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Operation and maintenance manual of 20

Operation and maintenance manual

for radial ventilators

LWN-Tornado
Standard version

Issued by: LWN Lufttechnik GmbH

Hhndorfer Hhe 7
01723 Wilsdruff
Germany
Phone +49 (325204) 2708-0
Fax +49 (325204) 2708-10
mailto:info@lwn-lufttechnik.de

25. 09. 2007

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Table of contents
1 Introduction .................................................................................................................3
1.1 General information ...............................................................................................3
1.2 Additional information ............................................................................................3
2 Safety ..........................................................................................................................4
2.1 General safety instructions. ...................................................................................4
2.2 Additional safety regulations..................................................................................4
3 Technical specifications..............................................................................................5
3.1 Features .................................................................................................................5
3.2 Areas of application ...............................................................................................6
4 Transport and storage ................................................................................................6

5 Installation (incl. dismounting) ....................................................................................7

6 Start-up........................................................................................................................7
6.1 Commissioning of radial ventilator ........................................................................8
6.2 Commissioning of axial ventilator..........................................................................8
6.3 Operating connection.............................................................................................9
6.4 Measuring preparations and instructions ........................................................... 10
7 Machine operation ................................................................................................... 11

8 Service ..................................................................................................................... 12
8.1 General................................................................................................................ 12
8.2 Maintenance and inspection............................................................................... 13
8.3 V-belt (depending on machine type) .................................................................. 15
8.4 Coupling (depending on machine type) ............................................................. 17
8.5 Lubrication........................................................................................................... 18
8.6 Cleaning .............................................................................................................. 18
9 Limits of vibration speed according to DIN 10816-3............................................... 19

Appendix......................................................................................................................... 20
Ventilator data sheet ...................................................................................................... 20
Characteristic curves ..................................................................................................... 20
Dimension sheet ............................................................................................................ 20
Motor data sheet ............................................................................................................ 20
Declaration of conformity ............................................................................................... 20
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1 Introduction
This information was written for the purpose of being read, understood and observed
in full by all persons responsible for the LWN ventilator. Full technical information is to
be kept close to the ventilator at all times. This operating manual contains all the
information that is essential for operating the LWN ventilator
It is referred to an operation of the fan, which corresponds to the specification of the
fan.
An operation outside of this range, particularly within the pumping range, specified by
the operator and manufacturer, is not permissible expressly.
.

1.1 General information

Follow the instructions of this operating manual closely
Knowledge of the basic safety instructions and safety regulations is a basic
prerequisite for the safe handling and trouble-free operation of this ventilator.
This operating manual contains the most important instructions for operating the
ventilator safely.
This operating manual, particularly the safety instructions, must be observed by
all those working with the ventilator.
Furthermore, please also observe the legal provisions and regulations regarding
accident prevention prevailing at the operation site.

1.2 Additional information

Warranty and liability
In principal, our general terms and conditions of sale and supply apply. These have
been at the operators disposal at the latest since the conclusion of the contract.
Warranty and liability claims for personal injury and damage to property are precluded
if they are caused by one or more of the following:

Inappropriate use of the ventilator

Improper installation, start-up, operation and maintenance of the ventilator
Operation of the ventilator despite defective safety equipment or wrongly
installed or malfunctioning safety and protection devices
Failure to observe the operating manual for this ventilator
Unauthorised modifications to the construction of the ventilator
Unauthorised modifications to the performance data
(E.g. the ventilators capacity-to-speed drive ratio)
Poor monitoring of ventilator parts, which are subject to wear and tear
Improperly conducted repairs
Disaster events caused by influences from extraneous elements and force
majeure
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2 Safety
2.1 General safety instructions.
Basic safety instructions
The ventilator operates trouble-free and safely when it is put to its intended use and
the impeller is cleaned regularly. Failure to observe the necessary external
requirements is potentially hazardous to:
The lives and physical conditions of persons in proximity to the ventilator
The ventilator and other material assets belonging to the operator
The efficient operation of the ventilator

All those involved in installing, starting and maintaining the ventilator need to
read carefully, understand and comply with the following instructions. It
concerns their safety!

