Nicotra AT Manuel

Nicotra S.p.A.- Via C.Cantù,1 – 20121 Milano – Italy

Factory.: Via Modena, 18 – Ciserano Loc. Zingonia (BG)– Italy

Factory.: Strada di Ronchis, 5 – Remanzacco (UD) - Italy

Cod. 985719 – 00 / Jan 2004

INSTALLATION AND MAINTENANCE

MANUAL

CENTRIFUGAL FANS

AT-AS-ASH-RSH-ADH-RDH

In accordance with ATEX directive

In issuing this guide-book maximum attention has been paid to ensure correct information. Nicotra S.p.A. does not accept any

responsibility for eventual errors or omissions.

Cod. 985719 – 00 / July 2004 2

SUMMARY

1. GENERAL INFORMATION.................................................................................. 4

1.1. ATEX VERSIONS..................................................................................................................... 4

2. RECEIVING AND INSPECTING THE PRODUCT................................................ 4

2.1. DATA ON THE RATING PLATE.............................................................................................. 5

2.2. WEIGHTS OF THE PRODUCTS.............................................................................................. 6

2.3. HANDLING AND LIFTING THE FAN ...................................................................................... 7

2.4. STORAGE ................................................................................................................................ 8

3. FUNCTION AND DESIGN OF THE FAN ............................................................ 8

3.1. OPERATING CONDITIONS..................................................................................................... 8

3.2. OPERATING LIMITS................................................................................................................ 8

3.2.1. Max installed power 8

3.2.2. Maximum speed 8

3.2.3. Operating temperature 9

3.3. BALANCING ............................................................................................................................ 9

3.4. BEARINGS ............................................................................................................................... 9

3.4.1. Bearing life 9

3.5. SHAFTS.................................................................................................................................... 9

4. INSTALLATION ................................................................................................... 9

4.1. FIXING THE FAN ..................................................................................................................... 9

4.2. INSTALLING THE DRIVE SYSTEM ...................................................................................... 11

4.2.1. Problems due to a too low belt tension 11

4.2.2. Problems due to a too high belt tension 11

4.2.3. Belt tension 12

4.3. SAFETY ACCESSORIES....................................................................................................... 13

4.3.1. Protection of moving components 13

4.3.2. Electrical insulation 13

4.4. INSPECTION AFTER INSTALLATION ................................................................................. 13

4.5. STARTING THE FAN ............................................................................................................. 13

5. MAINTENANCE ................................................................................................. 14

Cod. 985719 – 00 / July 2004 3

5.1. ORDINARY MAINTENANCE ................................................................................................. 14

5.1.1. ATEX version 15

5.1.2. Drive 15

5.1.3. Bearings 15

5.1.4. Bearings lubrication 15

5.2. REPLACING INSTRUCTIONSFOR BEARINGS .................................................................. 17

5.2.1. Dismantling the bearing with eccentric locking collar 17

5.2.2. Mounting the bearing with eccentric locking collar 17

5.2.3. Dismantling the plummer block with ball bearing and eccentric locking collar 18

5.2.4. Mounting the plummer block with ball bearing and eccentric locking collar 18

5.2.5. Dismantling the plummer block with ball bearing and adapter sleeve 18

5.2.6. Mounting the plummer block with ball bearing and adapter sleeve 18

5.2.7. Dismantling the SNL plummer block with self-aligning ball bearing and adapter sleeve 19

5.2.8. Mounting the SNL plummer block with self-aligning ball bearing and adapter sleeve 19

5.2.9. Dismantling ConCentra roller bearing 22

5.2.10. Mounting ConCentra roller bearing 23

6. ATEX – DECLARATION OF CONFORMITY ..................................................... 26

ADH ATEX - OPERATING LIMITS…………………………………………………..27

RDH ATEX - OPERATING LIMITS ..………………………………………………..28

AT ATEX - OPERATING LIMITS …..……………………………………………….29

ASH ATEX - OPERATING LIMITS ..………………………………………………..30

RSH ATEX - OPERATING LIMITS …..……………………………………………..31

Cod. 985719 – 00 / July 2004 4

1. GENERAL INFORMATION

The scope of this manual is to provide information about the correct installation, use and maintenance of the fans listed in

the title.

