O&m - Unilever Ventilation

Operation and Maintenance Manual
Mechanical System – Ventilation
FAST – UNILEVER HUB
WAREHOUSE
FAST SERVICES CORPORATION
Cabuyao, Laguna
OPERATION AND
MAINTENANCE MANUAL
FOR VENTILATION
1 Cabuyao, Laguna
TABLE OF CONTENTS
Section I Emergency / Vendors Contact Information
and
Warranties/ Guarantees Certificates
A. Emergency Vendors Contact information
B. Warranties/ Guarantees Certificates
Section II System Instruction and Information
A. System Description
B. System Operation
C. System Maintenance
Section III Equipment Data and Recommended Spares
A. Equipment Data
B. Recommended Spares
Section IV Manufacturer's Literature
Section V Commissioning Data
Section VI Drawing index and As-Built Drawings
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Section I Emergency / Vendors Contact
Information and Warranties/ Guarantees
Certificates
3 Cabuyao, Laguna
A. Emergency / Vendors Contact Information
4 Cabuyao, Laguna
GENERAL CONTRACTOR
Company Name: RIC-MALEN CONSTRUCTION INCORPORATED
Company Address: PHASE 3B BLK.1 LOT 28 SOUTHGROVE MACA-

RIA AVENUE
PACITA COMPLEX 1 BIÑAN, LAGUNA
Contact Persons / Designation: RICARDO FERNANDO / GENERAL MANAGER
Telephone Number: (02) 529 3763 / 868 3094
Facsimile Number: (02) 398 5818
Email Address: rgf_malen@yahoo.com
Webmail: www.rmci-ph.com
Warranty:
5 Cabuyao, Laguna
SUPPLIER:
• EXHAUST FAN
• TUBULAR CENTRIFUGAL IN-LINE
• CABINET TYPE CENTRIFUGAL FAN
• VANE AXIAL FAN
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B. Warranties/ Guarantees Certificates
7 Cabuyao, Laguna
CERTIFICATE OF WARRANTY
AS PART OF OUR RESPONSIBILITIES AND ACCOUNTABILITY FOR

OUR WORKMANSHIP IN THE JUST COMPLETED PROJECT FOR
FAST SERVICES CORPORATION – UNILEVER MEGA DC
WAREHOUSE. ALL VENTILATION UNITS (NIAGARA) ARE
GUARANTEED FOR:
• WORKMANSHIP INSTALLATION: ONE (1) YEAR
BRAND NAME: NIAGARA

TYPE:
• EXHAUST FAN
• TUBULAR CENTRIFUGAL IN-LINE
• CABINET TYPE CENTRIFUGAL FAN
• VANE AXIAL FAN
R & M (RIC-MALEN) CONSTRUCTION INC. WILL WARRANTY THE