Obligations of the operator

The operator is hereby obliged to permit only those persons to work with the ventilator,
who:
Are familiar with the fundamental regulations on work safety and accident
prevention and have received proper instructions on how to handle the ventilator.
Have read, understood and acknowledged by signing the operating manuals
chapter and warnings on safety.
Are safety-conscientious. Checks should be carried out at regular intervals to
ensure this.

Obligations of the staff

Before commencing their work, all persons who have been assigned to work with the
ventilator are obliged to:
Observe the fundamental regulations on work safety and accident prevention.
Read and acknowledge by signing that they have understood the chapter and
warnings on safety of this operating manual.
Keep all safety and danger warnings on the machine in a legible condition.

2.2 Additional safety regulations

Additional safety rules and accident prevention regulations in this manual are
highlighted by the following symbols:
Danger!
Denotes imminent danger. Failure to observe can lead to death or
serious injury.

Warning!
Denotes a possibly dangerous situation. Failure to observe can lead
to serious injury.
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Caution!
Denotes a possibly dangerous situation. Can lead to light or minor
injury if unavoided.

Important!
Denotes tips for operation as well as other useful information.
i

3 Technical specifications
3.1 Features
A type plate, such as illustrated below, is mounted to each LWN ventilator. The
performance data for motor speed maximum and impeller speed maximum specified
on the type plate may not be exceeded without the authorisation of the manufacturer!
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3.2 Areas of application

Intended use
This ventilator is intended exclusively for the conveyance of air or similar gaseous
mixtures. Any difference or divergence in use is deemed improper. The company LWN
GmbH shall not be liable for damages arising from such improper use. In addition, the
intended purpose of the device also includes:
Observance of all warnings contained in the operating manual, and
Compliance with inspection and maintenance work requirements.

The ventilator has been designed to convey air or similar gaseous mixtures. It is
therefore connected to the suction-side and pressure-side of a duct.

4 Transport and storage

Transport
Important! The ventilator is supplied completely pre-assembled. Upon arrival,
inspect the ventilator for possible damages in transit and, if need be,
i notify the shipping company. Heavy impacts will damage the
bearings of the ventilator.

Loading
Hang up the ventilator by the eye bolts at the centre of the ventilator housing (at the
motor for balance only). Do not remove the suspension equipment at the crane until
the device has been securely installed.
Danger!
Do not stand underneath the suspended ventilator! The suspension
equipment could break! The falling ventilator can kill or cause
serious injury!

Storage
Avoid storing the ventilator outdoors. Heavy corrosion can reduce
Important! the operating life of the ventilator and lower the maximum
permissible speed. In addition, the impeller can become unbalanced.
i Water can penetrate the ball bearings and lead to premature
terminal malfunction. For these reasons, the ventilator should be
stored under a roof or wrapped in foil.
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5 Installation (incl. dismantling)

Set-up
As far as nothing else has been agreed, the ventilator is supplied primed as standard.
If the ventilator is being set up outdoors, use corrosion-resistant surface protection
and put a roof over the ventilator. These steps to prevent erosion should also be
followed even if the ventilator is only being stored outdoors temporarily (roofing,
wrapping in protective foil). In addition, the bearings can become damaged from
standstill in a moist atmosphere over a long period of time. They, too, should be
covered up.

Take care when setting down the ventilator!

Caution!
Mind the beams at head level! You could walk into them and injure
yourself.

The ventilator should be set up in a location that leaves enough room for maintenance
work. Furthermore, it should be possible to lift and transport heavy parts of the
ventilator at all times using suitable lifting tools (fork lifts, cranes).

6 Start-up
Hazards of faulty connections
Keep foreign objects out of reach and prevent them from being sucked into the
ventilator on both the pressure- and suction-sides. Safety guards include a long duct,
which, for this purpose, keeps the impeller out of reach, as well as a grille at the
openings with a suitably small mesh. If the ventilator is operated to suck or blow
freestanding, a grille with a sufficiently small mesh should be fitted securely to its entry
or exit to prevent contact. Mount the ventilator on the vibration dampers that come
supplied with the ventilator. Make sure the device stands safely. Securely weld onto
the ground all points of support. The points of connection should not become a trip
hazard.
Warning!
Ventilator can fall over if installed unsteady. An unsteady ventilator
can cause serious injury! Ensure the device stands securely.
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Danger!
A bent axle can cause serious unbalance. The impeller can crack as
a result! Parts flying out can be fatal or cause serious injury. Please
check ventilator for unbalance during start.