The safety recommendations contained herein are of general level and can be applied to several models of Nicotra

range.

To know the specific characteristics of each model, please refer to the relevant catalogues.

It is customer’s responsibility to verify that all the operations on the ventilation equipment are carried out by professional

staff, who must apply all the safety recommendations required by the laws, rules and standards of the country where the

fans are installed.

The information contained in this manual must be read in conjunction with the contents of the catalogues of each model

and the selection program “Ventil”.

These recommendations cannot represent totally the methods or procedures required for safe operation. Care should

always be taken when working in close proximity to equipment or moving parts. Total safety depends on acquired skill,

experience and reasonable care in all operations.

1.1. ATEX VERSIONS

In this manual are listed specific information for fans intended for use in potentially explosive atmospheres for ATEX

“Group II”, “Categories 2G-2D-3G-3D” according to the directive 94/9/CE.

Design of fans is in accordance with the following standards: EN 1127-1, EN 13463-1, prEN 13463-5.

The information contained in this manual for ATEX fans, must be integrated with the contents of the catalogues of each

model and the selection program “Ventil”.

2. RECEIVING AND INSPECTING THE PRODUCT

All Nicotra products are carefully checked before delivery to assure the best standard quality.

It is customer responsibility to control that the received units are in accordance with the order and have not been

damaged during the transport.

If you discover any damage, please contact immediately the Forwarder Agent and start the damage notification

procedure.

After having accepted the goods, Nicotra will guarantee only what stated in the commercial agreement.

Cod. 985719 – 00 / July 2004 5

In particular we suggest to check the following points:

•The goods quantity, type and design must fit what was stated in the order and listed in the transport bill

•Make sure that there are not damaged or missing parts

•Verify if the housing or the flange have dents

•Check if some parts are not correctly fixed

•The wheel must rotate easily, without touching other parts; make sure that the wheel is still balanced and fixed

correctly on the shaft

•Verify the correct tightening of the screws

•Make sure that the inner ring of the bearings is locked on the shaft

•Check if shafts and frames have been bent during transport

•Couplings between the shafts must be aligned

•Atex fans must be accompanied by the following documents: “ Maintenance and Installation Manual”, “Atex

Certificate” and rating plate fixed on the housing

Note: for any other information, please refer always to the relevant drawing, catalogue or contact our Technical

Department.

2.1. DATA ON THE RATING PLATE

MOD: product description

COD: Nicotra code

SERIAL: serial number

COD. CLI: customer code (optional)

WATT MAX: max admissible power

RPM MAX: max admissible speed

MAX BEARING LOAD: max admissible radial load on bearing

Prod. Date: production date

Instr. Code: “Maintenance and Installation Manual” code

II 2 G: Atex Group II, Cat.1, Gas (only Atex version)

ctype of protection against ignition risk (only Atex version)

T5: max surface temperature class (only Atex version)

Cod. 985719 – 00 / July 2004 6

2.2. WEIGHTS OF THE PRODUCTS

Approximate weights (±10%) of the standard fans, excluding the packaging, are listed in the table below. The exact

weight of the fans is specified in the relevant drawing.

