CENTRIFUGAL FAN Owner's and Operator's Manual (CE Models)

Transcription

1 CENTRIFUGAL FAN Owner's and Operator's Manual (CE Models) ATTENTION Pay close attention when you see this triangular symbol. It will be located throughout this manual and on decals. Obey the Dangers, Warnings and Cautions. YOUR SAFETY IS INVOLVED! READ AND UNDERSTAND THIS MANUAL BEFORE OPERATING! DANGER DO NOT OPERATE THIS UNIT WITHOUT GUARD(S) SECURED IN PLACE. STOP FAN AND LOCKOUT POWER TO ADJUST, SERVICE OR CLEAN. KEEP CHILDREN AND PERSONS NOT FAMILIAR WITH EQUIPMENT AWAY. FAILURE TO HEED WILL RESULT IN SERIOUS INJURY OR DEATH! June Manufactured by Nebraska Engineering Company A Division of GLOBAL Industries, Inc North 45th Street Omaha, Nebraska USA

2 GENERAL STATEMENT WARNING Watch for this warning symbol! It will always be accompanied by important information regarding Safety, Warnings, and Precautions. ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED! Occupational safety is of prime concern to NECO. This Owner s and Operator s Manual is provided to help ensure the safety of the operator as well as others who may come in contact with the equipment. It is your responsibility as an owner, operator, or supervisor to know what specific requirements, precautions, and work hazards exist and to make these known to all persons working with the equipment or who are in the area, so that they may take any needed safety precautions. Failure to read this Owner s & Operators Manual or to understand and heed its safety instructions constitutes a misuse of the equipment. TO THE OWNER LIMITED WARRANTY* We at NECO are continually testing and improving our products to provide the most efficient and economical grain handling equipment available. We cannot be responsible, however, for upgrading or changing units previously sold when making improvement to subsequent models. The NECO equipment that you have just purchased will provide years of dependable service when properly maintained. Your work load will be lightened and you ll save valuable time. Welcome to the growing number of satisfied NECO equipment owners. For a period of one (1) year after shipment of goods by Buyer to the Buyer s customer, NECO will supply free of charge, F.O.B. NECO s factory, Omaha, Nebraska, replacement parts for any parts that prove to be defective due to workmanship or material.* Defective parts must be returned, freight-prepaid, to the NECO Factory in Omaha, Nebraska. You must obtain a Return Authority form from NECO prior to returning goods. GOODS NOT MANUFACTURED BY NECO CARRY ONLY THE MANUFACTURER S WARRANTY. THIS UNDERTAKING IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUD- ING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. FAILURE TO FOLLOW THE INSTRUCTIONS CON- TAINED IN THIS MANUAL AS WELL AS ANY OF THE CONDITIONS LISTED BELOW WILL CAUSE THIS LIMITED WARRANTY TO BE VOIDED. 1. Improper assembly 2. Improper installation (including power and wiring) 3. Unauthorized alteration of goods 4. Operating the unit when repairs are needed 5. Use of unauthorized parts 6. Operation by children or uninstructed personnel 7. Processing of materials that are abrasive, that do not flow freely, or that are otheriwise unsuited for processing in a grain dryer 8. Abuse or misuse of the unit or of any of its components 9. Accidents *This limited warranty does not extend to parts designed to wear in normal operation and be replaced periodically or to damage caused by negligence, accident, abuse, or improper installation or operation. LIMITATION OF LIABILITY BUYER AGREES THAT IN NO EVENT SHALL NECO HAVE LIABILITY FOR DIRECT DAMAGES IN EX- CESS OF THE CONTRACT PRICE OF THE GOODS FOR WHICH THE CLAIM IS MADE. Buyer further agrees that in no event shall NECO have liability for loss of use, loss of profits, or for any indirect, incidental, or consequential damages on any claim of any kind. 2