6.1 Commissioning of radial ventilator

This ventilator was designed for operating temperatures in built-in conditions. When
operated under different conditions, the following should be taken into account: With
the suctionside or pressure-side closed, the radial ventilator starts up with the least
amount of initial current. When the ventilator is re-started successively over a short
space of time, it should therefore be shut with a valve (if available) in order to keep the
heat of the motor to a minimum. Particularly for those ventilators that have been
designed for continuous operation under temperatures higher than the start-up
temperature, the initial current needs to be kept to a minimum. Specifications for the
start-up behaviour of the ventilator can be found on the ventilator data sheet. The
surface temperature of motors not equipped with thermistor motor protection must at
least be checked carefully (!) by touching the surface with the hands. Please see
documents relating to the motor.

Warning!
Only turn on the ventilator when the impeller is out of reach! You
could seriously injure yourself or be sucked in by the impeller! Do
not turn on until the ventilator has been connected up fully.

Warning! Do not turn on the ventilator until it has been fully connected at the
suction-side and pressure-side and has been safeguarded with
possibly necessary protective guards. Parts flying out can cause
serious injury.

6.2 Commissioning of axial ventilator

This ventilator was designed for operating temperatures in built-in conditions. When
operated under different conditions, the following should be taken into account: The
axial ventilator starts up freely without output pressure (duct connection) with the
least amount of start-up current. When the ventilator is re-started successively over a
short space of time, it is therefore advisable to open a throttle (if available) in order to
keep the heat of the motor to a minimum. In addition, keep the start-up current as low
as possible! Specifications for the start-up behaviour of the ventilator can be found on
the ventilator data sheet. The surface temperature of motors not equipped with
thermistor protection must at least be checked carefully (!) by touching the surface
with the hands. Please see the motor documentations.
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Warning!
Only turn on the ventilator when the impeller is out of reach! You
could seriously injure yourself or be sucked in by the impeller! Do
not switch on until the ventilator has been connected up fully.

Warning! Do not turn on the ventilator until it has been fully connected at the
suction-side and pressure-side and has been safeguarded possibly
and if necessary with protective guards. Parts flying out can cause
serious injury.

Electrical installation
The electrical installation must be carried out by a qualified electrician. The required
operating power operation can be found on the type plate. Do not operate the motor
without motor protection. Possible thermisor / thermo contact motor protection units
need to be up and running before the initial start-up! Install a switch for turning off the
direct power supply to the motor. This will disconnect the ventilator from the main
power supply in the event of an inspection.

6.3 Operating connection

The power supply frequencies are generally 50 or
60 Hz. The voltage between two prime line
conductors (L1L2L3) is the line voltage UL
(phase-to-phase voltage, power supply voltage).
The voltage between a prime conductor and the
central point conductor is known as the Y voltage
Uph (phase voltage). As a result, the following correlation holds true UL = 1.73 x Uph

Illustration 1)
The three beginnings (U1, V1, W1) and the three
ends (U2, V2, W2) of the windings are connected to
the six terminals in the terminal box. There, the three Windings configuration at
prime conductors (L1, L2, L3) are always connected 460V (440D)
to the phase beginnings.
When the phase ends (U2, V2, W2) are connected
together, the motor is connected in a star (Y)
configuration. At the star junction, the sum of all
voltages and currencies is equal to zero and phase
resistance is connected to phase voltage. The electric
current in the motor is equivalent to the current in the
winding phase.
When one end of a phase is connected to the
beginning of the next, the motor is connected in a
delta configuration. The phase resistance is
connected to phase voltage. The current of the motor is equal to the geometric sum of
two phase currents (Illustration 2).
These relationships illustrate that the motor can be connected both in a Y
configuration to a 400V mains voltage (50 Hz) as well as a delta-configuration to a
230V mains voltage (50 Hz). In both cases, roughly the same amount of electricity
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flows through the winding phase. The same applies to the new preferential voltages
690V (Y, 50 Hz) and 400V (delta, 50 Hz). When the alphabetic sequence of the
terminal descriptions (U1, V1, W1, U2, V2, W2) is consistent with the timing sequence
of the phases, the machine will then rotate clockwise. In case of an anti-clockwise
rotation, two external connection lines have to be swapped. According to standard
0530 by the Association for Electrical, Electronic & Information Technologies in
Germany, a terminal clamp for the protective earth conductor also has to be provided
for inside the terminal box. Furthermore, machines with a capacity of over 100kW
require an additional earthed clamp at the housing.
Vibrations of the ventilator
Because of its rest unbalance and its geometry, a ventilator produces vibrations at
different frequencies. The sum of all arising vibrations can be summarised as vibration
speed veff. or vibration force. The units of vibration force are measured in mm/s.

