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INDUSTRIE
Blowers & Exhausters
www.continental-industrie.com
INSTALLATION, USE
& MAINTENANCE Of
lowerS
xhausters
www.continental-industrie.com
COntinental industrie S.A.S
Route de BANEINS
01990 SAINTTRIVIERSUrMOIGNANS - FRANCE
Tel. : ++ 33 (0)4 74 55 88 77
Fax : ++ 33 (0)4 74 55 86 04
REV 062010-05GB
CONTINENTALINDUSTRIE
CONTENTS
1.0.0
1.1.1
1.2.1
1.3.1
GENERAL
Safety
Guarantee
Limit of liability
2.0.0
2.1.1
2.2.1
2.2.2
2.3.1
2.4.1
2.4.2
MACHINE ACCEPTANCE
Preliminary controls
Unloading and handling
Checks
Recommendations for lifting
Storage - short term
Storage - long term
3.0.0
3.1.1
3.2.1
3.2.2
3.3.1
3.3.2
3.3.3
3.3.4
3.3.5
3.4.1
3.4.2
3.5.1
page
page
8.0.0
8.1.1
8.2.1
8.3.1
8.4.1
INSTALLATION
Characteristics of the installation site
Fittings
Admissible static stresses on flanges
Piping
12
12
12
12
12
9.0.0
9.1.1
9.1.2
9.2.1
9.3.1
9.4.1
9.5.1
CONNECTIONS
Electricity supply
Steam
Lubrication system
Cooling water
Compressed air
Instrumentation
13
13
13
13
13
13
13
STANDARD FITTING
3
Base-plate
3
Shock-absorbing support blocks
3
Leveling plates and fixing bolts
3
Direct drive using a coupling
4
Drive using pulleys and belts
5
Pulley/belt drive with additional support 5
Pulley/belt drive with countershaft
5
Drive using a gearbox
5
Coupling guard
5
Safety housing
5
Painting
5
10.0.0
10.1.1
10.1.2
10.1.3
10.2.1
PERFORMANCES
Operation as a turbo blower
Operation as a turbo exhauster
Mixed operation
Surge limit
13
13
14
14
14
11.0.0
11.1.1
11.2.1
11.3.1
11.3.2
11.4.1
11.5.1
STARTING UP
Preparation
Checks
Valve settings
Butterfly Valve mounting
Direction of rotation
Commissioning
15
15
15
15
15
16
16
4.0.0
4.1.1
4.1.2
4.2.1
SPECIAL APPLICATIONS
Machines for high temperatures
Machines for low temperatures
Gas machines
6
6
6
6
5.0.0
5.1.1
5.1.2
5.1.3
5.1.4
5.1.5
5.1.6
5.2.1
5.3.1
5.4.1
MOTORS
Electric motors
Star connection
Delta connection
Direct start-up
Star/delta start-up
Reduced voltage start-up
Turbines
Internal combustion engines
Hydraulic motors
6
6
6
7
7
7
7
7
7
7
12.0.0
12.1.1
12.2.1
12.2.2
12.3.1
12.4.1
12.5.1
12.5.2
MAINTENANCE
16
Preventive maintenance
16
Grease lubrication
16
Oil lubrication
17
Replacement of transmission belts
19
Replacement of bearings
19
Alignment and tension of transmission belts 20
Alignment of transmission coupling
22
13.0.0
13.1.1
13.2.1
13.3.1
13.4.1
13.5.1
13.6.1
24
24
24
24
24
24
24
6.0.0
6.1.1
6.2.1
6.3.1
6.4.1
6.4.2
6.4.3
6.5.1
6.6.1
6.7.1
6.8.1
6.8.2
TYPICAL FITTINGS
Flanged adaptor
Flexible sleeve
Expansion compensator
Butterfly valves - manual operation
Butterfly valve - pneumatic operation
Butterfly valve - electrical operation
Non-return valve
Intake filter - silencer filter
Silencers
Anti-surge valve
Anti-surge circuit
8
8
8
8
8
8
9
9
9
9
10
10
14.0.0
14.1.1
14.2.1
14.3.1
SPARE PARTS
Recommended set
Consumables
Ordering
25
25
25
25
15.0.0
15.1.1
15.2.1
ASSISTANCE
On-site repairs
Repairs in our workshops
26
26
26
7.0.0
7.1.1
7.2.1
7.3.1
7.4.1
7.5.1
7.6.1
7.7.1
7.8.1
INSTRUMENTS
Ammeter
Capacity meter
Pressure gauge - vacuum gauge
Pressure regulator
Thermometer - thermostat
Pressurestat
Bearing temperature probes
Bearing vibration probes
10
10
10
10
11
11
11
11
11
1
1
1
1
2
2
2
2
2
2
2