3 Contents GENERAL STATEMENT... 2 MACHINE INSPECTION... 4 WORK AREA SAFETY... 4 AIR EXHAUST... 4 OPERATOR QUALIFICATIONS... 5 OPERATING PROCEDURES... 5 POWER LOCK OUT... 6 Roof Damage Warning... 6 AVOID STRUCTURAL DAMAGE... 6 TYPICAL INSTALLATION CONFIGURATION... 7 INSTALLATION INSTRUCTIONS:... 9 PROPER HANGING OF NECO CENTRIFUGAL FANS CENTRIFUGAL FAN LIST...11 MINIMUM COPPER WIRE SIZES REQUIRED WIRING DIAGRAMS PRE-START INSTRUCTIONS OPERATION AND MAINTENANCE CENTRIFUGAL FAN TROUBLE SHOOTING CENTRIFUGAL FAN REPLACEMENT PART CENTRIFUGAL FAN INSTALLATION LAYOUT DECAL EXPLANATIONS

4 MACHINE INSPECTION After delivery of your new fan and/or completion of assembly and before each use, inspection of the equipment is mandatory. This inspection should include but not be limited to: 1. Check to see that all guards listed in the assemble are secured in place and are functional. 2. Check that all fasteners are tight. 3. Before starting fan, be sure that fan interior and inlet is clear of any debris. 4. Make certain that impeller rotates freely. 5. Open roof hatches before use. 6. Inspect all electrical connections. 7. Are all safety decals clean and readable? WORK AREA SAFETY Under no circumstances should persons not involved in the operation be allowed to trespass into the area. It shall be the duty of all operators to see that children and/or any other unqualified persons stay out of the work area. Trespassing into the work area by anyone not involved in the actual operation, or trespassing into a hazardous area by anyone, shall result in an immediate shut down by the operator. Prior to start up and during operation, it shall be the responsibility of all operators to see that the work area is clear. It must be clean and free of any debris and misplaced tools which could cause accidental tripping and/or falling. AIR EXHAUST INSUFFICIENT AIR EXHAUST AREA MAY RESULT IN DAMAGE TO YOUR BIN. A minimum of 1 sq. Ft. [.09 sq. m.] opening for each 1000 CFM [28 CMM] of air is required. The operator must be sure that these openings are not constricted by chaff, ice or other materials during fan operation. 4

5 OPERATOR QUALIFICATIONS Operation of this farm equipment shall be limited to competent and experienced persons. In addition, anyone who will operate or work around power equipment must use good common sense. In order to be qualified, operator must also know and meet all other requirements, such as: 1. Some regulations specify that no one under the age of 16 may operate power machinery. This includes farm equipment, It is your responsibility to know what these regulations are in your own area or situation. 2. Unqualified persons are to stay out of the work area. The "Work Area" is defined as the area surrounding the grain handling equipment. 3. A person who has not read and understood all operation and safety instructions is NOT qualified to operate the machine. Please make sure you understand and adhere to your local regulations. OPERATING PROCEDURES During the operation of your farm equipment, one person shall be designated to monitor the machinery. It is also good practice for all qualified persons involved to visually inspect the equipment periodically during any actual operation. You should be alert for any unusual vibrations, noises, and loosening of any fasteners. CAUTION: 1. Observe work area restrictions. 2. Keep all safety shields and devices in place. 3. Make certain everyone is safely clear before operating or moving farm equipment. 4. Keep hands, feet, and loose clothing away from moving parts. 5. Always disconnect power before servicing equipment! AIR PRESSURE AGAINST THE FLOOR SUPPORTS CAN RESULT IN DAMAGE TO YOUR BIN. When filling a bind equipped with steel floor supports under a perforated floor, it is important to fill the bin with at least two feet (60 cm) of grain before the fans are turned on. The tremendous airflow from the fans will tilt the floor supports without the grain weight on the floor. 5