6.4 Measuring preparations and instructions

The following points need to be observed before starting to take measurements:

Speed
The oscillating force of a ventilator is determined by its operating speed. For
ventilators with variable speed, measuring the entire operating speed range is
recommended in order to detect the possible areas of resonance. Such areas of
resonance should be passed through as fast as possible.

Set-up
During measurements, the ventilator can either be set up under normal operating
conditions or, in case a smaller unit is involved, it can be put on or hung up on special
spring systems.

Measuring points
The preferred points for taking measures are the bearings areas or bearings levels,
though the housing of the bearing also suffices.

Measuring direction
Measurements should be made in the horizontal, vertical and axial directions but
particularly in the direction where the greatest oscillation amplitudes are to be
expected. This generally tends to be the horizontal measurement direction.

Vibration pick-up
A vibration pick-up should be used that can be held up to the measuring points by
hand or that can be attached or screwed on with a magnetic clamp. The resonant
mass of the machine should be larger than roughly 3kg so that the measurement
result is not inadmissibly falsified too much by the mass of the vibration pick-up (which
amounts to approx. 0.3kg).
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Verdict
Important! The measurements have to be taken at regular intervals of
operation. This is the only way to ensure an accurate prediction of
i the development of damage. We are happy to provide you with
further information about this.

7 Machine operation
The ventilator may only be operated by persons who have been trained to do so.

The ventilator may only be operated if:

All safety equipment and safety-related monitoring equipment is available and up
and running.
Nobody is present in the hazardous area of the machine
All control openings are secured and locked.

The ventilator should be checked at least once every shift for obvious external
damages and faults. Changes that may have arisen are to be reported to the person in
charge.

In the event of a defect, the ventilator should be stopped and the situation secured
immediately. Please initiate the removal of the malfunction immediately!

Danger! The ventilator may only be operated at maximum speed if t max has
not been exceeded! The impeller can crack! Parts flying out can be
fatal or cause serious injury. The stability of the impeller is only
guaranteed at the maximum operating speed identified on the type
plate.

Warning!
Only turn on the ventilator when the impeller is out of reach! You
could seriously injure yourself or be sucked in by the impeller! Do
not turn on until the ventilator has been connected-up completely.

Warning! Do not turn on the ventilator until it has been fully connected at the
suction-side and pressure-side and has been safeguarded with
possibly necessary protective guards. Parts flying out can cause
serious injury.
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8 Service
8.1 General
Caution!
Before carrying out maintenance or inspection work, you need to
have read and understood the operating manual.

Modifications
Unauthorised modifications and alterations of the ventilator are prohibited for safety
reasons. Consultation and written consent from LWN need to be obtained beforehand.
Danger!
Disconnect the ventilator from the main power suppy before
maintenace work and safeguard against it being switched back on
again. Sudden start-up of the ventilator can cause serious injury

Caution! Oil, grease and other impurites can cause the ventilator to fall over
and cause injury. The area in and around the ventilator must be
cleaned before maintenance work begins.

Warning! When a hot medium is being conveyed, the parts outside of the area
of isolation are equally as hot as the medium itself! You could burn
yourself. Wait until the ventilator has cooled-off before beginning
your work .

Important!
Please ensure the ventilator is safe before beginning maintenance
i work. Assume a healthy posture and lift heavy parts with a crane.

