RUCON Ventilatoren NV

WARNINGS AND INSTRUCTIONS FOR USE

DOCUMENTATION SUPPLIED WITH THE FAN
The documentation supplied with the fan consists of:
• a single document containing warnings and instructions for use
• a number of documents made up of:
1. Declaration by the Manufacturer in compliance with enclosure IIB of EC
Directive 98/37/CE
2. Transmission specifications list (for fans in arrangement 9-12-8-7D-11D-14D)

Check that the above documentation is present at the moment

Of delivery. If any is missing, ask for a new copy from
Rucon Ventilatoren NV
S . p . A.

Edition01/2001 rev.00
RUCON Ventilatoren NV

Main Index

1 INTRODUCTION 4

1.1 Purpose of this manual 4

1.2 General safety symbols used 4

2 GENERAL INFORMATION 5

2.1 Basic principles and terminology used 5

2.2 Mechanical layout of centrifugal fans 6
2.2.1 Motor positions in different installation types 6
2.2.2 Fan orientation 6
2.2.3 Standard motor positions for given fan orientations 7
2.3 Mechanical layout of axial fans 8
2.3.1 Motor positions in different installation types 8
2.3.2 Flow designation 8
2.4 Fan identification 9

3 WARNINGS AND MAIN SAFETY INDICATIONS 10

3.1 Installation 10
3.2 Risks involved in incorrect handling or use 11
3.3 Other risks related to fans 12
3.3.1 Specific risks involved in transporting and installation 12
3.3.2 Specific risks involved in fan maintenance 12

4 TRANSPORT AND INSTALLATION 13

4.1 Transport and lifting 13

4.2 Storage in a warehouse 13
4.3 Lifting methods for fans 14
4.3.1 Lifting centrifugal fans in arrangement 1 14
4.3.2 Lifting centrifugal fans in arrangement 4 14
4.3.3 Lifting double intake centrifugal fans 15
4.3.4 Lifting axial fans in arrangement 9 15
4.3.5 Lifting axial fans in arrangement 4 15
4.3.6 Lifting centrifugal fans in arrangement 8 15
4.3.7 Lifting fans packed in crates 15
4.4 Installation 16
4.4.1 Minimum distances between components 16
4.5 General warnings for lifting and installing parts disconnected from the fan for shipping 17
4.5.1 Single intake centrifugal fans 17
4.5.2 Centrifugal fans with double intake 19
4.5.3 Axial fans 20
4.6 Installing and adjusting belt drives and final checks 21
4.7 Electrical connections 22
4.8 Connections to pipes 23

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5 CHECKS TO BE MADE BEFORE AND AFTER STARTING 24

5.1 Preliminary checks 24

5.2 Checks to be carried out with the fan running 24

6 MALFUNCTIONS AND CAUSES 25

6.1 Centrifugal and axial fans 25

7 MAINTENANCE 27

7.1 Bearing lubrication 28

7.2 Checking pivoted roller bearings 30
7.3 Belt tension adjustment and cleaning 31
7.4 Flexible couplings 32
7.5 Checking and cleaning parts in contact with the fluid 33

8 TECHNICAL TABLES 34

8.1 “ST” Supports in installation types A-AL-B-BL 34

8.2 SN Supports in installation types B – BL – BL/B 35
8.3 Supports and bearings fitted as standard in belt driven fans 36

9 DISASSEMBLY 37

9.1 Intake nozzles 37

9.2 Housing 37
9.3 Fan rotor 38
9.4 Pulleys 38
9.5 Support 38

10 SCRAPPING THE FAN 39

11 TECHNICAL ENCLOSURES 40

11.1 Tightening torques for nuts and bolts 40

11.1.1 Tightening torques M for bolts with ISO metric thread 40

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Index of Figures

Fig. 2.1 Centrifugal fan installation types 6

Fig.2.2 Fan orientation 6
Fig. 2.3 Standard motor positions for given fan orientations 7
Fig. 2.4 Standard installation types with axial fans 8
Fig. 2.5 Flow designation 8
Fig.2.6 Example of an identification plate 9
Fig.2.7 Fan identification 9
Fig. 4.1 Example of lifting centrifugal fans in arrangement 1 14
Fig. 4.2 Example of lifting centrifugal fans in arrangement 4 14
Fig. 4.3 Example of lifting double intake centrifugal fans 15
Fig. 4.4 Example of lifting axial fans in arrangement 9 15
Fig. 4.5 Example of lifting axial fans in arrangement 4 15
Fig. 4.6 Example of lifting centrifugal fans in arrangement 8 15
Fig. 4.7 Example of lifting fans packed in crates 15
Fig. 4.8 Minimum installation distances with intake pipe 16
Fig. 4.9 Minimum installation distances with open intake 16
Fig. 4.10 Assembly of a fan in arrangement 12 18
Fig. 4.11 Assembly of a double intake centrifugal fan 19
Fig. 4.12 Assembly of an axial fan 20
Fig. 4.13 Electrical connection layouts for one and two-speed electric motors 22
Fig. 4.14 Minimum installation distances with intake pipe 23
Fig. 4.15 Minimum installation distances with open intake 23
Fig. 7.1 Checking the radial free play of the bearings 30
Fig.7.2 Checking the belt tension 31
Fig.7.3 Setting the belt tension 31
Fig.7.4 Axial slipping 32
Fig. 7.5 Angular misalignment 32
Fig.7.6 Parallel misalignment 32
Fig. 8.1 ST Supports in installation types A-AL-B-BL 34
Fig. 8.2 SN Supports in installation types B – BL – BL/B 35

Index of Tables

Table 7.1 Types of support and bearing and relative re-lubrication intervals and amounts of grease
used for fans 29
Table 7.2 Checking the radial free play of the bearings 30
Table7.3Setting the belt tension: test load and deflection 31
Table 7.4 Technical specifications of elastic couplings 32
Table 8.1 ST Supports in installation types A-AL-B-BL 34
Table 8.2 SN Supports in installation types B – BL – BL/B 35
Table 8.3 Supports and bearings fitted as standard in belt driven fans 36

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1 INTRODUCTION
1.1 Purpose of this manual

This manual contains instructions and warnings and constitutes the documentation that must be
supplied and kept together with the product, otherwise the product would be lacking in one of
its fundamental safety requisites.