AT 7/7 9/7 9/9 10/8 10/10 12/9 12/12 15/11 15/15 18/13 18/18

Skg 5,0 6,5 8,0 8,5 9,5 13 15 18 21 27 33

SC kg 6,0 8,5 9,5 10 11 16 18 21 25 33 38

AR kg -13,5 15 15,5 17 28 30 35 39 48 55

G2L kg 11,7 14,9 18 19 21 28 34 40 45 58 71

SC2 kg 13,7 18 22 22 24 35 40 46 53 70 82

G2C kg -24 27 27 31 46 51 57 68 91 106

G3C kg -----70 81 90 108 118 137

AT 20/15 20/20 22/15 22/22 25/20 25/25 28/20 28/28 30/20 30/28

TIC kg 71 78 73 82,5 93 120 127 131 138

G2C kg 137 150 141 165 195 202 210 235 245 302

G2C-C2 kg 144 158 148 173 202 210 218 244 253 310

G3C kg 315 355 340 425 432 480 474 539 505 577

G3C-C2 kg 319 359 347 438 436 484 478 543 509 581

RDH 180 200 225 250 280 315 355 400 450 500 560 630 710 800 900 1000

Lkg 5,2 6,5 7,7 13,3 17,8 21,2 29 36 50 62 79 104,1 148,7 - - -

Rkg 7,1 8,5 9,9 15,7 21,3 25 34 42 57 70 92 119,1 165,4 - - -

Kkg - 11,8 13,6 20,6 28 32 46 57 73 90 141,1 173,5 220 270,1 342,5 414,7

K1 kg - - - - - 34 47 58 75 92 148 180,4 240 296,8 355,4 -

K2 kg - - - - - - - - - 110 152,6 185,1 249,7 305,3 374,8 450,3

G2L kg 11,3 14 17 27 36 43 59 77 102 131 - - - - - -

G2R kg 15,5 19 22 33 44 53 74 91 121 152 203 - - - - -

G2K kg - - - 44,5 59,3 68,5 103,1 125,3 159,9 197 301 370 436 565 685 953

G2K2 kg - - - 42 56 66 93 114 144 183 289 359 443 572 692 960

ADH 160 180 200 225 250 280 315 355 400 450 500 560 630 710 800 900 1000

Lkg 5 6 7,1 8,5 10,5 14,2 17,8 23 31 42 57 72 91 118 - - -

Rkg 6,67,89,110,71318222938506586106135- - -

Kkg - - 12,6 14,5 18 24 29 41 52 66 85 134 170 201 249 306 333

K1 kg ------3042536786142175208261316-

K2 kg ----------105150180225278320360

G2L kg 10,512,61518223038496690120------

G2R kg 14,51720242939486382107140185230----

G2K kg ----38506084108135176268342532665801894

G2K2 kg ----44597398133159221319393537670806899

Cod. 985719 – 00 / July 2004 7

2.3. HANDLING AND LIFTING THE FAN

The fans must be handled by experienced and fully trained staff. A wrong handling or lifting could damage the fans. The

most frequent are the following:

•shifting of the wheel on the shaft due to loosening of the hub set screws

•bending or misalignment of the shaft

•bending of the frames

•dents on the housing

•damage of the bearings; in particular a wrong tightening of the locking system

The fans are supplied in a carton box, pallets or cages.

The lifting equipments must be chosen according to weight and type of the goods.

The fan fitted with side frames should be lifted by its lifting lugs (holes or slots) in four points.

The fans without frames may be lifted with a rope secured to the shaft ends.

Do not bend or misalign frames and shaft when lifting the twin and triple fans. We suggest to fix them on a pallet larger

than the dimension of the fan base.

The fans supplied in a carton box, must be handled with equipment which avoids damaging the packaging.

The units on pallet must be lifted by a forklift truck.

Cod. 985719 – 00 / July 2004 8

Do not hook the units in the following points:

•inlet cone

•wheel cone

•blade

•single shaft end

•motor (for complete units)

•bearing or bearing support bar/bracket

•cut-off

2.4. STORAGE

All Nicotra fans are designed to be stored for a maximum period of six months under the following conditions:

•storage temperature range: -25°C ÷+65°C

•relative humidity: < 60%

•protect the fans against direct rain or snow

•store the fans in premises, which are adequately ventilated and heated so that no condensation will occur on the

units

•rotate the wheel at least once a week, to permit the redistribution of the grease inside the bearing and prevent

corrosion

•protect the units from external loads or vibrations

•avoid the exposure to direct sunshine and UV rays

•protect the fans from corrosive agents

3. FUNCTION AND DESIGN OF THE FAN

3.1. OPERATING CONDITIONS

The operating data for fans in standard version are listed in the specific catalogues.

In general fans are designed for use with “clean air”.

