxes configured for multiple fans mounted on a common unit are modular in design and may be broken down into smaller segments for ease of installation and handling.
Figure 1. Lifting Locations
Extended storage requires monthly inspections. Check for corrosion or damage to the unit and for debris within the fan.
Bearings tend to take on moisture if the atmosphere in which they are stored is not at a constant temperature. To avoid corrosion, it is necessary to keep the bearings full of grease and to rotate them periodically. Even when full of grease, bearings will take on moisture, so it is necessary to purge the bearings with new grease to expel moisture every thirty days. It is recommended that the bearings be purged with grease while being rotated by hand. Do not use high pressure greasers as they may ruin the bearing seals.
The drives and belts should be removed if the fan is to be stored for a prolonged period. The drives should be labeled for service and stored in a dry place. Belts should be removed, coiled without kinks, placed in a heavy car­ton, and stored in a dry, well-ventilated place. To prevent belt deterioration storage conditions should not exceed 85°F and 70% humidity. If belts show signs of deteriora­tion, they should be replaced prior to startup.
Motors should be stored in a clean, dry, vibration-free location. The packaging should be opened up enough to allow air circulation around the motor. The winding tem­perature should be kept slightly above that of the sur­roundings to prevent condensation. This can be accom­plished by energizing the internal heaters, if the motor is so equipped, or by using space heaters. If it is impossible to heat the windings, the motor should be wrapped tightly with a waterproof material which also encloses sev­eral bags of desiccant. Replace the desiccant regularly to prevent moisture problems. The motor rotor should also be rotated regularly (monthly) to assure the bearing parts are well greased.
Start-Up – When the unit is removed from storage, all fan 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.
INSTALLATION
Pre-Installation Checklist
Prior to fully assembling and installing, inspect the fan and ancillary components to ensure it is in working order.
• Check all external and internal hardware on the fan, wheel, bearings, drive motor base and accessories for tightness.
• Rotate the fan wheel by hand and assure no parts are rubbing. Adjust components prior to installation as ad­justments are easier while lower to grad.
• Check proper wheel clearances to be sure near toler­ance. The wheel will need to be realigned after instal­lation, therefore, clearances should be near tolerance.
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Twin City Fan IM-1080
Roof Curb Installation
Caution: Roof curbs should be square and level to ensure safe fan installation and proper sealing of gas stream to the fan.
Roof curbs shall be installed and fully attached to struc­tural support (by others) which is typically steel or concrete using 1/2" diameter bolts w/ 1-3/8" washers (by others)
Figure 2. Bolted Installation
For attachment to structural steel the curb can be con­tinuously welded or stitch welded using 3/8" x 6" welds with a maximum of 3" spacing between welds. Welds should be evenly spaced along curb side and corners
Figure 3. Welded Installation
Mixing Plenum Box Assembly and Installation
The modular plenum mixing boxes are designed to allow for easy installation and future expandability. Single mixing plenum boxes are fully assembled (less any dampers) to expedite installation. Depending on the size, multi-unit mix­ing boxes may or may not be assembled. When installing the mixing box(es), it is important to follow the guidelines for lifting and rigging on page 2.
When a single-unit mixing plenum box is installed, prepare the roof curb or mounting structure. Lay gasket material on the top edge of the roof curb. Lift mixing box onto curb and square (level) mixing box.
Depending on the air intake (side or bottom), the mixing box must be oriented to allow for direct duct connection into the mixing plenum box. Match drill roof curb to mix­ing plenum box. Attach mixing plenum box to curb using 1/2” diameter bolts with 1 3/8” washers (by others).
For multi-unit configurations, some assembly may be required. There are at least two different assemblies in a multi-unit configuration. There is the mixing plenum box assembly and the mixing box spacer. See figure 4. There will be one less spacer than the quantity of mixing plenum boxes.
To assemble, space the mixing boxes a distance apart that is slightly more than the width of the spacer section. Utilize a gasket between the mixing box and the spacer section to provide a tight seal.
Install 316 stainless steel bolts to attach the spacer and the mixing box. Repeat as necessary for each section.
When the multi-unit mixing plenum box is assembled, rig the mixing box system into place in accordance with Figure 1 to avoid any damage.
Install mixing plenum box assembly onto a prepared (gas­ket material on mating surface) roof curb or mounting structure. Lay Square (level) mixing box. Install lag bolts
into the mixing plenum box to roof curb as indicated.
Figure 4. Mixing Box
Fan and Windband Installation
• Follow proper handling instructions as provided earlier.
• Identify each fan and component and match the equip-
ment up with the supplied customer drawing(s).
• Move the fan to the final mounting location.
• Remove skid, crates and packing materials carefully.
• For fans mounted directly to roof curb (supplied with a
curb cap), place the fan on properly installed roof curb. Fans mounted on a mixing plenum box (supplied with mixing plenum box transition) require the installation of the mixing plenum box prior to installing fan.
• Fans shipped as a single unit shall be broken down
into several parts. Install each item individually in the following order:
1. Fan and curb cap onto the installed roof curb
-or­Fan and mixing plenum box transition onto in­stalled mixing box.
2. Stack extension, if in the scope of supply (TFE/ QFE Only)
3. Windband
Note: When installing the components, lifting lugs shall be uti­lized for safe installation. Lifting lugs are designed for the weight of the component they are welded to and should not be used to lift assemblies.
Fan Housing Installation
1. Place supplied gasket around the perimeter of the mix­ing plenum box or roof curb.
2. Lower fan housing onto roof curb or mixing plenum box aligning the bolt holes on the two components. Allow for gasket to compress naturally prior to securing fan housing to the adjacent component.
3. Install 316 stainless steel hardware (provided) in all mounting holes. Use a commercially available anti­seizing compound formulated for 316 stainless steel to hardware. Carefully level the unit on the roof curb or mixing plenum box. Be careful not to force the fan to the mounting structure. This may cause misalignment which may unsafe operating conditions, cause vibration and premature failure.
4. Check the alignment of the bearings. Shim or reposition the bearings if necessary.
5. Check face alignment of sheaves on belt driven fans. Check tension of belts to see if it is sufficient. Sheaves on belt driven fans are often provided with taperlock bushings. When tightening bushing bolts, proceed in a progressive manner to avoid cocking the tapered sur­faces between the bushing and the sheave.
6. Check the tightness of the wheel on the shaft. Check the tightness of foundation bolts, motor bolts, sheaves, and bearings. Make sure there is no rubbing or binding and that the wheel-inlet cone clearances and overlap are correct.
Twin City Fan IM-1080
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