SPX Cooling Technologies Fan 07 1126 User Manual

Marley Ultra Low-Noise Fan  
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User Manual 07-1126  
 
Contents  
General Information...................................................................... 4  
Installation .................................................................................... 5  
Operation.................................................................................... 11  
Maintenance.............................................................................. 13  
Parts List .................................................................................... 16  
Trouble Shooting ........................................................................ 17  
3
 
General Information  
Description  
The Marley Ultra Low-Noise series of fans represent the top in the  
new generation of super low noise fans—the FRP blades have been  
developed to meet the most stringent noise limitations. The fans  
permitvariablepitchadjustmentatstandstillandfeatureasimplified  
design. Each blade is fixed to the hub with two bolted aluminum  
pillow blocks.  
Balancing  
When the rotor is dispatched in assembled form, each unit is dy-  
namically balanced within a degree of G = 6.3 in accordance with  
ISO 1940/1.  
When the fan is dispatched disassembled, the hub is dynamically  
balanced and the blades are statically balanced so that the reas-  
sembled unit correspond to a degree of G = 6.3 in accordance with  
ISO 1940/1. In this case, the blades have the same static moment,  
so that they can be positioned in any order on the hub; the blades  
of the same supply, are interchangeable.  
Storage  
Upon unloading the fan, inspect it for any damage. If damage oc-  
curred, file a claim immediately against the carrier and mark the bill  
of loading accordingly.  
After the fan delivery, check the full compliance between order and  
delivered goods. Shortages or inconformities have to be reported  
within two weeks from receipt of shipment at destination.  
If not installed immediately, it is recommended to store the fan in  
a dry and shaded area, and do not put any heavy materials of any  
kindupontheblades. Forlong-termstorage, itisnecessarytocheck  
the condition of the corrosion preventive coating on all machined  
surfaces.  
4
 
Installation  
Rotation and Flow Direction  
The rotation direction is correct when the airflow moves from the  
convex back (suction surface) of the blade, to the concave side  
(pressure surface). Figure 1 shows the conventional clockwise di-  
rection of rotation and normal direction of airflow as viewed from  
the discharge face of the rotor.  
Flow Direction  
Flow Direction  
Figure 1  
Installation Instructions  
1––Remove blade pillow block and fasteners 4, 5, 6, 7, 15 from the  
hub disk, one set a time (Figure 2).  
2––Ifthehubhasnotbeensuppliedalreadyassembledtotheange,  
install the coupling flange 2 on the disk 3, complying with torque  
settings, bolt orientation, tightening order, and pins as shown in the  
table following Figure 2.  
5
 
Installation  
10B  
10A  
3
9
7
5
1
2
8
6
Figure 2  
4
10  
6
 
Installation  
Torque hub assembly bolts 11 according to the following table:  
Bolt Torque  
Fan Diameter  
Flange Type  
Bolt Type  
inches  
N·m  
ft·lb  
169  
93  
M16 cl. 8.8  
230  
84" to 96"  
Type 115  
M16 cl. A4-70 126  
M16 cl. A4-80 168  
124  
329  
181  
241  
M20 cl. 8.8  
447  
108" to 168"  
Type 190  
M20 cl. A4-70 246  
M20 cl. A4-80 328  
3––Hub into driveshaft installation (Figure 2).  
• As for the hub with cylindrical bore, the hub is bored to attach  
directly to the drive shaft.  
Coat the output drive shaft with a thin layer of silicon grease.  
If a space ring 10A is supplied, drive it into the drive shaft until it  
comes in contact with the drive shaft shoulder.  
Drive the hub with cylindrical bore into the drive shaft until it comes  
in contact with the drive shaft shoulder (or space ring shoulder if  
supplied).  
Never power the drive shaft with special washer 16 and the retain-  
ing bolt 17 missing or loose.  
Warning  
• As for the hub with tapered bushing hole, be sure drive shaft,  
bushing and hub bore are not greased. Slide the bushing into the  
drive shaft to your design position.  
Position the hub core over the bushing taper; insert bushing screws  
throughthebushingangeintothethreadedholeinthehubcoupling;  
torque bushing screws according to the following table:  
Screw Torque  
Bushing Type  
N·m  
40  
ft·lb  
29  
Q1 and Q2  
R1 and R2  
40  
29  
7
 
