Documente Academic
Documente Profesional
Documente Cultură
WAREHOUSE
Cabuyao, Laguna
OPERATION AND
MAINTENANCE MANUAL
FOR VENTILATION
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Operation and Maintenance Manual
Mechanical System – Ventilation
TABLE OF CONTENTS
and
A. System Description
B. System Operation
C. System Maintenance
A. Equipment Data
B. Recommended Spares
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Certificates
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GENERAL CONTRACTOR
Webmail: www.rmci-ph.com
Warranty:
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SUPPLIER:
• EXHAUST FAN
• TUBULAR CENTRIFUGAL IN-LINE
• CABINET TYPE CENTRIFUGAL FAN
• VANE AXIAL FAN
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CERTIFICATE OF WARRANTY
SUBMITTED BY:
_______________________________
ENGR. RICARDO G. FERNANDO
General Manager
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Operation and Maintenance Manual
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A. System Description
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SYSTEM DESCRIPTION
INTRODUCTION
Ventilation is the intentional introduction of outdoor air into a space and is mainly used to control indoor
air quality by diluting and displacing indoor pollutants; it can also be used for purposes of thermal com-
fort or dehumidification.
The intentional introduction of outdoor air can be categorized as either mechanical ventilation, or natural
ventilation.[2] Mechanical ventilation uses fans to drive the flow of outdoor air into a building. This may
be accomplished by pressurization (in the case of positively pressurized buildings), or by depressuriza-
tion (in the case of exhaust ventilation systems). Many mechanically ventilated buildings use a combi-
nation of both, with the ventilation being integrated into the HVAC system. Natural ventilation is the in-
tentional passive flow of outdoor air into a building through planned openings (such as louvers, doors,
and windows). Natural ventilation does not require mechanical systems to move outdoor air, it relies
entirely on passive physical phenomena, such as diffusion, wind pressure, or the stack effect. Mixed
mode ventilation systems use both mechanical and natural processes. The mechanical and natural com-
ponents may be used in conjunction with each other or separately at different times of day or season of
the year.[3] Since the natural component can be affected by unpredictable environmental conditions it
may not always provide an appropriate amount of ventilation. In this case, mechanical systems may be
used to supplement or to regulate the naturally driven flow.
Categories of Ventilation
• Mechanical ventilation refers to any system that uses mechanical means, such as a fan, to introduce
subaerial air to a space. This includes positive pressure ventilation, exhaust ventilation, and bal-
anced systems that use both supply and exhaust ventilation.
• Natural ventilation refers to intentionally designed passive methods of introducing subaerial to a
space without the use of mechanical systems.
• Mixed mode ventilation (or hybrid ventilation) systems use both natural and mechanical processes.
• Infiltration is the uncontrolled flow of air from outdoors to indoors through leaks (unplanned open-
ings) in a building envelope. When a building design relies on environmentally driven circumstantial
infiltration to maintain indoor air quality, this flow has been referred to as adventitious ventilation.
Mechanical ventilation of buildings and structures can be achieved by use of the following techniques:
• Whole-house ventilation
• Mixing ventilation
• Displacement ventilation
• Dedicated subaerial air supply
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Exhaust/Supply Fan
Capacity: to 52,576 CFM, to 3/8” SP
Size: 18” to 60” wheel diameter
Arrangement: Direct drive or Belt driven
Use: Ventilation system, exhaust of warm air and fresh air supply
Vaneaxial Fan
Capacity: to 100,000 CFM, to 5” WG
Size: 12” to 60”(BD) & 18" to 60"(DD) wheel diameter
Arrangements: Direct drive or belt driven
For more info: Request for Bulletin 671
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Exhaust/Supply Fan
OPERATION
Start Up
Turn the fan on and inspect for the following.
• Direction of rotation
• Improper motor amperage
• Excessive Vibration
• Unusual Noise
• Improper belt tension or alignment
If a problem is discovered shut off the fan and refer to the section on troubleshooting to discover
the cause of the problem. The fan should be inspected after 30 minutes, 8 hours and 24 hours of oper-
ation to ensure all fasteners are tight and belts are properly tensioned and aligned.