6 POWER LOCK OUT It is essential to inspect your fan before turning on the power. Know how to shut down the fan power in an emergency! Prior to any servicing or adjusting of your equipment, makcertain to shut down the power and lock it out. 1. Electric motors and controls shall be installed by a qualified electrician. Installation must meet standards set by all local codes. 2. Always disconnect and lock out power before servicing the fan. 3. Reset and motor starting controls must be located so that the operator has a full view of the entire operation. Always keep children away from unit! 4. Make certain that all fan guards are reinstalled after servicing. A main power disconnect switch capable of being locked only in the OFF position shall be installed. This shall be locked out whenever the equipment is being serviced. Roof Damage Warning NECO cannot warrant any roof damages due to internal pressure or excessive vacuum caused by fans. Adequate "makeup" air or ventilation should be provided for all powered air handling units. NECO does not recommend the use of downward flow (suction) systems. Severe roof and bin structural damage can result from air passage blockage. Also running of fans during certain cold weather/high humidity conditions can cause freezing over of air exhaust or intake ports. WARNING! AVOID STRUCTURAL DAMAGE TO YOUR BIN. A. Make certain that all roof vents are open and unobstructed. Make sure that there are an adequate number of vents. NECO recommends a minimum of 1 square foot (929 cm^2) of vent area per every 1000 cfm (21 m^3/min) fan air input. B. Make certain that all fans are installed for positive pressure aeration (push system). C. Roof exhausters should be interlocked with aeration fans. Roof exhausters can only then be energized when aeration fans operate. D. Never operate your bin aeration system if conditions exist that can cause roof vent icing. Roof vent icing can occur when the ambient air temperature is below 35 deg. F (2 deg. C). and the relative humidity of the air is 90% or greater. If you have questions about icing conditions contact your local weather bureau. FAILURE TO HEED THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH! NOTE: IF YOU EXPERIENCE PROBLEMS WITH YOUR FAN, CONTACT YOUR DEALER FIRST. IF THEY ARE UNABLE TO HELP, CALL THE SERVICE MANAGER AT NECO. THE PHONE NUMBER AT THE NECO FACTORY IN OMAHA, NEBRASKA, USA IS

7 TYPICAL INSTALLATION CONFIGURATION Figure 1 and key 1a and 1b show dimensions of an Centrifugal Fan based on the fan horsepower. The letters in the figure correspond to the dimensions listed in the key. B E C A Front View Side View C hp Fan Power kw Figure 1 50 hz Centrifugal Fan Dimensions Fan RPM Hz A A (mm) B B (mm) C C (mm) D D (mm) E E (mm) Figure 1 Key 50 hz Centrifugal Fan Dimensions 7

8 Figure 2 shows necessary and optional drying components for a typical in-bin drying installation. Power Roof Exhauster (optional) Grain Bin Roof Vents with or without a peak (optional) Dual Burner Control Kit (necessary with multiple heaters) Thermostat Kit with Rain Cover (necessary with heater) Static Pressure Gauge (optional) Transition (Cutaway is used to show airflow.) Plenum Thermometer Kit (optional) Transition Centrifugal Fan Downstream Heater (optional) Shutters (optional) Adapter Plate (necessary for most transitions between Centrifugal Fan and Heater) Transitions should fit under the floor and be unobstructed for maximum airflow. Downstream Heater (optional) Shutters (optional) This Axial Fan is shown hanging from the bin Axial Fan Use pilings or make sure all concrete pads are deep enough to avoid frost heave. Note: A quarter of the bin has been cut away to show airflow and perforated floors. Perforated floors are shown incomplete. Only fan and heater-related in-bin drying equipment is shown. Stirring, loading, and unloading systems are not shown. Perforated floors are shown with galvanized floor supports only as a reference. Centrifugal fan and axial fan are shown on the same bin for the purpose of illustrating typical drying components. Figure 2. Typical Installation 8