The manual must be kept with care and made

available to all persons involved in operating the
equipment.

The warnings are intended to ensure the safety of persons exposed to the risks inherent in the
operation and handling of this equipment. The instructions in this manual describe how to
use the fan correctly as intended by the manufacturer.

IMPORTANT:
The safety measures adopted for using the fan must also be tailored to suit the specific
applications for which the fan will be used.

The safety measures taken differ depending on the type of fan

installation, as specified in paragraph 3.1. Therefore, the information in this
manual is indispensable for the appropriate and hazard-free use of the fan

This manual may not, even in part, be copied, reproduced or transmitted in any form or by any
electronic, mechanical, photographic or any other means without the express permission of.
The RUCON Ventilatoren Technical Department is at your complete service to clarify any query.

1.2 General safety symbols used

In this Manual, certain particularly important pieces of information may be preceded by one of
the following symbols:

DANGER: This symbol indicates

possible causes of personal injury.

DANGER: Electrified components.

IMPORTANT: This symbol indicates

particularly important information of
general interest

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2 GENERAL INFORMATION
2.1 Basic principles and terminology used

Rucon fans can be divided into the following Categories:

• Radial (or centrifugal) fans: these fans are so called because the fluid enters the fan axially
and exits it radially. The fan blades can have the following different configurations: negative
(the rear, or convex face of the blade works on the fluid), positive (the front, or concave face of
the blade works on the fluid), radial (straight, the blade can work on the fluid with the same
efficiency with its front and its rear face. Neither side of the blade has particular reinforcement);

• Axial fans: these fans are so called because the fluid enters the fan radially and exits it
axially. The fan blades are in aluminium and have a wing type profile.
The basic dimensions that determine a fan’s characteristics are as follows:

• Volumetric flow rate: this is the volume of fluid passing through the fan in a certain length
of time: per second (m3/s), per minute (m3/min), or per hour (m3/h);

• Static pressure: this is the force exerted by the fan blade to overcome the resistance that the
fluid encounters as it flows through a circuit (measure in mm WC or Pascal=Pa);

• Dynamic pressure: this is the force that the fluid has due to the kinetic energy conferred to it by
the rotating fan rotor as it exits the fan outlet (measured in mm WC or Pa);

• Total pressure: this is the algebraic sum of the static pressure and the dynamic pressure
(measured in mm WC or Pa);

• RPM: this is the speed of the fan rotor in revolutions per minute;

• Efficiency: this is the ratio, expressed as a percentage, between the amount of energy that
the fan confers to the fluid and the energy supplied to the fan rotor by the motor.
This value depends on the fan rotor configuration and is dimensionless;

• Power absorption: this is the power required (supplied by the motor) for the fan to work.
It is expressed in kW;

• Nominal motor power: this is the nominal power that the motor is able to supply. This value
must always be greater than the power absorption value for the fan, and is expressed in kW;

• Sound pressure level: this is the energy transmitted into the outer ear, which generates
vibrations in the eardrum: in other words, this is the noise level of the fan and is measured on
the decibel A scale (this scale evaluates the effects of sound on the human ear in relation to its frequency).

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2.2 Mechanical layout of centrifugal fans

2.2.1 Motor positions in different installation types

Arrangement type 1 Arrangement type 4

Beltdrive. Over hanging fan Direct drive. Fan rotor fitted
Rotor fitted on to the shaft. Shaft directly on to the mot or shaft .
supports mounted o n the frame Motor supported by the f rame.
outside the air f low. Maximum air temperature
Maximum air temperature, 60° C. Up t o 150°C for special
60°C without cooling fan, applications
300°C with cooling

Arrangement type 8 Arrangement type 9

Flexible coupling drive.
Overhanging fan rotor fitted onto
the shaft. Shaft supports and
motor mounted in the frame
outside the air flow. Maximum
air temperature 60°C without cooling
cooling fan, 300°C with cooling.
Belt drive. This layout is the
same as Installation 1, but
has the motor supported at the
side of the frame. Maximum air
temperature 60°C without
fan, 300°C with cooling

Arrangement type 1 2 Plan view showing motor

Belt drive. This layout is the position designation with
same as Installation 1, but belt drive.
the fan and motor are supported (position X and Y are only
by the machine foundation. Possible if special equipment
Maximum air temperature 60°C is fitted)
Without cooling fan, 300°C with
Cooling

Fig. 2.1 Centrifugal fan installation types

2.2.2 Fan orientation

Centrifugal fans can be built in 16 different
orientations (8 rotated clockwise, RD, and 8
rotated anticlockwise, LG).
Orientations RD, LG 180 and 225 are only possible if special mechanical modifications are made
The orientation of a fan is expressed as seen from the transmission side.

Fig. 2.2 Fan orientation

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2.2.3 Standard motor positions for given fan orientations

uses the standard motor positions
shown in Fig. 2.3; for space reasons, the DFR-
DFS series fits motors in position W with a fan
orientation of LG90-LG135 and fits motors in
position Z with a fan orientation of RD90 – RD135.

Fig. 2.3 Standard motor positions for given fan orientations

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2.3 Mechanical layout of axial fans

2.3.1 Motor positions in different installation
types

ARRANGEMENT TYPE 1 ARRANGEMENT TYPE 4

ARRANGEMENT TYPE 9 ARRANGEMENT TYPE 12

Fig. 2.4 Standard arrangement types with axial fans

2.3.2 Flow designation

This figure refers to arrangement type 4, but also applies to all other installation types :

A = Flow from the motor towards the f an rotor

B = Flow from the fan rotor towards the motor
U = Flow moving upwards
D = Flow moving downwards

F
i
g. 2.5 Flow designation
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2.4Fanidentification
The identification plate is only means of
identifying the fan that is recognized by the
manufacturer. This plate must be kept in good
condition over time and no modifications may be
made to it. Fig. 2.6 shows the plate fitted to the
fan.

Fig. 2.6 Example of an identification plate

Fig. 2.7 Fan identification

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3 WARNINGS AND MAIN SAFETY INDICATIONS

3.1 Installation

There are four possible installation types, in compliance with UNI 10615
specifications:

Type A: open intake and outlet;

Type B: open intake and outlet connected to a pipe;
Type C: intake connected to a pipe and open outlet;
Type D: intake and outlet connected to a pipe.