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MAINTENANCE
WARNING
Disconnect and secure to the OFF position all electrical power to the fan prior to inspection or servicing. Fail-
ure to comply with this safety precaution could result in serious injury or death.
• Ventilators should be checked at least once a year. For critical or severe applications a routine check
every two to three months is suggested.
• When removing or installing a belt don’t force the belt over the sheave. Loosen the motor mount so
that the belt can be easily slipped over the sheave.
• The belt, on belt driven units, should be removed and carefully checked for cracks, ply separation or
irregular wear. A small irregularity in the contact surface of the belt will result in noisy operation. If any
of these defects are apparent the belt should be replaced. At the same time check the sheaves for chips,
dents or rough surfaces that could damage the belt.
• The correct belt tension is important. Too tight a belt will result in excess bearing pressure, which can
cause premature bearing failure and may cause the motor to overload, too loose a belt will result in
slippage, which will burn out belts. Proper belt deflection should be 1/64” (half way between sheave
centers) for each inch of belt span when a force of approximately 5 lbs. is applied.
• The belt alignment should be checked to be sure that the belt is running perpendicular to the rotating
shafts. Motor and drive shafts must be parallel.
• A periodic inspection of all fasteners should be carried out to ensure they have not loosened due to
vibration. Particular attention should be paid to fasteners attaching the wheel to the shaft and those
attaching the shaft to the bearing.
• The standard pillow blocks on belt driven fans are factory lubricated. These bearings should be lubri-
cated on a semi annual basis (more frequently in severe applications) using a high quality lithium based
grease. With the unit running add grease very slowly, using a manual grease gun, until a slight bead of
grease forms at the seal. Be careful not to unseat the seal by over lubricating or by using excessive
pressure. When the bearings are obstructed from view use no more than three injections with a hand
operated grease gun
• Dust and dirt on the exterior surface of the motor, fan panel and the entire fan wheel should be re-
moved, at intervals determined by the severity of the application, to ensure proper service life and safety.
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In the course of regular maintenance the belts and pulleys may have to be changed and or adjusted the
recommended procedure is as follows.
• Do not change the pulley pitch diameter in order to tension the belts. This will result in a change in the
fan speed.
• Loosen the nuts on the motor plate or motor in order to reduce the belt tension such that the belts will
easily slip over the pulleys. Never force the belts over the rim of the pulley.
• Loosen the setscrews on the pulleys and remove from either the motor or fan shaft using a two or three
jaw puller.
• Remove any shaft imperfection such as setscrew mark using a file or emery cloth.
• Install the replacement pulleys tightening all setscrews to the recommended torque rating (see chart)
and ensuring that they are properly aligned.
• Pulley alignment is achieved by moving the pulleys on their respective shafts or moving the entire
motor until the pulleys are correctly aligned (see figure). Using a square with one edge parallel to the
motor shaft adjust the pulleys until the other edge is parallel to the belts.
• Slip the belts over the pulleys then adjust the motor/ motor plate until the proper tension is reached
(1/64” deflection, half way between pulley centers, per inch of belt span when pressed firmly).
• Tighten the motor plate/ motor adjusting nuts in place.
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Bearings Replacement
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PARTS LIST
MODELS: DDS, DDP, ADD
FAN ASSEMBLY
ITEM DESCRIPTION QUANTITY
1 WELDED FAN ASSEMBLY 1
2 PROPELLER 1
3 PROPELLER BUSHING 1
4 MOTOR 1
FAN ASSEMBLY
ITEM DESCRIPTION QUANTITY
1 WELDED FAN ASSEMBLY 1
2 PROPELLER 1
3 PROPELLER BUSHING 1
4 MOTOR 1
5 MOTOR SHEAVE 1
6 MOTOR SHEAVE BUHING 1
7 DRIVEN SHEAVE BUSHING 1
8 DRIVEN SHEAVE 1
9 PILLOW BLOCK BEARINGS 2
10 FAN SHAFT 1
11 "V" BELTS 2
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Filters missing
TOO MUCH AIR Static pressure lower than design
Fan speed higher than design
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loading. Use a set of matched belts whenever pos- above 200°F), moisture or contaminants - more fre-
sible. Do not pry belts on or off the sheave. Loosen quent lubrication is required. Lubricate bearings
belt tension until belts can be removed by simply lift- on UL 762 fans with high temperature grease
ing the belts off the sheaves. After replacing belts, conforming to NLGI Grade 2, such as Mobil Mo-
ensure that slack in each belt is on the same side of bilith SHC 100 or 200.