9 Proper and thorough installation of this fan unit will ensure years of trouble free service. Be sure that a qualified person is engaged to install this unit! A) PHYSICAL INSTALLATION This fan as shipped is basically a complete ready to operate unit that should be installed as follows: 1) TRANSITIONING The fan must be attached to the bin wall beneath the drying floor through a transition and entrance collar arrangement. These components are available from NECO although other designs can be used successfully. Be sure that minimum air leakage is present in the transitioning arrangement to preserve airflow to the grain bed. Transitioning should provide the same cross section as the fan outlet (or greater) to prevent excessive static pressure buildup. The fan should rest on a concrete pad. 2A) MOUNTING PAD It is very important that your fan be mounted on a solid surface. If you choose a poured concrete slab to mount your fan and heater on, it is recommended that the surface dimension of the slab be about one foot wider all around than the leveler leg pattern. The slab should be a minimum of 6 in. [15 cm] thick. Tip: in order to reduce the chances of frost heave, the pad can be poured on top of several metal or concrete pilings which extend lower than the average frost depth in your area. Using the fan's leveler legs make certain that the fan is adjusted level. If the fan is not mounted level this can lead to premature motor bearing failure, noise, and excessive vibration. Note: All leveling legs must be firmly on the pad. 2B) HANGING INSTALLATION Fans can also be hung off the side of the grain bin with cables. If properly done, hanging in- INSTALLATION INSTRUCTIONS 9 stallations can avoid pads and the cost and problems associated with them. Make certain the units are installed to prevent any sideways motion such as caused by wind. Centrifugal fans and heaters can also be hung by cables but due to their weight and size the installations usually require platforms built out of steel channel and wire rope. Speak to your dealer or local millwright about cable type installations. Make sure you heed the caution regarding the Proper Hanging of NECO Centifugal Fans on the following page. B) POWER HOOKUP Power hookup should be accomplished by a properly licensed electrician. 1) INCOMING POWER SUPPLY The incoming power supply must be connected to the bottom of the fan starter (if so equipped) in an approved manner. Power leads must be run above or below ground in approved weather tight conduit. The leads should be connected in order to provide counterclockwise wheel rotation when viewed from air inlet side of the fan. Be sure to check for low line voltages especially when connecting single phase motors. The recommended incoming phase, voltage, and frequency is embossed into the metal nameplate of the motor. 2) GROUNDING NECO recommends that your fan be connected to a ground rod that is no further than 8 feet away. The ground rod should be connected to the fan control panel with a minimum 6 AWG solid bare copper wire. The ground rod shall be copper-clad and 5/8 diameter. X 8 ft. long. Install the rod (2) feet away from the fan and/ or bin foundation, and in accordance with local requirements. The ground rod-to-fan connection provides additional safety in the event of a short or lightning strike. It also provides the necessary grounding for operation and long life of control circuits in the fan and heater.

10 NECO does not supply or sell ground rods and wires; please contact your local electrical parts supplier. It is recommended that the rod not be driven into dry ground. Follow the next few steps to ensure proper rod installation. 1. Dig a ditch large enough to hold 1-2 gallons of water. 2. Fill the ditch with water. 3. Push rod into the water and jab it into the ground. 4. Jab the rod up & down allowing the water to work its way down the hole. This technique will promote a good conductive bond with the surrounding soil. Drive rod completely down. 5. Connect one end of the ground wire to the rod with an appropriate ground clamp. 6. Connect the other end of the wire to a ground lug connector inside of the fan control box. The ground wire should not have any splices or breaks. Insulated wire is not recommended for grounding purposes. NECO recommends that previously installed units be checked for proper grounding. 3) DISCONNECT A separate lock out type disconnect for each fan should be mounted on the main power panel, especially if the fan unit is not entirely visible from the main power panel. 4) HEATER INTERLOCK If the fan unit is equipped with a factory supplied motor control unit, then an optional heater must be powered by this unit. This will prevent the heater from starting if the fan is not running. Bypassing or removing this interlock will allow the burner to start without the fan which will in turn start a fire. Therefore, NEVER plug the heater into a separate power source. Make absolutely certain that it is connected to the fan motor control box. Proper Hanging of NECO Centrifugal Fans CAUTION! Centrifugal fans require careful effort and attention to detail when being hung from the side of a grain bin. Check with the bin manufacturer if you decide to hang centrifugal fans from a bin. Make sure the bin manufacturer approves your installation plans. Also, please contact NECO for guidance when hanging your fans. 10

11 CENTRIFUGAL FAN LEGEND The fan model number is divided into sections for describing the features of the centrifugal fans. The model number shown below is broken down as an example. H S C B D 3 6 Centrifugal Fan Type: Wheel Size Horsepower Voltage Phase Hertz High Speed Centrifugal Type of Controls B = Basic Set Up S = Starter Controls 15 = 15" Diameter 18 = 18" Diameter 22 = 22" Diameter 03 = 3 hp 05 = 5 hp 07 = 7 hp 10 = 10 hp 15 = 15 hp 20 = 20 hp 25 = 25 hp 30 = 30 hp 40 = 40 hp 50 = 50 hp 60 = 60 hp D = 230/460 V 2 = 230 V 3 = 380 V 4 = 460 V 5 = 575 V 1 = 1 Phase 3 = 3 Phase 5 = 50 Hertz 6 = 60 Hertz The fan model number is divided into sections for describing the features of the centrifugal fans. The model number shown below is broken down as an example. 0 4 C H S Centrifugal Fan Type: Type of Controls Horsepower Voltage 50 Hz Motor Low Speed Centrifugal A = Basic Set Up S = Starter Controls 50 = 5 hp 75 = 7.5 hp 10 = 10 hp 15 = 15 hp 20 = 20 hp 25 = 25 hp 30 = 30 hp 40 = 40 hp 50D = 50 hp 5D = 50 hp 6D = 60 hp D = 230/460 V 3 = 230/460 V 3 = 230 V 3 = 380 V A = 460 V 5 = 575 V 11