Installation  
The drive shaft end must remain recessed at least 132" in the hub  
boretopreventdangerousrotorverticaltranslationonceretaining  
bolt 16 has been tightened to the shaft end.  
Caution  
Warning  
Never power the drive shaft with bushing bolts not torqued or  
bushing improperly positioned.  
4––Install the blade.  
Sandwich the blade shank between the pillow blocks 4 and 5, en-  
suring both the pins 7 are in proper position (Figure 2).  
Fit pillow blocks 4 and 5, pins 7, pillow block plate 6, blade and  
pillow block fasteners 15 on hub disk as shown in previous Figure  
3 without tightening bolts.  
Rotate fan to check tip clearance is in accordance with the specified  
value (tip clearance ratio x/D, where x = the distance from the blade  
tip to the fan ring and D = the rotor diameter). The gap between  
blade tip and fan ring must be measured along blade axis.  
Tighten the pillow block bolts 15, to hold the blade in extended  
position, leaving enough clearance to allow blade rotation on its  
own axis for pitch setting.  
5––Setting blade pitch.  
The pitch angle of each blade has to be set at the A° value specified  
in the rotor identification plate with a 0.5° maximum tolerance: in  
order to set the pitch, the quotes shown in following Figure 3 must  
beobserved;notethesequotesareshownonthefandatasheet,and  
are specific for each diameter of the Marley Ultra Low-Noise fan.  
8
 
Installation  
R
G X øH  
T
Z
V
K
S
D
U
øF  
øE  
øC  
Figure 3  
FAN DIAMTER (A)  
Rotate the blade on its axis until the required pitch angle is ob-  
tained.  
Check there is no gap between each blade shaft shoulder and cor-  
responding pillow block.  
Torque pillow block bolts 15 according to the following tables,  
complying with bolt orientation and tightening order as shown in  
Figure 4.  
1
4
3
2
Figure 4  
4 Bolt Pillow Block Tightening Order  
6––Repeat for each blade steps described in points 4 and 5. Before  
starting the pitch angle setting procedure, turn the fan till the blade  
to be set is at the same point in the fan ring where previous pitch  
angle was set.  
In order to determine the torque setting of standard bolts 15, with  
the 8.8 stamping, search in the following table the bolt type set for  
the diameter of the fan in object.  
9
 
Installation  
Bolt Torque  
N·m  
Fan Diameter  
inches  
Bolt 15  
ft·lb  
208  
294  
500  
84" to 96"  
108" to 120"  
132" to 144"  
M18  
M20  
M24  
282.5  
400.3  
679.8  
The screw class information is shown in the fan documenta-  
tion part list.  
Note  
Stainless steel bolts 15 with the A4-80 stamping:  
Bolt Torque  
N·m  
Fan Diameter  
inches  
Bolt 15  
ft·lb  
129  
181  
313  
84" to 96"  
108" to 120"  
132" to 144"  
M18  
M20  
M24  
175.6  
246.2  
425.7  
In the case of a structure equipped with multiple fans, before  
setting the pitch angle to all the fans, set the pitch on one fan  
only and follow the instructions for operation starting on page  
11.  
Note  
10  
 
Operation  
Prior to Start-Up  
1––Make sure all the pillow blocks are fixed to the hub boss—if any  
movement of the blocks is detected, do not operate the fan and  
check the torque of bolts 15.  
2––Rotatefantochecktipclearanceisinaccordancewiththespeci-  
fied value (tip clearance ratio x/D, where x = the distance from the  
bladetiptothefanringandD=therotordiameter). Thegapbetween  
blade tip and fan ring must be measured along blade axis.  
3––Check gear box oil level or belt tension to be as indicated by  
the manufacturer.  
4––Remove all tools from the area.  
5––Connect motor to power supply.  
6––Start fan for a few seconds, and then switch it off. While the fan  
is still turning, check that the direction of the blade rotation is cor-  
rect (see Rotation and Flow Direction).  
Post Start-Up  
1––Check power absorption: if excessive, reduce the blade pitch  
angle until the desired power is achieved (set the new pitch on all  
the fans of a same structure); if lower than predicted, increase the  
blade pitch angle until the desired power is achieved (set the new  
pitch angle on all the fans of a same structure).  
Power absorption varies in inverse proportion to the air tem-  
perature.  
Note  
2––Check the vibrations level in the position shown in Figure 5.  
Do not exceed the most restrictive amplitude values between the  
limits imposed by the normative of the structure where the fan is  
installed and the limits imposed by the VDI 2056 normative. In this  
case, shut down the unit and trace the cause of such excessive  
vibration by referring to section Possible Causes of Vibration in the  
following section.  
11  
 