For particular operating conditions such as temperature different from the standard range, airflow with corrosive agents,

high humidity, special applications or use outside the standard limits, please contact our Technical Department.

The fans in ATEX version are designed to work under the specific conditions of the “group”, “category” and “temperature

class” stated in the rating plate.

The standard limits for ATEX fans are listed in the tables enclosed in this manual. The specific limits of a special fan

could be different from those of the standard version and are listed in its rating plate.

3.2. OPERATING LIMITS

3.2.1. Max installed power

In the tables enclosed in each catalogue are listed the power limits and the minimum diameter of the smallest

transmission pulley according to the applied power.

The belt tension must never exceed the values calculated in the selection program “Ventil”. The values for the first

tensioning are indicated in the chapter “Belt tension”.

3.2.2. Maximum speed

Maximum permissible speed is listed in the tables enclosed in the catalogues.

Cod. 985719 – 00 / July 2004 9

3.2.3. Operating temperature

The standard operating temperature is indicated in the catalogues. For short periods it is possible to use the fan at a

temperature lower than –20°C, but it is dangerous to start a fan which was standing at a temperature lower than –20°C.

For special application please contact our “Technical Department”.

For use at temperatures higher than those indicated in the catalogue, the limit is controlled by the bearing grease; in this

case please refer to the paragraph “Maintenance”.

The operating temperature (airflow, ambient temperature) and the temperature class for the fans in ATEX version are

indicated in the rating plate.

3.3. BALANCING

The fan impellers are statically and dynamically balanced with grade G4 according to ISO 1940.

3.4. BEARINGS

In the “Maintenance” chapter are listed the bearings used on each fan.

3.4.1. Bearing life

The Nicotra bearings have been selected to achieve a bearing life L10h of 40.000 hrs according to ISO 281. This value is

calculated with common pulley sizes (see also the chapter “Pulley selection”) and at maximum load. In more common

load conditions, the bearing life can easily exceed this value.

If the bearing life depends on the applied loads, these are due to many factors; the most important is the belt tension

which is function of the installed power, pulleys diameter and number of grooves.

In the catalogue tables are listed the minimum diameter of the pulleys and the maximum number of grooves suggested in

order to respect the maximum permissible loads.

The belt tension must never be higher than the values calculated in the selection program “Ventil”.

3.5. SHAFTS

Shafts diameters are selected to have a critical speed higher than the maximum permissible speed with a safety factor

≥1.2.

4. INSTALLATION

Correct installation of the fan will ensure correct operation and avoid problems in the future.

Atex fans, must never be installed in presence of an explosive atmosphere. If they are connected to other components or

machines, such as motors, drive elements (pulleys, belts, couplings…) etc, these must also be Atex compliant and not

change the mechanical characteristics of the fan in such a way that the fan can not remain Atex compliant according to

the standard described in the paragraph 1.1.

The fan must always be connected to an earth cable. Category 2 fans have an earth screw, while for category 3 fans it is

necessary to connect an earth cable to the housing.

The painted frames can not guarantee a superficial resistivity lower than 1 Giga-Ohm, so are not suitable as earth

connection elements.

4.1. FIXING THE FAN

Pay attention to the following points:

•the fan must be fixed to a base or to a rigid frame designed to avoid vibrations and resonance

•use all the fixing points and verify that the frame or the feet will rest on the whole surface

Cod. 985719 – 00 / July 2004 10

•when tightening the screws, do not bend frames, fixing feet and sideplates. Avoid overloads that can compromise

the correct functioning of the fan

•Fix the fan on a plane base. The shaft must always be in horizontal position to avoid axial loads on bearings and

anomalous vibrations. Do not use the fan with the shaft in vertical position

•We suggest the use of antivibration mountings to isolate the system motor-fan from the machine structure. Motor

and fan must be fixed on a common base to avoid relative displacement which can create misalignment between

the pulleys

•If the fan is to be connected to a duct, we suggest the use of a flexible connection flange to compensate

misalignment between the outlet and the duct and avoid vibrations

•Make sure that the duct is as closely aligned as possible with the fan outlet

•Use gaskets to avoid losses

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