Axial fans

Installation and Operating instructions

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Contents

1 INTRODUCTION 6
1.1 Purpose of this manual 6
1.2 Safety symbols used in this manual 6
1.3 Safety symbols used on fans 7

2 GENERAL INFORMATION 8
2.1 Definitions, basic principles, terminology used and correlated documents 8
2.2 Construction details of axial fans 8
2.2.1 Versions and motor positions 8
2.2.2 Flow indications 9
2.3 Fan name plate 10
2.4 Fan Temperature types 12
2.5 Description of fan 11
2.6 Envisaged use and foreseeable uses according to experience, and prohibited uses 17
2.7 Life cycle of fan 18

3 WARNINGS AND MAIN SAFETY INDICATIONS 19

3.1 Installation instructions: general information 19
3.2 Installation type A: Instructions for assembly, installation and connections 20
3.3 Installation type B: Instructions for assembly, installation and connections 20
3.4 Installation type C: Instructions for assembly, installation and connections 21
3.5 Installation type D: Instructions for assembly, installation and connections 21
3.6 Risks involved in foreseeable incorrect handling and/or abnormal uses based on
experience 22
3.7 Other risks related to fans pursuant to UNI EN ISO 12499 23
3.7.1 Specific risks with fans during installation 23
3.7.2 Specific risks with fans during maintenance 24
3.7.3 Environmental risks 24
3.7.4 Vibration risks 24
3.7.5 Operating speed risks 25
3.7.6 Noise emission risks 27
3.7.7 General information on noise emission data 28

4 TRANSPORT, MOVEMENT AND STORAGE 30

4.1 Lifting and movement 30
4.2 General warnings for lifting separate fan parts 30
4.3 Fan lifting instructions 30

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4.3.1 Lifting version 1 and 9 axial fans 30
4.3.2 Lifting version 4 axial fans 31
4.3.3 Lifting fans packed in crate 32
4.4 Storage 33

5 INSTALLATION 34
5.1 General information 34
5.1.1 Minimum installation distances 35
5.2 Assembly of axial fans 36
5.2.1 Version 4 axial fans 36
5.2.2 Version 1 axial fans 37
5.2.3 Version 9 axial fans 38
5.3 Mounting Configuration 39
5.4 Installing and adjusting drive belts and final checks 40
5.5 Vibration Isolator Installation 41
5.6 Blade adjustment 41
5.7 Electrical connections 42
5.8 Connection to ducts 44

6 CHECKS TO BE MADE BEFORE AND AFTER STARTING 45

6.1 Preliminary checks 45
6.2 Checks to be made with fan fully operating 46
6.2.1 Visual checks on protection net 46
6.2.2 Checking and cleaning parts in contact with fluids 47
6.2.3 Visual checks on impeller and casing 47
6.2.4 Dimensional checks 48

7 AXIAL FAN OPERATING MALFUNCTIONS 49

7.1 Most frequent malfunctions 49

8 MAINTENANCE 51
8.1 Bearing lubrication 52
8.2 Adjusting drive belt tension and cleaning belts 54
8.3 Checking and cleaning parts in contact with fluids 55

9 DISMANTLING AND REASSEMBLING ESSENTIAL COMPONENTS 56

9.1 Fan impellers with hub 56
9.2 Replacing drive belts 56
9.2.1 Assembling and dismantling pulleys 56
9.2.2 Assembling and dismantling drive belts 61

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10 FINAL DISMANTLING AND DISPOSAL OF FANS 63
10.1 Version 4 axial fans 64
10.2 Version 1 and 9 axial fans 65

11 TECHNICAL APPENDICES 66
11.1 Tightening torques for nuts and bolts 66
11.2 Checklist before starting fans 68
11.3 Programmed maintenance intervals 69

