General Instructions

(Plenum & Plug Fan)

BNA-ANA- BPA-APA

IGB030.E0/1203

1
This manual is to guide the users in the proper storage, installation, operation and maintenance
procedures to ensure maximum equipment life and trouble-free operation. HANDLING AND
MAINTENANCE SHOULD ALWAYS BE PERFORMED BY EXPERIENCED AND TRAINED
PERSONNEL.

RECEIVING, HANDLING AND STORAGE

Rough handling during shipment and improper storage can cause damage that is not noticeable until
the fan is in operation. This can be avoided with proper storage and handling techniques.
Fan should be hoisted with slings placed around the fan housing. Touch up the scratch coated surfaces
during lifting, to prevent corrosion to occur at this area. Store the fan in a clean and dry place,
preferably indoor to ensure fan shaft, bearing and fan casing are protected against dust and corrosion.
Do not store the fan in a location where it will be subjected to vibration. This can cause the internal
surface to rub against each other and damage the bearings.

START-UP CHECK LIST

Before putting any fan into initial operation the manufacturer’s instruction must be followed. Complete
the following checklist to make sure that the fan is ready to run.

Lock out the primary and all secondary power sources.

Make sure the foundation or mounting arrangement and the duct
connections are adequately designed in accordance with recognized
acceptable engineering practices and with the fan manufacturer’s
recommendations.
Check and tighten all hold-down (securing) bolts.
Check the fan assembly and bearings for proper grounding to prevent
static electricity discharge.
Spin impeller to see whether it rotates freely and is not grossly out of
balance.
Inspect impeller for correct rotation for the fan design.
Check belt drive or coupling alignment, use recommended belt tension.
Check belt drive for proper sheave selection and make sure they are
not reversed.
Properly secure all safety guards.
Switch on the electrical supply and allow the fan to reach full speed.
Check carefully for :- (1) Excessive vibration
(2) Unusual noise
(3) Proper amperage and voltage values
(4) Proper belt alignment
If any problem is indicated, SWITCH OFF IMMEDIATELY. Lock out the electrical supply,
secure the fan impeller if there is a potential for wind milling. (Impeller turning due to a
draft through the system). Check carefully for the cause of the trouble and correct as
necessary.

2
The fan may now be put into operation but during the first 8 hrs of running, it should be periodically
observed and checked for excessive vibration and noise. Checks should be made on motor input
current and motor & bearing temperature to ensure that they do not exceed manufacturer’s
recommendation. After 8 hrs of operation, the fan should be shut down to check the following items :-

(1) All set screws and hold-down bolts

(2) Belt drive alignment
(3) Belt drive tension
(4) Bearing housing temperature

After 24 hrs of the satisfactory operation, the fan should be shut down, and the drive belt tension
should be readjusted to recommended tension.

TROUBLE-SHOOTING

Fan is developing or emitting abnormal or excessive noise

Possible cause Remedy

Drive system • Fan or motor sheave not properly tightened onto shaft • Re-tighten the sheaves
• Misaligned sheaves • Re-align the sheaves
• Belt hitting Belt Guard Check fan & motor sheave alignment & belt
• Belts are not tensioned enough and are too loose tension
• Belts too tight • Increase the belt tension
• Belts wrong cross section • Correct belt tension
• Belts worn • Change to right type
• Belts oily or dirty • Replace belts
• Belt guard is not properly fastened • Clean belts
• Motor, motor base or fan not securely anchored or • Tighten the fasteners
Secured • Tighten the fasteners

Motor • Lean-in cable not secure • Fasten the cable properly

• Noisy motor bearings • Replace bearing
• Single phasing a 3 phase motor • Check power supply
• Low voltage • Check power supply
• Cooling fan striking shroud • Check motor assembly
• Electromagnetic fault in motor • Replace motor
• AC hum in motor or relay
• Starting relay chatter

Fan • Impeller loose on shaft • Tighten impeller

Components • Impeller unbalance • Balance impeller
• Impeller not center in inlet or housing • Adjust impeller to center of inlet or housing
• Impeller in contact with inlet cone • Correct inlet cone position
• Blades rotating close to structural member • Correct the running clearance
• Cutoff or other parts loose (rattling during operation) • Tighten loose parts
• Cutoff damaged • Replace cutoff
• Cutoff improperly positioned • Reposition cutoff
• Impurities or foreign material inside fan housing • Clean inside fan and impeller
• Bearing defective or worn out • Replace bearing
• Bearing loose on bearing support or shaft • Re-tighten bearing
• Foreign material inside bearing • Clean bearing
• Fretting corrosion between inner race and shaft • Replace bearing or shaft
• Bearing not sitting on flat surface • Re-adjust bearing
• Rubbing noise between bearing seal and inner ring • Replace bearing
• Impeller worn as a result of abrasive or corrosive • Replace impeller
material moving through passages.
• Blades coinciding with an equal number of structural
members