Operation  
Figure 5  
3––After the rotor has been running for one hour, check the torque  
of the hub screws 15.  
4––Repeat the check of screws 15 after 24 hours from start-up.  
12  
 
Maintenance  
Maintenance and Operation  
1––Inspect the overall fan condition periodically.  
Inspection intervals depend on fan operating conditions and may  
vary from a minimum of 2 weeks to a maximum of 6 months.  
The following components should be specifically inspected when  
inspecting the overall fan conditions:  
- Screw torque.  
- Fasteners corrosion.  
- General condition of blade surface.  
2––Ice formation on the blades of operating fans must be strictly  
avoided.  
3––If ice has formed on a stationary fan, it must be removed prior  
to start-up to avoid damaging the blades. Snow formed on a sta-  
tionary fan must be periodically removed, according to the snow  
accumulation itself.  
4––Turn off 2-speed motor for at least 30 seconds before switching  
to low speed.  
5––Stop the unit completely before reversing the fan direction.  
6––Check the vibrations level in the position shown in Figure 5 at  
regular intervals.  
The vibration level must not exceed the most restrictive amplitude  
values between the limits imposed by the normative of the structure  
where the fan is installed and the limits imposed by the VDI 2056  
normative. In this case, shut down the unit and trace the cause of  
such excessive vibration by referring to page 14.  
It is advisable to keep a record of the readings taken on each oc-  
casion for comparison. Always take readings at the same positions  
and in the same manner. Observe the safety precautions insuring  
power supply is turned off. The fan vibration levels constitute an  
invaluable indication of the state of the plant and should be moni-  
tored frequently (e.g. monthly).  
Temperature Range  
This series of fans are designed to operate at these temperatures.  
Minimum is -20ºC (-4ºF)  
Maximum is +82ºC (+180ºF)  
13  
 
Maintenance  
Possible Causes of Vibration  
The actual causes of vibration may change considerably. Some of  
the most common are as follows.  
1–– Unbalance of one or more blades: the vibration caused by blade  
imbalance occurs on the tip path plane with a frequency equal to  
the fan RPM and at an amplitude which is dependent on the degree  
of imbalance and the square of the rotational speed.  
2––Blade pitch angle not included in the 0.5° tolerance: this con-  
dition causes vibration outside the tip path plane at a frequency  
equal to the fan RPM and at an amplitude which is dependent on  
the square of the rotational speed.  
3–Bladestooclosetosupports(periodicaerodynamicturbulence):  
thisconditionischaracterizedbyvibrationoutsidethetippathplane  
at a frequency equal to the product of the number of fan blades and  
RPM. The amplitude depends upon the extent of the aerodynamic  
turbulence.  
4––Resonance between one of the possible forcing frequencies of  
the fan and one or more of the vibration modes of the structure on  
which it is installed. The main forcing frequencies generated by the  
fan, normally correspond to the following frequencies:  
- Fan RPM  
- The product of fan RPM and the number of blades  
- The product of fan RPM and the number of structural  
supports capable of generating aerodynamic turbulence  
(if they are arranged in an axial-geometric fashion).  
5–Vibrationtransmittedbythestructureonwhichthefanisinstalled:  
thefrequenciesofsuchvibrationdependonboththeexternalforcing  
frequencies and the resonant frequencies of the structure.  
6––Resonance of the blades with one of the possible forcing fre-  
quencies; in the vast majority of cases the vibration occurs outside  
of the tip path plane.  
7––Misalignment of the drive shaft: this generates vibration with a  
frequency that is once or twice the RPM.  
8––Looseningofbladeand/orspeedreducerxingbolts.Thebehavior  
of the rotor under these circumstances is totally unpredictable, as  
it depends upon the extent and location of the loosening.  
14  
 
Maintenance  
9––Worn output shaft bearing: this condition generates vibration on  
the tip path plane at a frequency equal to the rotor RPM.  
10––The fan and/of the structure bolts are not tightened: in this case  
all the bolts have to be tightened.  
11––The draining holes of the blades are obstructed: they have to  
be opened.  
The amplitude of the fan vibrations is determined by the rigidity  
of its support. Vibration that would not be critical to a fan sup-  
ported by a sufficiently rigid structure is amplified by an overly  
flexiblesupport.Thissupportrigiditymayalsocauseunexpected  
variations in the resonant frequencies of the blades.  
Note  
15  
 