the drive. Belt dressing should never be used. With the unit running, add grease very slowly with a
Do not install new belts on worn sheaves. If the manual grease gun until a slight bead of grease
sheaves have grooves worn in them, they must be forms at the seal. Be careful not to unseat the seal
replaced before new belts are installed. by over lubricating or using excessive pressure.
The proper tension for operating a V-belt drive is the Bearings without grease fittings are lubricated for
lowest tension at which the belts will not slip at peak life.
load conditions. Belts are adjusted by raising or low- Fasteners attaching the bearings to the drive frame
ering the motor pivot plate. Use the bolts in the slot- should also be checked.
ted brackets and adjustment rods with bolts as ad-
justment points until proper belt tension is attained. Wheel, Fasteners and Set Screws
For initial tensioning, the proper belt deflection half- Wheels require very little attention when exhausting
way between sheave centers is 1/64-inch for each clean air, however, air heavily laden with grease or
inch of belt span. dirt will tend to accumulate on the wheel causing un-
Check belt tension two times during the first balance. Wheels exhausting dirty or grease-laden
24 hours of operation and periodically thereaf- air require frequent cleaning to assure smooth and
ter. safe operation.
All fasteners, including set screws in the bearing col-
Bearing Lubrication Schedule lars, should be checked for tightness each time
Shaft bearings are the most critical moving part of a maintenance checks are performed. Particular at-
fan. Therefore, special attention should be given to tention should be paid to set screws attaching the
keeping the bearings clean and well lubricated. wheel to the shaft and the shaft to the bearings.
Proper lubrication provides for reduction in friction Loose bearing set screws will lead to premature fail-
and wear, transmission and dissipation of heat, ex- ure of the fan shaft.
tended bearing life and prevention of rust. A proper maintenance program will help preserve
In order for a lubricant to fulfill these tasks, the the performance and reliability designed into the
proper grease applied at regular intervals is re- fan.
quired. See bearing manufacturer’s instructions or
label on the fan housing for lubrication schedule. Variable Frequency Drive Operation
In a clean environment and temperature above 32ºF For operation with variable frequency drive (VFD),
(0ºC) and below 200ºF (93ºC), fan shaft bearings always check motor amps when adjusting the oper-
with grease fittings should be lubricated semi-annu- ating frequency. Motor may be sized for the original
ally using a high quality lithium based grease. If un- selected operating speed under 60 Hz. Bypassing
usual conditions exist (temperatures below 32°F or the VFD or increasing the speed from this original
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selection, even if less than 60 Hz, may cause motor Cleaning Internal Components
to overload or fail. Consult factory with fan serial Entire wheel should be cleaned during routine duct
number, before increasing the upper limiting fre- cleaning. Partial cleaning may result in an unbal-
quency. anced wheel that can cause premature bearing fail-
Always check the fan rpm when adjusting the oper- ure or excessive vibration.
ating frequency. Do not exceed maximum class fan Grease / cleaning solution should drain freely
rpm of the wheel. through the provided drain connection. Remove any
obstructions inhibiting proper drainage.