3
Fan is vibrating excessively
Possible cause Remedy

Impeller • Impeller unbalanced due to deposits (dirt or grease) • Clean impeller, rebalance the system
• Impeller unbalanced due to wear • Replace impeller

Drive • Unbalanced pulleys • Balance the pulley or the system

• Belts may vibrate excessively • Proper sheave alignment and adjust to correct
belt tension

Required air volume not achieved

Possible cause Remedy

Impeller • Impeller not centered with inlet collar(s) • Adjust the impeller to the center of inlet collar(s)
• Impeller/inlet dirty or clogged • Clean the impeller or inlet
• Improper running clearance • Change to correct clearance
• Improper inlet cone to wheel fit • Adjust to correct fit
• Impeller installed or running wrong direction • Change to correct rotation by changing poles of
electrical feed line to motor
• Incorrect speed of impeller because of:
i) Wrong motor speed i) Change motor or belt drive
ii) Belt drive ratio not correct ii) Change belt drive
iii) Too high slip of V-belt iii) Increase tension of belts
iv) Wrong calibration of inverter iv) Adjust inverter calibration

Duct System • Shutters or dampers of the system are closed • Open damper or IVC
• Object obstructs fan or duct • Clear obstructed ducts
• Inlet guide vanes are partly close • Open grill/diffuser damper
• Dampers closed • Open Damper
• Registers closed • Open Register
• Leaks in supply duct • Seal the Leakage
• Obstructions near fan outlet or inlet • Clear obstruction
• Sharp elbows near fan outlet or inlet • Redesign and change elbow
• Improper designed turning vanes • Redesign and change vanes
• Insulating duct liner loose
• Pressure resistance offered by the system higher than
the design value
• Fluid density higher than the design value
• Improper set inlet vane or damper
• Actual system is more restrictive (more resistance to
flow) than expected
• Obstructed fan outlet inlets
Elbows, cabinet walls or other obstructions restrict air
flow. Inlet obstructions cause more restrictive
systems but do not cause increased negative
pressure readings near the fan inlet(s)
Fan speed may be increased to counteract the effect
of restricted fan inlet(s). Caution! Do not increase
speed beyond the fan manufacturers
recommendations
• Projections, dampers or other obstruction in a part of
the system where air velocity is high
• Obstructions in high velocity air stream

4
Fan does not start or operate
Possible cause Remedy

Electrical • Blown fuses • Check fuses/circuit breakers

Supply • Electricity turned off • Check for switched off or disconnected
• Wrong voltage • Check for correct power supply
• Failure of one or two phases • Check for correct power supply
• Low voltage, excessive line drop or inadequate wire • Check for correct wire size
size

Motor • Motor not correctly connected • Connect the motor according to the motor label
• Load inertia too large for motor • Change motor
• Motor protection unit or switch are stopping as • Reduce temperatures, check and change
temperature are too high insulation class, increase motor rating
• Motor too small and overload protector has broken • Change motor
circuit

Drive System • Broken belts • Replace belt

• Loose pulleys • Tighten pulley

Excessive air flow

Possible cause Remedy

Fan • Excessive rotational fan speed • Reduce fan speed

Duct System • Pressure resistance offered by the system lower than

the design value

Gas Density • Gas density higher than the design value

High power absorption

Possible cause Remedy

Impeller • Air flow already rotating in the opposite direction to

the fan rotation direction
• Backward curved impeller installed backwards

Motor • Faults in the motor windings • Replace motor

• Motor power supply voltage lower than the value • Check with motor supplier
indicated on the identification plate

Fan • Forward curved or backward blade fan operating below

design pressures.

System • Oversized ductwork • Redesign ductwork

• Filter(s) left out • Add in filter(s)
• Access door are open • Close access door
• Face and by-pass dampers oriented so coil dampers
are open at same time by-pass dampers are open

Gas Density • Calculated horsepower requirements based on light

gas (eg. High temperature) but actual gas is heavy
(eg. Cold start up)

Fan selection • Fan not selected at efficient point of rating • Check selection

5
GUIDELINES FOR PLENUM AND PLUG FANS INSTALLATION

Adjacent Walls

The distance between the fan and walls or ceilings will affect the fan performance. The recommended
distance between the fan wheel and any wall is a minimum of 0.5 wheel diameter. Multiple walls reduce
the performance even more.

0.5 D

Side by Side

When two or more plenum fans are in parallel, there should be at least one fan diameter spacing between
the wheels. Applications with less spacing will experience performance losses.