12 Item No. Fan Model LOW SPEED (1450 RPM - 50 Hz) CENTRIFUGAL FANS Wheel Size hp Power kw Table 1. Centrifugal Fan Features for 50 Hz. 12 Phase Hz Voltage F. L. Amps CHA No /380/ / 4.4 / CHS Yes* CHA No /380/ / 8.1 / CHS Yes* CHA No /380/ / 12.3 / CHS Yes* CHA No /380/ / 16.2 / CHS Yes* CHA No /380/ / 24 / CHS Yes* CHA No /380/ / 29 / CHS Yes* CHA No /380/ / 35 / CHS Yes* CHA No /380/ / 46 / CHS Yes* CHA No /380/ / 57 / CHS Yes* CHA No /380/ / 71 / CHS Yes* Item No. Fan Model * Full-voltage starter; For WYE Start / Delta Run Starters, Contact NECO Factory. HIGH SPEED (2900 RPM - 50 Hz) CENTRIFUGAL FANS Controls Controls Wheel Size hp Power kw Phase Hz Voltage F. L. Amps. 144 HSCB No /380/ / 4.7 / HSCS Yes* HSCB No /380/ / 7.6 / HSCS Yes* HSCB No /380/ / 11.3 / HSCS Yes* HSCB No /380/ / 14.5 / HSCS Yes* HSCB No /380/ / 24 / HSCS Yes* HSCB No /380/ / 29 / HSCS Yes* HSCB No /380/ / 35 / HSCS Yes* HSCB No /380/ / 46 / HSCS Yes* HSCB No /380/ / 57 / HSCS Yes* HSCB No /380/ / 71 / HSCS Yes* * Full-voltage starter; For WYE Start / Delta Run Starters, Contact NECO Factory. NOTE: For the most up-to-date F.L. Amps Data, Check Motor nameplate.

13 Load In Amps MINIMUM COPPER WIRE SIZES REQUIRED for loads up to 400 AMPERES at v Length of run in feet. *Length of run in meters 40' 50' 60' 70' 80' 90' 100' 125' 150' 175' 200' 12.2* 15.2* 18.3* 21.3* 24.3* 27.4* 30.5* 38.1* 45.7* 53.3* 60.9* Table 2. Minimum Copper Wire Sizes Required for Loads up to 400 Amperes at 230 to 240 Volts 13

14 WIRING DIAGRAMS The figures in the following tables show wiring diagrams of varies centrifugal fans. The wiring shown here is recommended, refer to your fan's control box for exact wiring diagram. Any necessary wiring must be done by a qualified electrician. Refer to your fan's control box for exact wiring diagram. Figure 3 shows a wiring diagram of a three phase centrifugal fan with M2P/M3P starters. Figure 3. Wiring Diagram 3 Phase Fan with M2P/M3P. 14