Removal of Dust and Dirt Only the access door is removed during routine duct
Dirt clogs cooling vents on the motor housing, con- cleaning. The bearing cover is not removed during
taminates bearing lubricant, and collects on the im- routine cleaning. The bearing cover is removed only
peller causing severe imbalance if left unchecked. when inspecting or changing the bearings, fan shaft
The exterior surface of the motor and impeller or driven pulley.
should be thoroughly cleaned periodically. Use cau-
tion and do not allow water or solvents to enter the Damper Inspection and Service, Model TCBRU
motor or bearings. Under no circumstances should Level 1 or 2
motors or bearings be sprayed with steam or water. Butterfly dampers should be inspected for proper
operation at each service interval. Check for free-
dom of movement and general condition of the
damper blades and hinge rods.
Parts List
Each fan bears a manufacturer’s nameplate with model number and serial number embossed. This information,
in addition to the parts list shown, will assist the local representative and the factory in providing service and
replacement parts.
Troubleshooting
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WARNING AVVERTISEMENT
Before taking any corrective action, make certain unit is Avant d’entreprendre toute action corrective, s’assurer
not capable of operation during repairs. que l’appareil ne pourra pas fonctionner durant les
réparations.
* Always check motor amps and compare to nameplate rating. Excessive fan speed may overload the motor
and result in motor failure. Do not exceed the maximum cataloged rpm of the fan.
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Vaneaxial Fan
Routine Maintenance
When performing any service to the fan, disconnect the electrical supply and secure fan impeller.
Once the unit has been put into operation, a routine maintenance schedule should be set up to accomplish the
following:
1. Lubrication of bearings and motor.
2. Impeller, housing, bolts and set screws on the entire fan should be checked for tightness.
3. Any dirt accumulation on the impeller or in the housing should be removed to prevent unbalance and possible
damage.
4. Isolation bases should be checked for freedom of movement and the bolts for tightness. Springs should be
checked for breaks and fatigue. Rubber isolators should be checked for deterioration.
5. Inspect fan impeller and housing looking for fatigue, corrosion, or wear.
Motors
Motor maintenance is generally limited to cleaning and lubrication. Cleaning should be limited to exterior sur-
faces only. Removing dust and grease build up on the motor housing assists proper motor cooling. Never wash-
down motor with high pressure spray. Many fractional motors are permanently lubricated for life and require no
further lubrication. Motors supplied with grease fittings should be greased in accordance with the manufacturer’s
recommendations.
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Shaft Bearings
Bearings are the most critical moving part of the fan; therefore special care is required when mounting them on
the unit and maintaining them.
Refer to the table and the manufacturer’s instructions for grease types and intervals for various operating condi-
tions. Never mix greases made with different bases. This will cause a breakdown of the grease and possible
failure of the bearing.
Recommended Bearing Lubrication Schedule Relubrication
Schedule in Months*
Standard Grease
Bearing Bore (inches)
1 15⁄16 4 15⁄16
Fan RPM 1 1 ⁄8 - 1 5 ⁄8 - 2 7 ⁄16 - 3 3 ⁄16 - 3 15⁄16
1 ⁄2 - 1 - 23 - 57
1 1 ⁄2 1 7 ⁄8 3 3 1 ⁄2 - 4 1 ⁄2
⁄16 ⁄16
To 250 12 12 12 12 12 12 10 8
500 12 12 11 10 8 7 5 4
750 12 9 8 7 6 4 3 2
1000 12 7 6 5 4 3 2 1
1250 12 6 5 4 3 2 1 0.5
1500 12 5 4 3 2 1 0.75 -
2000 12 4 3 2 1 0.5 0.25 -
2500 12 3 2 1 0.5 0.25 - -
3000 12 2 1 0.5 0.25 - - -
3500 12 1 0.5 0.25 - - - -
4000 12 0.5 0.25 - - - - -
5000 12 0.25 - - - - - -
Number
4 8 8 10 16 25 41 57
of
* Lubrication interval is based on 12 hour per day operation and maximum 160˚F housing temperature.
For 24 hour per day operation, the interval should be cut in half.
** Lubricant should be added with the shaft rotating and until clean grease is seen purging from the bearing. The
lubrication interval may be modified based on the condition of the purged grease. If bearing is not visible to
observe purged grease, lubricate with number of shots indicated for bore size.
