Technical Manual on Installation, Operation, & Maintenance

Centrifugal / Axial Fan

ISO 9001:2000
VENTEC AMBIENTAL EQUIPAMENTOS E INSTALAES LTDA
Rua Andr Adolfo Ferrari, n 550 - Distrito Industrial Nova Era - Indaiatuba - So Paulo
CEP: 13.347.395 - C.Postal: 2086 - Fone: (19) 3801-8800 / Fax: (19) 3935-6906
e-mail: [email protected] - site: www.ventec.com.br

Centrifugal / Axial Fan

ISO 9001:2000

CONTENTS

1 INTRODUCTION .................................................................................................................................................. 03
2 GENERAL CONCEPTS ....................................................................................................................................... 03
3 DESIGN OF THE EQUIPMENT
3.1 Arrangement 4 - Fans with rotor/helix coupled directly to motor axle end ........................................... 04
3.2 - Arrangements 3 & 12 - Fans actuated by pulleys and belts.................................................................. 04
3.3 - Arrangements 7 & 8 - Fans actuated with elastic coupling (direct rotor rotation) ................................. 05
3.4 - Arrangements 4 Axial Fan .................................................................................................................. 05
3.5 - Arrangements 9 Axial Fan .................................................................................................................. 06
4 ASSEMBLY
4.1 - Transport ............................................................................................................................................... 07
4.2 Storage ................................................................................................................................................. 07
4.3 Foundation ............................................................................................................................................ 07
4.4 Seating and Connections...................................................................................................................... 08
4.5 Inlet cones............................................................................................................................................. 08
4.6 Valves
4.6.1 - Rectangular Venetian blind with parallel blades ......................................................................... 09
4.6.2 - Rectangular Venetian blind with opposing blades ...................................................................... 09
4.6.3 Radial Venetian blinds ............................................................................................................... 09
4.7 Couplings
4.7.1 Direct coupling ........................................................................................................................... 09
4.7.2 Coupling by gears ...................................................................................................................... 09
4.7.3 Coupling by mean of pulleys and belts ...................................................................................... 10
4.8 Power Supply ........................................................................................................................................ 11
4.9 Axial Fan Preparation of start ............................................................................................................ 11
5 OPERATION
5.1 - Rotor ...................................................................................................................................................... 12
5.2 Internal part of body .............................................................................................................................. 12
5.3 External part of body............................................................................................................................. 12
5.4 Valves ................................................................................................................................................... 12
5.5 Equipment start-up ............................................................................................................................... 12
5.6 Care ...................................................................................................................................................... 12
6 MAINTENANCE
6.1 General Comment ................................................................................................................................ 14
6.2 Vibrations .............................................................................................................................................. 14
6.3 Rotor disassembly ................................................................................................................................ 14
6.4 Body ...................................................................................................................................................... 14
6.5 - Bearings ............................................................................................................................................... 14
6.6 Belts ...................................................................................................................................................... 15
6.7 Lubrication ............................................................................................................................................ 15
6.8 Troubleshooting .................................................................................................................................... 16
6.9 List of spare parts for 2 years of Operation .......................................................................................... 17

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1 INTRODUCTION
The recommendations provided in this manual have been prepared based on the data of the project involved and
experimental laboratory know-how that made it possible to apply the products supplied.
However, the user has additional information about hands-on operating conditions and about the workplace.
Therefore, the user can join this know-how to the hands-on recommendations in this guide; information and more
specific details on each component supplied by the manufacturer and prepare a good installation and operation
scheme and a safe maintenance program.
Several data sheets specific to the sets and to key accessories are part of this Manual. They indicate the most
relevant technical and construction characteristics.
Besides the recommendations in this manual, which must be considered as supplementary, we recommend not
leaving aside the usual norms relating to good operation, maintenance and installation techniques.
It must be pointed out that the use of qualified personnel, both in operation and in maintenance of the equipment
means eliminating countless problems.

2- GENERAL CONCEPTS
_____________________________________________________________________
Centrifugal /Axial fans are rotating machines, volumetric displacers of gaseous fluids.
They key characteristics to select the fans are fluid volume and air pressure to be overcome for this displacement.
Together with these two characteristics are density (specific weight) and aggressiveness of the displaced fluid.
Based on this information from the customer process, the project for the equipment is carried out.
However, it is important to use the equipment as designed. In case of equipment altering the equipment, please
inform the manufacturer to optimize your operation.
In sight of the constructive differences between centrifugal and axial fans, the recommendations of these manuals
must only be considered where applicable.