DEFECTS IN MATERIALS AND WORKMANSHIP INCLUDING THE
COMPRESSOR FROM THE DATE OF PROJECT TURN OVER TO
FAST SERVICES CORPORATION.
NOTE: THIS SERVE AS OUR OFFICIAL SERVICE WARRANTY.
SUBMITTED BY:
_______________________________
ENGR. RICARDO G. FERNANDO
General Manager
8 Cabuyao, Laguna
Section II System Instruction and Information
9 Cabuyao, Laguna
A. System Description
10 Cabuyao, Laguna
SYSTEM DESCRIPTION
INTRODUCTION
Ventilation is the intentional introduction of outdoor air into a space and is mainly used to control indoor
air quality by diluting and displacing indoor pollutants; it can also be used for purposes of thermal com-
fort or dehumidification.
The intentional introduction of outdoor air can be categorized as either mechanical ventilation, or natural
ventilation.[2] Mechanical ventilation uses fans to drive the flow of outdoor air into a building. This may
be accomplished by pressurization (in the case of positively pressurized buildings), or by depressuriza-
tion (in the case of exhaust ventilation systems). Many mechanically ventilated buildings use a combi-
nation of both, with the ventilation being integrated into the HVAC system. Natural ventilation is the in-
tentional passive flow of outdoor air into a building through planned openings (such as louvers, doors,
and windows). Natural ventilation does not require mechanical systems to move outdoor air, it relies
entirely on passive physical phenomena, such as diffusion, wind pressure, or the stack effect. Mixed
mode ventilation systems use both mechanical and natural processes. The mechanical and natural com-
ponents may be used in conjunction with each other or separately at different times of day or season of
the year.[3] Since the natural component can be affected by unpredictable environmental conditions it
may not always provide an appropriate amount of ventilation. In this case, mechanical systems may be
used to supplement or to regulate the naturally driven flow.
Categories of Ventilation
• Mechanical ventilation refers to any system that uses mechanical means, such as a fan, to introduce
subaerial air to a space. This includes positive pressure ventilation, exhaust ventilation, and bal-
anced systems that use both supply and exhaust ventilation.
• Natural ventilation refers to intentionally designed passive methods of introducing subaerial to a
space without the use of mechanical systems.
• Mixed mode ventilation (or hybrid ventilation) systems use both natural and mechanical processes.
• Infiltration is the uncontrolled flow of air from outdoors to indoors through leaks (unplanned open-
ings) in a building envelope. When a building design relies on environmentally driven circumstantial
infiltration to maintain indoor air quality, this flow has been referred to as adventitious ventilation.
Mechanical ventilation of buildings and structures can be achieved by use of the following techniques:
• Whole-house ventilation
• Mixing ventilation
• Displacement ventilation
• Dedicated subaerial air supply
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B. System Operation and Maintenance
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Exhaust/Supply Fan
Capacity: to 52,576 CFM, to 3/8” SP
Size: 18” to 60” wheel diameter
Arrangement: Direct drive or Belt driven
Use: Ventilation system, exhaust of warm air and fresh air supply
Tubular Centrifugal Inline Fan

Capacity:to 140,000 CFM, to 14” WG
Size: 12” to 73” wheel diameter
Arrangements: Direct drive or belt driven
For more info: Request for Bulletin 171
Vaneaxial Fan
Capacity: to 100,000 CFM, to 5” WG
Size: 12” to 60”(BD) & 18" to 60"(DD) wheel diameter
Arrangements: Direct drive or belt driven
For more info: Request for Bulletin 671
13 Cabuyao, Laguna
Exhaust/Supply Fan
OPERATION
Pre Start Inspection

• Lock out all power sources
• Inspect all fasteners and set screws and tighten as required
• Inspect belt alignment and tension
• Confirm power source voltage and motor voltage are the same and that the motor is wired correctly
• Rotate the fan blade to ensure that neither the fan blade nor the belts come into contact with the
housing
• Inspect the fan and the ductwork to ensure they are free of debris
• Check to ensure that all guards and accessories are securely mounted
• Check to be sure the propeller rotation is correct
Start Up
Turn the fan on and inspect for the following.
• Direction of rotation
• Improper motor amperage
• Excessive Vibration
• Unusual Noise
• Improper belt tension or alignment
If a problem is discovered shut off the fan and refer to the section on troubleshooting to discover
the cause of the problem. The fan should be inspected after 30 minutes, 8 hours and 24 hours of oper-
ation to ensure all fasteners are tight and belts are properly tensioned and aligned.
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MAINTENANCE
WARNING
Disconnect and secure to the OFF position all electrical power to the fan prior to inspection or servicing. Fail-
ure to comply with this safety precaution could result in serious injury or death.
• Ventilators should be checked at least once a year. For critical or severe applications a routine check
every two to three months is suggested.
• When removing or installing a belt don’t force the belt over the sheave. Loosen the motor mount so
that the belt can be easily slipped over the sheave.
• The belt, on belt driven units, should be removed and carefully checked for cracks, ply separation or
irregular wear. A small irregularity in the contact surface of the belt will result in noisy operation. If any
of these defects are apparent the belt should be replaced. At the same time check the sheaves for chips,
dents or rough surfaces that could damage the belt.
• The correct belt tension is important. Too tight a belt will result in excess bearing pressure, which can
cause premature bearing failure and may cause the motor to overload, too loose a belt will result in
slippage, which will burn out belts. Proper belt deflection should be 1/64” (half way between sheave
centers) for each inch of belt span when a force of approximately 5 lbs. is applied.
• The belt alignment should be checked to be sure that the belt is running perpendicular to the rotating
shafts. Motor and drive shafts must be parallel.
• A periodic inspection of all fasteners should be carried out to ensure they have not loosened due to
vibration. Particular attention should be paid to fasteners attaching the wheel to the shaft and those
attaching the shaft to the bearing.
• The standard pillow blocks on belt driven fans are factory lubricated. These bearings should be lubri-
cated on a semi annual basis (more frequently in severe applications) using a high quality lithium based
grease. With the unit running add grease very slowly, using a manual grease gun, until a slight bead of
grease forms at the seal. Be careful not to unseat the seal by over lubricating or by using excessive
pressure. When the bearings are obstructed from view use no more than three injections with a hand
operated grease gun
• Dust and dirt on the exterior surface of the motor, fan panel and the entire fan wheel should be re-
moved, at intervals determined by the severity of the application, to ensure proper service life and safety.
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Belt and Pulley Replacement
In the course of regular maintenance the belts and pulleys may have to be changed and or adjusted the
recommended procedure is as follows.
• Do not change the pulley pitch diameter in order to tension the belts. This will result in a change in the
fan speed.
• Loosen the nuts on the motor plate or motor in order to reduce the belt tension such that the belts will
easily slip over the pulleys. Never force the belts over the rim of the pulley.
• Loosen the setscrews on the pulleys and remove from either the motor or fan shaft using a two or three
jaw puller.
• Remove any shaft imperfection such as setscrew mark using a file or emery cloth.
• Install the replacement pulleys tightening all setscrews to the recommended torque rating (see chart)
and ensuring that they are properly aligned.
• Pulley alignment is achieved by moving the pulleys on their respective shafts or moving the entire
motor until the pulleys are correctly aligned (see figure). Using a square with one edge parallel to the
motor shaft adjust the pulleys until the other edge is parallel to the belts.
• Slip the belts over the pulleys then adjust the motor/ motor plate until the proper tension is reached
(1/64” deflection, half way between pulley centers, per inch of belt span when pressed firmly).
• Tighten the motor plate/ motor adjusting nuts in place.
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Bearings Replacement
Leader Fan Industries uses pillow block bearings.

