Transcript
The AcoustiFLO Modular Fan
Model 686q Operation and Maintenance
CONTENTS Nomenclature…………...……..………………..page 2 Regular Maintenance…...………..…………….page 3 Repairs…..……………...………..……………...page 3 Inspections.……………...……..…………..…...page 4 Motor Removal……...…………..………………page 5 Motor Replacement…………….….……………page 5 Shipping and Handling………….……….……..page 7 Flow Measurement…………...………………...page 8 Adjustments……………………....…...……….page 11 Specifications..……………………...……...….page 13 Contact Information……………………...…….page 14 Motor Data Appendix…..……...………...........page 15 The AcoustiFLO Modular Fan integrates a centrifugal fan with a unique diffuser assembly that reduces outlet noise and enhances fan performance. Some models may be equipped with an optional inlet silencer, flow measurement instrumentation, or motor shaft grounding. All modules are equipped with a seismically restrained internal spring isolation system to minimize vibration transmitted to building structure. Modules may be equipped with a variety of motors (7.5-30 hp) and fan wheels. Modules may be mounted on floor legs, in vertical stacks, or in nested stacks. Maintenance procedures for all modules, however, are essentially the same and are described in this manual.
U. S. Patents 7,001,140 and 7,357,621 Revised: 3/2/2011
Module nomenclature Outlet View Top arm
Fan
Lift Point
Outer diffuser
Restraint bolt
Motor tunnel
Motor Motor base
Inner diffuser
Floor leg Side arm
Spring base Snubber bolts
Spring isolator
Inlet View Inlet silencer
Inlet cone
Revised:3/2/2011
2
Lift Point
Regular maintenance Normally, the 686q modular fan will not require any regular maintenance other than periodic motor lubrication in accordance with motor manufacturer instructions. See the “Motor Data” section of this manual. At lubrication intervals or other shut-downs the fan module should be inspected for fastener tightness and damage. Spring isolators should be checked for proper alignment and free motion of the motor-fan assembly. See “Adjustments” in this document for proper procedures.
Repairs Slotted liners: The slotted aluminum liners on the inner and outer diffusers may be damaged by improper handling of the module during maintenance or installation. The most common damage is bending of liner. Most bends can be removed by inserting a blade screwdriver into a slot and bending the liner to match the original contour. Missing rivets should be replaced as necessary. Appearance: The rubber trim on the outer diffuser can be replaced and re-riveted in place. Touch-up paint is available for the powder coated parts of the module. Paint colors are given in the “Specifications” section of this manual.
Revised: 3/2/2011
3
Inspections The module should be inspected during regular maintenance to ensure the security of fasteners and proper adjustment. Fasteners: All fasteners should be regularly checked. The sixteen 1/4-in bolts attaching legs or brackets should all be tightened to 125 +/- 5 in-lb. The six 3/8-in bolts attaching the outer diffuser to the side arms should be tightened to 180 +/- 5 in-lb. The eight 3/8-in bolts attaching the spring base should be tightened to 180 +/- 5 in-lb.
Spring snubbers: The seismic nuts should be checked for tightness against the nut plates and adjusted if necessary (see “Adjustments”). The snubber bolts should be adjusted to provide 1/8-inch of travel above and below the foot of the motor base. This permits proper operation of the spring isolators.
Revised:3/2/2011
4
Motor removal and replacement Removal and installation of the motor is described in the following section. Prior to starting work on the unit ensure that motor circuit is de-energized in accordance with local procedures.
Motor removal WARNING LOCK-OUT AND TAG-OUT ELECTRICAL POWER TO THE FAN MODULE BEFORE MAINTENANCE
1. De-energize the motor circuit using approved procedures. 2. Disconnect the motor leads from the motor. 3. Tighten the four spring base bolts until the nut plate is firmly seated on the motor base. 4. Tighten the two upper restraint bolts until the inner diffuser is firmly clamped. 5. Match mark the inlet cone or inlet silencer and remove it from the module. 6. Remove the fan wheel. 7. Attach overhead lifting equipment to the motor to prevent accidental movement of the motor. Arrange the lifting equipment so that it does not stress or damage the upper arm. 8. Mark the foot position before removing the old motor. 9. Remove the four bolts from the motor C-face and retain them for later use. At this point the motor should be free from the inner diffuser. Support the inner diffuser to prevent damage to the aluminum liner. 10.Remove the bolts from the motor feet. The motor can now be removed from the motor base.
Motor replacement 1. Using approved handling equipment place the motor on the motor base and position the C-face of the motor 10.5 (+/- 1/8) inches from the center of the spring bolt. 2. Tighten the motor foot bolts after adjusting the motor position and ensuring that the motor is centered on the motor base. 3. Re-install the four 1/2-inch bolts in the C-face to attach the inner diffuser. Revised: 3/2/2011
5
Tighten restraint bolts to hold inner diffuser. .
Tighten snubber bolts to hold motor base.
Motor replacement (continued) 4. Install the fan on the shaft and position the fan so that the back plate is approximately 17.5 inches from the front surface of the module. After tightening the fan attachment fasteners ensure that the back of the fan does not contact the C-face bolts or the inner diffuser. Re-adjust as necessary. 5. Reinstall the inlet cone or inlet silencer and adjust as necessary to achieve a nominal 0.5-inch overlap on the fan wheel. 6. Loosen the four spring base bolts and adjust for approximately 1/8-inch free motion. 7. Adjust the upper restraint bolts until the inner diffuser is vertical. 8. Adjust the position of the fan if necessary as described in the “Adjustments” section Revised:3/2/2011
6
Shipping and handling Shipping: Modules need to be prepared for shipment to prevent damage. The 3/8-inch locking bolts on the spring base should be tightened to lock the motor base in place. Access the bolts from the underside of the spring base.
WARNING NEVER LIFT THE MODULES FROM THE FEET OR SIDE ARMS
Handling: The modules should only lifted from the two lifting holes on the upper arm or when bolted to a pallet.
Lift Point
Revised: 3/2/2011
7
Flow Measurement All fan modules are equipped with inlet static pressure connections that can be used for monitoring the air flow through individual modules.
Modules without inlet silencers have a barbed connection for 0.17 inch ID tubing on the top of the outer diffuser shell. This port connects to four static taps in the throat of the inlet cone.
Modules with inlet silencers have the 0.17 inch barbed connection on the top of the inlet silencer. This port connects to four static taps in the throat of the inlet of the silencer.
The approximate airflow through the module can be calculated using the differential static pressure measured at these connections. The reference pressure must be the static pressure in the fan inlet plenum. The reference pressure should be measured in a region of the inlet plenum without significant air velocity. When the atmospheric pressure and air temperature are known the airflow should be calculated using the following relation: Q = C x ( deltaP / (Patm/ (T + 460) ) )0.5 Q: Airflow, cfm C: Inlet nozzle constant (Inlet Cone = 926.7, Inlet Silencer = 1602.6) deltaP: Measured inlet differential pressure, in. w.g. Patm: Atmospheric pressure, in. Hg T: Air temperature, deg. F Revised:3/2/2011
8
If the actual atmospheric pressure and air temperature are not known, it is possible to use an altitude adjusted constant (Calt) to calculate a fairly accurate flow using the following simplified formula: Q = Calt x ( deltaP )0.5 Altitude, feet
Calt, Inlet Cone
Calt, Inlet Silencer
0
3893
6732
1000
3964
6855
2000
4037
6982
3000
4112
7111
4000
4189
7244
5000
4268
7381
6000
4349
7520
7000
4432
7664
8000
4517
7811
9000
4604
7963
Table calculated for an air temperature of 60 deg F.
Graphs on the next page show the airflow versus static pressure for sea level and 6,000 feet at 60 deg F. The graphs were calculated using the constants from the table above.
Flow Measurement—troubleshooting An unreliable or inaccurate pressure/flow measurement may be due to a faulty connection to the pressure taps in the module or the reference pressure in the fan inlet plenum. If the connection appears to be broken inside the module, the problem can be resolved by removing the inlet cone or the bellmouth of the inlet silencer and re-connecting the static taps.
Revised: 3/2/2011
9
Airflow, cfm
Module Flow vs Inlet Static Pressure (Inlet Cone, 60 deg F) 22,000 20,000 18,000 16,000 14,000 12,000 10,000 8,000 6,000 4,000 2,000 0
0 6000
0
2
4
6
8
10
12
14
16
18
20
22
24
Inlet Static Pressure, in w g
Airflow, cfm
Module Flow vs Inlet Static Pressure (Inlet Silencer, 60 deg F) 22,000 20,000 18,000 16,000 14,000 12,000 10,000 8,000 6,000 4,000 2,000 0
0 6000
0
1
2
3
4
5
6
Inlet Static Pressure, in w g
Revised:3/2/2011
10
7
8
9
Adjustments The position and alignment of the fan may need to be adjusted after motor or fan wheel replacement. The position of the fan wheel may be adjusted using the spring adjustment bolts, the upper restraint bolts, and the position of the fan wheel on the motor shaft. If the fan is rubbing on the inlet cone, the cone can be repositioned so that there is uniform clearance. The gap can be increased by moving the fan forward on the motor shaft. The best fan performance is achieved with the smallest gap possible between the fan and the inlet cone. Adjusting tilt and left/right angle: •
• •
•
Check the rotation of the fan and the clearance between the inlet cone and the fan wheel. If the position of the fan wheel needs to be adjusted, use the restraint bolts as shown. Turning both bolts clockwise raises the fan wheel inlet. Turning the left bolt clockwise and the right bolt move the fan wheel to the left (as viewed from unit.) Turning the right bolt clockwise and the left bolt move the fan wheel to the left (as viewed from unit.
counter-clockwise will the motor side of the counter-clockwise will the motor side of the
Vertical position: The vertical position of the fan wheel can be adjusted by turning the upper caps on the spring isolators. A 7/8-inch wrench can be used to turn the upper caps to raise or lower the motor base. The spring adjustment can also be used to rotate the inner diffuser to adjust the clearance of the upper restraint bolts. This is accomplished by raising one spring bolt and lowering the other.
CAUTION LOOSEN THE SEISMIC NUTS WHEN ADJUSTING THE SPRING BOLT HEIGHT TO ALLOW FREE MOTION OF THE MOTOR/FAN Revised: 3/2/2011
11
Spring snubber adjustment: The motion of the motor assembly is limited by the seismic nut and nut plate on either side of the motor base. The proper gap is set by tightening the seismic against the nut plate and then turning the four 1/2-inch bolts until the gaps are equal on either side of the motor base.
1/2-in Bolt
Nut Plate
Upper gap
Seismic Nuts
Lower gap
In addition, the bolts should be approximately centered in the holes in the feet of the motor base. The centering can be adjusted by unpinning and moving the lower spring cup. This should not normally be necessary. Motor Base
Lower Spring Cup
Two 3/8-inch bolts are threaded into the bottom of the spring base and are used to lock the motor base in place for shipping. The motor base must be securely locked for shipping. The locking bolts must be loosened to allow the motor assembly to float for normal operation.
Revised:3/2/2011
12
Specifications General specifications for all modules are summarized below. Specifications are subject to change. Configurations may be project specific. Basic Module Dimensions*
Basic Module Characteristics
Airflow: 5,000-15,000 cfm Pressure: 1-10 in w.g. Motor Power: 5-30 hp Motor Frames: 213-286 Vibration Isolation: Internal springs Weight: 500-700 lb Mounting: Floor, Nested, Vertical Flow measurement Shaft grounding (optional) Inlet silencer (optional) Fan Blade Count (9 or 12) Fan Wheel Width (Full or Partial)
*Note: Inlet silencer replaces inlet cone and extends 19 inches from module pressure wall face.
Module Configurations
686q1 686q2 686q3 686q4 686q1+ i 686q2+ i 686q3+ i 686q4+ i
9 Blade, Partial Width 9 Blade, Full Width 12 Blade, Partial Width 12 Blade, Full Width 9 Blade, Partial Width with inlet 9 Blade, Full Width with inlet 12 Blade, Partial Width with inlet 12 Blade, Full Width with inlet
Touch-up Paint Specification
Touch-up paint is available in aerosol containers from Cardinal Industrial Finishes (cardinalpaint.com) Blue: (side arms, legs, inlets) Beige: (inner and outer diffusers) Orange: (spring hardware) Yellow: (nested brackets) Revised: 3/2/2011
T009-BL01 P009-BG02 T009-OG01 T009-YL01 13
Support contact information:
Phone: Fax: Email:
303.770.1500 303.444.0372
[email protected]
Notes:
Revised:3/2/2011
14