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3 EQUIPMENT DRAWING
3.1 - Arrangement 4 Fans with rotor coupled directly to motor axle end

7 Motor
8 Sealing
9 Body
10 Flexible collar
11 Register at discharge

1 Flexible collar
2 Radial register at aspiration
3 Cap and cone
4 Rotor
5 Hub
6 Motor base

3.2 - Arrangement 3 & 12 Fans actuated by pulleys and belts

14 Motor rail optional
15 Motor
16 Register for discharge optional
17 Discharge flexible collar
18 Sealing
19 Cooling propeller
20 - Hub

1 Flexible collar - optional

2 Radial register - optional
3 Cap and cone
4 Rotor
5 Axle
6 Bearings
7 Bearing base
8 Fan pulley
9 Actuating pulley
10 Belts
11 Belt protection
12 Body
13 Unique base - optional

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3.3 - Arrangement 7 & 8 Fans actuated with elastic coupling (rotor direct rotation)

8 Coupling
9 Motor
10 Flexible collar
11 Register at discharge
12 Body
13 Cooling propeller
14 Sealing
15 - Hub

1 Flexible collar - optional

2 Radial register at aspiration
3 Cap and cone
4 Rotor
5 Axle
6 Bearings
7 Bearing base & motor

3.4 - Arrangement 4 Axial Fan

1 Body
2 Motor
3 Helix
4 Screen protection
5 Flange
6 Eletroduto
7 Rotatable Connection
8 Electric Cable
9 Fixed Connection

3
2
1
9

8
7
6

5
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3.5 - Arrangement 9 Axial Fan

1 Body
2 Motor
3 Helix
4 Screen protection
5 Flange
6 Berings
7 Pulley
8 Belts
9 Axie
10 Belt protection
11 Motor Base

4
10

11
6

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4 ASSEMBLY
4.1 - Transport
Before shipping, all pieces of equipment are visually controlled as to construction and finishing. They are strictly
tested under operation. Operation of all parts and accessories involved in manufacturing and assembly is checked.
However some damage may occur in transport. For this reason the customer should inspect the unit upon delivery
and any irregularities should be reported to manufacturer.
When transporting parts and equipment, suspending or sustaining spots should be avoided such as rotors, helixes,
motors, valves, bearings, axles etc. Only lifting eyelets should be used. Flange holes should be used as the last
resort.
Do not allow any kind of chocks or damage due to poor transport because they might misalign mouthpieces,
bearings, and cause consequent assembly problems.

4.2 - Storage
If equipment is not immediately assembled, we recommend storing them in a dry place, free of dust, gases and
corrosive smokes. If this is not feasible due to local conditions, do the following at least:
- Cover the equipment and/or accessory with waterproof canvas.
- Block the rotor/helix so as to prevent abrupt movements.
- Do not place any materials on the equipment and/or accessories.
After 15 days of storage, take the following care:
- Fill bearings thoroughly with grease
- Put high-viscosity or anti-corrosive oil on machined parts such as axles, coupling etc.
- Turn the rotor 450 weekly.

4.3 - Foundation
Through the specific drawings supplied, you can obtain the basic dimension required to prepare the foundations,
always considering the main characteristics of the implantation place, as well as the load values of the equipment.
The influence of transmission of vibrations and shocks to the floor or structures and vice-versa must be well
analyzed to establish the need or not to use Vibration bumpers. Note that rubber cushions and/ or springs have
complex application in fans and, for full effect, depend on factors such as symmetrical distribution of loads, degree
of rigidity (or freedom) of the metallic base and work frequency, For this reason, we do not recommend the use of
these tricks without contacting the manufacturer first.
In these cases, we can also observe noise emission through structures firmly connected to the equipment,
transforming them into sources of noise. This negative aspect can be prevented by installing flexible collars in fan
connections.
Centrifugals Fans supported only on the floor need to stay on a very solid and rigid base at least 100 mm larger all
around to prevent cracks when tightening anchor bolts. Metal structures and supports are not recommended;
however if they are required, they must be adequately projected to support static and dynamic loads and take
machine frequency into consideration.
On base spots where anchor bolts will be set, larger holes should be made, if possible, and leave a circle with a
radius of approximately 30 mm for later adjustment of the correct position.
If this is not possible, drilling should be made taking in consideration the dimensional tolerances set by the
standards.
Type of fixation used:
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4.4 - Seating and connections