CONTINENTALINDUSTRIE
1.0.0
GENERALLY
Safety
Guarantee
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CONTINENTALINDUSTRIE
2.0.0 MACHINE ACCEPTANCE
2.2.2 Checks
-26
CONTINENTALINDUSTRIE
3.0.0 STANDARD FITTING
The typical fittings for CONTINENTAL turbo blowers and
turbo exhausters include a base-plate common to the
machine and the motor, a series of foundation fixings,
the machine/motor coupling and the protective guard
over the coupling.
3.1.1 Base-plate
Small machines are generally given an OMEGA baseplate made of pressed steel plate strengthened with
appropriate reinforcements - Fig. 3.1.
Other machines, in contrast, have an electro-welded
steel section base-plate - Fig. 3.2.
All the base-plates have screws to align the motor and
tighten any transmission belts. The base-plates must be
level if the machine is to work correctly.
This should be checked with particular care in oil
lubricated machines.
Fig. 3.1
Fig. 3.2
If the machine is to operate correctly, all the shockabsorbing support blocks must be loaded uniformly.
At installation, it is therefore necessary to check that
none of the shock absorbers has been left unloaded.
-26
CONTINENTALINDUSTRIE
DETAILB
DETAILA
FINISHED
SPIRITLEVEL
SENSITIVITY 0,02 mm/m
SURFACE
DETAILC
CASTINGUPTOTHISLEVEL
ENCLOSURE
ISOLATOR
Fig. 3.4
In particular:
- for lowering, the levelling screw must be slackened
and the anchor bolt nut tightened
- for raising, the anchor bolt nut must be slackened and
the levelling screw tightened.
7 - When all surfaces are levelled transversally and
longitudinally as specified, ensure that no screws or nuts
are slack. If any are, they must be tightened manually so
as not to disturb the level obtained.
All lock nuts are also to be tightened manually.
8 - Clean the surfaces of the plinth and prepare it for
grouting. Provide an enclosure as shown in detail C of
Fig. 3.4. If it is being installed in the open air, provide
appropriate drainage for rainwater, taking account of
the base-plate shape.
Pour grout under the base to the level indicated in
detail C of Fig. 3.4. Avoid the use of mechanical vibrators
so as not to disturb the level surface obtained. Instead,
promote grout penetration with bars or chains.
BASEPLATE
METHODOFLEVELLINGANDANCHORINGWITH
ANCHORBOLTS
3.3.1 Direct transmission using a coupling
Direct drive to the motor with a coupling is used where
the speed of rotation of the machine is the same as that
of the motor.
This is the case particularly with machines driven by 60
Hz electrical motors and for turbine-driven machines.
The couplings commonly used are of the geared or
lamellar type.
A spacer is always fitted to enable the bearing at
the coupling end to be replaced without disturbing the
alignment.
IMPORTANT:
All gear-type couplings must be grease-lubricated.
Machines fitted with gear-type couplings at the factory
are already greased and ready for use.
On the other hand, where the gear-type coupling is
fitted by the client, the spaces between the teeth of the
two hubs and the two sleeves must be completely filled
with grease.
In models with holes for lubrication, once assembly
is finished, the coupling must be completely filled by
injecting grease under pressure until this escapes from
the opposite hole.