• Before removing the bearings mark the positions of the fan blade, bearings and pulley on the
shaft.
• Note the clearance between the fan blade and the venturi.
• Remove the pulley and fan blade from the shaft using a puller.
• Unbolt the bearings and remove the shaft and pillow blocks as one unit.
• Clean the shaft and remove any marks using a file or emery cloth then remove the bearings
using a bearing puller.
• Inspect the shaft and replace if necessary.
• Mount the new bearings on a section of the shaft that is not worn by tapping the inner ring
face using a soft mallet.
• Align the setscrews on the bearings and then tighten one setscrew on each bearing.
• Loosely install the bearings on the bearing mount.
• Rotate the shaft to find the center of free movement.
• Install the propeller adjusting the bearing location to center the blade in the venturi.
• Tighten the bearing bolts to the proper torque rating (see chart)
• Turn the propeller by hand the propeller should rotate freely with the same resistance as be-
fore the bearing bolts were tightened.
• Tighten all setscrews to the proper torque rating (see chart)
• Install pulley and adjust belt tension.
You should go through the start up steps as outlined above.
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PARTS LIST
MODELS: DDS, DDP, ADD
FAN ASSEMBLY
ITEM DESCRIPTION QUANTITY
1 WELDED FAN ASSEMBLY 1
2 PROPELLER 1
3 PROPELLER BUSHING 1
4 MOTOR 1
FAN ASSEMBLY
ITEM DESCRIPTION QUANTITY
1 WELDED FAN ASSEMBLY 1
2 PROPELLER 1
3 PROPELLER BUSHING 1
4 MOTOR 1
5 MOTOR SHEAVE 1
6 MOTOR SHEAVE BUHING 1
7 DRIVEN SHEAVE BUSHING 1
8 DRIVEN SHEAVE 1
9 PILLOW BLOCK BEARINGS 2
10 FAN SHAFT 1
11 "V" BELTS 2
18 Cabuyao, Laguna
FAN TROUBLE SHOOTING GUIDE
PROBLEM POSSIBLE CAUSES

Impeller or sheaves loose
Belts not tensioned properly
Bent shaft
VIBRATION Out of balance impeller
Loose fasteners
Loose or worn bearings
Drive misalignment
Fan not properly installed
Mismatched belts
Out of balance sheaves
Improper fan installation
Static pressure higher than design

