Centrifugal Fans - Flaktwoods

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INSTRUCTION MANUAL Page 2 of 41
UID NO.:FAN MANUAL/Flakt2003
CONTENTS
INTRODUCTION
GL SERIES 4 - 5
FUNCTIONAL DESCRIPTION & DESIGN

GL 6
SAFETY PRECAUTIONS 7
CONDITION ON DELIVERY 8
ERECTION
ASSEMBLED FAN 9
ASSEMBLY PROCEDURE OF BEARINGS 10 - 14
IMPELLER LOCKING ARRANGEMENT 15
SOME IMPORTANT NOTES 16
FANS ON VIBRATION ISOLATOR 17
ACCESSORIES 18 - 20
COMMISSIONING PROCEDURE
ASSEMBLY & START UP CHECK LIST 21
PRECAUTIONS BEFORE STARTING 22
CHECK UP DURING RUNNING 23
CONTENTS
MAINTENANCE
RUNNING MAINTENANCE 24
SHUTDOWN MAINTENANCE 24
LUBRICATION 25 - 27
VIBRATION ACCEPTANCE NORMS 28 - 29
LOCATION FIXED & FREE BEARINGS 30
AFTER MOUNTING CLEARANCE OF BEARINGS 31
INLET DIMENSION
GF 32
LIST OF SPARE 33
ANNEX
DATA RECORDED DURING TRIAL RUNNING
34
OF FAN
DOS & DON'T'S 35
BRIEF DESCRIPTION OF FAN COMPONENTS 36
TROUBLE SHOOTING CAN HELP WHEN YOU
37 - 39
SUSPECT A PROBLEM
HOW TO ORDER 40
ADDRESS & CONTACT NO. 41
YOUR FANS.. .. DESCRIPTION AND IDENTIFICATION

INTRODUCTION
GL FAN
GL series is a centrifugal fan suitable for application such as ventilation, air

conditioning, air handling units and also industrial purpose. It is belt driven and
available in single and double inlet versions. The side plates of the casing are
rectangular and this facilitates the installation of the fans in plants and air
handing units. It eases transportation problems for large sized fans which may be
dispatched in a dismantled condition if required.
GF is available in the following arrangements :
Arrangement 3 :
In this arrangement, the impeller is single inlet single width (SISW) and
simply supported design, i.e. the impeller is placed between bearings. The
fan is belt driven
Arrangement 5 :
In this arrangement, the impeller is double inlet double width (DIDW) with
simply supported design and is belt driven.
Arrangement 3 :
Arrangement 5 :
FUNCTIONAL DESCRIPTION AND DESIGN

GF FAN
STANDARD CONSTRUCTIONAL FEATURES
Mechanical Design (Fig 10)
The static parts of the fan consist of the following:
1. Casing (either single piece or of bolted design) including inlet cone and bearing
pedestal.
2. Motor bracket (optional accessory).
3. Inbuilt fan guide vane (optional accessory).
The rotor of the fan consist of the following parts:
4. Impeller
5. Shaft with bearing and bearing housing.
6. V-belt drive with guard.
Additional Accessories and Features
In case flow control is needed by means of damper an in-built guide vane alongwith
driving lever is provided. A standard design of motor bracket is also available. The
fan is also suitable to be mounted on vibration isolators with a common base frame.
SAFETY PRECAUTIONS
The operation and maintenance of machinery of any kind requires a person to be

cautions and aware of the damages that exist. In order to avoid injuries to
personal and damage to machinery, the following precautions are very important.
1. Never apply power to the fan motor for any reason until the fan has been
completely installed in its system, and the system inspected to be sure that no
debris has been left in the fan & ducts, and it is known that the inspection
doors at the inlet and outlet of the air passages are shut. The usual procedure
is to remove the fuses from the disconnect switch and open its safety
isolation switch until the installation is completed and inspected.
2. Start the fan momentarily and disconnect it. Observe rotation of the wheel or
the drive rotation is correct. Do not allow the fan to run backward, except
momentarily.
3. Do not open or access inspection doors while the fan is running.
4. Always open the disconnect switch and lock it in the open position with a
padlock before doing any service or maintenance work on the fan.
5. After service of any kind make certain that all adjustment have been properly
made and tightened ,inspection doors closed, there is no debris in the air
passages and all tools have been removed before unlocking the disconnect
switch to place the fan in operation.
6. Make a periodic inspection of the fan wheel, bearings and coupling to be sure
that corrosion has not set in to weaken them. Where there are signs of
corrosion there is danger of mechanical failure. Corroded parts should be
replaced.
7. Always use caution in every maintenance or operational procedure.

CONDITION ON DELIVERY
A. Transport :
The fans are dispatched in dismantled condition with proper packing.
Handle all fan parts with care. Use lifting lugs and good rigging techniques. Slings and
timbers should never be passed through the casing and impeller in order to assist in
rigging.
Pay particular attention to rotor assembly consisting impeller, hub, shaft, bearing
housings and bearings. Avoid any shocks that could damage the parts and their
coatings or alter the impeller balance. If the impeller is damaged slightly, it will have
to be repaired and balanced again.
B. Check for Transportation Damages :

