D R I V E S &

S W I T C H G E A R

O n some electric motors, the internal and/or external fans can be fitted in
either direction. Frequently repair companies do not properly identify and
mark the fans and this results in fans being incorrectly re-fitted.

Centrifugal fans -
direction of rotation explained
There seems to be some confusion in the by Henk de Swardt, Marthinusen & Coutts
electric motor repair industry regarding
the rotation direction of a motor’s
cooling fans. We have seen cases where
the fans removed from the motor were
incorrectly installed. This paper explains
the basic principles behind correct fitting
of fans.
For general applications the rules listed
here should hold true.
Centrifugal fans can in general turn in
both directions. The performance of the
fan may however not be identical for
both directions. Centrifugal fans can
only blow air radially outwards. Fig. 1: Example of a bi-directional fan. Fig. 2: Example of a uni-directional fan
with curved blades.
Bi-directional fans
A “bi-directional fan” has straight
blades, perpendicular to the shaft,
which may or may not extend to the boss
(inside section of the fan that holds the
fan on the shaft).
This type of fan can rotate in both
directions, without any change in fan
power consumption and air volume.
Fig. 4: The “backwardly curved blades”
These fans are frequently used on principle is used in determining
a “slow” speed motor, i.e. a motor the direction of rotation for angled
with a rotational speed of less than Fig. 3: Example of a uni-directional fan, or curved blades.
1300 rpm. with straight blades.

Uni-directional fans
A “uni-directional fan” may have
straight or curved blades. The blades
are however at an angle to the shaft,
which may or may not extend to the boss
(inside section of the fan that holds the
fan on the shaft).
Fig. 2 shows an example of a uni-
directional fan with curved blades.
Fig. 3 shows an example of a uni-
directional fan with straight blades.
In these examples, the correct direction
of rotation is clockwise as viewing
the fans from the inlet side (as shown
currently in the Figs).
Using these fans in the opposite
direction from that shown here will
result in an increase in the fan’s power
consumption, fan noise and also the air
volume it moves.
The principle used for determining the
direction of rotation is “backwardly
curved blades”. Fig. 4 shows how this
principle is used.
Consequences of incorrect
direction of rotation
Although the increase in air volume is
good, unfortunately in most cases the
increase in fan power usage outweighs

July 2008 - Vector - Page 45

 Item @ % Load Value Unit investigation it was found that the
Power Output 100% 1200 kW direction of the fans was incorrect. We
75% 900
0% 0
corrected this mistake and the motor
could deliver the correct full load power
Item @ % Load Direction of rotation Unit while still complying with the specified
Correct Incorrect temperature rise.
Air flow rate coefficient 3,03 3,33
"Fan losses increase: Power of" 3 5 Energy costs
Fan losses 35,0 46,6 56,4 kW
Current 100% 122,4 123,4 124,3 A To put the cost of incorrect fan fitment
75% 94,7 95,7 96,5 into perspective, the direct energy costs
0% 35,6 35,7 35,8 will be calculated using equation 1.
Speed 100% 2985,3 2985,2 2985,1 The rate for the energy will be used
75% 2989,1 2989,0 2988,9
Total losses 100% 64,5 76,6 86,8 kW
as 23c/kWh. The calculations will be
75% 54,8 66,7 76,8
annualised, assuming running times of
0% 42,2 54,4 64,2 firstly for a light duty, 12 hour per day,
Efficiency 100% 94.90% 94,00% 93,25% 5 days per week, and secondly for a
75% 94,26% 93,10% 92,13% normal duty, 24 hours per day, 7 days
Input Power 100% 1264 1277 1287 kW
per week. (See table 2).
75% 955 967 977
Temperature rise 75,4 77,6 80,8 °C

Table 1: Changes when rotation is reversed.

I
Item
Power Output
Item
Fan losses increase: Power of
Fan losses
Current
Total losses
Efficiency
Power Factor
"Light duty Energy cost
(one year)"
"Standard duty Energy cost
(one year)"
the benefit of an increase in air flow.
In practical terms, it is difficult to estimate
exactly what the increase in flow and
power will be for a specific fan without
extensive finite element modelling.
Let’s assume some values for a specific
application and study the effects on the
motor’s performance.
C o n s i d e r a 1 2 0 0 k W, 2 p o l e ,
6600 V motor that has been designed
to turn in an anti-clockwise direction.
This motor is coupled to a load that
requires a clockwise direction of
rotation and is electrically connected
accordingly. Let’s also assume the
three (two internal and one external)
fans will produce as much as 10%
more air flow (even with the increased
pressure drop through the heat
exchanger) because of the incorrect
direction of rotation. In general the
increase in power would be between
the cube and the power of five of
the increase in flow, thus the power
consumption of the fans would
increase by between 33 and 61%.
Let us compare the performance
characteristics for the correct and
incorrect direction of rotation of the fans
Eqn. 1: Calculating the direct energy cost.
Value Unit
1200 kW
where:
Direction of rotation Unit h = hours running per day
Correct Incorrect
3 5 d = days running per year
35,0
122,4
46,6
123,4
+ 24,9%
+ 0,9%
56,4
124,3
+ 37,9%
+ 1,6%
kW
A
If we apply this calculation to the case
64,5 76,6 + 15,7% 86,8 + 25,7% kW study, we can see the additional costs as
94,90% 94,00% - 0,9% 93,25% - 1,7% a result of the lower efficiency.
0,905 0,906 + 0,1% 0,933 + 2,9%
R 910 k R 919 k + 0,9% R 926 k + 1,7% Although the percentage change
R 910 k R 919 k + 0,9% R 926 k + 1.,%
looks relatively small, the result on a
population of a few hundred or a few
Table 2: Case study calculation. thousand motors of various sizes can
have huge implications on the energy
bill of the company. And these additional
for both the best case of 33% increase in costs could have been easily avoided.
fan losses as well as for the worst case
of 61% increase in fan losses. Conclusion
Even though the air flow increased In order for the electric motor to operate
significantly through the motor, which at its peak designed performance,
results in better cooling of the motor, the the fan needs to be correctly installed
and designed to suit the specific
much higher increase in the fan losses
far outweighs this improved cooling and application.
results in a motor that consumes more It must be noted that the influence of the
direction of rotation on the air flow and
power and runs at a higher temperature.
fan losses become less important in slow
The motor’s efficiency is greatly reduced
speed motors.
and the full load current is increased.
In many cases the direction of rotation
An interesting development is that
in relation to the construction of the
customers may experience overheating external fan can easily by checked by
problems as a result of higher operating means of visual inspection on site.
loads, as demands on production Whenever a motor is overhauled or
increases. We have seen cases where repaired it is recommended that the
motors have run for years at less than full correctness of the orientation of the
load power and at a lower temperature. internal and external fans should be
The customer did not know that the fan checked.
losses actually increased the running In instances where there is doubt, it is
temperature of the motor, since the better to contact experts in the motor
overall temperature was well below repair and manufacture industry to
the limits. However, when production ensure the motor and plant’s long term
demands increased, and the load at reliability and dependability.
which the motor ran increased, it was Contact Henk de Swardt,
found that the motor actually could Marthinusen & Coutts,
not drive the driven load at the full Tel 011 616 2320,
load power without overheating. On henkd@mandc.co.za D

July 2008 - Vector - Page 46