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CONTINENTALINDUSTRIE
The coupling is lubricated in the same way, at intervals
which are multiples of those set for bearing lubrication.
As the lubricating power of the grease diminishes over a
period of time, due to the effect of mechanical stresses,
ageing and pollution (possible regardless of the presence
of gaskets), the regular replacement of all the grease in
the coupling is recommended.
With regard to the alignment of the transmission coupling,
refer to item 12.5.2.
3.3.2 Transmission using pulleys and belts
Pulley and belt couplings are widely used as they enable
a better speed of rotation to be selected and the machine
can therefore be used close to the point of top output.
In many cases, it also allows 4-pole motors to be used to
reduce the overall noise level of the unit and also enables
the throttle curve of the machine to be changed to a
certain extent by the simple replacement of the pulleys.
With regard to the alignment and tensioning of the
transmission belts, refer to item 12.5.1.
3.3.3 Pulley/belt transmission with additional support
Where the tension of the belts on the machine bearing
needs to be reduced, an additional support and a third
bearing can be used.
This support is provided by a housing connected by screws
to a wide flange which bolts onto the blower outlet head
- Fig. 3.5.
The replacement of transmission belts, which must be
carried out in accordance with the general instructions
given in item 12.3.1, involves the removal of the housing.
With regard to the alignment and tensioning of the
transmission belts, refer to item 12.5.1.
Thebeltsshallbeputundertensiononlywhenthe housing
has been refitted.
3.3.4 Pulley/belt transmission with countershaft
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CONTINENTALINDUSTRIE
4.0.0 SPECIAL APPLICATIONS
5.0.0 MOTORS
STARCONNECTION
DELTACONNECTION
Fig. 5.1
Fig. 5.2
The three links fitted in the terminal box must be set out
as shown in Fig. 5.1.
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CONTINENTALINDUSTRIE
At the first start-up, the direction of rotation must
always be checked as, if necessary, it can be reversed
quite simply by swapping two of the three supply cables
R, S and T.
5.2.1 Turbines
Direct turbine coupling is generally used because of the
specific characteristics of the installation. The special
instructions required are provided separately.
5.3.1 Internal combustion engines
The use of internal combustion engines is generally
restricted to machines installed on self-propelled
equipment and machines in fixed installations where
there are plenty of natural or biological gases.
A clutch is inserted between the motor and the
transmission which can be made by belts and pulleys or
by a gearbox.
The special instructions required are provided separately.
5.4.1 Hydraulic motors
The use of hydraulic motors is generally restricted to
machines installed on self-propelled equipment.
The hydraulic motor is supplied with pressurized oil by
the main motor of the equipment itself.
Transmission is usually by means of belts and pulleys.
The special instructions required are provided separately.
-26
CONTINENTALINDUSTRIE
6 0.0 TYPICAL FITTINGS
Depending on the application for which CONTINENTAL
turbo blowers and turbo exhausters are intended, they
can be provided with certain fittings to enhance the
installation and enable it to be used correctly.
As the machine ports must not be stressed with forces
and/or moments greater than limits depending on their
size, it may be necessary to provide for the support of
certain fittings.
The values of the static stresses admissible on the
openings are given in item 8.3.1.
Expansion compensator
made in reinforced
rubber
Expansion compensator
made in stainless steel
Fig 6.2
6.4.1 Butterfly valves - manual operation
Fig 6.1
6.3.1 Expansion compensator
For working temperatures of up to 110, the expansion
compensator is made of reinforced rubber with an
omega section; for higher temperatures, the use of a
stainless steel compensator is preferred.(See fig 6.2)
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CONTINENTALINDUSTRIE
6.4.3 Butterfly valve - electrical operation
This valve has the same function as that described in
item 6.4.1 but is operated using an electric motor.
It can also be used as an overflow valve in anti-surge systems.
Its operating speed is fixed.
The maximum open and maximum closed positions can
be controlled using two end-of-run contacts.
The valve is suitable both for on-off operation and for
regulation. Naturally, where used for regulation, the
signal from the system must be processed by a suitable
electric circuit. Where necessary, specific instructions are
provided separately.