MOTOR OVERLOADING Impeller rotating in the wrong direction
Improper fan speed
Defective motor
Fan speed higher than design
Filters missing
TOO MUCH AIR Static pressure lower than design
Fan speed higher than design
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Lack of elctricity to the fan

Fan wired improperly
Broken or missing belt
FAN DOES NOT OPERATE Missing or blown fuses
Overload protection has broken circuit
Defective motor
Impeller or sheaves loose

Belts not properly tensioned
Sheaves not properly aligned
Impeller out of balance
Sheaves out of balance
EXCESSIVE NOISE Bent shaft
Bearings defective or need lubrication
Worn belts
Vibration or lack of isolation
Loose fasteners
High velocity air
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Tubular Centrifugal Inline Fan
Routine Maintenance and Operation

on bearings, and redistributes grease in the bear-
WARNING
ings (motor and shaft).
Disconnect and secure to the "OFF" position all
electrical power to the fan prior to inspection or
servicing. Failure to comply with this safety Motors
precaution could result in serious injury or death Motor maintenance is generally limited to cleaning
WARNING and lubrication. Cleaning should be limited to exte-
Pour écarter les risques de blessure grave ou de rior surfaces only. Removing dust and grease
mort, débrancher et verrouiller l’alimentation buildup on the motor housing assists proper motor
électrique en position « Arrêt » avant tout contrôle
cooling. Never wash-down motor with high pressure
ou entretien.
spray.
Once the unit has been put into operation, a routine
Greasing of motors is only intended when fittings
maintenance schedule should be set up to preserve
are provided. Many fractional motors are perma-
the reliability and performance of the fan and ac-
nently lubricated for life and require no further lubri-
complish the following:
cation. Motors supplied with grease fittings should
1. Lubrication of bearings and motor.
be greased in accordance with the manufacturer’s
2. Wheel, housing, bolts and set screws on the en-
recommendations. When motor temperature does
tire fan should be checked for tightness.
not exceed 104ºF (40ºC), the grease should be re-
3. Any dirt accumulation on the wheel or in the hous-
placed after 2000 hours of running time.
ing should be removed to prevent unbalance and
possible damage.
Belt Drive Maintenance
4. Inspect fan impeller and housing looking for fa-
V-belt drives must be checked on a regular basis for
tigue, corrosion, or wear.
wear, tension, alignment and dirt accumulation.
Fan Operation
Premature or frequent belt failures can be caused
All fans should be run every thirty (30) days, or at
by improper belt tension (either too loose or too
least “bumped” every thirty days. It is preferred that
tight) or misaligned sheaves. Abnormally high belt
each fan is run as this causes all electrical and me-
tension or drive misalignment will cause excessive
chanical components to get up to temperature, dis-
bearing loads and may result in failure of the fan
placing any formed condensation, redistributes load
and/or motor bearings. Conversely, loose belts will
cause squealing on start-up, excessive belt flutter,
IMPORTANT slippage and overheated sheaves. Either exces-
When operating conditions of the fan are to be changed sively loose or tight belts may cause fan vibration.
(speed, pressure, temperature, etc.), consult manufacturer When replacing V-belts on multiple groove drives all
to determine if the unit can operate safely at the new belts should be changed to provide uniform drive
condition.
21 Cabuyao, Laguna
loading. Use a set of matched belts whenever pos- above 200°F), moisture or contaminants - more fre-
sible. Do not pry belts on or off the sheave. Loosen quent lubrication is required. Lubricate bearings
belt tension until belts can be removed by simply lift- on UL 762 fans with high temperature grease
ing the belts off the sheaves. After replacing belts, conforming to NLGI Grade 2, such as Mobil Mo-
ensure that slack in each belt is on the same side of bilith SHC 100 or 200.
the drive. Belt dressing should never be used. With the unit running, add grease very slowly with a
Do not install new belts on worn sheaves. If the manual grease gun until a slight bead of grease
sheaves have grooves worn in them, they must be forms at the seal. Be careful not to unseat the seal
replaced before new belts are installed. by over lubricating or using excessive pressure.
The proper tension for operating a V-belt drive is the Bearings without grease fittings are lubricated for