When packages are received at site, check all parts with the help of the packing list
and drawing. If necessary ,make a list of the missing parts ( in case of shortage)
and initiate action for replacement, insurance etc. Check the condition of the parts
that may have been damaged during transport. In case of damages, take steps to
repair the damages in consultation with manufacturer
C. Storage :
General :-
As soon as received ,the different parts of the fan should be placed in clean and dry
covered premises.
Long term storage
Storage for a period of more than three months must be ensured in the best
possible condition, basically protected from dampness so as to avoid oxidisation of
the different parts of the fan unit.
The mechanical parts with machined surfaces are coated with anti-corrosion varnish.
In the case of prolonged storage, before putting in to service, the equipment will be
inspected periodically and the machined parts will be protected from time to time
using protective coating in case of need.
They will be stored in sufficiently large premises, thus providing space for inspection
and easy maintenance of the equipment stored. Moreover , the storage premises will
protect the equipment from sudden changes in temperature, dust, foreign matter,
etc.
The impeller and bearing assembly should be rotated at a very low speed ( rotation
by hand) for about thirty minutes, once a week.
Storage of bearing
As a general rule, the bearings are given a rust prevention treatment in the works
before being packed. They can be preserved for several years, in their original
packing , on a condition that the relative humidity in the storage premises is not over
60 % A higher degree of relative humidity, up to 75% is however permissible for
short term storage.
ERECTION
ASSEMBLED FANS
1. Ensure that the concrete foundation has been made at site as per general assembly
drawing.
2. Check foundation for evenness, and its different levels.
3. Mark centre lines of fan and foundation pockets on the foundation.
NOTE: REFER ENCLOSED GENERAL ASSEMBLY DRAWING.
FOUNDATION BOLTS, FAN ON BASE FRAME: -
4. Place the foundation bolts in all foundation pockets as required and hook up with the
common holding rods provided in the foundation.
5. Clean the threaded portion of the bolt.
6. Generally the concrete block foundation provided to support the fan unit should be at a
level lower than the final installation level by about 50mm. This clearance allows
correction of the civil engineering false level. It is therefore necessary to maintain the
center of the fan and the level of installation.
7. Place the steel packers in between the foundation bolts to the required height.
8. Place the base frame on the packers and bolt together at four corners.
9. Fasten the foundation bolts with base frame.
10. Adjust the horizontal level of the base frame by adjusting steel packers by using dumpy
level. The dimensions to be maintained as per the GA drawing. Check up the diagonal
dimensions for assuring the squareness of the base frame.
11. Place the Fan on Base Frame ; ensure that the fastening bolts are tightened with taper
washer.
ASSEMBLY PROCEDURE FOR BEARING AND BEARING HOUSING
The following procedure will be applicable rotor, loose bearings and bearing housings, if and
when used.
1. PRE -ASSEMBLY CHECKING :
As the bearings are finished to high precision, thorough inspection and checking on the
following points are essential prior to assembly :
a) On opening the packing of bearings, the same shall be thoroughly checked for dirt or
other foreign matter and if found, same shall be carefully washed unless and until it is
necessary.
b) The shaft shall be checked for damage due to transport and handling. Particularly the
surfaces where the bearings are to be mounted should be checked for rusting, scoring
etc. Rust, if found, should be removed by rust remover. Heavy pitting on bearing
surfaces of shaft is not acceptable.
Localized scorings could be removed using oil stone.
If the shaft is found to have a bend, the same should not be used for assembly.
c) Bearing housings although made by precision machining to the given specifications, a

thorough checking is essential to make sure against any defects in the bearing seating
surfaces or dirt inclusion which can possibly result from handling, transportation etc.
The flaw, if any, is to be carefully corrected with the use of an oil stone or fine emery
paper and the dirt to be thoroughly washed off and cleaned.
d) Bearing to be mounted shall be taken out of the original protective packing only
immediately before mounting.
e) The mounting and dismounting tools and necessary jigs must be of proper dimension and
simple design so that they do not cause any mechanical damage to the bearings.
2) GENERAL INSTRUCTIONS :-
With tapered bore:
A bearing with tapered bore, which is seated direct on a shaft, or which is mounted with
an adapter sleeve, ordinarily requires a somewhat tighter fit than a bearing with
cylindrical bore. This fit is achieved by pressing on the inner ring by means of a nut or
by driving in the sleeve. In both cases, the inner bearing is expanded and this results in
a reduction of radial bearing clearance.
If a double row self aligning ball bearing is mounted on an adapter sleeve, the sleeve
nut might be tightened but not so much as to prevent the outer bearing from turning
easily and it must be possible to swing the outer race easily from one side to the other
side.
Double row spherical roller bearings which are used mostly in heavy load applications are
mounted with greater interference. The radial clearance is adapted to this fit and its
reduction can be measured while mounting by means of a feeler gauge. For checking the
correct fit of the inner ring, both the reduction of radial clearance and the distance of
the inner ring is driven axially on the tapered seating or on the adapter sleeve and is
measured. For solid shafts, the axial displacement is approximately fifteen times as
large as the desired clearance reduction.
ASSEMBLY PROCEDURE
a) Keep the bottom half of bearing housings on the bearing pedestal.
b) Clean the shaft with the use of white sprit.
c) Insert the brass seal on to the shaft at impeller end.
d) Insert the M.S cover plate on to the shaft at impeller end.
e) Keep the rotor assembly in position but slightly elevated position on supports above
the bearing housing bottom halves.
f) Insert the double - lip seal on to the shaft at impeller end if applicable.
g) Insert the taper sleeve on to the shaft to the location with thread portion outside.
h) Locate the bearing position and assemble the lock washer and nut with the taper
sleeve. (no locating ring for this bearing as this is free bearing).
i) Keep the gap between bearing to bearing housing to accommodate the expansion of
shaft as shown in our drawings.
j) Tighten the lock nut on the taper sleeve. For tightening the nut, do not use steel
chisel or rod but use either brass or copper rod for taking the force of hammer. The
necessary tightness is achieved when the brass or copper rod flares at the load
transfer end. Check for the clearance between roller and outer race as mentioned in
SKF catalogue.
k) Insert the another double-lip seal on to the shaft if applicable.
l) Now start assembly of drive side (coupling side) bearing by inserting the double lip
seal on to the shaft if applicable.
m) Insert the lock nut and lock washer on to the shaft.
n) Arrange the locating ring on one side or either side of bearing , as the case may be.
o) Insert the bearing with large dia of bore facing outside.
p) Insert the taper sleeve on to the shaft.
q) Locate the bearing position and assemble the lock washer and nut with the taper
sleeve.
r) Tighten the lock nut as explained in point no.
s) Now keep the lock washer teeth locked to the lock nut groove by bending.
t) Insert the another seal on to the shaft.
u) Rest the rotor on the bottom half of bearing housing.
v) Lubricate the bearings with recommended grease from one side of the bearing with
pressure, so that the grease comes at the other side of the bearing through roller
gapes. Check that the bearing is greased uniformly on both sides all around. Fill the
bottom half of the bearing housing with grease.
w) Place the top half bearing housing without applying any grease. Check for free
rotation of the rotor assembly.
x) Tighten the parting off bolts to the correct tightness.