6.5.1 Non-return or check valve
The check valve is used wherever the return of the gas
processed needs to be prevented.
The most common case is where two or more turbo
blowers or two or more turbo exhausters are connected
in parallel.
A very common non-return valve comprises a disc fixed
to the body at a single point on its circumference. This
must always be fitted with a vertical axis and so as to
remain normally closed due to the effect of the force of
gravity alone. Therefore, this valve must always be fitted
on the process side of both turbo blowers and turbo
exhausters. (fig 6.3)
Another type of non-return valve comprises two flaps
fitted diametrically on to the body and loaded with two
springs which keep them closed in any position. There
are therefore no restrictions with regard to its fitting.
"Wafer" body non-return valves can be fitted directly
on the machine ports before the flanged adaptor or the
expansion compensator.
CHECKVALVE
SINGLEFLAP
CHECKVALVE
DOUBLEFLAP
Fig 6.3
6.7.1 Silencers
IMPORTANT:
An arrow on the silencer body indicates that the flow is
one-directional and that the silencer must be placed in
the right direction.
The inlet, the outlet and any overflow valves are the
major sources of noise in the machine.
The purpose of the silencer is to attenuate the
propagation of this noise into the atmosphere.
Absorption, full flow or annular silencers and low
pressure drop silencers are generally used on inlet and
outlet or discharge lines.
On overflow lines, in certain special cases, combined
type silencers may be preferred.
The silencing of the inlet line must be given priority for
turbo blowers as it is in direct communication with the
atmosphere.
For the same reason, the silencing of the discharge line
must be given priority in turbo exhausters.
Inlet and outlet or discharge silencers must be isolated
from the machine by expansion joints or flexible sleeves
and must be fixed with suitable brackets. These must be
fitted as close as possible to the respective openings.
Flanged silencers are often used at one end with a
flexible sleeve and a flanged adaptor at the other.
These must be fitted with the flexible sleeve nearer to
the machine opening.
Silencers on overflows to the atmosphere used in the
anti-surge circuit of turbo blowers must be fitted as
close as possible to the overflow valve.
If a piece of pipe needs to be fitted to connect the
overflow valve and the silencer, the use of very thick
pipe is recommended.
At the end of the discharge, silencers on overflows
to the atmosphere must have a fluted curve and a
protective wire mesh.
Overflow silencers used in the anti-surge circuit of turbo
exhausters must be fitted as close as possible to the
overflow valve.
If a piece of pipe needs to be fitted to connect the
overflow valve and the silencer, the use of very thick
pipe is recommended.
At the end of the inlet, overflow silencers for turbo
exhausters must have a filter and, if installed in the open
air, they must be protected from rain.
-26
CONTINENTALINDUSTRIE
6.8.1 Anti-surge valve
7.0.0 INSTRUMENTS
IMPORTANT:
In some cases, the efficiency of the antisurge valve can
be impeded by the operation of the cutoff/regulation
butterfly valve fitted at the machine inlet.
7.1.1 Ammeter
This is installed mainly to have an approximate
indication of the capacity of the machine driven by the
electric motor.
10-26
CONTINENTALINDUSTRIE
7.4.1 Pressure regulator
CONTINENTALINDUSTRIE
8.0.0 INSTALLATION
Throughout the installation phases, both the machine
flanges must be kept well sealed by means of suitable
protective devices provided directly by the works.
Before commencing installation, the following items
must be read:
2.2.1
2.3.1
3.1.1
3.2.1
3.2.2
XIS
INLET
A
OR
RO
Fig 8.3
8.4.1 Piping
Piping must be accurately designed so that its dimensions
are appropriate for the nominal performances of the
machine served.
An excessive pressure drop produced by the passage of
the nominal capacity would reduce the performance
available for the consumer.
Normally, piping is fitted after having put the machine
in its final position.
Before erecting piping, it is essential to isolate the
machine by inserting a sheet metal disc between each
flange and the element immediately adjacent to it
(valve, flanged adaptor, expansion joint etc.).