lowest tension at which the belts will not slip at peak life.
load conditions. Belts are adjusted by raising or low- Fasteners attaching the bearings to the drive frame
ering the motor pivot plate. Use the bolts in the slot- should also be checked.
ted brackets and adjustment rods with bolts as ad-
justment points until proper belt tension is attained. Wheel, Fasteners and Set Screws
For initial tensioning, the proper belt deflection half- Wheels require very little attention when exhausting
way between sheave centers is 1/64-inch for each clean air, however, air heavily laden with grease or
inch of belt span. dirt will tend to accumulate on the wheel causing un-
Check belt tension two times during the first balance. Wheels exhausting dirty or grease-laden
24 hours of operation and periodically thereaf- air require frequent cleaning to assure smooth and
ter. safe operation.
All fasteners, including set screws in the bearing col-
Bearing Lubrication Schedule lars, should be checked for tightness each time
Shaft bearings are the most critical moving part of a maintenance checks are performed. Particular at-
fan. Therefore, special attention should be given to tention should be paid to set screws attaching the
keeping the bearings clean and well lubricated. wheel to the shaft and the shaft to the bearings.
Proper lubrication provides for reduction in friction Loose bearing set screws will lead to premature fail-
and wear, transmission and dissipation of heat, ex- ure of the fan shaft.
tended bearing life and prevention of rust. A proper maintenance program will help preserve
In order for a lubricant to fulfill these tasks, the the performance and reliability designed into the
proper grease applied at regular intervals is re- fan.
quired. See bearing manufacturer’s instructions or
label on the fan housing for lubrication schedule. Variable Frequency Drive Operation
In a clean environment and temperature above 32ºF For operation with variable frequency drive (VFD),
(0ºC) and below 200ºF (93ºC), fan shaft bearings always check motor amps when adjusting the oper-
with grease fittings should be lubricated semi-annu- ating frequency. Motor may be sized for the original
ally using a high quality lithium based grease. If un- selected operating speed under 60 Hz. Bypassing
usual conditions exist (temperatures below 32°F or the VFD or increasing the speed from this original
22 Cabuyao, Laguna
selection, even if less than 60 Hz, may cause motor Cleaning Internal Components
to overload or fail. Consult factory with fan serial Entire wheel should be cleaned during routine duct
number, before increasing the upper limiting fre- cleaning. Partial cleaning may result in an unbal-
quency. anced wheel that can cause premature bearing fail-
Always check the fan rpm when adjusting the oper- ure or excessive vibration.
ating frequency. Do not exceed maximum class fan Grease / cleaning solution should drain freely
rpm of the wheel. through the provided drain connection. Remove any
obstructions inhibiting proper drainage.
Removal of Dust and Dirt Only the access door is removed during routine duct
Dirt clogs cooling vents on the motor housing, con- cleaning. The bearing cover is not removed during
taminates bearing lubricant, and collects on the im- routine cleaning. The bearing cover is removed only
peller causing severe imbalance if left unchecked. when inspecting or changing the bearings, fan shaft
The exterior surface of the motor and impeller or driven pulley.
should be thoroughly cleaned periodically. Use cau-
tion and do not allow water or solvents to enter the Damper Inspection and Service, Model TCBRU
motor or bearings. Under no circumstances should Level 1 or 2
motors or bearings be sprayed with steam or water. Butterfly dampers should be inspected for proper
operation at each service interval. Check for free-
dom of movement and general condition of the
damper blades and hinge rods.
Parts List
Each fan bears a manufacturer’s nameplate with model number and serial number embossed. This information,
in addition to the parts list shown, will assist the local representative and the factory in providing service and
replacement parts.
Troubleshooting
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WARNING AVVERTISEMENT
Before taking any corrective action, make certain unit is Avant d’entreprendre toute action corrective, s’assurer
not capable of operation during repairs. que l’appareil ne pourra pas fonctionner durant les
réparations.
Problem Cause Corrective Action