The centrifugals fans must be installed in a position that is suitable to the foundations so that they stay in the right
position (as in drawing). The equipment must be leveled with the help of shims until it receives the anchorage bolts
in the right holes. Only after this procedure, the fixing elements should be tightened.
With the set firmly fixed to the operation position, check the following items:
- Correct leveling of rotor axle.
- Alignment of bearings, lubrication, tightening of collar and plays;
- Existence of play between rotor/cone, considering that the rotor must rotate freely (see item 3.5)
- Suitable tightening of bolts of rotor key,
- Correct fixation of transmission elements such as: pulleys / keys / bolts, etc. (see item 3.7):
- Belt alignment and tension (any corrections by the rails/stretchers) (see item 3.7.3);
- Correct fixation of motor.
Connections to pipes must for both type of fans be made only after the fan is ready to operate. Flanges that do not
fit should not be forced to prevent body distortions/deformation or misalignment to pipes.
In the event the fan is used at high temperatures, efficient sealing and suitable expansion joints should be provided
to avoid additional efforts in pipes or even in the fan.
Never submit the fan to unnecessary effort. Their bodies must never support pipes, filters, chimneys, etc..

4.5 - Inlet cones

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4.6 Valves Centrifugals Fans

4.6.1 - Rectangular Venetian blind with parallel blades
For use in inlet air boxes, usually to control flow or also used in the function of equipment insulation for starting. Its
principle is air centrifugal action at rotor inlet. Besides flow control, it also saves power considerably.
4.6.2 - Rectangular Venetian blind with opposite blades
Used for fan discharge. The key function is equipment insulation for starting. It can be used also as a flow
controller, although with less efficiency than parallel blades at inlet, particularly for large flow restrictions. It does not
provide energetic gains.
4.6.3 Radial Venetian blinds
Often used to control flow and for equipment insulation for starting. Its principle is air centrifugal action at rotor inlet.
Besides flow control, it also saves power even more than parallel blades.

4.7 Coupling
4.7.1 Direct coupling
In case of transmission in relation to speed, direct coupling via reducers is also usual.
Attention: Align axle ends carefully using a flexible coupling, whenever possible.

4.7.2 Coupling by gears

Coupling made with poorly aligned gears causes jogging, which leads to vibrations in motor transmission.
Therefore care should be taken so that the axles are perfectly aligned, strictly parallel in case of straight gears, and
in the right angle in the case of conical or helical gears.
Perfect gearing can be controlled by inserting a sheet of paper, in which appears a complete revolution copy of all
teeth.

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4.7.3 Coupling by mean of pulleys and belts

When a speed ratio is necessary, belt transmission is the most commonly used one.
Assembly of pulley: To assemble pulleys on shaft ends with key beds and threaded holes at the end, it must be
fitted up to halfway of the bed key only by manual effort of assembler.
For axles without threaded holes, we recommend to heat the pulley around 80 C or to use an adequate device. It
must be avoided to use a hammer in pulley and bearing assembling, because using this procedure, in case of
bearing it can cause marks on its tracks These marks, initially small, however can develop to an extent to totally
discard the bearings.
The correct pulley positioning is shown on the figure below.
Right mode: If the shaft
end is bigger than
pulley use shims

Remark: Avoid unnecessary radial efforts on bearings by locating the parallel axles between them and the
perfectly aligned pulleys.
Belts that work laterally oblique transmit alternated knocks to the rotor and can damage bearing stops. Belt sliding
can be avoided by applying a resinous material such as tar.
Belt tension must be only enough to avoid sliding when operating, as shown in the figure below.

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4.8 Power supply

Be sure to get from the electric power network a frequency with as little oscillation as possible and tension not
exceeding + 10%. For the starting system, it is recommended a minimum protection against short circuits and over
charges through appropriate fuses and thermal relays.
Attention must be paid to standards set by power supply companies and to manufacturers recommendation on the
equipment to be used. Additional relay protection against lack of phase and subtension would also be desirable.

4.9 Axial Fan Preparation of start

The recommendations, when applicable, are:
- Lubricate the shaft and keyway;
- Put the propeller in place, without foreign, as the adjustments are sliding;
- Correctly set screw plant, using flat washer and lock washer;
- Check the clearance between the propeller and carcass, to make sure they are well distributed.

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5 OPERATION
5.1 Rotor / Helix
Make sure the rotor turns freely when actuated manually, that is, any noises or blocking must be checked and
completely eliminated. The rotor must be centered on the body and perfectly positioned in relation to breathing.

5.2 Internal part of the body

Check for strange bodies or scraps of material inside the fan body, pipes or valves.

5.3 External part of the body

Make sure all bolts and nuts are well fixed. Although they are the manufacturers responsibility, vibrations and
efforts produced during transportation, assembly and installation may cause play in the tightening of certain
components.