Clearly RUCON Ventilatoren NV can not be aware of which of these four installation types
will be used by the user.
Therefore, the installer or end client themselves must analyse the risks involved
for the chosen installation type used in the specific application.

Depending on the applications that the client intends to use the fan for in the factory and on the
type of installation chosen, the following safety shields must be fitted:

Type A installation: fixed shields at the intake and outlet;

Type B installation: shield fitted only at the outlet;
Type C installation: shield fitted only at the intake;
Type D installation: no shield at either the intake or outlet.

The user or the installer of the fan must ensure that adequate shielding is fitted to the pipe
system, at the points where it connects to the working pipes, as follows:

Type A installation: no shield necessary;

Type B installation: shield fitted to the outlet pipe;
Type C installation: shield fitted to the intake pipe;
Type D installation D: shields fitted to the intake and outlet pipes.

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The shielding must be constructed to impede access to the parts of the fan that could cause injury.
It must be robustly built enough to stand and by environmental conditions.
It must be securely fixed in position by devices that will not become loosened by vibrations and that cannot
be removed without the use of tools. It is, in any case, the person installing the fan who is
responsible for ensuring that adequate contact with the fan’s moving parts. The installer and the user must
also take into
account other types of risks present, in particular and the aspiration of explosive, inflammable or
there is a risk of explosion. toxic gases at high temperatures. The user must also bear in mind the risks inherent
in maintenance work, which must always be carried out in conditions of the utmost safety, and with the fan
separated from the motor or isolated using suitable equipment.

Once the installer and/or user has decided which installation type is to be used and all the above
procedures have been applied, the machine can now be considered a “complete machine” as described
by machine
use regulations. An overall risk evaluation must be made and a declaration of compliance with enclosure
IIA of EC directive 98/37/CE must be drawn up.

3.2 Risks involved in incorrect handling or use

• Never, for any reason whatsoever, disable, the vibrations and stress caused by the machine
remove, modify or render inoperative in any other way any of the safety, protective or
control devices of any single component or of the fan itself.
• Never place hands, arms or any other part of The body near any moving part.
• Never extend any part of the body past the limits of the safety barriers. Do not use any means that
• will increase normal accessibility to the fan components.
• Never use the fan in atmospheres where there is risk Of explosion
• Unauthorized operators must not attempt to rectify any malfunction of the fan and/or
modify the functional characteristics or installation type .
• After any unprogrammed maintenance operation that required the removal of shields
• barriers or any other protective device, before restarting the fan ensure that all these
components have been refitted and are fully functional.
• All protective and safety devices must be kept in perfect working order at all times. All
indicative and warning plates fixed to the fan must also be kept in perfect condition at all
times and must never be removed of from their original position.
• When troubleshooting for the cause of malfunction of the fan, ensure that all precautions described in this manual
have been taken to prevent personal injury and/or damage to property.
• Remember to tighten every screw, bolt and lock ring of every component subject to adjustment or maintenance.
• Before starting the fan, ensure that all safety devices have been correctly installed and are
in perfect working order; if the above is not the case, do not start the fan and inform the head of safety or
department manager immediately.
• The operator must be equipped with Personal protection Equipments in accordance with
current legislation; the use of bulky clothing and accessories (ties, loose sleeves, etc.) is prohibited.

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3.3 Other risks related to fans

The following is a list of specific hazards related to the fan’s mechanical characteristics.
A person may receive injuries as a
Result of:
a) becoming caught up between a moving part and a stationary part,
for example, between a fan rotor and the fan housing or any other
stationary fan component;
b) becoming caught up between two moving parts, for example, between a belt
and a pulley;
c) suction of a part of the body into the fan and subsequent contact with the shaft or rotor;
d) contact with a moving part, such as the rotor;
e) an object becoming sucked into the intake of the fan and expelled at high speed from the outlet of the fan;
f) contact with surfaces of the fan at dangerous temperatures, for example, temperatures below -20°C or
above +50°C;
g) hazards caused by the over speed of a fan component, which can lead to the breakage of parts of the
machine;
h) the aspiration of air at temperatures above the specified operating range, which can lead to the deformation
and breakage of the housing

3.3.1 Specific risks involved in transporting and installation

• The fans must be transported and handled carefully to avoid damage through excessive force or careless loading/
unloading. Any impact-, tension- or compressive stress on the plastic enclosure must be avoided.
• For transport by truck, rail or ship the fans must be loaded and secured in such a way that skidding,
tilting and friction are avoided.
• Lifting and moving of the fans can be made manually depending on size.
• When using a fork lift truck the fans must be transported on pallets and if necessary are to be fastened on these.
• Before installation, the user must prepare perfectly level surface onto which the fan will be mounted. If this
surface is not perfectly level, this can cause abnormal vibrations in the fan. This can, over time, lead to the
deformation and/or breakage
of fan components with the subsequent expulsion at speed of broken parts: these expelled parts can cause even
fatal
injuries to any persons exposed.
• Before installation, the user must also prepare adequate connections to earth for the fan case or for the fan
structure to
• prevent the build-up for electrostatic charges.
• All installed protective devices must remain fixed to the fan together with their respective fixings (screws, bolts,
etc.) The removal of one or more fixing may compromise the functionality and tightness of the safety shield.
• In its standard form, the fan is not intended for use in a potentially explosive environment.
• The installation location of the fan must be kept clean at all times. Any eventual oil or water spillages not caused
by the fan must be removed immediately.
• The minimum installation distances specified in the manual must always be respected to ensure correct
functionality
without any further hazards. The incorrect positioning of a component can compromise the functionality of the
fan.
• Use only the specific lifting points on the fan and ensure that the fan’s weight is distributed evenly.