Adjust wheel and/or inlet cone.
Wheel Rubbing Inlet
Tighten wheel hub or bearing collars on shaft.
Tighten sheaves on motor/fan shaft. Adjust belt tension
V-Belt Drive Align sheaves properly.
Excessive Noise
Replace worn belts or sheaves.
Replace defective bearing(s). Lubricate bearings.
Bearings
Tighten collars and fasteners.
Wheel Unbalance Clean all dirt off wheel. Check wheel balance.
Fan Check wheel for correct rotation.
Low CFM
Duct System Higher pressure than design. Filters need replacement.
Fan Decrease fan speed.
High CFM
Duct System Resize ductwork. Access door, filters, dampers not installed.
Duct system has more Remove obstructions in system. Use correction factor to
Static Pressure Wrong or less restriction than adjust for temperature/altitude. Resize ductwork. Clean
anticipated filters/ coils. Change fan speed.*
Fan Check rotation of wheel. Reduce fan speed.
High Motor Amp Draw Resize ductwork. Check proper operation of isolation and
Duct System
bypass dampers. Check filters and access doors.
Check fuses/circuit breakers. Check for switches turned off
Electrical Supply
or disconnected. Check for correct supply voltage.
Fan Doesn't Operate Drive Check for broken belts. Tighten loose pulleys.
Assure motor is correct horsepower and not tripping
Motor
overload protector.
Lubrication Check for excessive or insufficient grease in the bearing.
Overheated Bearing Replace damaged bearing. Relieve excessive belt tension.
Mechanical
Align bearings. Check for bent shaft.
Adjust tightness of belts. Replacement belts should be a
Belts
matched set.
Excessive Vibration Check alignment of shaft, motor and pulleys. Adjustable
System Unbalance pitch pulleys with motors over 15 hp are especially prone to
unbalance. Check wheel balance, rebalance if necessary.
* Always check motor amps and compare to nameplate rating. Excessive fan speed may overload the motor
and result in motor failure. Do not exceed the maximum cataloged rpm of the fan.
24 Cabuyao, Laguna
Vaneaxial Fan
Routine Maintenance
When performing any service to the fan, disconnect the electrical supply and secure fan impeller.
Once the unit has been put into operation, a routine maintenance schedule should be set up to accomplish the
following:
1. Lubrication of bearings and motor.
2. Impeller, housing, bolts and set screws on the entire fan should be checked for tightness.
3. Any dirt accumulation on the impeller or in the housing should be removed to prevent unbalance and possible
damage.
4. Isolation bases should be checked for freedom of movement and the bolts for tightness. Springs should be
checked for breaks and fatigue. Rubber isolators should be checked for deterioration.
5. Inspect fan impeller and housing looking for fatigue, corrosion, or wear.
Motors
Motor maintenance is generally limited to cleaning and lubrication. Cleaning should be limited to exterior sur-
faces only. Removing dust and grease build up on the motor housing assists proper motor cooling. Never wash-
down motor with high pressure spray. Many fractional motors are permanently lubricated for life and require no
further lubrication. Motors supplied with grease fittings should be greased in accordance with the manufacturer’s
recommendations.
Variable Frequency Drive Operation