5.4 Valves
Close all line valves, if any, so that the first start-up of the system is made with the fan operating with no load.

5.5 Equipment start-up

1- Check if the motor is duly earthed.
2- Watch if motor electric connections are made according to the connecting scheme printed on the identification
plate and confirm if all terminal bolts and nuts are duly tightened.
3- Before starting the motor, observe carefully the respective manufacturer instructions.
4- After these procedures, check the correct rotation side, turning quickly on off the motor. The rotor/helix rotation
direction must be compatible with indicating arrow fixed on body side. If there is no coincidence the correction can
e done simply by inverting the terminal connection to supplying network.
5- Start again, turn off when apparatus reaches nominal rotation and let it run until it reaches the state of rest.
Between start-up and rest, watch out for noises and abnormal vibrations.

5.6 Precautions
1 Start the set again and, after reaching nominal rotation, make sure the current and tension are correct. Turn off
after 5 minutes of operation in the mentioned rotation and evaluate:
1.1- Tightening of the fixing elements;
1.2- Tightening of rotor/helix key fixing bolt;
1.3- Position of the key mentioned above;
1.4- Play between rotor and inlet cone/helix and body;
1.5- Actuate the set again for a period of 1 hour and observe:
- Noise detection and/or abnormal vibrations;
- Motor excessive heat;
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Excess heating of bearings. Initial friction can cause heating above normal. The same will be normal in case you
can hold the bearing for 5 seconds. Bearings lubricated with grease can operate with temperature up to 90C. In
case the temperature is above 90C, Ventec Ambiental must be communicated immediately, operation must be
interrupted right away if the temperature reaches 110C.

1.6- Compare the current absorbed by the motor in the three phases to the one stated on the plate. On a
continuous rate, without charge oscillation in the current absorbed, the number should not exceed the nominal
current value multiplied by the service factor stated on the plate.
1.7- The valves, when existent, must be opened individually and slowly, at the same time carefully observing the
current value absorbed. After this operation is completed, the fan will be operating on charge.
The final value of the absorbed current in the three phases should not exceed the limit set in 1.6.
1.8- Turn off after 1 hour, wait for total rest and repeat the procedures stated in 1.1 to 1.4.
1.9- At the end of the procedures above, the equipment will be ready to operate continuously in a normal rate of
operation. However, as a safety measure, it is recommended to do the following:
1.10- During the first 8 hours of operation, check the temperature of bearings every hour;
1.11- After 72 hours of operation, align and stretch the belts correctly, and repeat the procedures stated in 1.1 to
1.4.

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6 MAINTENANCE
6.1 General Comment
Rotating machines must be inspected at regular intervals. The frequency of these inspections is set according to
the characteristics of use, degree of use and type of application.
Fans are manufactured in an extensive range of models and for a wide variety of applications. Therefore, the way
and periodicity of maintenance vary from case to case.
As previously shown, you have been supplied with all data required to establish a perfect maintenance program.
However it is recommended to acknowledge the below recommendations:

6.2 Vibrations
All fans manufactured by Ventec Ambiental have their rotors balanced statically and dynamically on a highsensitivity SCHENCK electronic machine. However, if a rotor works in an abrasive material environment or
between materials that stick to the blades, there will be a change in the original balancing conditions.
The consequence will be vibrations causing immediate reduction of bearing service life.
Whenever vibrations appear, the fan must be removed from operation and the rotor/helix must be checked. If it is
worn but, if it still can be used, it must be balanced again before assembling. If there is any material adhered to the
rotor, good cleaning must solve the problem.
Vibrations can, however, be of aerodynamic nature, caused by turbulence in air or gas flow. Non-recommendable
breathing condition such as a wall near and frontal to fan, a breathing curve with a very small radius, etc., can
cause this turbulence.
Also if the calculation of resistance of a system is not correct, this phenomenon may happen and the solution to
adopt is to decrease this resistance by removing unnecessary valves, increasing the discharge area, curve radius,
etc...
6.3 Rotor/Helix Disassembly
First of all, remove the bolt and washer from shaft end, using an appropriate extractor to disassemble the rotor,
when necessitate.
To reassemble, grease the shaft end with oil and introduce the rotor/helix manually as much as possible. Put the
key in its position and, with the help of a stop stud, introduce the rest of the hub.
6.4 - Body
All inspection ports must be tightly sealed. Any leaks must be immediately repaired.
Renew external painting whenever necessary to avoid corrosion.
6.5 Bearings
Because the component is manufactured by third parties, more specific information must be requested to the
manufacturer.
Just for guidance, however, below we reproduce some important instructions, which, in most situations, meet fully
all maintenance requirements.
The purpose of maintenance of rotors/helixes is to extend service life of bearing systems as much as possible.
Maintenance covers:
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a) Observation of general condition of the bearings .