This prevents foreign bodies from getting into the
machine during this phase.
12-26
CONTINENTALINDUSTRIE
9.0.0 CONNECTIONS
10.0.0 PERFORMANCE
1.0.0
5.0.0
6.0.0
7.0.0
General
Motors
Typical fittings
Instruments
9.1.2 Steam
Where machines are driven by steam turbines and/
or in the presence of steam-driven fittings, specific
instructions are provided separately.
9.2.1 Lubrication system
Where the machine has a separate system for the
circulation, filtering and cooling of lubricating oil, for
example where there are gearboxes for high power
levels, specific instructions are provided separately.
9.3.1 Cooling water
Cooling water is required where heat exchangers are
used to cool the lubricating oil and/or where there are
cooled bearing housings. In these circumstances, the
machine must be connected to the water supply and the
drainage system.
The connection to the water supply system must have
an isolating valve. An electric isolating valve can be used
which allows water to circulate only to the machine in
operation. For safety reasons, it is advisable to use an
electric valve which is normally open or to fit the circuit
with an alarm and cut-off system in case of breakdown.
The connection to the drains system must be such that it
allows a direct view of the water drained.
The capacity must be adjusted with a valve fitted up line
from the exchanger or the housing so that it can be kept
under pressure during operation.
9.4.1 Compressed air
9.5.1 Instrumentation
CONTINENTALINDUSTRIE
the volume varies, if the volumetric capacity remains the
same, resulting in a reduction in the mass capacity.
The discharge pressure also falls due to the effect of
the increase in the compression ratio following the
reduction in the inlet pressure.
A new throttle curve is thus created which starts close to
the previous one but moves further away from it as the
volume increases.
The greater the scale of the pressure drop introduced at intake,
the more rapid is the new curve shift from the previous one.
Similarly to the new throttle curve, a new power absorption
curve is also produced, likewise lower than the previous one.
The changing of the inlet pressure too, achieved for
example by means of a butterfly valve, can constitute a
valid method of controlling machine capacity.
The choice of the type of regulation is generally
determined by the characteristics of the application;
however, where possible, regulation at inlet is preferred
as this allows for greater energy economy.
This is because with regulation at outlet, the power
absorption reduction shown in the basic curve is
obtained whereas with inlet regulation, for the abovementioned reduced fluid density, the power absorption
curve obtained is lower than that of the standard curve.
This is illustrated by Figs. 10.1 and 10.2 below.
Power absorption - %
REGULATIONAT OUTLET
Fig 10.1
Power absorption - %
REGULATIONAT INLET
Fig 10.2
10.1.2 Operation as a turbo exhauster
Operation as a turbo exhauster is characterized by constant
pressure at discharge and variable inlet pressure depending
on capacity.
Changes in pressure and temperature at inlet affect
the density of the fluid processed and can produce
14-26
CONTINENTALINDUSTRIE
11.0.0 STARTING UP
The instructions given below are generic and must be
completed by the technician responsible for start-up on
the basis of the specific characteristics of the machine,
installations and system served.
11.1.1 Preparation
To prepare the machine for start-up, the following must
be carried out:
- clean the inlet and outlet or discharge piping internally to prevent
any extraneous matter reaching the inside of the machine;
- remove the fitting closest to the inlet opening and the outlet
or discharge opening, taking care to leave the sheet metal discs
protecting the openings in position, fitted in accordance with
the instructions given in item 8.4.1;
butterfly valve
inlet
outlet
inlet
Fig 11.3
- check that the screws anchoring the motor to the baseplate are tight;
CONTINENTALINDUSTRIE
* to keep the start-up time close to the minimum
value possible, the valve must be set to its minimum
aperture;
* excessive closing of the valve causes the machine to go
into surge operation.
Small machines can be started up with the valve closed
as they are characterized by non-violent surging.
Medium and large machines, on the other hand, must
be started up with the inlet valve set for a capacity
slightly greater than that provided for surging.
As this setting can only be determined experimentally,
the first start-up should be with an opening of 15 and
subsequently modified.