WITH CYLINDRICAL BORE: -
The force needed to mount a bearing increases rapidly with bearing

size. Larger bearing can not easily be pressed on to a shaft or in to
a housing because of the mounting force required. Therefore, the
bearing or one bearing ring is heated before mounting.
The temperature difference between the bearing and its seating

depends on the magnitude of the interference fit and the bearing
size. Normally a bearing temperature of 80 to 90C (175F to 195F).
ing to a temperature greater than 125C(255 F), however, be-

cause the material may change metallurgically and produce alterna-
tions in diameter or hardness. Local overheating must be avoided.
When using a heating device, use a thermometer to check the
bearing's temperature.
Wear clean protective gloves when mounting a hot bearing. Lifting

(hoisting) gear can facilitate mounting. Push the bearing along the
shaft to its abutment and hold the bearing in position, pressing until
a tight fit is obtained.
SKF can supply heating tools, such as oil baths, induction heaters,
heating cabinets and electric and electric plates with adjustable thermostat and
cover, for all common mounting needs.
When a bearing requires an interference fit in the housing, a moder-

ate inctrease in the housing temperature, from 20 to 50C (70 to
120F) is normally sufficient, since the amount of interference is
seldom large. A heater or oil bath can be used for the job.
Bearings with
shields or seats
should not be
heated.
Lifting gear
(housing)
To facilitate future dismounting equip shafts with ducts

and distribution grooves for pressurized oil
SKF heaters are generally equipped with

adjustable thermostats Nevertheless it is
advisable to use a separate thermometer
to check bearing temperature immediately
before mounting. The thermometer is
also useful during test runs and Use clean protective gloves to hold the hot
for monitoring bearings bearing press it hard against the abutment
during operation face so that the inner ring fits snugly on the
A cabinet equipped wiyh an adjustable thermostat and a fan is a

versatile tool suitable for many heating operations. Bearings of dif-
ferent sizes or a large number of bearings can e heated together in a
cabinet. Small bearing housings can also be heated. Keep the cabi-
net clean to reduce the risk of bearing contamination. Bearings can
also be stored hot, ready to mount.
In addition to bearings, couplings, sleeves and other components

can also be heated in a cabinet.
Oil baths ensure even heating. They

also make it possible to heat and
maintain a bearing at a certain
temperature. Keep the oil in a clean
bath to prevent bearing contamination.
Bearing rings, or even complete bearings, can be

suspended in an oil bath.
Never place a bearing directly in contact with the sides
IMPELLER LOCKING ARRANGEMENT
SIMPLE SUPPORTED FAN OVERHUNG FAN
Fitting of impeller on shaft

Some important notes
! Direction of discharge
The fans are supplied in discharge direction as specified in order . This can be altered at
site .
! Connection of duct
Duct connection of the fan casing must not exert any load directly on the fan as the
casing may be deformed and the inlet cone may come in contact with impeller .
! Direction of impeller
The direction of rotation is indicated in fan casing .

Erection on vibration isolator
! Ensure of grouting pocket positions in civil foundation are as per GA drg.

! Bolt the isolators with base frame .
! Insert the grouting bolts in mounting holes of isolators.
! Place the base frame in position and at it's required elevation , level it in X- Y axis ;
provide temporary support under base frame .
! While positioning the base frame , ensure the grouting bolts are positioned at center
in their respective pockets .
! Grout the isolator pockets Use non shrinkable cement .
! Remove temporary support only after curing is complete . The isolators are loaded
now.
! Check level of shaft . If required , place shims between base frame and isolator .
Important point to be noted
! The main idea of providing vibration isolator is to avoid transmission of undue

vibration from the equipment to the surrounding structure and not to reduce
equipment vibration , in fact equipment vibration may be on higher side due to soft
foundation and vibration value 10 mm/s ( Peak Value ) is acceptable for Fans.
! We do not normally recommend to use vibration isolator when fans are installed at
ground level.
ACCESSORIES ( REFER ASSEMBLY DRAWING FOR ITEMS APPLICABLE)
1. Fix the evase with fan outlet.
2. Fix the inlet damper with inlet box (wherever applicable) /inlet
Ensure correct damper orientation; the close to open direction of damper will be same
with that of impeller rotation.
3. Fix the inlet and outlet flexible connection.
Ensure flexibility after installation ; For dust application flexible connection are
provided with sleeve . Follow the air flow mark for correct installation.
4. Fix the actuator bracket on the casing/foundation
5. Fix the actuator with actuator bracket.
6. Fix the linkage between actuator and damper. The operating lever on the actuator and
the lever on the damper should be in parallel and of equal length , for proper
operation of the damper.
7. Fix the sealing arrangement on inlet box as shown in fig. 20
8. Bolt the cooling disc halves together on the shaft.
Guard for cooling disc Tightening torque

Shaft
A kpm Nm
Dia. D ft lb
kgfm Nm
25-65 0 3 29.4 21.7
80 10
90-100 15 5 49 36.1
110 25
A
Assembly of disc halves
9. Weld the cooling disc guard fixing angle on the bearing pedestal as shown in fig. 21.
10. Weld the coupling guard fixing angle on the bearing pedestal.
11. After completing all erection and alignment work, full grouting of the foundation bolts
shall be carried out.
NOTE :
Whenever welding is carried out on the fan parts during erection at site condition, direct
earthing to be given, to avoid current passing through the bearings.
52. Installation of belt pulley.
12
13
11
11) TENSIONING SCREW