WARNING
For operation with Variable Frequency Drive (VFD),
always check motor amps when adjusting the
operating frequency. Motor may be sized for the
original selected operating speed under 60 Hz.
Bypassing the VFD or increasing the speed from this
original selection, even if less than 60 Hz, may cause
motor overload or failure. Consult factory with fan
serial number before increasing the upper limiting
frequency.
Always check the fan rpm when adjusting the
operating frequency. Do not exceed maximum fan rpm
stated on the unit identification nameplate.
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Shaft Bearings
Bearings are the most critical moving part of the fan; therefore special care is required when mounting them on
the unit and maintaining them.
Refer to the table and the manufacturer’s instructions for grease types and intervals for various operating condi-
tions. Never mix greases made with different bases. This will cause a breakdown of the grease and possible
failure of the bearing.
Recommended Bearing Lubrication Schedule Relubrication
Schedule in Months*
Standard Grease
Bearing Bore (inches)
1 15⁄16 4 15⁄16
Fan RPM 1 1 ⁄8 - 1 5 ⁄8 - 2 7 ⁄16 - 3 3 ⁄16 - 3 15⁄16
1 ⁄2 - 1 - 23 - 57
1 1 ⁄2 1 7 ⁄8 3 3 1 ⁄2 - 4 1 ⁄2
⁄16 ⁄16
To 250 12 12 12 12 12 12 10 8
500 12 12 11 10 8 7 5 4
750 12 9 8 7 6 4 3 2
1000 12 7 6 5 4 3 2 1
1250 12 6 5 4 3 2 1 0.5
1500 12 5 4 3 2 1 0.75 -
2000 12 4 3 2 1 0.5 0.25 -
2500 12 3 2 1 0.5 0.25 - -
3000 12 2 1 0.5 0.25 - - -
3500 12 1 0.5 0.25 - - - -
4000 12 0.5 0.25 - - - - -
5000 12 0.25 - - - - - -
Number
4 8 8 10 16 25 41 57
of
* Lubrication interval is based on 12 hour per day operation and maximum 160˚F housing temperature.
For 24 hour per day operation, the interval should be cut in half.
** Lubricant should be added with the shaft rotating and until clean grease is seen purging from the bearing. The
lubrication interval may be modified based on the condition of the purged grease. If bearing is not visible to
observe purged grease, lubricate with number of shots indicated for bore size.
• For conditions including high temperatures, moisture, dirt or excessive vibration, consult the factory for a spe-
cific lubrication interval for your application.
• Lubricant should be a high quality lithium complex grease conforming to NLGI Grade 2.
• The use of synthetic lubricants will increase lubrication intervals by approximately three times.
• Storage periods of three months or longer require monthly rotation of the shaft and purging grease prior to
start-up.
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V-Belt Drives
V-belt drives should be checked for wear, tension, alignment and dirt accumulation on a regular basis. Premature
belt failure is frequently caused by improper belt tension (excessively tight or loose) or misaligned sheaves.
Excessive belt tension creates high bearing loads which reduce bearing life. Belts which are too loose may cause
squealing on start-up, belt flutter, slippage and overheating of the sheaves. Belts which are overly tight or loose
may cause vibration and noise.
When replacing V-belts on multiple groove drives, all belts should be changed to provide uniform drive loading.
Do not pry belts on or off the sheave. Loosen belt tension until belts can be removed by simply lifting the belts
off the sheaves. After replacing belts, ensure that slack in each belt is on the same side of the drive. Belt dressing
should never be used. Do not install new belts on worn sheaves. If the sheaves have grooves worn in them, they
must be replaced before new belts are installed.
Belt Tension
The proper tension for V-belts is the lowest tension at which the belts will
not slip at peak load conditions. For initial tensioning, the belt should deflect
1/64 inch for each 1 inch of belt span. For example, a belt span of 32 inches
should deflect 1/2 inch with moderate thumb pressure at midpoint of the
drive. Check belt tension after 24 hours of operation and periodically there-
after.
V-Belt Replacement
Changing V-belt drive components could result in unsafe operating conditions which may cause personal injury
or failure of fan components.
1. Remove the protective coating from the end of the fan shaft using mineral spirits
or another similar solvent. Check to ensure that the shaft is free of nicks and burrs.
2. Slide sheaves on shafts. Do not drive sheaves on as this may result in bearing
damage.
3. Align fan and motor sheaves with a straight-edge or string and tighten.
4. Place belts over sheaves. Do not pry or force belts, as this could result in damage
to the cords in the belts.
5. Adjust the tension until the belts appear snug. Run the unit for a few minutes (refer to unit start-up section)
and allow the belts to “set” properly.
6. With the fan off, adjust the belt tension by moving the motor pivot plate. (Belts are adjusted by raising or
lowering the motor pivot plate). When in operation, the tight side of the belts should be in a straight line from
sheave to sheave with a slight bow on the slack side.
27 Cabuyao, Laguna
Blade Pitch Adjustment for Belt and Direct Drive
Blade Pitch Adjustment Procedure
1. Disconnect all electrical power to the fan and lock in the “off” position.
2. Remove the aluminum nose cone on the impeller assembly. Record the location of all balancing weights
located under the nose cone bolts.
3. Locate the blade with blade pitch graduations stamped into the blade base and index line on the impeller (Fig.
4). This is the master blade.
4. Loosen the self locking nut (Fig. 5) attaching the master blade until the blade
can be rotated by hand.
5. Set the new blade pitch on the master blade by aligning the desired blade
pitch number with the index mark. Tighten the self-locking nut slightly to prevent
the master blade from moving.
6. At the tip of the master blade, use a thin marker pen to scribe the blade profile
on the interior of the fan housing from the leading to the trailing edge of the
blade tip (Fig. 6).
7. Loosen the self-locking nuts on the remainder of the blades and set each
blade to align with the blade profile scribed on the fan housing. Tighten the self-
locking nut slightly to prevent blade from moving.
8. After all blades are adjusted to the proper setting, tighten the self-locking
nuts to 125 ft. Ibs. of torque. Verify that all the blades tips follow the profile on
the fan housing.
9. Replace the nose cone and any balancing weights removed earlier. All fas-
teners and washers must be reinstalled in the exact spot they were removed.
10. IMPORTANT: Motor load amperes must be checked and compared to the
nameplate rating before returning the fan to service. Increasing blade pitch be-
yond the capacity of the motor will result in motor burn-out and void the warranty.
28 Cabuyao, Laguna
Section III Equipment Data and Recommended
Spares
29 Cabuyao, Laguna
A. Equipment Data
30 Cabuyao, Laguna
31 Cabuyao, Laguna
B. Parts Recommended Spares
32 Cabuyao, Laguna
Parts Identification and Recommended Spares