Important! Extremely hot and cold work environments can impact the ability to
concentrate. Watch out for acoustical and optical warning signals of
i neighbouring system parts!
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8.2 Maintenance and inspection

Cleaning, maintenance
In order detect possible damages on time and prevent terminal malfunction, the
ventilator has to be inspected regularly. Only use protectively-isolated electronic
equipment for maintenance!

Maintenance work is due if:

The ventilator impellor has become unbalanced due to irregular use or foreign
solid parts have been sucked in and have damaged the impeller or the housing.
Protective grilles at the suction-end and pressure-end have become dirty causing
a higher system resistance.
A dirty air inlet grille of the belt guard prevents the V-belt from being cooled
down.
The V-belts become worn out
The V-belts need to be re-tensioned as a result of normal stretching.
Abrasive residue from the couplings plastic element indicates wear down
The vibration dampers have rusted or the rubber is damaged or worn out
The lubrication interval has elapsed
An increased BCU level of the bearings area indicates that the bearings have
broken down.

Bearings
The bearings may reach a maximum temperature of 125C when operated
continuously at maximum capacity! Lubricate the bearings sufficiently. Insufficient
lubrication leads to premature terminal malfunction of the bearings. Lubricated
bearings (with possible occasional lubrications) have to be re-lubricated after 1,000
operating hours and should generally be dismantled, cleaned and freshly lubricated
(see the enclosed bearing manufacturers manual) after 10,000 operating hours. All
bearings contained in LWN ventilators operate at minimum for 40,000 hours. Please
observe the lubrication directions on the lubrication plate / lubrication instructions /
motor documentation! Document the maintenance regime.
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Caution! The bearings have an operating temperature of 80-100C. You

could burn yourself. Do not inadvertently touch the housing of the
bearings.

Strong vibrations of the impeller can lead to permanent breakage!

The impeller could burst! Parts flying out can be fatal or cause
serious injury!
Danger! Dirt that adheres during operation of the ventilator can cause
unbalances.
Check the ventilator regularly for vibrations and, if necessary, clean
the impeller, preferably with the aid of revision equipment. When
abrasive or corrosive media is being conveyed, the materials should
be replaced when they begin to wear out. Regular inspection is
indispensable! Documented evidence of conformity has to be
carried out!

The wearing out of materials leads to loss of stability. The impeller

Danger! could burst! Parts flying out can be fatal or cause serious injury!
Replace the impeller in case of material wear out! Check the
impeller on a regular basis in order to detect any changes.
Open the cleaning hatch
Steam blast the impeller
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8.3 V-belt (depending on the machine type)

Clamp in the belts as directed. The technical specifications for this can be found on
the ventilator data sheet. Replace belts at the first signs of excessive wear and
replace the complete set to guarantee that all belts have the same amount of tension.
Caution!
When replacing the belts! You could crush your fingers. Follow the
instructions for belt replacement as directed.

Belt replacement
Loosen the belt drive by drawing the pulleys together. Do not lever the belts out with a
screwdriver. Fit the new set of belts. Align the belt drive and clamp it in accordance
with our recommendations.
After 30 minutes of operation under load, check the belt tension and, as needed, re-
tension it.
No maintenance work will be necessary to the belt drive during its life time.

Wrong Wrong Correct

Alignment
A flawless alignment is very important as the belt notches will otherwise wear out
quickly. Do not force the belts into the grooves using a screwdriver or similar object.
Make sure the pulley sides are aligned well. To ensure a long belt life, check the belt
tension regularly.

Storage of V-belts
The V-belts should be stored in a dry place. Keep away from heat and direct sunlight.
If possible, they should be stored hanging freely and under no circumstances should
they be tied tightly together.