12) TENSIONING PAD
13) SLIDE RAILS
Force required to deflect V-Belt

16 mm per metre of centre distance
V-Belt
Section Kilogramforce (Kgf) P Newton (N)
A 1.0 to 1.5 10 to 15
B 2.0 to 3.1 20 to30
C 4.1 to 6.1 40 to 60
D 7.1 to 10.7 70 to 105
E 12.2 to 18.3 120 to 180
C/C
Never hammer the belt pulley on to or off the shaft, since even light blows
and shock may damage the pulley and this will give rise to noise and an
abnormally high temperature at bearings.
To remove :
a) Remove the screws marked 14, oil them sparingly and screw one of them
into the extractor holes marked 15 i.e., the tapped holes in the shaft .
b) Tighten the screw until the bush is free of the hub and the unit can be
removed from the shaft.
c) Remove the pulley and bush from the shaft as one unit.
To fit :
a) Clean the bottom of the pulley and the inside and outside of the bush
to remove any dirt corners or region and make certain that the surfaces
are completely free from oil and dirt. Now fit the bush into the pulley.
b) Oil the screws sparingly and screw them loosely into the tapped holes
in the pulley.
c) Clean the shaft and fit the pulley and bush as one unit on to the shaft.
d) Tighten the screw alternately until they are all securely tight.
15
14
14
14) SCREW
15) EXTRACTOR HOLE
COMMISSIONING PROCEDURE
ASSEMBLY AND STARTING UP CHECK LIST.
DESCRIPTION REMARKS & MEASURED VALUES
Tightening of foundation bolts :
STATIC PARTS:
Positioning of the inlet cone :
Tightening of fixing bolts on the ducts :
Tightening of the fixing bolts of static :

parts
Closing of the inspection door :
ROTOR PARTS:
Shaft alignment :
Tightening of fixing bolts impeller / hub :
Expansion clearance on the free bearing :
Alignment of the coupling
LUBRICATION:
Fan bearings lubrication :
Inlet damper lubrication :
UTILITIES:
Connection to the electric circuit :
Connection to the control system :

PRECAUTIONS BEFORE FIRST STARTING OR BEFORE STARTING

AFTER DISMANTLING
1. Check the mounting of the bearing housings and electric motor.
2. Check that the coupling is tightened properly.
3. Check that the foundation bolts are properly tightened.
4. Check that the connecting flanges between the fan and ducting are good, and proper
packing is provided.
5. Check that the different components of the control system are correctly connected.
6. Check that the Inlet damper is fully closed.
7. Check that no foreign object has been left anywhere in side the fan.
8. Check that no water stays in the bottom of the casing and inlet box.
9. Check that the specified guards have been fitted.
10. Check that the inspection door on the casing and inlet box are correctly shut.
11. Check that the rotor can turn freely without rubbing with any static parts.
12. Check that the bearings have been correctly filled with bearing lubricant as it is
noted in the section `LUBRICATION.
FIRST START AFTER ASSEMBLY

1. People responsible for the starting must always stay nearest as possible to the
emergency stop switch.
2. The fan is rotating in correct direction
T IMPELLER
P IMPELLER
B IMPELLER
3. The fan inlet must be shut.

4. During the acceleration phase, that there is no abnormal noise.
Once the fan has reached full speed, open the damper.
5. Check bearing vibration level. The vibration levels indicated in below are in full
accordance with the standard VDI 2056.
VELOCITY IN mm/sec (RMS)

FAN HEALTH FAN ON FANS ON
CONDITION CONCRETE VIBRATION
FOUNDATION ISOLATOR
ADMISSIBLE 4.5 7
STILL 11 18
ADMISSIBLE
ALARM LEVEL 12.0 19

TRIP LEVEL 13.0 20
Check that the bearing temperature is good.

Normally this temperature first raises and then decreases and stabilizes at particular
temperature.
SET THE ALARM POINT AT 100 C.
SET THE TRIPPING POINT AT 110 C.
If the bearing temperature is too high, this Improper assembly

generally indicates: Inner clearance is too small
Jamming of bearings
Excessive friction of seal
Improper lubrication in quantity or quality.
Check up the noise of the bearing housings :
Grinding noise : Inadequate lubrication (Surface rubbing directly against one

another
Whistling : Improper lubrication (Grade or quantity)
Clear noise at : Imprints in race of outer ring because of abnormal vibration.
regular intervals
Intermittent : Rolling part deteriorated or damaged
noise
Cracking noise : Presence of foreign particles
Whining or high : Axial thrust from motor.

pitch noise
MAINTENANCE
RUNNING MAINTENANCE
1. Fill bearing lubricant of recommended specification and quantity at the specified

intervals for bearing housings. The interval should be determined based on local
condition like working environment etc.
2. Check periodically vibration levels of the fan at both bearings.
3. Check periodically the proper seating of fan on the foundation and for abnormal
vibration at any location.
4. Check for looseness of any bolts in the fan pedestals, casing, etc.
SHUT DOWN MAINTENANCE:
1. Open inspection door in casing. Clean the impeller blades and internals.
2. Check for erosion of the impeller.
3. Check the overlap and radial clearance between impeller shroud and inlet cone. If found
disturbed adjust the same.
4. Remove used bearing lubricant from bearing housing.
5. Check the bearing condition like roller clearance and the rolling surfaces of races.
6. Fill new lubricant in the bearing housing.
7. Check alignment of fan and motor. If necessary correct the same.
8. Check the Inlet damper flaps movement.
9. Apply grease for Inlet damper bearing housings.
10. Check the tightness of all fixing bolts.

LUBRICATION
FAN BEARINGS (GREASE LUBRICATION)
Requirement : Consistency class : NLGI 2 (National Lubrication Grease Institute scale)
COMPANY BRAND NAME

IOCL SERVO Grease WR 2
Quantity : Press grease from one side of the bearing till it comes out through the opposite end.
Continue the process and rotate the impeller slowly by hand till the bearing is completely filled with
grease. Put some extra grease (not more than 1/3 rd of inside volume of Plummer block) inside the
Plummer block.
Before Commissioning Existing Grease to be taken out from the Bearing Housing and SERVO Grease
WR 2 to be filled as per the above mentioned procedure.
Note : Over greasing will cause overheating of bearing .
FAN BEARINGS (Oil LUBRICATION)
Requirement : Viscosity Grade 68
Type of Lubrication: Oil bath and circulation ring.