THE USER IS RESPONSIBLE FOR THE SELECTION OF EQUIPMENT, ROPES,

BELTS AND CHAINS BEST SUITED FOR BOTH LOAD AND FUNCTIONALITY;
 RUCON Ventilatoren NV

3.3.2 Specific risks involved in fan maintenance:

Operational reliability and service life of the fans also depend on proper inspection and maintenance.
Fans in continuous and trouble-free operation must be checked every six months as follows:
• Visual check for vibration cracks and/or fractures in the fan enclosure by vibration
• Visual check of the impeller for wear and/or caked-on deposits caused by abrasive media
• Check V-belt tension
• Tightness of the duct connections, the casing cover and the shaft seal (if any)
• During maintenance and cleaning of the fan rotor, be particular careful of the rotor. This can lead to parts of the
body
becoming trapped and seriously injured between the rotor itself and fixed parts of the fan housing.
• Even when the fan is disconnected from the power supply, the rotating parts can still turn due to any air movements
through the fan. This air flow may be natural or may be caused by the current induced by another fan installed
elsewhere
in the connected tubing system. This can also lead to parts of the body becoming trapped and seriously injured
between
the rotor itself and fixed parts of the fan housing.
• A fan maintenance program must be drawn up and followed to prevent the mechanical failure or breakage due to
wear or insufficient maintenance.

DANGER: IT IS ABSOLUTELY FORBIDDEN TO:

• Carry out any maintenance work without first ensuring that the fan rotor is effectively stationary.
• Start any maintenance work on the fan (including lubrication) without first disconnecting the fan from the
main power supply.
• Clean the fan while it is running.
• Open any shield or section hatch while the fan is running

4 TRANSPORT AND INSTALLATION

Lifting and handling the fan may create hazards for any persons in the vicinity; it is
therefore important to follow the indications given by and to use suitable equipment.

All installation and assembly work must be carried out only by specialised technicians.

4.1 Transport and lifting

Therefore, all operations involving the lifting and handling of the fan must be carried out with
the utmost caution, avoiding any knocks that could compromise the functionality or damage the
fan components. Use only the specific lifting points on the fan and ensure that the fan’s weight is distributed evenly.

THE USER I S RESPONSIB LE F OR THE SELECT ION OF EQUI PMENT ROPES

BE LTS AND CHAINS BEST SUITED FOR BOTH LOAD AND FUNCTIONALITY

4.2 Storage in a warehouse

Should it be necessary to store the fan in a warehouse, it must be protected from atmospheric
conditions, humidity, dust and any harmful substances present in the air.
We recommend that you periodically check that the fan is in a good condition and turn the fan
rotor manually approximately once a month to prevent the deformation of its bearings.

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4.3 Lifting methods for fans

4.3.1 Lifting centrifugal fans in arrangement 1

Fans in installation type 1 are not fitted with a

motor, To lift these fans, use the specific lifting

holes in the fan structure itself (as shown Fig. 4.1)

Fig. 4.1 Example of lifting centrifugal fans in arrangement 1

4.3.2 Lifting centrifugal fans in arrangement 4

Fans in installation type 4 are equipped with a

motor. When lifting these fans, as well as using
the specific holes in fan structure, the eyebolt for
lifting the motor must also be used (as shown Fig. 4.2).

Fig. 4.2 Example of lifting centrifugal fans in arrangement 4

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4.3.3 Lifting double intake centrifugal fans 4.3.6 Lifting centrifugal fans in arrangement 8

Fig. 4.3 Example of lifting double intake Fig. 4.6 Example of lifting centrifugal fans in
centrifugal fans arrangement 8

4.3.4 Lifting axial fans in arrangement 9

4.3.7 Lifting fans packed in crates
The weight of the crate is indicated on its side.

Fig. 4.4 Example of lifting axial fans in

arrangement 9

4.3.5 Lifting axial fans in arrangement 4

Fig. 4.7 Example of lifting fans packed in crates

THE EXAM PLES GIVEN ABOVE ARE

GENERIC EXAMPLES AS IT IS IMPOSSIBLE
TO KNOW IN ADVANCE EVERY
POSSI B LE CONF IGURA TI ON FOR
LIFTING A RUCON F A N

ANY OTHER LI FT ING POINT NOT SHOWN

ABOVE IS IN DICATED BY THIS SYMBOL

Fig. 4.5 Example of lifting axial fans in

arrangement 4

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4.4 Installation
The fan does not require the preparation of a special machine bed for its installation. A well-
levelled concrete surface that can support the weight of the fan is sufficient.

ALWAYS USE ANTI-VIBRATION SUPPORTS AND COUPLINGS TO PREVENT THE

TRANSMISSION OF VIBRATIONS WHILE THE FAN IS RUNNING.

The support base must be perfectly level and flat to prevent any torsional effects or misalignment of the supports:
if necessary, install metal shims between the machine base and the concrete surface to ensure a perfect fit.
Use the factoryfitted anchoring points and take care not to deform the fan structure while tightening bolts.
All connecting tubing must be supported sperately and must be axially aligned with the fan’s intake and outlet
nozzles,
to prevent any deformation occurring while tightening the bolts.

ALL INSTALLATION WORK MUST ONLY BE CARRIED OUT BY QUALIFIED AND

AUTHORISED PERSONNEL USING SUITABLE EQUIPMENT

4.4.1 Minimum distances between components

If the available space permits, in installations where the intake is connected to a pipe, we recommend fitting a
straight length
of pipe with a length approximately 2.5 times the diameter of the fan rotor, to guarantee correct air flow into the
intake.

Fig. 4.8 Minimum installation distance with intake pipe

With installations with an open air intake, we recommend leaving a distance equal to approximately 1.5 times the
diameter of the fan rotor between the fain intake and the nearest wall or machine.

Fig 4.9 Minimum installation distances with open intake

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4.5 General warnings for lifting and installing parts disconnected from

the fan for shipping

For transport purposes, the fan may be delivered with a number of its components disconnected.

WARNING: ALL TRANSPORT, INSTALLATION AND ASSEMBLY OPERATIONS MUST

ONLY BE CARRIED OUT BY QUALIFIED PERSONNEL.

WARNING: DISCONNECTED OR DISASSEMBLED COMPONENTS MUST ONLY BE

HANDLED AND HANDLED USING SUITABLE TRANSPORT EQUIPMENT.

USUALLY, NO SPECIAL OR DEDICATED EQUIPMENT IS REQUIRED FOR LIFTING

AND REFITTING THE FAN COMPONENTS.