Parts List  
Item  
Standard  
Material  
Standard  
Description  
Figure 6  
Protection  
1
2
Blade  
FRP  
––  
Coupling Flange  
Steel  
Steel  
Epoxy Paint  
Epoxy Paint  
––  
3
Hub Disk  
4
Lower Pillow Block  
Upper Pillow Block  
Pillow Block Plate  
Pins  
Aluminum  
Aluminum  
Steel  
5
––  
6
Epoxy Paint  
Zinc Plated  
HDG  
7
Steel  
8
Coupling Flange Washer  
Coupling Flange Lock Washer  
Coupling Flange Nut  
Space Ring (if needed)  
Taper Bushing (if required)  
Coupling Flange Bolt  
Pillow Block Washer  
Pillow Block Lock Washer  
Pillow Block Nut  
Steel - R40  
Steel - R40  
Steel - 8.8 class  
Steel  
9
HDG  
10  
10A  
10B  
11  
12  
13  
14  
15  
16  
17  
HDG  
Zinc Plated  
Burnished  
HDG  
Malleable Cast Iron  
Steel - 8.8 class  
Steel - R40  
Steel - R40  
Steel - 8.8 class  
Steel - 8.8 class  
––  
HDG  
HDG  
HDG  
Pillow Block Bolt  
HDG  
Screw (not included)  
Washer (not included)  
––  
––  
––  
For special applications, materials and protective coatings  
could be different. In this case, make reference to the fan docu-  
mentation.  
Note  
16  
 
Parts List  
11  
2
8
15  
12  
6
5
1
16  
17  
4
7
3
12  
13  
14  
8
9
10  
10B  
10A  
Figure 6  
17  
 
Troubleshooting  
Trouble  
Cause  
Remedy  
System congestion.  
Clean the entire system.  
Check the real obstacles area and the inlet shape towards  
the original design.  
Obstacles to the air flow.  
In dry-coolers the minimum free height of the inlet area has  
to be 1 time the fan diameter at least; this height has to be  
higher in case of multiple units in line.  
Low air flow  
Static pressure higher than the specified Increase blade pitch angle (till 3º after checking the data  
Low power absorption  
one.  
sheet selection.  
Pitch angle lowered by blade rotation  
(e.g. screw (15) not tightened at the right  
torque).  
Set the right pitch angle and refer to the operation manual  
to set the right torque of screws and bolts.  
Increase blade pitch angle (till 3º after checking the data  
sheet selection.  
Temperature higher than the design.  
Temperature lower than the design.  
Static pressure lower than the design.  
Decrease blade pitch angle (till 3º after checking the data  
sheet selection.  
High power absorption  
Decrease blade pitch angle (till 3º after checking the data  
sheet selection.  
Screws and bolts of the fan and/or the  
structure loosened.  
Torque all screws and bolts.  
Rubbing between the  
blades and the fan ring  
Fan not centered.  
Center the fan.  
Tip clearance too small.  
Unbalance of one or more blades.  
Increase the fan ring diameter.  
Contact SPX Cooling.  
Blade pitch angle not included in the 0.5º  
tolerance.  
Set right blade pitch angle.  
Contact SPX Cooling.  
Blades too close to supports (periodic aero-  
dynamic turbulence).  
Resonance between one of the possible  
forcing frequencies of the fan and one or  
more of the vibration modes of the structure  
on which it is installed.  
Contact SPX Cooling.  
Vibration transmitted by the structure on  
which the fan is installed.  
High vibration level  
Contact SPX Cooling.  
Contact SPX Cooling.  
Resonance of the blades with one of the  
possible forcing frequencies.  
Misalignment of the drive shaft.  
Worn output shaft bearing.  
Realign of the drive shaft.  
Contact the supplier.  
The fan and/or the structure bolts are not  
tightened.  
Tighten screws and bolts at the right torque.  
Open the draining holes.  
The draining holes of the blades are ob-  
structed.  
18  
 
 
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7401 WEST 129 STREET OVERLAND PARK, KANSAS 66213 UNITED STATES 913 664 7400 [email protected] spxcooling.com  
In the interest of technological progress, all products are subject to design and/or material change without notice.  
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©2009 SPX Cooling Technologies, Inc. Printed in USA  
M07-1126  
 

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