• For conditions including high temperatures, moisture, dirt or excessive vibration, consult the factory for a spe-
cific lubrication interval for your application.
• Lubricant should be a high quality lithium complex grease conforming to NLGI Grade 2.
• The use of synthetic lubricants will increase lubrication intervals by approximately three times.
• Storage periods of three months or longer require monthly rotation of the shaft and purging grease prior to
start-up.
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V-Belt Drives
V-belt drives should be checked for wear, tension, alignment and dirt accumulation on a regular basis. Premature
belt failure is frequently caused by improper belt tension (excessively tight or loose) or misaligned sheaves.
Excessive belt tension creates high bearing loads which reduce bearing life. Belts which are too loose may cause
squealing on start-up, belt flutter, slippage and overheating of the sheaves. Belts which are overly tight or loose
may cause vibration and noise.
When replacing V-belts on multiple groove drives, all belts should be changed to provide uniform drive loading.
Do not pry belts on or off the sheave. Loosen belt tension until belts can be removed by simply lifting the belts
off the sheaves. After replacing belts, ensure that slack in each belt is on the same side of the drive. Belt dressing
should never be used. Do not install new belts on worn sheaves. If the sheaves have grooves worn in them, they
must be replaced before new belts are installed.
Belt Tension
The proper tension for V-belts is the lowest tension at which the belts will
not slip at peak load conditions. For initial tensioning, the belt should deflect
1/64 inch for each 1 inch of belt span. For example, a belt span of 32 inches
should deflect 1/2 inch with moderate thumb pressure at midpoint of the
drive. Check belt tension after 24 hours of operation and periodically there-
after.
V-Belt Replacement
Changing V-belt drive components could result in unsafe operating conditions which may cause personal injury
or failure of fan components.
1. Remove the protective coating from the end of the fan shaft using mineral spirits
or another similar solvent. Check to ensure that the shaft is free of nicks and burrs.
2. Slide sheaves on shafts. Do not drive sheaves on as this may result in bearing
damage.
3. Align fan and motor sheaves with a straight-edge or string and tighten.
4. Place belts over sheaves. Do not pry or force belts, as this could result in damage
to the cords in the belts.
5. Adjust the tension until the belts appear snug. Run the unit for a few minutes (refer to unit start-up section)
and allow the belts to “set” properly.
6. With the fan off, adjust the belt tension by moving the motor pivot plate. (Belts are adjusted by raising or
lowering the motor pivot plate). When in operation, the tight side of the belts should be in a straight line from
sheave to sheave with a slight bow on the slack side.
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1. Disconnect all electrical power to the fan and lock in the “off” position.
2. Remove the aluminum nose cone on the impeller assembly. Record the location of all balancing weights
located under the nose cone bolts.
3. Locate the blade with blade pitch graduations stamped into the blade base and index line on the impeller (Fig.
4). This is the master blade.
4. Loosen the self locking nut (Fig. 5) attaching the master blade until the blade
can be rotated by hand.
5. Set the new blade pitch on the master blade by aligning the desired blade
pitch number with the index mark. Tighten the self-locking nut slightly to prevent
the master blade from moving.
6. At the tip of the master blade, use a thin marker pen to scribe the blade profile
on the interior of the fan housing from the leading to the trailing edge of the
blade tip (Fig. 6).
7. Loosen the self-locking nuts on the remainder of the blades and set each
blade to align with the blade profile scribed on the fan housing. Tighten the self-
locking nut slightly to prevent blade from moving.
8. After all blades are adjusted to the proper setting, tighten the self-locking
nuts to 125 ft. Ibs. of torque. Verify that all the blades tips follow the profile on
the fan housing.
9. Replace the nose cone and any balancing weights removed earlier. All fas-
teners and washers must be reinstalled in the exact spot they were removed.
10. IMPORTANT: Motor load amperes must be checked and compared to the
nameplate rating before returning the fan to service. Increasing blade pitch be-
yond the capacity of the motor will result in motor burn-out and void the warranty.
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Spares
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A. Equipment Data
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Manufacturer’s Literature
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Commissioning Data
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