A list detailing replaceable equipment, quantity, assemblies & components
Item No. Part Number Description Quantity Manufacturer

1 V-BELT B-66 6 pcs MDP POWER BELT
2 Grease Lubrication 1L -
3
4
33 Cabuyao, Laguna
Section IV Manufacturer's Literature
34 Cabuyao, Laguna
Manufacturer’s Literature
Complete set of Manufacturer’s Literature, catalogs, brochures, product description

and performance details with each application. The operation and Maintenance details
manuals and instructions. Method of operation and control and protective measures,
cleaning and maintenance and safety consideration requirements. (SEE APPENDIX
1)
35 Cabuyao, Laguna
Section V Commissioning Data
36 Cabuyao, Laguna
Commissioning Data
37 Cabuyao, Laguna
Section VI Drawing index and As-Built Drawings
38 Cabuyao, Laguna
Drawing Number Title Remarks
Drawing Index & Approved As-Built Drawings
39 Cabuyao, Laguna

O&m - Unilever Ventilation

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Operation and Maintenance Manual

Mechanical System – Ventilation

FAST – UNILEVER HUB

FAST SERVICES CORPORATION

Section I Emergency / Vendors Contact Information

Warranties/ Guarantees Certificates

A. Emergency Vendors Contact information

B. Warranties/ Guarantees Certificates

Section II System Instruction and Information

Section III Equipment Data and Recommended Spares

Section IV Manufacturer's Literature

Section V Commissioning Data

Section VI Drawing index and As-Built Drawings

Section I Emergency / Vendors Contact

Information and Warranties/ Guarantees

A. Emergency / Vendors Contact Information

Company Name: RIC-MALEN CONSTRUCTION INCORPORATED

Company Address: PHASE 3B BLK.1 LOT 28 SOUTHGROVE MACA-

Contact Persons / Designation: RICARDO FERNANDO / GENERAL MANAGER

Telephone Number: (02) 529 3763 / 868 3094

Facsimile Number: (02) 398 5818

Email Address: rgf_malen@yahoo.com

B. Warranties/ Guarantees Certificates

AS PART OF OUR RESPONSIBILITIES AND ACCOUNTABILITY FOR

• WORKMANSHIP INSTALLATION: ONE (1) YEAR

BRAND NAME: NIAGARA

R & M (RIC-MALEN) CONSTRUCTION INC. WILL WARRANTY THE

NOTE: THIS SERVE AS OUR OFFICIAL SERVICE WARRANTY.

Section II System Instruction and Information

B. System Operation and Maintenance

Tubular Centrifugal Inline Fan

Pre Start Inspection

Belt and Pulley Replacement

Leader Fan Industries uses pillow block bearings.

FAN TROUBLE SHOOTING GUIDE

PROBLEM POSSIBLE CAUSES

Static pressure higher than design

Lack of elctricity to the fan

Impeller or sheaves loose

Tubular Centrifugal Inline Fan

Routine Maintenance and Operation

Problem Cause Corrective Action

Variable Frequency Drive Operation

Blade Pitch Adjustment for Belt and Direct Drive

Blade Pitch Adjustment Procedure

Section III Equipment Data and Recommended

B. Parts Recommended Spares

Parts Identification and Recommended Spares

Item No. Part Number Description Quantity Manufacturer

Section IV Manufacturer's Literature

Complete set of Manufacturer’s Literature, catalogs, brochures, product description

Section V Commissioning Data

Section VI Drawing index and As-Built Drawings

Drawing Number Title Remarks

Drawing Index & Approved As-Built Drawings

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