Axial Fan

Operation
&
Maintenance
Manual

(CC, CC-JD, CC-HP, CC-HT, TA-HP, TA-HT)

AXIAL FAN

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AXIAL FAN

TABLE OF CONTENT
1. INTRODUCTION.......................................................................................................... Pg. 4

2. GENERAL INFORMATION ........................................................................................... Pg. 4

3. GENERAL SAFETY & WARNING ................................................................................. Pg. 4

4. TRANSPORT ACCEPTANCE & STORAGE.................................................................... Pg. 6

5. DESCRIPTION AND TECHNICAL FEATURES OF FANS................................................ Pg. 8

6. GUIDELINES FOR DUCTED AXIAL FLOW FAN INSTALLATION .................................. Pg. 9

7. ELECTRICAL CONNECTION DETAILS.......................................................................... Pg. 12

8. STARTUP CHECK LIST AND PROCEDURE .................................................................. Pg. 14

9. ROUTINE MAINTENANCE ............................................................................................ Pg. 16

10. TROUBLE SHOOTING & COMMON OPERATING PROBLEMS .....................................Pg. 18

11. STANDARD SPARE PARTS........................................................................................... Pg. 21

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AXIAL FAN

1 . INTRODUCTION

The Axial fans are used to handle flow of clean or slightly dusty air (unless otherwise stated), adhering to the
operating conditions shown in the technical catalogues and in the technical data sheet, it can also be used ,more
complex system, machines or plants. All fans can also manufactured in special versions, which must be previ-
ously agreed with the manufacturer. The dynair short/long cased Axial fans range is produced in a range of sizes
400mm to 1600mm diameter.
Casings are manufactured from various material such as per galvanized steel or hot deep galvanized steel. Impel-
lers are selected to meet the specific performance and are available in a variety of materials to ensure suitability
for the application.

2. GENERAL INFORMATON

Carefully read the instruction contained in this manual.

Special attention should be paid to the section following word ‘WARNING’ as if not complied with, can cause
injuries to people and / or damage to the fan.

NOTE : Store this manual for future reference, we reserve the right to improve and make changes to the manual,
product and accessories without any obligation to update previous production and manuals.

2.1 SCOPE OF RELEVANCE OF THIS MANUAL

This manual, produce by the manufacturer, is an integral part of the fans as such, the manual must be always kept
with the fan until the fan is scrapped and it must be easily available for quick consultation by installers and users.
Should the machine be sold, the manual must be given to the new owner as integral part of the fan. Before start-
ing any operation with or on the fan, it is compulsory for the staff involved to carefully read this manual. Should
this manual go missing, get damage or partly illegible a new copy must be requested to the approved retailer
or directly to the manufacturer and it must be checked that date of the change is earlier than date of purchase
of the machine. This manual has been produced in order to ensure a safe installation & use of the fans and it
contains safety warning and information to avoid accidents at work, therefore the instruction it contains must be
fully and strictly applied. Furthermore these instruction and do not represent the only procedure to be followed to
ensure the safety. Each operation carried out on moving and / or live parts such as installations and maintenance
operations requires special care to be taken and must be carried out by qualified and trained person. The safety
regulation enforced by current standards must be strictly adhered to by all the operation of the machine.

NOTE : Qualified person regarded staffs that have a specific technical knowledge in aerodynamic and electric
system components should handle the fan maintenance

3. GENERAL SAFETY & WARNING

WARNING: The manufacturer cannot know the type of installation and therefore supplies the Guard (for inlet and
outlet) on customer request, who is responsible to assessing the system safe conditions. Should other type of
guard be required, the final installer or whoever acts on his behalf, must carry out a risk assessment specifically
related to the type of installation required and therefore insert the suitable safety systems according to the type
of application. In order to ensure full compliance with Machine Directive 2006142/EC these systems must be well
built, in order to avoid any risk of injury and must be fixed securely by requiring special tool to remove them.

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AXIAL FAN

The provision of safety net changes the aeraulic efficiency of the fans: all losses of load, including those generated
by safety nets or by other accessories, must be assessed at the design stage according to the speed, the air den-
sity, the temperature and all other issues which contribute to change their impact in the system.
Both final user and installer must take in account other type of risk, more specifically those caused by foreign
bodies entering the fan, or by mixtures different from those allowed. It is also necessary to take into account other
risks during the routine and unscheduled maintenance operations, which must be carried out safely by discon-
necting or isolating the motor power supply with suitable safety devices and with other precautions specified in
more details in the following sections, which list the safety warnings and maintenance sections.

WARNING: Fitting safety nets does not fully avoid foreign bodies from entering the fan. If hazardous bodies or
particles should get mixed up with the treated air, the user must carry out a full risk assessment able to identify
their possible dimensions. If the diameter of the standard safety net is not enough to ensure the minimum safety
requirements the user must take all the precautionary measures required to avoid any residual risk.

WARNING: Periodically check the efficiency of the guard should they become faulty or too worn which could
negatively affect their operation, they must be replaced. After the installation, all the main technical features of the
fan must be checked (that the guards have not been removed and/or damaged and/or changed) and if necessary
a global risk assessment for the fan in relation to its application.

3.1 RISKS CAUSED BY IMPROPER USES

• Do not insert your hands or other parts of the body near moving parts.
• Do not insert your hands or other parts of the body beyond the guards.
• Do not remove, dispose of or change the guards.
• Do not remove dispose of or change any monitoring devices.
• Do not use the fan environment different from those specified.
• Unauthorized operators are not allowed to carry out any kind of operation on the fan.
• Reset the safety systems before restarting the fan after carrying out operations which required their removal.
• Make sure that all safety devices are in full working order.
• Make sure all safety and information plates are fitted on the fans in good conditions.
• Securely tighten all drives or adjusting screws.
• The staff who carries out any operation on the fan must use the required PPE.
• Do not use loose clothing.

3.2 FAN INHERENT RISKS

• Dragging by moving parts
• Dragging by the fan inlet
• Violent ejection of an object entered in the fan through the outlet
• Risk of burns or scalding caused by very hot outer surfaces of the fan.
• Risk of breakages for: Too many vibrations
• Over speed
• Over temperature

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AXIAL FAN

• Carry out a routine maintenance plan to avoid structural subsidence and mechanical faults over time
• When cleaning the impeller, even with the power supply disconnected, the impeller could still move by inertia
or by natural or forced air currents coming from the other equipment connected to the same system, therefore a
serious risk of shearing and/or pinching. For this reason, the impeller must be mechanically locked. It is strictly
forbidden:
- To work on the fan whilst in operation.
- To remove the guards when the fan is operating.
- To work on the fan without disconnecting the power supply.

NOISE: The fan noise levels are stated in dB (A) and are shown in the technical data sheet (enclosed).

WARNING: The user may detect different values from those shown according to the fan operating environment.
It is always recommended to isolate the fan from the ground and from the ducting with anti-vibration mountings
couplings and when necessary provide effective sound proofing system in order to protect the staff health.

The user and the employer must comply with current legislation in terms of assuring daily protection from exces-
sive noise to all operators (as required by current European and National standards) and if needed to require as
mandatory the use of personal Protective equipment (ear defender etc.) according to the overall sound pressure
level identified in a single working area and to the daily levels operators are exposed to.

3.3 MECHANICAL RISKS

There is no mechanical risk. The fan is protected by accident preventing fixed of removable guard fitted to all
moving part in compliance with standard UNI16015.

The material inlet and outlet openings are protected by the installer or by a grille which avoids people from coming
into contact with moving parts or by another device. In any case, for all maintenance operations and after making
the machine safe it is compulsory for the operator to use the personal protective equipment. It is forbidden to
stop the fan before the fluid inside has reached the fan temperature lower than 60°C to avoid excessive heat from
damaging the motor or the monopoly. Should it be impossible to reach this temperature, external cooling systems
must be provided. When the fan is not working if its internal temperature increases the user must use all means
available to reduce the temperature to values lower than 60°C before starting up the fan. Before starting up the
fan, make sure all guards are correctly installed, The inspection door must be removed only with special tools and
only when the fan has been stopped. The maintenance operations must be carried out in totally safe conditions by
disconnecting the fan from the motive power. The manufacturer shall not be responsible for damages to things or
injuries to people caused by missing safety devices if at the time of ordering, the customer does not specifically
require them.