0.5 D
D 0.5 D

V-BELT DRIVE INSTALLATION

• Remove the protective coating from the end of the fan shaft and assure that it is free of nicks and
burrs.
• Check fan and motor shafts for parallel and angular alignment.
• Slide sheaves on shafts – do not drive sheaves on as this may result in bearing damage.
• Align fan and motor sheaves with a straight-edge or string and tighten.
• Place belts over sheaves. Do not pry or force belts, as this could result in damage to the cords in the
belts.
• Adjust the tension until the belts appear snug. Run the unit for a few minutes (see section on unit
start-up) and allow the belts to “set” properly.
• Switch off the fan, adjust the belt tension by moving the motor base. 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.

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• Aligning sheaves
with a straight edge. Proper Offset Pigeon- Toed Angle

BELT TENSION

Proper belt tension is important for long belt life. Too much tension puts excessive loads on the belts and
the bearings, reducing the lives of both components. Not enough tension allows belt slippage, which
generates heat and drastically reduces the life of the belt.
Belt tensioning gauges can be used to determine whether the belts are tensioned properly. A chart that
comes with the gauge specifies a range of force required to deflect the belts a given amount based on the
centre distance of the sheaves and the belt cross section. The belts are properly tensioned when the force
required to deflect the belt, the specified amount falls within this range.
If a belt tensioning gauge is not available, re-tension the belts just tight enough so that they do not squeal
when starting the fan. A short “chirp” is acceptable; a squeal lasting several seconds or longer is not
acceptable.
Before starting the fan after tensioning the belts, recheck the alignment and realign the sheaves if
necessary. New belts may stretch a little at first, so recheck belt tension after a few days of operation.

Belt tension indicator

applied to mid-centre
CENT distance.
RE
DIST
ANCE
16mm
of spa deflection
n per 1
metre

7
Tensioning Forces

Force required to deflect belt

16mm per metre of span
Belt Section
Small Pulley Kilogram
Newton (N)
Diamter (mm) force (Kgf)

56 - 95 13 - 20 1.3 - 2.0
SPZ
100 - 140 20 - 25 2.0 - 2.5

80 - 132 25 - 35 2.5 - 3.6

SPA
140 - 200 35 - 45 3.6 - 4.6

112 - 224 45 - 65 4.6 - 6.6

SPB
236 - 315 65 - 85 6.6 - 8.7

224 - 335 85 - 115 8.7 - 11.7

SPC
375 - 560 115 - 150 11.7 - 15.3

A 80 - 140 10 - 15 1.0 - 1.5

B 125 - 200 20 - 30 2.0 - 3.1

BEARING LUBRICATION

• Fan equipped with deep grooved ball bearing inserted in rubber damper has sufficient high
grade grease sealed in at the time of manufacture, there is no need for replenishment while in
use at normal speed & normal condition.

• Fan equipped with deep grooved ball bearing inserted in pillow block also has sufficient high
grade grease sealed in at the time of manufacture, there is no need for replenishment while in
use at normal speed & normal condition. The pillow block housing has lubrication point suitable
for lubricating when the bearing operating temperature exceeding its nominal of 70 degree, or
the bearing is used in very dusty or damp or high contamination environment.

• Fan equipped with spherical roller bearings and CARB toroidal roller bearings, assembled in
plummer block housings has lubrication point when the life of grease is expectancy.

Experience from bearing manufacture indicates a first relubrication exercised after a few days of
operation is very beneficial to all rollers bearings and may even be a prerequisite if the expected
relubrication interval is to be attained when operating speeds are high. For this first
relubrication, half of the normal quantity recommended for regular relubrication is sufficient.

• Type of grease used for relubrication should be the same as that used during first fill
(mounting). Never mix greases if it is not known whether they are compatible.

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• Referring to manufacturers’ instructions, the amount of grease required for relubrication can be
determined from

Gp = 0.006 D B
Where
Gp = Grease quantity for periodic relubrication, g
D = Bearing outside diameter, mm
B = Bearing width, mm

The relubricating interval may be determined from the following diagram. At bearing temperatures
above 70 C, relubricating interval obtained from the diagram should be halved for every 15 C
increase.

Caution: Do not over-lubricate. This is a major cause of bearing failure. Make sure dirt and contaminants are not introduced
when adding grease.

Scale a: Radical ball bearing

Scale c: Spherical roller bearings

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Type of bearing Type of grease Temperature

NSK Deep Groove Ball Bearing Alvania Grease #3 Normal

SKF Deep Groove Ball Bearing SKF Grease LGMT 3 Normal

SKF Spheriodical Roller Bearing

SKF Grease LGMT 3 Normal / High
SKF Carb Roller Bearing

VIBRATION ISOLATOR INSTALLATION

• Choose proper isolator

(Isolator can be selected from Kruger selection programme)

• Adjust deflection based on the selected isolator.