15 PRE-START INSTRUCTIONS With the power supply disconnected and locked out, make certain that the fan and transition is free of debris. Rotate the fan wheel to make sure that it revolves easily and does not rub against the inlet cone. Make certain the fan guard is secured into place. Inspect ALL fasteners to make sure they are tight. If any are loose, check for proper clearance and retighten. (Caution: Do not over tighten.) BE SURE THAT DISCONNECT SWITCH AND FAN ARE WELL GROUNDED. The first time the fan is to be started, run it momentarily to make sure the fan is rotating in the proper direction and that the air is flowing in the direction indicated on the fan housing. If it is flowing in the wrong direction, the motor connections will have to be reversed by your electrician. OPERATION AND MAINTENANCE Motors used in centrifugal fan units utilize a standard NEMA* frame. Most of the replacement parts for these motors are handled by authorized service centers of various motor manufacturers. These motors are specially designed for use in crop drying fans. If not so equipped from the factory, motors will have to be protected by an overload heater on the customer's supplied and installed motor starter unit. Motor protection must be installed per local electrical codes. FAN SHOULD BE RUN 30 MINUTES EVERY 3 WEEKS TO ELIMINATE ANY DAMAGING MOISTURE BUILDUP IN THE MOTOR. Motor bearings are of a double seal construction and require little, if any, servicing. Servicing should be referred to an authorized motor service center. It is important to keep the fan inlet guard free of any debris. If debris is allowed to accumulate, the motor will eventually shut down due to overheating. Debris will also retain moisture and cause corrosion on metal surfaces. Replace any damaged fan guards as soon as possible! *NEMA- refers to (USA) National Electrical Manufacturer's Association 15

16 CENTRIFUGAL FAN TROUBLESHOOTING Problem Reason Solution Fan fails to start No power Replace fuse (main power supply) Bad coil Replace coil on contactor Reset switch on overload relay is out Reset and set for automatic No ground Be sure there's a good ground connection Fan fails to come up to Low amps and low voltage Check with amp probe and speed within 10 seconds consult power supplier Fan blows fuses or trips Undersize fuse or circuit breaker Use FRN Fusetron or larger circuit breakers circuit breaker Short exists in fan contorls or motor Check for hot wires Fan vibration Cover on inlet of fan Remove cover Blade is out of balance Balance or replace blade Debris is on blade Remove debris from blade Not all leveling legs are firmly on pad Adjust leveling legs. Make sure fan is level Fan pad movement due to frost Stabilize pad or hang fan from heave or ground settlement bin Fan quits after operating Weak coil (magnetic starter) Replace coil only a few hours Heater strip (if equpped) Replace heater strip with next larger size Control box is in sun on a hot day Cool control box by shading or venting Adjustable overload relay is set too low Shut down fan. Adjust overload relay 16

17 CENTRIFUGAL FAN REPLACEMENT PART Figure 4 (with key on the following page) shows five of the most commonly replaced parts. Control Box These parts are referred to by their company part number and organized by model number. Wheel Motor Inlet Cone Leveling Leg (010678) Guard Screen Figure 4. Centrifugal Fan Replacement Parts 17

18 Fan Model hp NEC Low-Speed (1,450 RPM) Centrifugal Fan Parts List Power kw Motor Wheel Guard Screen Control Box Inlet Cone 04CHA N/A CHA N/A CHA N/A CHA N/A CHA N/A CHA N/A CHA N/A CHA N/A CHA N/A CHA N/A Figure 4 key. Low speed (1450 rpm) Centrifugal Fan Parts List. 18

19 CENTRIFUGAL FAN INSTALLATION LAYOUT The following pages are sample installations of various fans. If you require a drawing for a specific installation, Please contact Fan/Heater NECO. Figure hp 60 hz Low Speed Centrifugal Fan Installation 19

20 Figure hp 50 hz Low Speed Centrifugal Fan with Downstream Heater Installation 20

21 Figure hp 60 hz High Speed Centrifugal Fan Installation 21

22 Figure hp Low Speed Centrifugal Fan Installation 22

23 Figure hp 60 hz Low Speed Centrifugal Fan with Downstream Heater Installation 23

24 Figure 10. Top View, Low Speed Centrifugal Fan with Downstream Heater Installation 24

25 Figure 11. Low Speed (1450 rpm) Centrifugal Fan 25

26 DECAL EXPLANATIONS (CE Models Only) GENERAL CAUTION: Read owners manual before installation, maintenance or repair to any part of the heater / fan assembly. HOT SURFACE: Keep a safe distance from heater while in operation. Hot surfaces can cause severe burns to hands and fingers. FIRE OR OPEN FLAME : Do not try to access the heaters interior during operation. ELECTRICAL SHOCK / ELECTROCUTION: Disconnect heater and power supply before accessing heater for repairs or maintenance. 26

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28 MANUFACTURED BY NECO A Division of GLOBAL Industries, Inc North 45th Street Omaha, Nebraska USA TEL: FAX: