Marley Ultra Low Noise Cooling Tower Fan User Manual
Contents
1. Marley Ultra Low Noise Fan User Manual 07 1126 SPX COOLING TECHNOLOGIES Contents General Information 4 a 5 Operati Oesia nes 11 M intenaN an a nn 13 PATES LISE neue 16 TOUS SIGN cae neuen 17 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 permit variable pitch adjustment at standstill and feature a simplified 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 ord2. Printed in USA 07 1126
3. and bolts of the fan and or the structure loosened Torque all screws and bolts Fan not centered Tip clearance too small Center the fan Increase the fan ring diameter High vibration level Unbalance of one or more blades Contact SPX Cooling Blade pitch angle not included in the 0 5 tolerance Set right blade pitch angle Blades too close to supports periodic aero dynamic turbulence Contact SPX Cooling 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 Contact SPX Cooling Resonance of the blades with one of the possible forcing frequencies Contact SPX Cooling Misalignment of the drive shaft Realign of the drive shaft Worn output shaft bearing Contact the supplier The fan and or the structure bolts are not tightened Tighten screws and bolts at the right torque The draining holes of the blades are ob structed Open the draining holes 18 SPX COOLING TECHNOLOGIES 7401 WEST 129 STREET OVERLAND PARK KANSAS 66213 UNITED STATES 913 664 7400 spxcooling spx com spxcooling com In the interest of technological progress all products are subject to design and or material change without notice 2009 SPX Cooling Technologies Inc
4. and check the torque of bolts 15 2 Rotate fan to check tip clearance is in accordance with the speci fied 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 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 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 se
5. ction 11 Operation por 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 formation on the blades of operating fans must be strictly avoided 3 lf 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 amplit
6. e Bolt Type NE ftlb M16 cl 8 8 230 169 84 to 96 Type 115 M16 A4 70 126 93 M16 cl A4 80 168 124 M20 cl 8 8 447 329 108 to 168 190 M20 cl 4 70 246 181 20 4 80 328 241 3 Hub into driveshaft installation Figure 2 e 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 e 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 through the bushing flange into the threaded hole in the hub coupling torque bushing screws according to the following table Screw Torque Bushing T ushing Type Q1 and Q2 40 29 R1 and R2 40 29 A Caution Warning Installation The drive shaft end must remain recessed at least 1 2 in the hub bore to prevent dangerous rotor vertical translation once retainin
7. er 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 kind upon the blades For long term storage it is necessary to check the condition of the corrosion preventive coating on all machined surfaces Figure 1 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 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 lf the hub has not been supplied already assembled to the flange 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 Figure 2 Installation 09 De 2 U le 2020 Q 4 ij LAT 2 Warning Installation Torque hub assembly bolts 11 according to the following table Fan Diameter Bolt Torque inches Flange Typ
8. g bolt 16 has been tightened to the shaft end Never power the drive shaft with bushing bolts not torqued or bushing improperly positioned 4 lInstall 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 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 be observed note these quotes are shown on the fan datasheet and are specific for each diameter of the Marley Ultra Low Noise fan Figure 3 Figure 4 Installation 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 sh
9. he 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 flexible support This support rigidity may also cause unexpected variations in the resonant frequencies of the blades 15 Note 16 Parts List Item one Standard Standard Figure 6 Descnpton Material Protection 1 Blade FRP 2 Coupling Flange Steel Epoxy Paint 3 Hub Disk Steel Epoxy Paint 4 Lower Pillow Block Aluminum 5 Upper Pillow Block Aluminum 6 Pillow Block Plate Steel Epoxy Paint 7 Pins Steel Zinc Plated 8 Coupling Flange Washer Steel R40 HDG 9 Coupling Flange Lock Washer Steel R40 HDG 10 Coupling Flange Nut Steel 8 8 class HDG 10A Space Ring if needed Steel Zinc Plated 10B Taper Bushing if required Malleable Cast Iron Burnished 11 Coupling Flange Bolt Steel 8 8 class HDG 12 Pillow Block Washer Steel R40 HDG 13 Pillow Block Lock Washer Steel R40 HDG 14 Pillow Block Nut Steel 8 8 class HDG 15 Pillow Block Bolt Steel 8 8 class HDG 16 Screw not included 17 Washer not included Fo
10. oulder 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 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 Installation Bolt Torque ou US N m i ft lb 84 to 96 M18 282 5 208 108 to 120 M20 400 3 294 132 to 144 M24 679 8 500 The screw class information is shown in the fan documenta Note tion part list Stainless steel bolts 15 with the A4 80 stamping Bolt Torque more N m i ft lb 84 to 96 M18 175 6 129 108 to 120 M20 246 2 181 132 to 144 M24 425 7 313 nthe case of a structure equipped with multiple fans before Note 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 10 Note 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
11. r special applications materials and protective coatings could be different In this case make reference to the fan docu mentation Parts List FLANGE MOUNTING FOR THE REVERSE CONFIGURATION FLANGE MOUNTING FOR THE STANDARD CONFIGURATION 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 case of multiple units line Low air flow Low power absorption Static pressure higher than the specified one Increase blade pitch angle till 3 after checking the data sheet selection Pitch angle lowered by blade rotation e g screw 15 not tightened at the right torque Temperature higher than the design 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 3 after checking the data sheet selection High power absorption Temperature lower than the design Decrease blade pitch angle till 3 after checking the data sheet selection Static pressure lower than the design Decrease blade pitch angle till 3 after checking the data sheet selection Rubbing between the blades and the fan ring Screws
12. ude 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 20 C 4 F Maximum is 82 C 180 F 13 14 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 Blades too close to supports periodic aerodynamic t
13. urbulence this condition is characterized by vibration outside the tip path plane 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 Vibration transmitted by the structure on which the fan is installed the frequencies of such vibration depend on both the external forcing 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 Loosening of blade and orspeed reducer fixing bolts The behavior of the rotor under these circumstances is totally unpredictable as it depends upon the extent and location of the loosening Note Maintenance 9 Worn output shaft bearing this condition generates vibration on t
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