Overflow valve is found in systems with protection
against surge operation and is actuated automatically
by an appropriate electrical circuit.
Butterfly valve at outlet in the first start-up phase,
it is advisable to use a butterfly valve at inlet to control
capacity; however, this valve must be kept open if the
system served can take the fluid processed; otherwise
an overflow to the atmosphere or an appropriate bypass
must be provided.
11.4.1 Direction of rotation
The machine shaft must rotate as indicated by the arrow
on the outlet or discharge head.
For high power electric motors, it is preferable to ensure
the correct direction of rotation when connecting the
motor and electrical equipment to the supply cable.
The direction of rotation can also be checked when the
motor is uncoupled.
For machines with a more modest power, on the other
hand, it is possible to check the direction of rotation of
the electric motor by observing the cooling fan after a
short supply impulse.
The direction of rotation can be corrected by following
the instructions given in section 5.0.0.
11.5.1 Commissioning
- start up any pumps and compressors which ensure the
circulation of any service fluids (lubricating oil, cooling
water, compressed air etc.);
- start up the machine, paying particular attention
during the start-up and during the first seconds of
operation, to irregular noise and/or high levels of
vibration, in which case stop the machine immediately
and carry out the necessary checks;
- check the start-up time to optimize timer regulation for
changeover to delta in the case of star/delta start-up;
- check power absorption and correct as follows:
- if power absorption is unstable, the machine is in surge
operation and volume must be increased using the valves;
- if power absorption is excessive, the volume needs to
be reduced by means of valve regulation;
- let the machine run for approximately 30 mn., then check the
vibration level and temperatures (see section 13.0.0);
12.0.0 MAINTENANCE
The intrinsic design characteristics of CONTINENTAL
turbo blowers and turbo exhausters are such as to allow
maintenance operations to be kept to a minimum.
12.1.1 Preventive maintenance
If, during the normal routine maintenance programme
to keep the machine efficient, the condition of the few
components subject to wear is assessed, it is possible to
obtain information to allow non-routine maintenance
operations to be programmed and unexpected stoppages,
with their attendant inconvenience, to be avoided.
Therefore, in addition to the normal lubrication
operations to be carried out at pre-set intervals, it is
advisable to keep a log for each machine, on which a
record is kept of the progress over time of parameters
which reflect the condition of the parts more commonly
subject to wear.
In particular, it is recommended that the vibration
level on the bearing housings is measured regularly; a
study of the large number of readings thus obtained
gives valuable information for assessing the need for
replacement and thus for programming this operation.
The above also applies to the electric motor bearings.
The level of wear of transmission belts, assessed
visually, must also be recorded so that the replacement
operation can be carried out at programmed intervals.
12.2.1 Grease lubrication
The main purposes of the lubrication of the ball bearings
fitted on the machine (and normally the electric motor
too) are:
- to avoid metal-to-metal contact between the rolling
bodies, tracks and cage;
- to protect the bearings from corrosion and wear.
In comparison with oil, grease has the advantage of
being more easy to handle in situ and therefore better
suited to the function of protection against impurities
and corrosion.
Therefore, the use of grease is preferable wherever the
use of oil is not essential.
Lubricating greases are composed of mineral oils
or synthetic fluids dispersed in a thickening agent
which determines its consistency, normally assessed
in accordance with the NLGI classification (National
Lubricating Grease Institute).
The consistency, the range of temperatures of use and
the rust-proofing properties are the main determining
factors when choosing a grease.
The operating characteristics of CONTINENTAL machines
require a consistency 3 grease which can be used in the
16-26
CONTINENTALINDUSTRIE
temperature range of -20 - +140.C.
HP-ST Grease
Density at 15C
Melting point
Ash content
Soap
Temperature range
EQUIVALENT GREASES
ESSO :
ELF :
TOTAL :
SHELL :
MOBIL :
: 0.900
: 200C
: 0.8 %
: Lithium
-20C to 140C
BEACON 3
ROLEXA 3
MULTIS TIR
ALVANIA EP3
MOBILUX EP3
CONTINENTALINDUSTRIE
of the rotors, smaller machines can be grease-lubricated
whereas larger machines need to be oillubricated.