b) Lubrication and cleaning.
c) More careful bearing check.
Bearing noise must be observed in regular intervals from 30 to 60 days. A well-trained ear is perfectly able to
distinguish abnormal noises, even using simple ways (a screwdriver, etc.), with no need to resort to stethoscopes
normally found in the market. A uniform buzz is a signal that the bearing is working in perfect condition.
Temperature control of a bearing is part of routine maintenance. When a bearing is correctly lubricated,
temperature will not exceed 60C. Temperature can be permanently controlled with thermometers located outside
the bearing or with inserted thermal elements.
Bearings are re-lubricated at general reviews, when bearings are disassembled.
With the bearings disassembled and without removing the bearings from axle, all grease should be removed. Wash
the bearings with diesel oil, kerosene or other thinner until they are completely clean. After washing, fill immediately
with grease the existing spaces between the rollers or rollers and bearing races. Never rotate dry bearings after
washing. To inspect them put some drops of machine oil.
When carrying out these operations, maximum care with cleaning is recommended to avoid penetration of any
debris and dust that can damage the core. Note that, when removing bearing cap, it will be necessary to shim the
axle.
Bearing disassembling is not difficult, if right tools are used (bearing extractor). Extractor grips must be applied on
ringside face to be disassembled or on an adjacent face.
It is essential to disassemble bearings under very clean conditions and this must be made by competent people to
assure good operation and avoid damages.
New bearings must only be removed from their package at the time of assembling. Before putting the new bearings
it will be necessary to check if fittings have signs of burrs or shocks.
Bearings cannot receive direct shocks during assembly. The support to press or hit the bearing must be applied on
the internal ring.

6.6 Belts
Every belt has a determined service life and this may vary according to its application. Verification of service life
should be made visually, i.e., when deviations, twisting or raveling appear, replacement should be made.
It is recommended that, after replacement, alignment and tension of new parts must be carefully checked.

6.7 Lubrication
In this topic we will talk about the use of grease as lubricant, since it applies to most cases.
Lithium-based grease with (NGLI) 2 consistency, with anti-oxidant additive.
The initial amount of grease is 1/3 of the free volume of the bearing case when he equipment revolution does not
exceed 50 % of the maximum rotation allowed by the bearing, or 2/3 when this does not happen. Note that excess
grease may lead to over-heating of bearings.
Interval of lubrication is 700 (seven hundreds) hours.

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6.8 Troubleshooting

Effects
Items

Causes

Installation

1- Incorrect assembly
2 - Incorrect electric connection
Foundation 3- Foundation poorly made
4- Deformed concrete
Bases
5- Deformation
Body
6- Strange body
7- Deformation
8- Unbalanced
9- Erosion or corrosion
10- Strange body suction
Rotor/helix 11- Strange body adherence
12- Inlet cone scraping
13- Deformation
14- Invert construction position
15- Warped
Axle
16- Adjustment badly done
17- Body scraping
18- Key with play
19- Play above normal
20- Play below normal
21- Lubricant dirty or old
22- Inadequate lubricant
Bearings
23- Excessive lubricant
24- Lack of lubricant
25- Loose bolts
26- Locking ring damaged
27- Strange body
28- Unbalanced
29- Belt too stretched
Pulley
And Belts 30- Loose belt
31- Wear belt
32- Strange body
33- Revolution above normal
34- Revolution below normal
35- Inverted rotation
36- Valve working badly
General
37- Valve damage
38- Increase load loss
39- Decrease load loss
40- Unbalanced
ABCDEFG-

A
X
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B
X
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C
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H
X

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Vibration increase
Bearing over heated
Bearing damaged
Starting motor over loaded
Motor over load in operation
Reduce of load in operation of motor
Reduction on capacity and/or efficiency of fan

H- Excessive noise
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6.9 List of spare part for 2 years of operation

For fans actuation direct Arrangement 4:
- 01 rotor / helix
For fans actuation indirect Arrangement 3 and 12:
- 01 rotor and axle set
- 02 bearings
- 02 bearings
- 02 bushings
- 01 Belt set
For fans actuation direct Arrangement 8:
- 01 rotor and axle set
- 02 bearings
- 02 bearings
- 02 bushings
- 01 Elastic coupling
Note: See technical data on set drawing.

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