Lubrication : Mineral oil with anti foam, corrosion and anti oxidation additives.
Suggested lubricants : BHARAT HYDROL 68 , SERVO SYSTEM 68 or Equivalent.
Filling per bearing housing: As per maximum and minimum mark given on the Oil level
indicator.(revert to us in case of any doubt)
Note : Do not exceed the maximum mark , since excess oil would result overheating
And oil leakage thru the shaft passage.
INLET DAMPER
According to the installation conditions and the operating frequency of the inlet damper following
should be lubricated.
VANE BEARINGS : Make sure when topping up that the spent grease is discharged normally.
LINK ROD PINS : Apply grease after cleaning if required.
Lubrication interval : Normally three months, to be changed as and when required.

Lubrication interval and amount
Grease
For fans provided with spherical roller bearing, the bearings housing are
fitted with grease nipples and are fitted with the correct amount of grease
when requested.
The lubrication intervals and the amount of grease necessary for relubrication
The chart is based on a temperature of 70C. For every 15C increase in
temperature the lubrication interval should be reduced to 50% of the value
obtained from the chart.
(Example : For a fan fitted with spherical roller bearings with the bearing bore
diameter of 120mm and running at 1000RPM the relubrication interval will be
800 operating hours if the bearing's temperature does not exceed 70C).
Oil
When inspecting the oil level of a bearing, check to ensure that the right type of
oil is in use and that the oil level gauge's air vent is unobstructed.
Take a small sample of the oil and compare it with fresh oil. If the sample look's
cloudy, then it is mixed with water and should be replaced.
Dark or thick oil is a sign of dirt or indicates that the oil has started to carbonize.
Change the oil completely and, if possible, clean the bearing by flushing it with
fresh oil . When changing the oil, be sure that you are using the same type of oil ,
and that you refill to the required level .
A more reliable method for determining the oil condition is to analyze a sample .
If the oil is contaminated it may be worthwhile to change the seals or consider
filtration .
Oil in oil bath circulation systems requires change only once each year, providing
that the operating temperatures does not exceed 50 to 60 C and the oil does
not become contaminated . Change the oil four times each year for operating
temperatures of 100 C ; monthly for operating temperature of 100 C.
RELUBRICATION INTERVALS IN OPERATING HOUR

c b a t = operating hours
2.5 2.5 3
4
10 2 2.5
6 1.5 2
4 4
1.5
10
2 8
4
3 10 D = DIAMETER OF BEARING
10 6 9
8 4 87
d=
6 3 6
10
5 2.5 5
m
m
20
4 2 4
40
60
100
120
80
160
3 1.5 3
200
240
280
360
2.5 2.5
420
500
2 10 2
1.5 7.5 1.5
3
10 5 103
9 4.5 9
8 4 8
7 3.5 7
6 6
5 2.5 5
4 2 4
3 1.5 3
2
2 10 2
1.5 7.5 1.5
2 2
10 10 2
10 2 3 4 5 6 789 103 2 3 4 5 6 7 89 104 2
N = RPM
a : radial ball bearings

b : cylindrical roller bearings
c : spherical roller bearings, taper roller bearings, thrust ball bearings; full complement cylindrical
roller bearing (0.2 t); crossed cylindrical roller bearings with cage (0.3 t); cylindrical roller thrust
bearings, needle roller thrust bearings, spherical roller thrust bearings (0.5 t).
General formula for

relubrication amount :
G = 0.005 DB SHAFT DIAMETER - mm
G = Grease qty. in gm
D = Bearing OD in mm
65 80 90 100 110 125 135 140 150 160
B = Bearing width in mm
AT MOUNTING gm 240 310 340 380 470 680 850 1000 1800 2200
AT RE-LUBRICATION gm 24 40 55 70 80 110 130 150 130 150

VIBRATION ACCEPTANCE NORMS AS PER VDI2056/ISO2372
FOR RIGIDLY MOUNTED FANS
400

315
250
Displacement s
200
160
s
IN
Displacement amplitude s
A
125
D
RM M
IS
100
S- S
va IB
80 lue
S of LE
T vib
63
IL ra
L tio
50 A nv
D elo
M cit
40 IS y
A S v
31.5
D I B
M LE =
IS rm 11
25 s mm
S /s
20 IB
G LE
v rm
16 O
O
s
=
D
4.
12.5
5m
m/
v rm
10
s
=
1.8
mm
/s
6.3
5
Vi
br
4 at
ion
lev
3.15
el
v of
rm hu
2.5
s= ma
0. np
11
2.0 mm er
/s ce
pt
1.6 ion
1.25
1.0
315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000 6300 8000 10000 12500 16000 20000 25000
Fig. 13 Example of Vibration Severily for Machine Class III. Frequency in cpm
VIBRATION ACCEPTANCE NORMS AS PER VDI2056/ISO2372
FANS ON VIBRATION ISOLATOR
MACHINE CLASS IV
400

315
250
Displacement s
200
Displacement amplitude s
160
I
s
RM N
125 A
S- D
va M
100 lu I
S e S
of S
80 T vib I
I B
L ra L
63 L tio E
A n
D ve
50 M lo
I ci
S ty
40 A S
D I v
M B
31.5
I L
S E =
S 18
25
I mm
B /s
L
v rm
20 E
s
=
G
7m
16
O
m/
O
D
s
v rm
12.5
s
=
2.
8m
10
m/
s
6.3
5
Vi
br
4 at
io
n
le
3.15
ve
v lo
rm f
2.5 s = hu
0. ma
11
2.0
mm n pe
/s rc
1.6 ep
tio
n
1.25
1.0
315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000 6300 8000 10000 12500 16000 20000 25000
Fig. 14 Example of Vibration Severily for Machine Class IV. Frequency in cpm
NSTRUCTION MANUAL Page 30 of 41
LOCATION OF FIXED AND FREE BEARING
FREE BRG.
FIXED BRG.
AFTER MOUNTING CLEARANCE OF BEARING WITH TAPERED BORE
NUT
ADEPTER BEARING LOCKING

SLEEVE WASHER
Bearing bore Reduction in Axial drive-up Taper 1:30 Minimum permissible residual
diameter radial internal Taper 1:12 on diameter clearance after mounting
d clearence on diameter bearings with initial clearance
Over incl. min max min max min max Normal 3 4