Heavy duty:
- continuous operation (24 hours/day);
- operation in humid, dusty or chemically
aggressive atmosphere;
- installation in open air;
Light-duty:
- non-continuous operation (4 hours/day or less)
in a clean and protected environment.
JAROGEAR Z.150 :
Extreme-pressure oil Service API - GL5
Properties :
Extreme pressure, anti oxydating, anti corrosive, anti
foam, anti-rust.
Resistant to alteration at high temperature.
Medium characteristics :
Density at 15C
0.892/0.917
Cinematic viscosity in Cst :
at 40C
143/148
at 100C
14.3/15.5
Viscosity index 103
Flash point VO > or = 215C
Flow point < or = -24C
1. filling plug
2. level plug
3. drain plug
18-26
CONTINENTALINDUSTRIE
The position of the machine in relation to the baseplate,
on the other hand, must not be changed in any way.
2. INCORRECT
1. CORRECT
LITER PER
HOUSING
LITER PER
OILER
77
0.67
0.11
1.56
151
0.67 or 1.67
0.11
1.56 or 3.56
1.91
0.11
4.04
600 / 700
5.11
0.11
10.44
CONTINENTALINDUSTRIE
however, advisable to mark their position with regard to
the shaft before removing them.
Important :
The bearing extracted in this way cannot be re-used as
the rolling bodies and tracks have been stressed.
20-26
CONTINENTALINDUSTRIE
The face of the machine pulley is taken as a reference
and the bar is placed on this, checking contact at points
C and D.
The motor is then moved, keeping the 4 fixing screws
only slightly slackened and adjusting screws 1, 2, 3 and
4 until contact at points A and B is also made.
Any axial movements can be made by means of small
knocks with a lead or plastic mallet, if the motor size
so allows, or by means of screws provided for this
purpose.
Of course, the operations of pulley alignment and belt
tensioning affect each other.
A good practical way of streamlining these operations
is as follows:
- carry out a rapid and approximate alignment with the
belts slack and tighten screws 1, 2, 3 and 4 manually;
make a preliminary and approximate tensioning of
the belts taking care, however, to turn the abovementioned screws equally (for example, if screws 4 and
2 are slackened by a complete turn, turn screws 1 and 3
a complete revolution too);
complete alignment with the necessary precision;
complete belt tensioning to the final value, always
taking care to ensure that the 4 screws are rotated
by the same amount (as, in the final phase, parts of a
revolution can be required, it is advisable to mark the
head);
before fully tightening the motor anchoring screws,
check the alignment once more which, given the method
followed, may require just a small final correction by an
axial shift of the motor.
This correction does not affect the tensioning obtained.
Fig. 12.6
Shims are only rarely needed under the motor feet to
correct parallelism defects on the horizontal plane of
the axes of the motor and machine.
Excessive belt tension results in an unnecessary increase
in the load on the bearings and the bending moment
on the shaft.
In extreme cases, it can even cause the shaft to break
due to fatigue.
f = I
100
(deflection in mm)
A=D-d
I
CONTINENTALINDUSTRIE
The following can now be calculated :
T = 45 x (2.5 - G) x N + M x V2 (static tension in kg)
G x c x V
Fmi n = T + Y
Fmax = 1.5 T + Y
25
25
Fmin and Fmax are the values between which force F
must lie, which applied to the center of the section, to
a single belt, is perpendicular to it as shown in Fig. 12.8
and is able to produce a deflection equal to f mm.
1. RADIAL
2. ANGULAR
MIS-ALIGNMENT MIS-ALIGNMENT
Fig. 12.9
Radial mis-alignment and angular mis-alignment are
shown in Fig. 12.9. Naturally, these can be present at
the same time.
Due to thermal expansion and other causes such as, for
example, the lubricating oil film in the plain bearings,
radial thrusts by the gears etc., the position of the two
shafts coupled with the machine in normal operation
can be very different from their position when the
machine is off and cold.