SHOULD THE INSTALLATION OF A COMPONENT REQUIRE A SPECIAL PROCEDURE,

RUCON WILL SUPPLY THE SUPPLEMENTARY INFORMATION NEEDED FOR A
CORRECT INSTALLATION.

4.5.1.1.1 Single intake centrifugal fans

For fans in installation types 1-8-9-12, which are supplied disassembled in two or more parts,
carry out the following procedures.

STEP 1: Positioning the house [1] (or positioning the lower part of the housing if it has been
disassembled into two or more parts). The housing must be positioned correctly on the concrete
surface so that tightening is fixing bolts will not cause tension of deformation. If necessary,
fit shims at the fixing points.

STEP 2: Positioning the frame [2] (where the frame is supplied dismounted from the housing).
Proceed as described in step 1.

STEP 3: Positioning the supports [3].

Rucon fans are fitted with one of the following types of support:

Single block construction ST supports, with ball and/or roller bearings.

SN type upright supports with self-aligning ball and/or roller bearings.

While installing the bearings on the shaft, we recommend that you follow the guidelines given below:
When installing upright supports with ball or roller bearings, fits the bearings into position on the shaft
without securing them.Position the lower part of the support on the frame and fit the securing bolts without
tightening them. Position the shaft so that the bearing fits into its seating in the support. Secure the bearing
and check the free play against the values given in table 12.1 “Checking the radial free play of the bearings”
while securing the conical bushings.The bearing caps in upright supports are not interchangeable.
Finally, secure the support to the frame
by tightening the bolts. The support must be positioned so that the shaft can be subsequently levelled and so
that the rotor position can be set at the right distance from the nozzle (see step 7).

STEP 4: Fitting the fan rotor onto the shaft [4].

Ensure that all the mating surfaces are free of any of burrs or imperfections. If necessary, remove with a fine
file or an abrasive cloth. Position the key into the special slot and lubricate the shaft with a light layer of
grease. Fit the rotor onto the shaft, ensuring that it is kept perpendicular to the motor shaft or support
centre line. It is of vital importance that no resistance should be encountered during this operation
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and the rotor must be fixed in place by the action of the securing screw alone. Do not tighten the
securing screw in the rotor hub completely until final alignment has been performed.

STEP 5: Completion of assembly of the housing (only where the housing was supplied in more than
one piece). This is carried out after fitting the rotor. Spread adhesive on the mating surfaces and fit the
sealing cord (supplied with the fan). Position all the components of the housing and tighten all the bolts.

WHEN PUTTING THE COMPONENTS INTO

POSITION, TAKE CARE NOT TO KNOCK THE
ROTOR, AS THIS COULD COMPROMISE ITS BALANCE.

STEP 6: Fitting the intake nozzle [9] (only for fans fitted with one).
The nozzle must be secured between the side of the housing and the intake pipe flange. It can be moved
horizontally and vertically to align it perfectly with the rotor.Tighten the bolts only after the nozzle has
been correctly aligned with the rotor and after turning the rotor manually to ensure that there is no contact
between the two components. Allen reference screws are installed to maintain the original centred
position during any subsequent disassembly and reassembly.

STEP 7: Levelling the shaft

This operation must be carried out with all the bolts tightened completely. Check that the shaft is
perpendicular relative to the housing and that it is level. Check that distance between the rotor and the
nozzle is exactly correct and remains constant. The exact position is achieved by lifting and shifting the
supports slightly. All the bearings are self-aligning, however, to ensure perfect fan operation and that the
gaskets seal properly, the shaft must be perfectly aligned in its seats in upright supports.

STEP 8: Fitting and tensioning pulleys and belts [6] (only for installation types 1, 9 and 12,
see figure bellow)

Fig 4.10 Assembly of a fan in arrangement type 12

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4.5.2 Centrifugal fans with double intake

To install fans in installation type 3D, proceed as

follows:
STEP 1: Positioning the housing [1] (or
positioning the lower part of the housing if it has
been disassembed into two or more parts)
Proceed as described in step 1 for the installation
of single intake centrifugal fans.
STEP 2: Completion of assembly of the
housing (only where the housing was supplied in
more than one piece) .
See step 5 in the previous description.
STEP 5: Installation of the shaft [8].
Fit the shaft with the rotor already installed onto it
into the housing.
.
STEP 6: Positioning the nozzle [9] and the
support holder drum [10].
Install the above components on the side opposite
the transmission.
STEP 7: Levelling the shaft.
Proceed as described in step 7 for the installation
of single intake centrifugal fans.

STEP 3: Positioning the nozzle [6] and the

support holder drum [7]. STEP 8: Fitting and tensioning pulleys and
belts [11]
(Only for installation types 3D and 11D,
Install the above components on the transmission
side. see Fig. 4.11 and see section 7.3 for tensioning
procedure) .
STEP 4: Positioning the supports [3]

This installation type is always fitted with SN type upright supports (follow the indications given in
Step 3 of theinstallation of single intake centrifugal fans).

Fig. 4.11 Assembly of a double intake centrifugal fan

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4.5.3 Axial fans

STEP 1: Positioning the motor [1]

STEP 2: Positioning the support [2]

(only for installation types 9 and 12)
Belt driven axial RUCON fans are all fitted with mono-block construction ST supports (see Table
8.1 "ST-Supports in installation types A-AL-B-BL").
The indications for installation are the same as those given for single intake centrifugal fans (see step 3).

STEP 3: Fitting and tensioning pulleys and belts [4]

(Only for installation types 9 and 12, see section 7.3 for tensioning procedure).

STEP 4: Fitting the rotor [3] onto the shaft

Check that the rotor is coaxially aligned with the drum. If necessary, fit the compensator shims
Tighten the securing nuts completely.

Fig. 4.12 Assembly of an axial fan

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4.6 Installing and adjusting belt drives and final checks

If the fan is fitted with V-belt drive, install the transmission as follows:

Clean the conical components and the hole in the bushing carefully before fitting into the pulley.

Fit the bushing into the pulley, ensure that the threaded half-holes in the pulley match up with the
non-threaded half-holes in the bushing.

Hand-tighten only the screws.

Fit the whole unit onto the shaft, after having cleaned it tho Roughly.

Position the pulleys and check their alignment with a ruler.

Secure the unit tightening all screws diagonally.

Fit the belts.

Do not use a lever to force the belt into place, as this could break the belt’s internal reinforcing fibres.

Before tensioning the belt, mark off a known length along the tensioned side (e.g. 100 mm).

Then tension the belt gradually while turning the transmission (as described in section 7.3 "Belt
tension adjustment and cleaning") until the belt has been extended by:

0.8% with uniform torque;

1% with irregular torque.

E XCESSIVE B E LT TENSION CAN DAMAGE

THE BEARINGS AND LEAD TO THE
BREAKAGE OF THE SHAFT

With flexible coupling type transmissions, the alignment must be checked before the fan is run,
as the frame may have been subjected to distortion due to transport or loosening of the foundation bolts.

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4.7 Electrical connections

The fan’s power supply line must have a sufficiently high power rating.
Connection to the main power grid must only be carried out by qualified personnel. Also, the client is responsible
for the entire electrical system up to motor terminal board.
We remind you of the importance of installing a safe connection to earth for the fan.
The earth connection system must comply with legislation in effect in the country of installation and must be
periodically checked by qualified personnel.
Make the connection to earth before any other connection.
Check that the connection layout (see figure bellow) is suited to the main power voltage.
Usually, standard electric motors can run in both directions indifferently. To invert the direction of the rotation,
simply swap over any two power cables directly on the terminal board.
The client must also install an electrical disconnecting device near the fan so that maintenance personnel can have
direct control over the power supply to the fan.
CAUTION: THE CLIENT AND/OR THE INSTALLER OF THE ELECTRIC SYSTEM IS RESPONSIBLE FOR CHOOSING THE
EQUIPMENT AND CABLES USED FOR CONNECTING THE FAN ELECTRICALLY, BASED ON THE DIMENSIONS OF THE
MOTOR INSTALLED AND THE CHARACTERISTICS OF THE MAIN POWER SUPPLY.
All work performed on the electrical system must only be carried out with the fan at rest and electrically
disconnected from the mains.
Before installing/starting up, ensure that the information on the identification plate on the motor is compatible
with the main power supply.

Fig. 4.13 Electrical connection layouts for one and two-speed electric motors

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4.8 Connections to pipes

Connections between the fan and pipes must be made ensuring that all components are correctly
aligned and that there are no obstructions in the tubing caused by gaskets or flexible parts. The
weight of the tubing must not be supported by the fan and care must be taken not to deform any part
of the fan during tightening of the connections to the pipes.
If the available space permits, in installations where the intake is connected to a pipe, we recommend
fitting a straight length of pipe with a length approximately 2.5 times the diameter of the fan rotor,
to guarantee correct air flow into the intake.

Fig. 4.14 Minimum installation distances with

intake pipe

With installations with an open air intake, we recommend leaving a distance equal to approximately 1.5
times the diameter of the fan rotor between the fain intake and the nearest wall or machine.

Fig. 4.15 Minimum installation distances with open

intake

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5 CHECKS TO BE MADE BEFORE AND AFTER STARTING

5.1 Preliminary checks
PRELIM INARY CHECK S MUS T ONLY B E
PERFORM ED WITH THE FAN AT REST AND
DISCONNECTED FROM THE POWER SUPPLY

When starting the fan for the first time, the

following preliminary checks are necessary:

1. Check that all bolts are correctly tightened

2. (rotor, supports, foundation bolts, transmission components).
3. Check the lubrication of the fan and motor
bearings; if necessary, regrease (see section 7 Maintenance).
4. Check that all rotating parts can turn freely.
5. Check that there are not foreign objects inside the fan.
6. Check that the fan turns in the correct direction: power the motor for a brief moment
to see if it turns in correct direction indicated by the arrow on the fan housing; if necessary,
invert the direction of rotation (see Electrical connections).
You may now start the fan. With centrifugal fans, close off the air intake partially to reduce the
power peak at start-up and the motor starting time. Axial fans must never be run with completely closed nozzles.

5.2 Checks to be carried out with the fan running

Check that the power absorption does not exceed the value indicated on the motor identification plate,
if it does, stop the fan immediately and contact the manufacturer.
The fan must run without excessive vibration and noise.
Check, with the fan at rest and at an outside air temperature of 20°C, that the bearings do not
exceed the maximum operating temperature (maximum bearing temperature 70°C). During the
first few hours of operation, it is normal for the bearings to reach slightly higher temperatures, as
long as they later stabilise at a lower value. In the event of overheating of the bearings, contact the
technical assistance department. After 3-4 operating hours, with the fan at rest and
disconnected from the power supply, check again that all bolts are correctly tightened, the bearing
temperature, and, with belt driven fans, the temperature and tension of the belts.

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6 MALFUNCTIONS AND CAUSES
6.1 Centrifugal and axial fans
The following table lists the main problems that you may encounter using a fan. For
problems that are not common to both types of fan, we have specified whether it is
specific to centrifugal or axial fans
PROBLEM
Power absorption lower
Than nominal value
High power absorption
High power absorption
Insufficient pressure
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REASON
Insufficient air flow
(centrifugal fans only)
Excessive air flow
(centrifugal fans only)
CAUSE
Rotational speed too low
Nozzle or tubing partially
obstructed (centrifugal fans only)
Fan rotor partially obstructed
(centrifugal fans only)
the system higher than the
design value (centrifugal fans only)
density higher than the design value
Inverted direction of rotation
(centrifugal fans only)
Excessive rotational speed
Pressure resistance offered by
the system lower than the
design value (centrifugal fans only)
Fluid density higher than the design
value
Air flow already rotating in the
opposite direction to the fan
rotation direction
Motor power supply voltage
lower than the value indicated
on the identification plate
Faults in the motor wind i ngs
Air flow value lower than the
design value (axial fans only)
Rotational speed too low
Fluid density lower than the
design value
Inverted direction of rotation
(axial fans only)
Air flow value higher than the
design value (axial fans only)
RUCON Ventilatoren NV

PROBLEM REASON CAUSE

Low air flow

Fluctuations in air flow due to
Fluctuating fan operation Unstable air flow fans working in parallel
Vortices in the air induced by
equipment near the air intake