• Maintain the operating / free height at the same level through step 2.
(The entire assembly must be levelled)

• Check all the deflection and operating / free height is properly maintained.

Operating / free height

ROUTINE MAINTENANCE

Maintenance should always be performed by experienced and trained personnel. Do not attempt any
maintenance on a fan unless the electrical supply has been locked out or tagged out and the impeller
has been secured.
Under normal circumstances, handling clean air, the system should require cleaning only about a Year.
However, the fan and system should be checked at regular intervals to detect any unusual
accumulation.
The fan impeller should be specially checked for build-up of material or dirt which may cause an
Imbalance with resulting undue wear on bearings and belt drives. A regular maintenance program
should be established as needed to prevent material build-up.
Periodic inspection of the rotating assembly must be made to detect any indication of weakening of the
rotor because of corrosion, erosion, or metal fatigue.

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KRUGER GROUP (VENTILATION)
SINGAPORE SINGAPORE
Kruger Ventilation Industries Pte Ltd Kruger Engineering Pte Ltd
No. 17 Tuas Avenue 10 No. 17 Tuas Avenue 10
Singapore 639141 Singapore 639141
Tel.+65 68611577 - Fax +65 68613577 Tel. +65 68631191 - Fax +65 68631151

MALAYSIA THAILAND
Kruvent Industries (M) Sdn Bhd Kruger Ventilation (Thailand) Co. Ltd
Lot 8, Jalan Perusahaan 2 Batu Caves 1/19 Moo 2 Rama II Rd, Tasai Mueng
Industrial Area, 68100 Batu Caves Selangor Samuthsakorn 74000, Thailand
Tel. +603 61888293 - Fax +603 61898843 Tel. +66 34-490164-9 - Fax +66 34-490170

BEIJING GUANGZHOU
Bejing Kruger M&E Equipment Co. Ltd Guangzhou Kruger M&E Ind. Ltd
No. 1A Fuyuan South Road, Beijing No 1270 Maogang Road, Huangpu
Economical and Technological Development Guangzhou, P.R. China 510700
Area, Beijing China 100176 Tel. +8620-82287634 - Fax +8620-82287624
Tel. +8610-67881366 - Fax +8610-67880566

HONG KONG SHANGHAI

Kruger Ventilation (Hong Kong) Limited Shanghai Kruger M&E Industries Ltd
Flat B, 9/F, Yeung Yiu Chung (No. 8) Industrial No.500 Yuanguo Road, Anting, Jiading, Shanghai
Building, 20 Wang Hoi Road, Kowloon, Hong Kong 201814 P.R. China
Tel. +852 22469182 – Fax +852 22469187 Tel. +86 21-69573266 - Fax +86 21-69573296

WUHAN TAIPEI
Wuhan Kruger M&E Industries Ltd Kruger Ventilation (Twn) Co. Ltd
108 Fangjicun, Yangyuan Street No. 157, Ping-an Rd, Hengfeng Village,
Wuhan, P.R China 430063 Dayuan Shiang Taoyuan County 337, Taiwan (ROC)
Tel. +8627-86718165 - Fax +8627-86825719 Tel. +886 3-3859119 - Fax +886 3-3859118

PHILIPPINES AUSTRALIA
Kruger Ventilation Industries Phils. Inc Kruger Ventilation (Australia) Pty Ltd
FAPI Compound, E. Rodriguez Ave. 4 Blackfriar Place, Wetherill Park
Tunasan, Muntinlupa City, Philippines 1773 NSW 2164, Australia
Tel. +63-2 862-2891 - Fax +63-2 862-1287 Tel. +61-2-97562008 – Fax +61-2-97560808

INDONESIA INDIA
P.T KrugerIndo Adhiteknik Kruger M&E Ind. (India) Pvt Ltd
Ruko Mahkota Mas Blok C No. 20 Pardhy House 1st Floor
Jl. M.H. Thamrin – Cikokol Tangerang 15117 Junction of Hanuman Road & MG Road
Tel. +6221-5543107/8 – Fax +6221-5543016 Vile Parle (East) Mumbai 57
Tel. +9122-56926095/6/7 – Fax +9122-56926098

KOREA
Neomate Technology&Consulting Co. Ltd
No. A-407-1, Ansung B/D, 410-13
Shindorimdong, Kuro-Gu, Seoul, Korea
Tel. +82 2-2679-2052/3 - Fax +82 2-2679-2052/3