Therefore when aligning cold, radial mis-alignment
values can be prescribed calculated so as to obtain
perfect alignment when the machine is running in normal
operation.
Fig. 12.8
If the belts are new, Fmi n and Fmax need to be
increased by 30% to take account of the rapid fall in
tension occurring during the running-in period.
Tensioning is checked after the first 4 hours of operation
and corrected to the nominal Fmi n and Fmax values
calculated above. The checks are repeated until they are
found to be stable.
12.5.2 Alignment of transmission coupling
The correct alignment of the transmission coupling
allows the machine to operate at minimum vibration
levels and enables the useful life of the bearings to be
utilized to the maximum.
Before carrying out this operation, it is essential to read
the following items:
3.3.1 Direct drive using a coupling
3.3.3 Pulley/belt drive with countershaft
3.3.5 Drive using a gearbox.
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CONTINENTALINDUSTRIE
Angular mis-alignment can be assessed by means of a
caliper, internal micrometer or a thickness gauge, but it
is preferable to use a gauge fitted as shown in Fig. 12.11
B. The ratio between the T.I.R. reading (Total Indicator
Reading) provided by the gauge for a 180 rotation
and the diameter of the circle described by the rotation
of the tracer point axis represents the tangent of the
misalignment angle.
With reference to Fig. 12.10, from the reading for a 180
rotation from 0 to 180, the angular mis-alignment is
determined by the height of the couplings. From the
reading for a 180 rotation from 90 to 270, the angular
mis-alignment is determined by the transversal position
of the couplings.
Machines and/or motors are moved laterally by means
of appropriate adjustment screws provided in the works.
A lead mallet may be needed for smaller machines
without adjustment screws.
Machines and/or motors are moved vertically by using
shims placed under the feet as required. When adjusting
the height of machines and/or motors with shims, the
following precautions are recommended:
Fig. 12.11
CONTINENTALINDUSTRIE
13.0.0 ANOMALIES: CAUSES AND REMEDIES
The performance of CONTINENTAL turbo blowers and
turbo exhausters remains absolutely unchanged over time.
The efficiency, noise level and operating temperatures
remain at their initial values indefinitely.
However, it is possible that anomalies may occur for
various reasons of ageing.
13.1.1 Reduced performance
Fig. 13.2
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CONTINENTALINDUSTRIE
The areas in the graph are defined by the curves of the
three effective reference velocities (R.M.S.). Naturally,
the amplitude values vary depending on the speed of
rotation of the machine.
Causes and remedies:
Deterioration in ball bearings.
Replace bearings.
Mis-alignment following maintenance operations. Check
and correct alignment.
Imperfect contact between the feet of the machine
and/or the motor and/or the base-plate following
maintenance operations.
Check and correct the contact of the feet of the machine
and/or motor with the base-plate.
Imperfect contact between the base-plate and its
supports on the foundation following maintenance
operations.
Check and correct the contact of the base-plate with
supporting shock-absorbing blocks.
Belt defective following maintenance operations.
Identify the defective belt using a stroboscopic
Rotor imbalance due to excessive tension of belts
following maintenance operations.
Check and correct
present)
present)
present)
present)
present).
14.2.1 Consumables
These are restricted to:
- filter cartridges
- lubricant.
(if present)
CONTINENTALINDUSTRIE
15.0.0. ASSISTANCE
Requests for technical assistance should be adressed to :
CONTINENTAL INDUSTRIE S.A.S
Route de Baneins
01990 Saint Trivier sur Moignans
TEL.: ++33 (0) 4 74 55 88 77
FAX: ++33 (0) 4 74 55 86 04
email : export@continental-industrie.com
26-26
S.A.S au capital de 1 795 200 euros (Share capital) - 304 328 800 RCSBOURG EN BRESSE - APE2813Z - TVA.FR 05 304 328 800
Route de BANEINS - 01990 SAINT TRIVIER SUR MOIGNANS - FRANCE