Vibrations Fluctuating fan operation (see previous cause)

Vibrations Unbalanced rotating Fan rotor wear

components Deposits on the fan rotor

Contact between moving and

stationary components
Vibrations Mechanical malfunction Intrinsic fault in the bearings
or defects Malfunction of the bearings
due to unbalanced rotor or
excessive belt tension

Contact between moving and

stationary components Vibrations
Excessive noise Fluctuating fan operation
Electromagnetic fault in motor
Orifices or sharp angles in tubing

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7 MAINTENANCE

Read this section carefully before starting any maintenance work on the fan: these indications
will ensure safer working conditions for the personnel involved and more reliable results of
the maintenance work carried out. Safety procedures adopted during fan
maintenance must take into account the following:
• Maintenance and lubrication operations must only be carried out by qualified and expert
personnel, authorised by the factory technical management department in accordance with
safety directives and regulations and using only suitable tools, equipments and materials for the job.
• While performing maintenance work, all personnel involved must wear appropriate
clothing, such as tight fitting work overalls and accident prevention shoes. Loose fitting
clothes or clothes with hanging parts must be avoided at all costs.
• During maintenance, cordon off the fan and place signs around the fan indicating
“FAN UNDERGOING MAINTENANCE”

During any maintenance procedure, the fan must be:

• disconnected and insulated from the electric power supply;

• disconnected from elastic coupling to the motor, if fitted;

• disconnected from the drive belts by removing the belts from the pulleys, where fitted.

The head of maintenance must set up a team made up of persons capable working in a
coordinated fashion and ensuring the utmost safety of those surrounding them. All persons
Involved in maintenance must be in constant visual contact among themselves to be able to
warn each other of any hazards present.
:

CAUTION: ANY TRANSPORTING OPERATION OF PARTS DISMANTLED FROM THE FAN OR TO BE FITTED TO THE

FAN MUST ONLY BE CARRIED OUT WITH SUITABLE TRANSPORT EQUIPMENT.

USUALLY, NO SPECIAL OR DEDICATED EQUIPMENT IS REQUIRED FOR LIFTING AND REFITTING THE

FAN COMPONENTS.

AN INTEGRATED MAINTENANCE PROGRAM IS NECESSARY FOR NORMAL AND CORRECT OPERATION OF THE FAN,

AND ALSO ENSURES GREATER SAFETY FOR THE OPERATOR.

REGULAR CLEANING AND MAINTENANCE, TOGETHER WITH LUBRICATION, ARE VITAL FOR ENSURING

CORRECT OPERATION AND GREATER DURABILITY OF THE FAN

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7.1 Bearing lubrication

Check and follow the programmed lubrication intervals correctly.

The bearings installed in the supports of transmission driven fans must be lubricated according to a program of
lubrication intervals with the amount of grease indicated on the transmission specifications enclosed with the
documentation delivered together with fans supplied with transmissions. For fans types 1 or 3D (exposed shaft, no
transmission) consult the following table for the correct lubrication intervals. Perform lubrication using the grease
specified or an equivalent. Lubricating intervals must be reduced if the fan is operated in a dusty, hot, humid or
corrosive environment, by approximately 40% or more relative to the value indicated in the transmission specifications
list, depending on actual operating conditions. An excessive quantity of grease caused overheating of the bearings,
therefore do not fill the supports with more grease than is specified.
Unless stated otherwise, the following is used as standard during the construction of Rucon fans:

SHELL ALBIDA GREASE RL2

This is a lithium soap complex based grease and has a dropping point of 260°C (IP132/ ASTM D566) and a working
penetration value at 25°C – 0.1mm (IP50/ ASTM D217) of 265÷295. Kinematic viscosity (IP71/ ASTM D445): at 40°C,
100cSt; at 100°C, 11.2 cSt.

The following greases have compatible characteristics:

Usually, the bearings on motors up to size 160 are lubricated for life and therefore do not require re‐greasing.

Check and follow the programmed lubrication intervals specified by the motor manufacturer. However, we recommend
periodically replacing the bearings with the type indicated on the motor identification plate.

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7.2 Checking spherical roller bearings

Before fitting a bearing, the internal radial free play under the highest roller must be measured with a feeler gauge
(see figure below). During installation, check repeatedly the reduction in internal free play under the lowest roller.
Correct installation requires the reduction of the internal free play and a residual minimum free play value as specified
in this table:
BEARING TYPE REDUCTION IN RADIAL FREE PLAY RESIDUAL MINIMUM FREE PLAY
(mm) AFTER INSTALLATION (mm)

22216 EK From 0.040 till 0.050 0.025

22218 EK From 0.045 till 0.060 0.035

22220 EK From 0.045 till 0.060 0.035

22222 EK From 0.050 till 0.070 0.050

22224 EK From 0.050 till 0.070 0.050

22228 CCK/W33 From 0.065 till 0.090 0.055

Fig 7.1 Checking the radial free play of the bearings

7.3 Belt tension adjustment and cleaning

The following is a simplified method for setting the tension of V‐belts: Consult the table at the next page to
determine the profile type and, for the diameter of the smallest pulley, the load for each belt value, P. The same
table also gives you the L value.
LxI

Using the formula: Le= 100

Where:
Le= deflection in [mm] at the centre point of the length between pulley axes I
L= deflection per 100mm of length between pulley axes
I= length between pulley axes [mm]
Calculate the value Le by applying a load P perpendicularly to the section of belt, the transmission should reach
the calculated deflection value Le.

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Fig 7.2 Checking the belt tension

As a general rule, check the belt tension after the first 8 operating hours and then after every 800 operating hours.
Reset if necessary. Replace all belts if their wear is liable to compromise correct operation of the transmission
due to an insufficient pretension value or due to slippage over 4‐5%. Belt wear depends on many factors, among
which environmental conditions, number of operating hours and how many start‐ups the fan has undergone.
Manufacturers of standard V‐belts recommend that they should not be used at environmental temperatures
over 80°C, special belts are required for operation at higher temperatures. Dirty belts must not be cleaned with
solvents such as petrol or benzene, turpentine etc., or with abrasive or sharp objects. When cleaning belts, we
recommend the use of a 1:10 mixture of alcoholand glycerine. Transmissions fitted on Rucon fans have two or
more belts.