C C
mm mm mm mm
30 40 0.020 0.025 0.35 0.4 0.015 0.025 0.040
40 50 0.025 0.030 0.4 0.45 0.020 0.030 0.050
50 65 0.030 0.040 0.45 0.6 0.025 0.035 0.055
65 80 0.040 0.050 0.6 0.75 0.025 0.040 0.070
80 100 0.045 0.060 0.7 0.9 1.75 2.25 0.035 0.050 0.080
100 120 0.050 0.070 0.75 1.1 1.9 2.75 0.050 0.065 0.100
120 140 0.065 0.090 1.1 1.4 2.75 3.5 0.055 0.080 0.110
140 160 0.075 0.100 1.2 1.6 3.0 4.0 0.055 0.090 0.130
160 180 0.080 0.110 1.3 1.7 3.25 4.25 0.060 0.100 0.150
180 200 0.090 0.130 1.4 2.0 3.5 5.0 0.070 0.100 0.160
200 225 0.100 0.140 1.6 2.2 4.0 5.5 0.080 0.120 0.180
225 250 0.110 0.150 1.7 2.4 4.25 6.0 0.090 0.130 0.300
250 280 0.120 0.170 1.9 2.7 4.75 6.75 0.100 0.140 0.220
280 315 0.130 0.190 2.0 3.0 5.0 7.5 0.110 0.150 0.240
315 355 0.150 0.210 2.4 3.3 6.0 8.25 0.120 0.170 0.250
355 400 0.170 0.230 2.6 3.6 6.5 9.0 0.130 0.190 0.290
400 450 0.200 0.260 3.1 4.0 7.75 10 0.130 0.200 0.310
450 500 0.210 0.280 3.3 4.4 8.25 11 0.160 0.230 0.350
500 560 0.240 0.320 3.7 5.0 9.25 12.5 0.170 0.250 0.360
560 630 0.260 0.350 4.0 5.4 10 13.5 0.200 0.290 0.410
630 710 0.300 0.400 4.6 6.2 11.5 15.5 0.210 0.310 0.450.
710 800 0.340 0.450 5.3 7.0 13.3 17.5 0.230 0.350 0.510
800 900 0.370 0.500 5.7 7.8 14.3 19.5 0.270 0.390 0.570
900 1000 0.410 0.550 6.3 8.5 15.8 21 0.300 0.430 0.640
1000 1120 0.450 0.600 6.8 9.0 17 23 0.320 0.480 0.700
1120 1250 0.490 0.650 7.4 9.8 18.5 25 0.340 0.540 0.770
Inlet dimension - GF
FA N T YPE
FAN G F ( A ,B ) B GFAF
S IZ E G (M M ) H (M M ) S (M M )
m m m m
M IN MAX M IN MAX
025 3 to 6 2 5 4 6
031 3 to 6 2 5 5 9 ,3
040 3 to 6 2 8 6 10
050 3 to 6 2 ,5 9 ,5 6 10
063 3 to 6 4 11 6 15
071 3 to 6 9 +- 4 6 15
080 3 to 6 10 +- 4
090 3 to 6 11 +- 4
10 0 3 to 6 1 2 ,5 +- 4
112 3 to 6 16 +- 4
12 5 3 to 6 16 +- 4
14 0 3 to 6 18 +- 4
16 0 3 to 6 20 + 5
-
IMPELLER S
H
G
INLET INLET
LIST OF SPARES
The following spare parts are recommended to be kept as stand by for two years normal
operating condition. Quantity of replacement depends on individual application.
1. Impeller with shaft and hub.

2. Fixed bearing . Refer drg. for brg. No.
3. Free bearing . . Refer drg. for brg. No.
4. Brass sealing plates(if applicable)
5. Coupling : - . Refer drg. for type and size.
ANNEX
DATA RECORDED DURING TRIAL RUNNING OF FAN
CUSTOMER: FAN TYPE:
ORDER REF. No.: APPLICATION:
DATE : STARTED AT : RUNNING
DURATION :
AMBIENT TEMP: ACCEL.TIME : STOPPED AT :
MEDIUM TEMP.: NO LOAD CURRENT :
VIBRATION LEVEL RECORD:
DISPLACEMENT IN MICRONS (PEAK TO PEAK) -VELOCITY IN mm / sec.(RMS).
H - Horizontal, V - Vertical, A - Axial
MEASUREMENT H V A FAN SPEED

LOCATION Dis. / Dis. / Vel. Dis. / Vel. & DAMPER
Vel. POSITION
FAN DE. BEARING
FAN NDE. BEARING
MOTOR DE. BEARING
MOTOR NDE. BEARING
SL.NO. TIME FAN BRG.TEMP C MOTOR BRG.TEMP C MOTOR POWER

kW
DE NDE DE NDE
1
2
3
4
5
6
7
CHECKED BY: WITNESSED BY :

ANNEX
DOS & DONTS
DOS :
1. FILL BEARING LUBRICANT OF RECOMMENDED SPECIFICATION AND
QUANTITY AT THE SPECIFIED INTERVALS FOR BEARING HOUSING.
2. CHECK PERIODICALLY THE VIBRATION LEVELS ON BOTH THE BEARINGS OF
THE FAN.
3. CHECK PERIODICALLY THE PROPER SEATING OF THE FAN FOUNDATION AND
FOR ABNORMAL VIBRATION AT ANY LOCATION.
4. CHECK FOR LOOSENESS OF ANY BOLTS IN THE FAN PEDESTALS AND
CASING ETC.
5. AT THE TIME OF ERECTION / COMMISSIONING, OPEN THE BEARING
HOUSING AND CHANGE THE OLD OIL. CHECK IF ANY DIRT OR DUST IS
SETTLED INSIDE THE HOUSING AND CLEAN THOROUGHLY BEFORE
POURING NEW OIL.
6. ENSURE THE DAMPER IS IN CLOSED CONDITION WHILE STARTING THE FAN.
7. PROVIDE INSULATION OVER THE ENTIRE AREA OF FAN COMPONENTS FOR

HIGH TEMPERATURE FAN.
DONTS :
1. DONT REMOVE THE INSPECTION DOOR WHEN THE FAN IS IN RUNNING
CONDITION.
2. WHILE SHUT DOWN, ENSURE THE MOTOR POWER CONNECTION IS REMOVED
BEFORE ANYBODY ENTERS IN TO THE FAN FOR ANY VERIFICATION.