Belt protection
Where belt protection is required, a protective grille construction for better ventilation
should be favoured over an enclosed unit.
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Spanning the narrow V-belt drive

Only the proper belt pre-tension guarantees an optimum operating life of the belt and
the best possible degree of efficiency of the drive.
We recommend the use of a belt pre-tension measuring device.
Belt tension gauge

Deflection in mm Deflection force

Determining the belt pretension force:

The correct pretension force is to be set in the plant using electronic testing
equipment. If this should not be available, the pretension force can be set as follows:

1. Measure the distance between the axles.

2. Multiply the distance between the axles in meters by 16. The result is the belt
deflection in mm.
3. Using the lower marking ring, the belt deflection is set on the deflection scale of
the tension gauge in mm.
4. The upper marking ring is positioned near the end of the tube on the deflection
force scale.
5. Place the gauge in the centre of the belt span at a right angle to the belt. Apply
pressure to the top sleeve of the belt. Apply force until the marked deflection has
been reached.
6. The deflection force can now be read off from the position of the marking ring.
7. Compare the deflection force reading with the ranges of the table below. In the
case of new belts, the higher values should be selected for the start-up phase.
After 30 min. of operation under load the deflection distance should be re-tested
and if need be retensioned.

Belt deflection - 16mm for

every 1000mm of belt span.
Measure at a right angle from
the centre of the axle
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Profile Force axle distance for 16mm deflection

Effective diameter of
small pulley [mm] Newton [N]

Belt tension gauge is positioned at centre of

the belt span at a right angle to the belt

8.4 Coupling (depending on the machine type)

The elastic element of the coupling has to be renewed before it is completely worn
out. This usually involves moving the motor to the side. When bringing together the
two coupling halves motor and bearing attention should be paid to optimal
alignment.
Caution!
Take care when bringing together the two coupling halves at the
motor and bearing! You could crush your fingers! Pay attention to
the movement of all parts.

Caution!
Do not remove the couplings residues from abrasion with
compressed air! The dust can get in your eyes.
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8.5 Lubrication
Bearings which are lubricated with grease can also be lubricated during operation. If
the bearings are lubricated with oil, the oil level has to be checked during machine
standstill. The oil sight glass needs to be half covered up. For lubrication intervals
please see the lubrication plate on the bearing block of the ventilator or on the
ventilator data sheet.
When replacing the bearings, we recommend replacing the whole bearings unit. You
will then receive the renovated unit back for your spare parts inventory.

Bearings (Block bearings or vertical bearings)

See 8.2 for lubrication

Caution! The bearings have an operating temperature of approx. 80 - 100C.

You could scald yourself. Do not inadvertently touch the bearings
housing! Lubricate the bearings sufficiently! The bearing can
become hot and you could scald yourself. Re-lubricate as directed
and check temperature!

8.6 Cleaning
Impeller maintenance
Dirty-conveying media can coat the impeller unevenly and thereby cause unbalance.
The vibrations, measured at the bearings, should not permanently exceed 8mm/s. In
such an event, the impeller should be cleaned with blasted steam.
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9 Limits of vibration speed according to DIN 10816-3

ISO 10816-3 Limits of vibration speed

v.r.m.s. in
mm/s

2 - 1000Hz n > 120 min-1

10-100Hz n > 600 min-1
Vibration speed
11
7,1
4,5
3,5
2,8
2,3
1,4
0,71

rigid soft rigid soft rigid soft rigid soft foundation

Medium-sized
Pumps > 15kW machines Large machines
radial, axial, diagonal 15kW < P < 300kW 300kW < P < 50MW Machine type
Intermediate axle / Motors Motors
Direct drive
Belt drive 160mm H < 315mm 315mm H
Group 4 Group 3 Group 2 Group 1 Group
A commissioned new
B Unlimited long-term operation
C Short term operation
D Vibration causes damages

We would like to point out that vibrations are measured in a loose installation situation,
i.e. not fixed to the ground, before the ventilator is delivered. The readings taken in the
test bay will therefore be higher than when it has been installed and mounted on-site.
From experience, the actual vibration speed readings will therefore be less by 1..2
mm/s .
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Appendix
In the appendix you will find the relevant technical documentations for all components
that form part of the LWN ventilator, but were not manufactured by LWN (e.g. drive
motor). As these are vital to the flawless efficiency of the ventilator, these operating
manuals should be considered just as much as the LWN manual itself. Possible
damages arising from non-observance of the operating manuals are self-inflicted!

Ventilator data sheet

Characteristic curves
Dimension sheet
Motor data sheet
Declaration of conformity