4. TRANSPORT, ACCEPTANCE AND STORAGE

4.1 TRANSPORT
All fans are packaged in cardboard boxes or fixed on pallets to easy the transport process. The manufacturer shall
be responsible up to the time of loading. Transport must be carried out in total safety the haulier is responsible for
suitability of securing the load the fan should be moved by equipment, as prescribed by directive 89/391/EECand
later directives. Manual handling from the ground is specified by directive 89/391/EEC and later directives; a
weight or 20 Kgs is generally accepted when lifted below the shoulder but above the ground level.

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AXIAL FAN

WARNING: When handling objects over long distances and over uneven ground, the impeller must be locked
in position to avoid vibrations from damaging the bearing races. When handling the fans in particularly adverse
environments, such as when travelling on a ship or on uneven grounds, or when lifting the fans with a crane to
reach elevated installation sites, all warranties supplied will become void for drive parts and more specifically, for
bearing and mountings, if they are not suitably protected. If in doubt ask the manufacturer. The transport position
specified by the manufacturer for the fans or its single components must be complied with.

WARNING: Stacking or applying loads onto the fans is strictly forbidden.

4.2 ACCEPTANCE
All fans are tested balanced and inspected before shipping. The fan is identified from the data printed on the
identification label affixed to the fan itself. The fan is supplied with legally required warranty. The warranty start
from delivery date and cover all faults caused by poor workmanship or construction faults when the goods are
received, damages are noticed, they must be immediately reported to the haulier and to the manufacturer: the
manufacturer shall not be held responsible for damages caused during transport. Damaged fans should not be
used or repaired, as this would make all warranties void. Check that the fan matches with the order (design,
rotation, power and polarity of the motor installed, accessories, etc.); no non conforming returns will be accepted
after installation has taken place.

WARNING: The range of fans is completed with all safety devices in compliance with current standards, available
on request (see technical data sheet), The manufacturer shall not be responsible for damages to things and inju-
ries to people caused by missing safety devices, nor shall it be responsible for any damages caused by misuse
and/or failure to adhere to the instructions described in this manual.

4.3 STORAGE
4.3.1 SHORT TERM STORAGE
As soon as the fan is received at the site the complete fan unit and/ or different parts of the fans should be placed
in a well ventilated and dry preferably under shed.
Avoid the fan from being subject to knocks, which could damage it.

4.3.2 LONG TERM STORAGE

Storage for relatively long time should be ensured in the best possible condition and should be positively pro-
tected from dampness so as to avoid oxidation leading to rusting of the different parts of the fan motor units. For
such long term storage it is strongly recommended to keep the complete fan unit under a shed. In the case of
prolonged storage the fan unit should be inspected periodically and machined parts should be covered adequately
after using protective rust preventive. During such storage period the impeller and shaft bearing assembly should
be rotated at a very low speed manually at frequent intervals.

• Do not store fans near machines which generate Vibrations, to avoid the bearings from being subject to
the same type of stresses. Special care must be taken when handling large impellers or shafts, if they are
received disassembled for transport reasons, to avoid balancing problems.
• The manufacturer shall not be responsible for damages to drive parts caused by prolonged fan inactivity.

PRECAUTION DURING STORAGE

• The impeller must be spin in regular intervals (once per month).
• If storage last for more than 3 months, the bearings must be opened before start-up and checked for cor-
rosion damage caused by condensate.
• If required, the old grease has to be removed, the bearings must be cleaned and provided with new grease.
• If the fan is stored for longer than 9 months it must be preserved once more.

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AXIAL FAN

5. DESCRIPTION AND TECHNICAL FEATURES OF FANS

Axial fan features an axial air flow in a cross flow configuration. Their performance is suitable for medium and
high air flow and for medium or high pressures. The performance of each fan is shown in the technical cata-
logues. The range of axial fans includes standard versions, suitable to handle clean or slightly dusty air with a tem-
perature between -20°C and +50°C or special versions. Such features are described in the technical catalogues
and in the enclosed technical data sheet, which must be consulted to identify the suitability of the fan to handle
the fluid treated by the plant where the fan will be installed. Based on their construction they can essentially be
divided in two types:

(A) Ducted axial fan: consisting of an impeller and a motor mounted in a cylindrical casing, the fan is driven
directly from the motor (direct coupling) or by means of pulleys and belts (indirect coupling)

(B) Wall-mounted axial fan: with directly coupled impeller and motor mounted on a panel or ring.
For further information, please refer the technical catalogues.

• CC-AL Ducted Axial Fan W/ Aluminum Impeller (Hot Dipped Galvanized) with Feet Support(HDG) and Ext
Terminal Box - Dynair
• TA/CC-HP High Performance Ducted Axial Fan ( Hot Dipped Galvanized) with Feet Support(HDG) and Ext
Terminal Box - Dynair
• TA/CC-HT Ducted Axial Fan rated at 300°C/2hrs. (Hot Dipped Galvanized) with Feet Support(HDG) and Ext
Terminal Box - Dynair

ASSESSING SAFETY CONDITIONS

The fans can be installed in 4 different working conditions:
• A - Free inlet and outlet (Not ducted).
• B - Free inlet and ducted outlet.
• C - Ducted inlet and free outlet. TYPE A: Free Inlet,Free Outlet

• D - Ducted inlet and outlet.

TYPE B: Free Inlet,Ducted Outlet

TYPE C: Ducted Inlet, Free Outlet

TYPE D: Ducted Inlet, Ducted Outlet

Fig.1

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AXIAL FAN

TYPICAL INSTALLATION

Tunnel jet fan

Roof fan Axial fan

6. GUIDELINES FOR DUCTED AXIAL FLOW FAN INSTALLATION

In both axial and centrifugal fans, inlet & outlet ducts should be independently supported and never supported
by the fan flanges. Flexible duct connections are recommended. These connection will also minimized the noise
and reduce the vibration

The independent mounting of stack and duct to the fan flanges will assure that the fan will not be subjected to any
external forces which may twist or deform fan housing. This also will ensure that the impeller will not strike the
housing or cause misalignment of the sheaves and bearing.

Its recommended that the access door to be placed in duct work just ahead of the fan inlet and just behind for easy
of inspection and maintenance. Access door in duct system should never be open with the fan running, to avoid
possible equipment and damage personal injury.

No turns in duct should be closer to than two and one half fan diameter away from the inlet and outlet of the
fan. Walls and flat surface also should not be closer than one fan diameter from the inlet side.

Branch entries into the main duct should be spaced such that they do not enter directly opposite each other. A
maximum of 45 degree angle between main branch and entering branch should be used as a guideline. Avoid
sudden changes in duct size, Use a 14 degree included angle, or less, in reducing a duct to a fan, and not more
than 30 degrees included angle to the discharge. Elbow turns should be kept to a centerline radius of at least one
and one-half diameters of the duct.

Typical installation of Free inlet / Free outlet fan as that of tunnel & jet fans to follow special installation procedure
and varies with respect to mounting requirements to that of ceiling or wall of installation.

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AXIAL FAN

INSTALLATION GUIDELINES

Fig.2

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AXIAL FAN

INSTALLATION METHOD

Fig.3

FAN WITH SHORT CASING INSTALLATION

Thread rod
Point-B
SPRING ISOLATOR

Point-A

Point-D
Point-C

Fig.4

Fig.5

Fig.6

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AXIAL FAN

7. ELECTRICAL CONNECTION DETAILS

Electrical connections for the fan motor must be connected by a qualified electrician, confining to the National
Electrical code and local codes and practices. When making electrical connections, the motor must be connected
following electrical characteristics as indicated by the motor nameplate, and adhere to the wiring diagram on the
motor nameplate or in the motor terminal box.

Motors may fail immediately if improperly connected. It is also recommended that an overload device to protect
the motor to be install between the current supply and the motor. Recommended tolerances for overload devices
should be plus 10 % of the motor Full load amperage rating, including the allowance for the motor service factor.

NOTE: It is common for motors to draw several times full load amperage during startup, for approximate fifteen
seconds. Larger sized fans may require twenty seconds or longer.

Note : We advise to check the motor data to ensure the connection details.

MOTOR CONNECTION FOR SINGLE PHASE FAN.

230 VAC, 50Hz 230 VAC, 50Hz

230 VAC, 60Hz 230 VAC, 60Hz

Fig.7 Fig.8

400V 50Hz Y STAR

400V 60Hz Y STAR
W2 U2 V2
W2 U2 V2 HI H2
H1 H2

To starter
To starter Control circuit
Control circuit
TI T2
T1 T2

U1 V1 W1
To starter
Control circuit L1 L2 L3
To starter
Control circuit L1 L2 L3

Fig.9 Fig.10
(Three Phase Up to & including 3 Kw) (Three Phase - 4kw and Above)

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AXIAL FAN

Sample SLD for switchgear panels

MOTOR TERMINALS

Fig.11

Motor connection, 4/6 pole, 6/8pole

Fig.12

KM3 KM1 KM2

# For High Speed KM3 & KM2 shall be ENERGIZED

# For Low Speed KM1 shall be ENERGIZED

Fig.13

Motor connection: 2/4 pole, 4/8pole

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AXIAL FAN

8. START-UP CHECK LIST / PROCEDURE

A complete inspection should be made of all duct work and the fan interior. Make sure there is no foreign mate-
rial, which can be drawn into or blown through the fan or ductwork. Appropriate protective measures and safety
practices should be observed when entering or working within these areas. There measures may include the use
of goggles, respirators, or other personal protective devises.

Before putting any fan into initial operation the manufacturer’s instruction must be followed. Complete the follow-
ing checklist to make sure that the fan is ready to run.

♦ Lock out the primary and all secondary power sources.

♦ Make sure the foundation or mounting arrangement and the duct connections are adequately designed in
accordance with recognized acceptable engineering practices and with the fan manufacturer’s recommenda-
tions.

♦ Check and tighten all hold-down (securing) bolts.

♦ Ensure power and drive component such as motor starter, variable frequency drive are properly matched and
connected to the fan.

♦ Check the fan assembly and bearings for proper grounding to prevent static electricity discharge.

♦ Spin impeller to see whether it rotates freely and is not grossly out of balance. Inspect impeller for correct
rotation for the fan design.

♦ Properly secure all safety guards.

Switch on the electrical supply and allow the fan to reach full speed.
Then check carefully for :-
• Excessive vibration
• Unusual noise
• Proper amperage and voltage values

If any problem is indicated, SWITCH OFF IMMEDIATELY. Lock out the electrical supply, secure the fan impeller if
there is a potential for wind milling (impeller turning due to a draft through the system).
Check carefully for the cause of the trouble and correct as necessary.

The fan may now be put into operation but during the first 8 hrs of running, it should be periodically observed and
checked for excessive vibration and noise. Checks should be made on motor input current, motor and bearing
temperature to ensure that they do not exceed manufacturer’s recommendation limits. After 8 hrs of operation,
the fan should be shut down to check the following items:-

• All set screws and hold-down bolts

• Motor cable
• Terminal box
• Vibration isolators

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AXIAL FAN

WARNING: Do not touch the terminals during and immediately after the measurement as the terminals are live.
Note the impeller direction of rotation shown by the arrow (if provided) located on the impeller blades or on the
fan itself. The installer must interface the machine with the required start-up/stop controls, emergency stop, reset
after an emergency stop button complying with current standards (EN 60204-1, EN 1037, EN 1088, and EN 953).

WARNING: The fan frame must be earthed; furthermore, it must be verified that all its components have a same
potential. The installer must connect the fan to the earthen circuit and check the potential is effectively the same
on all its components before starting the machine.

OPERATING INSTRUCTION

Checks
Check all screwed unions, especially foundation bolts, at intervals of six months for tightness and retighten them,
if required
Also check the impeller every six months by a visual inspection.
Pay special attention to the condition of the weld seams and irregular deposits of dirt.
If fluids which contain dust are conveyed through the fan, monthly checks are necessary
The results of these visual inspections should be recorded.
The motor must be checked in accordance with the manufacturer’s requirements.
Vibrations represent a very high stress to the entire mechanical system of the fan! Therefore, measurements are
required at regular intervals
Schedule maintenance by the manufacturer every 8000 operating hours
Shutdown
Switch off motor
Switch off main switch
Shut all control devices to prevent the impeller from running.
Make sure that the motor cannot be switched on again by unauthorized persons.
The valid regulations for prevention of accidents must be observed

OPERATIONS TO BE CARRIED OUT AFTER START-UP:

(1) Check that the direction of rotation matches with the direction shown by the arrow.
(2) Check the input current does not exceed the current shown on the product identification label and motor
nameplate.
(3) To have reliable information, allow a reasonable period of stabilizing time. In the delta/triangle connection,
the reading must be carried out upstream of the change-over switch; if this is not possible, detect the live
current on any of the six wires at the terminal box and multiply this value by 1,73.
(4) Avoid consecutive start-ups of the motor as this would cause continuous overloads, and overheat the elec
trical parts.
(5) Before start-up, allow enough time to cool down.
(6) Check the bearing temperature after the first hour of operation, as these are the most critical. If necessary,
stop the fan and restart it only after reaching the ambient temperature.
(7) Then check that the temperature is lower than the previously measured temperature. By means of a vibrome
ter check that the vibrations are not excessive by referring to the following paragraph. After few hours of
operation, check that the vibrations have not slackened the tightness of nuts.

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AXIAL FAN

9. ROUTINE MAINTENANCE

Periodic inspection of all the fan parts is the key to good maintenance and trouble free fan operation. Frequency
of inspection must be determine by the user and its dependent upon the severity of the application. Prepare
maintenance schedule and make sure it is strictly adhere too.

NEVER SERVICE OR ADJUST ROTATING EQUIPMENT WHILE IT IS IN OPERATION. LOCK OUT THE POWER
SOURCE BEFORE PERFORMING MAINTENANCE.

Regular fan maintenance should include following.

Maintenance should always be performed by experienced and trained personnel. Do not attempt any maintenance
on a fan unless the electrical supply has been locked out or tagged out and the impeller has been secured.

♦ Under normal circumstances, handling clean air, the system should require cleaning only about a year. How
ever, the fan and system should be checked at regular intervals to detect any unusual accumulation.

♦ The fan impeller should be specially checked for build-up of material or dirt which may cause an imbalance
with resulting undue wear on bearings and belt drives. A regular maintenance program should be established
as needed to prevent material build-up.

♦ Periodic inspection of the rotating assembly must be made to detect any indication of weakening of the rotor
because of corrosion, erosion, or metal fatigue.

BEARINGS
Small motors (frame 80-132), greased for life must be replaced after 20,000 running hours. Check motor name-
plate for determining the used bearing type.

ATTENTION! :- The lubrication intervals are based on bearing operating temperature of 75 °C (frame 63 to 200)
and 85 °C (frame 225 to 500). Some designs may present different references.

• Grease nipples are usually used in motors frame above and included 160.
• The purpose of this maintenance is to extend bearing lifespan.
• The bearings life depends essentially from the maintenance cares and RE-greasing procedures, otherwise,
the bearings may have their life shortened drastically.

MAINTENANCE INCLUDES
• Attention to the overall bearing status
• Cleaning and lubrication;
• Detailed inspection of the bearings
IMPELLER
• In case of long shutdowns spin the impeller once per week.
• Here the final position should be offsett by 90° compared to the previous idle position.
• Apart from the regular visual inspections (at least once a year) the impeller must be cleaned whenever it
is dirty.
• The cleaning intervals depend on the fluid conveyed.

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AXIAL FAN

MOTOR
• A well-programmed maintenance of electric motors can be summed up as a periodical inspection (like: 7
days, 15 days, 1 month, 1,5 month, 3 months, 6 months, etc…). These inspections must include checking
procedures like:
• Cleanness (fins, fan cover, etc…)
• Current and Voltage;
• Bearings and Windings temperature;
• Ambient temperature;
• Vibration levels;
• Seals conditions (V’ring, taconite, oil seal, etc.…)
• Wears in general;
• Noisy;
• Lubrication conditions and useful life (listed on a specific topic);
• Connections conditions;
• Screw tightness in general;
• Winding life (listed in a specific topic);
• Insulation resistance;

BELT DIRVE
• The drive must be visually inspected after the first 24 hours of operation. Afterwards, it should be checked
every three months.
• Protect the belts against oil mist, dripping oil and other chemicals.
• Permanent exposure to these fluids causes early wear of the belts.

SPECIAL NOTES FOR REGULAR MAINTENANCE

• Maintenance should always be performed by experienced and trained personnel.

• Do not attempt any maintenance on a fan unless the electrical supply has been locked out or tagged out and
the impeller has been secured.
• Under normal circumstances of handling clean air, the system should require cleaning only about a Year.
• The fan impeller should be specially checked for build-up of material or dirt which may cause an Imbalance
with resulting undue wear on bearings and belt drives. A regular maintenance program should be estab-
lished as needed to prevent material build-up.
• Periodic inspection of the rotating assembly must be made to detect any indication of weakening of the rotor
because of corrosion, erosion, or metal fatigue.
• Moreover fan vibration, unusual noise, power cables, termination, tightening, bearing lubrication must
checked and recorded.
• Control panels & field devices functional test must be carried out at regular intervals to ensure about sys-
tem operation. Where motor ampere, Voltages, RPM to me measured and recorded.

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AXIAL FAN

♦ Under normal circumstances, handling clean air, the system should require cleaning only about a year. How
ever, the fan and system should be checked at regular intervals to detect any unusual accumulation.

♦ The fan impeller should be specially checked for build-up of material or dirt which may cause an imbalance
with resulting undue wear on bearings and belt drives. A regular maintenance program should be established
as needed to prevent material build-up.

♦ Periodic inspection of the rotating assembly must be made to detect any indication of weakening of the rotor
because of corrosion, erosion, or metal fatigue.

10. TROUBLE SHOOTING & COMMON OPERATING PROBLEMS

Bear in mind that if and an aeraulic system is not working, there may be more than one cause. All causes must
be identified and systematically removed.

Some possible faults, causes and solutions for account: systems:

• Reduced power voltage. • Check the motor nameplate data

• Motor start-up torque too low.
• Unsuitable fuses for the start-up
conditions.
1 Difficult start-up
• Unsuitable assessment of the
fan inertia and of the coupling
components
• Too much power drawn.
• Close the shutters until full speed is
reached (does not apply to axial fans) If
this is case, replace the motor with a
more powerful motor.
• Replace.
• Work out again the inertial momentum &
if needs be fit a new motor on the fan,

• Replace the motor and/or the pulleys and/

• Rotation speed too high. Air density or redesign the system.
higher than the project data. • As above,
Power Value Higher than • The fan works with excessive • Redesign the system or replace the type
the value shown on the
2 pressure. of fan.
identification label or the
motor name plate • The motor turns at a lower speed • Check the power voltage and, if needs
than its normal rotating speed. be, rectify it, Check that the winding is not
defective and, if so, repair or replace.

• Clean pipes and hoods, check shutter

Air flow rate to low. At the position.
• Obstructed pipes and/ or blocked up
nominal rotation speed, inlet points • Check power voltage and check motor
the input power is reduced, connections, check drive ratios; if needs
especially for the centrifugal • Rotation speed too low. Working be, rectify it. Check that the belts do not
3 fans with forward curve pressure higher than the design slip; if they do, restore their correct
blades or with radial blades. specific pressure. tension.
The power input is less • Blocked up impeller.
affected for centrifugal • Design error; replace the motor and/or the
backward blade fans. pulleys, replace and/or adapt the circuit.
• Clean the impeller.