ANNEX
BRIEF DESCRIPTION OF FAN COMPONENTS
1. CASING WITH INLET BOX " IT HOUSES ROTOR & INLET CONE.
2. BASE FRAME " IT SUPPORTS CASING, INLETBOX,

BEARING PEDESTAL & MOTOR.
3. BEARING PEDESTALS " THIS IS FOR MOUNTING OF

BEARING HOUSING.
4. BEARING & BEARING HOUSING " THIS HAS BEEN BRIEFED IN OUR
O&M MANUAL UNDER THE
HEADING ASSEMBLY PROCEDURE
FOR BEARING & BEARING
HOUSING
5. INLET CONE " IT GUIDES THE ENTRY OF FLOW

MEDIA TOWARDS THE IMPELLER.
6. DAMPER/IVC " TO GUIDE AND CONTROL THE

FLOW AT THE INLET SIDE.
7. INLET/OUTLET FLEXIBLE CONNECTIONS " THIS IS TO TAKE CARE OF THE

CONNECTION DUCT MOVEMENTS
WHEN THE FAN IS IN OPERATION.
8. ROTOR ASSEMBLY " THIS IS COMPRISING OF

IMPELLER,SHAFT,HUB, BEARING &
BEARING HOUSING. IMPELLER
BLADES ARE BACKWARD CURVED
DESIGN.
ANNEX
Troubleshooting can help when you suspect a problem
TYPICAL AREA TO CHECK SOLUTION

POSSIBLE CAUSE
PROBLEM
Mounting of Fan Inadequate mass or stiffness Stiffen /Increase
of supporting structure weight
Misalignment during Shaft, coupling between shaft Correct alignment
installation and drive, belt pulley , shaft
got bent
Impeller Unbalance during Material build-up, corrosion, Install vibration
operation wear monitor to check the
trend ; Clean the
impeller periodically ;
Take preventive action
for corrosion and wear;
In-situ balancing of
impeller
Looseness In the mounting, Between Tighten fastening bolts
VIBRATION shaft and impeller, coupling / ; Replace coupling
pulley or bearing .pulley; tighten bearing
adapter sleeve as per
tolerance given in SKF
catalogue.
Aerodynamics Inlet condition non-uniform, Duct layout to be
pre-rotation of the air, system modified; baffle plate
effect, pulsation due to fan /straighteners may be
operating at surge zone used to achieve
uniform flow; Selection
of fan to be reviewed.
Vibration Impeller unbalance during In-situ balancing
operation
Mounting Inadequate mass or stiffness Stiffen /Increase
of supporting structure weight
PREMATURE
Lubrication Wrong type, overlubrication Check recommended
BEARING
lubrication , quantity
FAILURE
and interval
Environment Contaminants in lubricant, Change lubricant
Ambient temperature high . immediately; Review
selection of lubricant .
ANNEX

POSSIBLE CAUSE
PROBLEM
Alignment Shaft alignment, overtightened Correct alignment
bearings ;dismantle the bearing
refit with specified
PREMATURE
tolerance
BEARING
Loading Radial and/or thrust Review bearing
FAILURE
selection
Load Overload from belt drive or Review bearing
coupling selection
Thermal Shock Malfunctioning controls, Check controls and
sudden operational change system
Vibration System pulsation, looseness Check system ; check
fastening of bolts .
PREMATURE Abrasion/corrosion Excessive dust from system Ensure fan inlet dust
MATERIAL .Fans running with bypassed concentration within
FAILURE dust arrestor. Water/acid specified limit. Review
fume ingress in fan selection of impeller
material for aggressive
condition .
System Effect Turbulent Inlet condition, non- System correction
uniform flow, deviation of required
actual system resistance from
PERFORMANCE predicted one ,
DEFICIENCY IN pre-rotation or swirl at inlet
VOLUME OR Clearances Impeller and inlet Check for deviation
PRESSURE from drawing/manual;
correction .
Driver Belt slippage Belt tightness to be
adjusted.
Environmental Problems Problems Material build-up in Check and clean
casing , inlet or ductwork periodically. System
blockage correction required
Rotation Incorrect motor connection, Follow the indicated
improper Impeller rotation direction of rotation
given on casing by
arrow mark
ANNEX

POSSIBLE CAUSE
PROBLEM
Mechanical Interference Touching between impeller and Adjust inlet gap taking
inlet cone due to external forces care of expansion in
on casing or hot condition , check
Impeller /shaft movement or for expansion provision
thermal expansion and distortions in casing foot ; fixed
and expansion joint
wherever provided are
in place ; remove duct
NOISE load from fan casing by
providing flexible
connection piece.
Bearings Inadequate lubrication, pitted Replace bearing ;
bearing worn balls, races, seal correct alignment
failure, alignment improper,
Airborne High velocities Install Attunuator
Foreign Material in Fan Buildup on fan Impeller, casing Check and clean
Casing preiodically , system
correction required
Drive Belts too loose and squealing Adjust belt tension
Too much grease in Consult manual for
bearing lubrication amount and
interval
Poor alignment Correct
Bent shaft Replace
OVER HEATED Abnormal end thrust Check antithrust blade
BEARING in impeller
Dirt in bearing Clean
Pinching effect on bearing Interference fit of bearing outer Repalce housing with
outer race race in housing correct tolerance
Bearing outer race in Loose housing fit Repalce housing with
rotating in housing correct tolerance
HOW TO ORDER .
YOUR DATA ABOUT THE :

Installation
process details and position of the fan
site elevation m electrical frequency Hz
Inlet conditions
Pressure : TOTAL or STATIC + mm W C
flow : m 3/s
temperature : C
relative humidity %
Outlet conditions
Pressure : TOTAL or STATIC mm W C
Gas
dust concentration g/m 3
Possibility of: BUILD UP CORROSION EROSION
Fan
design temperature C
flow regulation with : IN LET DAM PER IN LET VAN E CONTROL
VARIABLE SPEED
general arrangement :SINGLE INLET DOUBLE INLET COUPLING
OVER HUNG IM PELLER IMPELLER BETW EEN BEARINGS BELT DRIVE
M ATERIAL or SEALS impositions