Table en Fig. 7.3 Setting the belt tension: test load and deflection

IN THE EVENT OF THE BREAKAGE OF ONE OR MORE BELTS, WE RECOMMEND THE REPLACEMENT OF ALL
BELTS IN THE TRANSMISSION.

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7.4 Flexible couplings

Periodically, and in accordance with operating conditions, check the axial free play S, the angular alignment Amax‐Amin
and the parallel alignment R (figure below) of flexible couplings. Check the condition of hubs and lubricate every 3000
operating hours, using the recommended types and quantities of lubricant (see table). The couplings normally used are
Falk Steelflex T10 and Hansen Ecoflex BT (for further information, contact the respective manufacturer.)

Table 7.4 Technical specification of elastic couplings

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7.5 Checking and cleaning parts in contact with the fluid

The fan rotor should be cleaned regularly to prevent vibration caused by dust accumulating on the blades during
operation.
If the fan is used to pump even slightly dusty air, air containing abrasive powders or for the pneumatic transport
material, the cleanliness and wear of the fan rotor must be checked regularly.
Dirt deposits on the rotor or wear of parts of the rotor can cause undesirable vibrations during fan operation.
If any part of the rotor is excessively worn, it is imperative that the rotor is replaced (for this you must contact Rucon
Technical Service).

For any information and before carrying out any modification to one of our fans, please contact the Rucon technical
department and quote the serial number found on the fan identification plate.

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8 Technical tables
8.1 “ST” supports in installation types A-AL-B-B-BL

Fig 8.1 ST supports in installation types A-AL-B-BL

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8.2 SN Supports in installation types B-BL-BL/B

Fig 8.2 SN Supports in installation type B-BL-BL/B

Table 8.2

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8.3 Supports and bearings fitted as standard in belt driven fans

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9 Disassembly
ALL THE DISASSEMBLY AND RE‐ASSEMBLY OPERATIONS DESCRIBED BELOW MUST ONLY BE CARRIED OUT BY
QUALIFIED AND AUTHORISED PERSONNEL. FOR NO REASON WHATSOEVER MUST THE OPERATOR OR FACTORY
MAINTENANCE PERSONNEL CARRY OUT THESE OPERATOINS
CAUTION: ALL DISASSEMBLY AND RE‐ASSEMBLY MUST BE CARRIED OUT WITH THE FOLLOWING CONDITIONS:

A) YOU MUST BE ABSOLUTELY CERTAIN THAT THE FAN IS COMPLETELY STATIONARY (FAN ROTOR AT REST); DISCONNECT THE
ELECTRICAL POWER AT THE MAIN PANEL WITH THE SWITCH, LOCK THE SWITCH WITH A PADLOCK AND HAND THE KEY OF
THE LOCK TO THE HEAD
OF MAINTENANCE
B) THE WORKING ENVIRONMENT MUST BE EQUIPPED WITH EVERY TOOL NECESSARY AND MUST BE FREE OF ANY HAZARDS
C) EVERY PIECE TO BE REFITTED MUST BE THOROUGHLY CLEANED, DEGREASED AND LUBRICATED AS NECESSARY BEFORE
REFITTING.

9.1Intake nozzles

Undo the nozzle securing nuts from the fan housing. Slide out the nozzle.

9.2Housing

With all orient able fans, the housing is secured to the frame by bolts. Simply undo the securing nuts at the frame plate.
With non‐orient able fans with single‐piece housings, the housing cannot be disassembled.
The housing in certain fan types may be divided into two or more pieces, secured together by bolts.
9.3Fan rotor

Remove the nozzle and, where possible, the fan housing.

With single intake fans: remove the screw together with the lock‐ring and use a suitably sized extractor.
We recommend setting up a support for the rotor before extracting it completely.
With double intake fans: remove the drive belts and pulley. Remove the securing bolts from the supports and remove the
nozzle
from the transmission side. This operation requires the support on the transmission side to be held up using the eyebolt,
which must
be screwed into the threaded hole at the end of the shaft. Extract the support complete with the rotor. Loosen the lock ring
and slide
off the rotor.
With axial fans: unscrew the lock nut, remove the conical bushing and slide out the rotor, using an extractor if necessary.
If any event, this operation must always be carried out with great care, avoiding any knocks that could alter the balance of
the rotor or deform it.

9.4 Pulleys

The pulleys installed on transmission‐fitted Rucon fans are pulleys for taper lock type conical bushing. To remove a pulley,
remove the locking screw and fit another one in the free hole. Screw this screw in until the hub is free.

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9.5 Support

If the support is fitted with a two‐piece cooling fan, loosen the bolts and remove it.
With single‐block construction supports: remove the securing screws for the covers and slide the shaft out.
Slide the bearings out with an extractor.
With upright supports: remove the screws and open the upper covers. Remove the arrestor half rings, loosen the ring from
the safety washer and slide out the traction bushing.

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10 Scrapping the fan

At the end of the fan’s useful life, the user company is responsible for scrapping the fan, taking care in particular of emptying
all lubricating liquids, generally cleaning all components and then separating the fan’s parts into components and electrical
material. Different materials must be collected separately, for example: electric motors (copper windings), metal
components (structural components, etc.), plastics, etc., and then correctly disposed of separately.

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11 Technical enclosures

11.1 Tightening torques for nuts and bolts

The tightening torques M given in the table are applicable in the following conditions:

- Hexagonal head UNI 5737 type screws, cylindrical head UNI 5931 and UNI 6107 type screws, in the normal conditions in
which they are supplied.
- Tightening torques must be applied slowly using a torque wrench.

While maintaining the same pre‐load values, tightening torques must be modified as described below in the following cases:

- Increased by 5% for wide‐head UNI 5712 screws

- Reduced by 10% for zinc plated oiled screws
- Reduced by 20% phosphor coated oiled screws
- Reduced by 10% if the screw is tightened with an impulse tightener.
-
11.1.1 Tightening torques M for bolts with ISO metric head

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RUCON VENTILATOREN NV
INDUSTRIEWEG 7
2630 AARTSELAAR – BELGIUM
TEL : + 32 (0)3 877 07 76
FAX + 32 (0) 3 877 08 57