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AXIAL FAN
Air pulses.
4 create unstable air inlet conditions
Reduced performance after
5 a period of satisfactory
operation
Too much noise. Normally
all fans generate noise
but this should become
a worrying issue when
the level is unacceptable.
This as a noise caused
by air mechanical parts,
electrical buzzing noise
or a combination of these
6 factors. While the noise
caused by air can increase
because of obstructions
near the fan inlet or outlet,
an excessive noise is more
commonly caused by the
wrong choice or installation
of the fan.
7 Too many vibrations
• The fan operate at almost zero flow
rate conditions
• Unstable flow
• Connection which creates
unstable air inlet connection which
(vortexes).
• Alternative flow disconnection and
reconnection at a diverging channel
walls
Loss in the fan upstream and/or
downstream circuit
- Too many revolutions are required
to achieve the required performance
• The impeller scrapes on the
enclosure.
* Bearings worn,
• Eccentricity between rotor and stator.
* Winding vibrations
• Positioning in a resonant area
• Unbalanced rotating parts.
• Unsuitable mounting structure: • Strengthen and/or change the natural
with a natural frequency close to frequency of the mounting structure by
the fan rotation speed natural using weights.
frequency.
• Slackened screw connections
• Defective bearings
• Change the circuit and/or replace the fan.
• Redesign the inlet by placing deflectors
clean and/or restore the inlet.
• Redesign the circuit and/or replace the
fan.
• Check the circuit and restore its original
condition.
• Check lhe impeller and if require replace
it with a genuine part.
• Use of soundproofed casings and/or sound
dampers. Replace the fan with a larger fan
able to give the same performance or with
a lower Peripheral speed.
• Check the fitting position of the impeller
and the pipes if require correctly restore
their position.
• Check the condition of the bearings if
require lubricate them or replace them with
an identical bearing,
• Check that the axis is identical; if require
restore or replace the electrical motor with
a Suitable type.
• Can be reduced with higher quality motors
• Move the ran or use soundproofed casings.
• Check impeller balance; if necessary reset
it to the values shown in, Check the drive
alignment or the pulley balance. Check that
the shafts are straight
• Tighten the nuts and bolts
• Check the wear of the bearings (specially
the watertight bearings) and their
lubrication.
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AXIAL FAN

Fig.14

Three-phase motors have fewer components that may malfunction than other motor types. Therefore, 3Ø motors
usually operate for many years without any problems. If a 3Ø motor is the problem, the motor is serviced or
replaced. Servicing usually requires that the motor be sent to a motor repair shop for rewinding. If the motor is
less than 1 HP and more than 5 years old, it should be replaced. If the motor is more than 1 HP, but less than 5
HP, it may be serviced or replaced. If the motor is more than 5 HP, it is usually serviced.

TROUBLESHOOTING THREE-PHASE MOTORS

The extent of troubleshooting a 3Ø motor is dependent upon the motor’s application. If the motor is used in an
application that is critical to the operation or production, testing is usually limited to check the voltage at the
motor. If the voltage is present and correct, the motor is assumed to be the problem. Unless it is very large, the
motor is usually replaced at this time so production can be resumed. If time is not a critical factor, further tests
can be made in order to determine the exact problem.

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AXIAL FAN

SEE FIGURE 14. TO TROUBLESHOOT A THREE-PHASE MOTOR APPLY THE FOLLOWING PROCEDURE:

1. Using a voltmeter measure the voltage at the motor terminals. If the voltage is present and at the correct level
on all three phases, the motor must be checked. If the volt-age is not present on all three phases, the incoming
power supply must be checked.

2. If voltage is present but the motor is not operating, turn the handle of the safety switch or combination starter
OFF. Lock out and tag the starting mechanism per company policy.

3. Disconnect the motor from the load.

4. Alter the load is disconnected, turn power ON to try restarting the motor. If the motor starts, check the load.

5. If the motor does not start, turn it OFF and lock out the power.

6. With an ohmmeter, check the motor windings for any opens or shorts. Take a resistance reading of the Tl-T4
coil. This coil must have a resistance reading. If the reading is zero, the coil is shorted. If the reading is infinity, the
coil is opened. Since the coil winding is made of wire only, the resistance is low. However, there is resistance on
a good coil winding. The larger the motor, the smaller the resistance reading.

After the resistance of one coil has been found, the basic electrical laws of series and parallel circuits are applied.
When measuring the resistance of two coils in series, the total resistance is twice the resistance of one coil. When
measuring the resistance of two coils in parallel, the total resistance is one half the resistance of one coil.

11. STANDARD SPARE PARTS

The following spare parts are recommended to be kept as a stand by for two year normal operating condition.
• Impeller
• Motor
• Flexible connectors
• Control panel accessories (Fuse link, Breakers, OLR)
• Filters
• Hardware
• Terminal box
• Cable

NOTE: While ordering for fan spares please mention Dynair Reference number and fan type from the name plate
of existing fan.

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