ADDRESS AND CONTACT NOS.
WORKS
ADDRESS TEL. NO FAX NO
KOLKATA
Budge Budge Trunk Road,
+91 33 24901811 +91 33 24902411 / 1643
Maheshtala,
Kolkata 700 141
CHENNAI
147, Poonamallee High Road,
+91 44 26272023 +91 44 26272606
Village : Numbal
Chennai 600 077
MARKETING OFFICES
DELHI
1st Floor, Front Position,
Plot No. 28, +91 11 41814600 +91 11 26920112
Okhla Industrial Estate, Phase 3,
New Delhi 110 020
KOLKATA
1E & 1, Sristi
+91 33 22820207 +91 33 22810208
12, Ho Chi Minh Sarani,
Kolkata 700 071
MUMBAI
301 303, Chintamani Plaza,
3rd Floor,
+91 22 67830200 +91 22 66978944
Andheri Kurla Road,
Chakala, Andheri East,
Mumbai 400 099
CHENNAI
147, Poonamallee High Road,
+91 44 26272023 +91 44 26272606
Village : Numbal
Chennai 600 077
PUNE
Master Executive Centre,
Sneha Leela 1237 Apte road, +91 20 25539079 / 4402 +91 20 25530874
Deccan Gymkhana,
Pune 411 004
BANGALORE
Shreyas
157, 9th Cross, +91 80 41635050
Indiranagar, 1st Stage,
Bangalore 560 038
INSTRUCTION MANUAL
DESCRIPTION
IDENTIFICATION SHEET
FLAKT REFERENCE
REF. DRG. NO.
APPLICATION
CUSTOMER
FAN DESCRIPTION :-
MAIN CHARACTERISTICS
DEFINITION UNIT RATED LOAD
RATED GAS FLOW KG/S

DIFFERENTIAL STATIC PRESSURE (mmWC)/Pa
TOTAL EFFICIENCY %
RATED OPERATING TEMPERATURE C
MECHANICAL DESIGN TEMPERATURE C
FAN SPEED RPM
DENSITY AT 180 C Kg/AM
CRITICAL SPEED RPM
RATED FAN POWER KW
MOTOR POWER KW
FAN WEIGHT KG
FAN ACESSORIES WEIGHT KG
MOTOR WEIGHT KG.
DYNAMIC LOAD DUE TO ROTOR KGF.
GD VALUE kg.M
IMPELLER DIA mm
IMPELLER WEIGHT KG.
DAMPER OPERATING FORCE N
ACTUATOR STROKE LENGTH mm
BEARING LUBRICATION
INSULATION AREA (M2)
SHAFT DIA AT BRG. mm
Goto that URL
Click on Customer Care

Click on Customer Complain Entry
Please fill up the Form, after
Submission you will get
a Complain No.
Keep the Complain

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reference

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FUNCTIONAL DESCRIPTION & DESIGN

ADDRESS & CONTACT NO. 41

YOUR FANS.. .. DESCRIPTION AND IDENTIFICATION

GL series is a centrifugal fan suitable for application such as ventilation, air

GF is available in the following arrangements :

FUNCTIONAL DESCRIPTION AND DESIGN

STANDARD CONSTRUCTIONAL FEATURES

Mechanical Design (Fig 10)

The static parts of the fan consist of the following:

The rotor of the fan consist of the following parts:

Additional Accessories and Features

The operation and maintenance of machinery of any kind requires a person to be

3. Do not open or access inspection doors while the fan is running.

7. Always use caution in every maintenance or operational procedure.

B. Check for Transportation Damages :

2. Check foundation for evenness, and its different levels.

3. Mark centre lines of fan and foundation pockets on the foundation.

NOTE: REFER ENCLOSED GENERAL ASSEMBLY DRAWING.

FOUNDATION BOLTS, FAN ON BASE FRAME: -

5. Clean the threaded portion of the bolt.

9. Fasten the foundation bolts with base frame.

ASSEMBLY PROCEDURE FOR BEARING AND BEARING HOUSING

1. PRE -ASSEMBLY CHECKING :

c) Bearing housings although made by precision machining to the given specifications, a

With tapered bore:

a) Keep the bottom half of bearing housings on the bearing pedestal.

b) Clean the shaft with the use of white sprit.

c) Insert the brass seal on to the shaft at impeller end.

d) Insert the M.S cover plate on to the shaft at impeller end.

k) Insert the another double-lip seal on to the shaft if applicable.

m) Insert the lock nut and lock washer on to the shaft.

o) Insert the bearing with large dia of bore facing outside.

p) Insert the taper sleeve on to the shaft.

r) Tighten the lock nut as explained in point no.

t) Insert the another seal on to the shaft.

u) Rest the rotor on the bottom half of bearing housing.

x) Tighten the parting off bolts to the correct tightness.

WITH CYLINDRICAL BORE: -

The force needed to mount a bearing increases rapidly with bearing

The temperature difference between the bearing and its seating

ing to a temperature greater than 125C(255 F), however, be-

Wear clean protective gloves when mounting a hot bearing. Lifting

When a bearing requires an interference fit in the housing, a moder-

To facilitate future dismounting equip shafts with ducts

SKF heaters are generally equipped with

A cabinet equipped wiyh an adjustable thermostat and a fan is a

In addition to bearings, couplings, sleeves and other components

Oil baths ensure even heating. They

Bearing rings, or even complete bearings, can be

IMPELLER LOCKING ARRANGEMENT

SIMPLE SUPPORTED FAN OVERHUNG FAN

Fitting of impeller on shaft

Some important notes

The direction of rotation is indicated in fan casing .

Erection on vibration isolator

! Ensure of grouting pocket positions in civil foundation are as per GA drg.

Important point to be noted

! The main idea of providing vibration isolator is to avoid transmission of undue

ACCESSORIES ( REFER ASSEMBLY DRAWING FOR ITEMS APPLICABLE)

1. Fix the evase with fan outlet.

3. Fix the inlet and outlet flexible connection.

4. Fix the actuator bracket on the casing/foundation