12 INDEX 70

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Index of Diagrams

Fig. 2-1 Axial fan versions 9

Fig. 2-2 Flow indications 9
Fig. 2-3 Name plate of fan described by this manual 10
Fig. 2-4 Key to reading fan name plate 10
Fig. 2-5 TDA fan components indicated 11
Fig. 2-6 TDA-V fan components indicated 12
Fig. 2-7 TDB-II fan components indicated 13
Fig. 2-8 MXA fan components indicated 14
Fig. 2-9 TBE fan components indicated 15
Fig. 2-10 MXC fan components indicated 16
Fig. 4-1 Example of lifting version 1 and 9 axial fans 32
Fig. 4-2 Example of lifting version 4 EF axial fans 33
Fig. 4-3 Example of lifting fans packed in crate 34
Fig. 5-1 Minimum installation distances with inlet duct 36
Fig. 5-2 Minimum installation distances with free inlet 36
Fig. 5-3 Assembly of version 4 axial fans 37
Fig. 5-4 Assembly of version 1 axial fans 38
Fig. 5-5 Assembly of version 9 axial fans 39
Fig. 5-6 Vibration Isolator setup 41
Fig. 5-7 Diagram of electrical connections for single-speed and two-speed motors 43
Fig. 5-8 Example of positioning of external terminal box 43
Fig. 5-9 Assembly tolerances for flexible joints 44
Fig. 5-10 Minimum installation distances with inlet duct 44
Fig. 8-1 Checking drive belt tension 53
Fig. 9.1 Pulley holes 56
Fig. 9.2 Angular misalignment 58
Fig. 9.3 Parallel misalignment 58
Fig. 10-1 Exploded view of version 4 fan 63
Fig. 10-2 Exploded view of version 1 and 9 fan 64

Index of Tables
Table 2-1 Types of fans 11
Table 8-1 Bearing Grease Weight Standard of TACBECON SGHT 200S (Class F)/ 600 (Class H) 52
Table 8-2 Relubrication intervals and quantity of grease according to fan rotation speed 53
Table 8-3 Setting drive belt tension: test load and deflection 54
Table 9-1 Tightening torques 60
Table 11-1 Tightening torques M for bolts with ISO metric threads 66
Table 11-2 Tightening torques for blade fixing bolts on fans with steel hub 67

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1 INTRODUCTION
1.1 Purpose of this manual
This manual contains instructions and warnings, and constitutes documentation that must compulsorily
accompany the product. Otherwise the product is lacking one of its essential safety requisites.
The manual must be kept with care, and must be made available to all persons involved with the product.
The warnings are intended to safeguard the safety of persons exposed to residual risks.
The instructions provide indications for the most appropriate conduct for the correct use of fans as intended
by the manufacturer.

WARNING:
The safety precautions used for the fan must also be adapted to its specific destination
of use.
The safety precautions differ according to the type of fan installation, as specified in
paragraph 3.1 below.
The information given in this manual is therefore indispensable for the use of fans in
conformity with the destination of use of the product and without risks.

In this manual the letters “KRUGER” stand for Kruger Ventilation Industries Asia Co., Ltd.

No part of this manual may be copied, reproduced or transmitted in any form whatsoever and by any
electronic, mechanical or photographic means without the express authorization of KRUGER.

The KRUGER Technical Office is fully at your disposal for all information required.

1.2 Safety symbols used in this manual

Certain items of particular interest in this manual may be preceded by one of the following symbols:

DANGER: Indicates situations that might cause personal injuries.

DANGER: Live electrical components.

WARNING: Indicates important information of particular general interest

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1.3 Safety symbols used on fans
The following safety symbols are used on KRUGER fans:

Prohibited to lubricate and/or adjust moving parts.

Prohibited to remove protection net.

Hazard due to presence of moving parts.

This symbol is applied near the inspection hatches provided on fans.
It is permitted to open inspection hatches only when all moving parts
have reached a complete standstill.

Indication of a lifting point.

This symbol is applied near the points identified by KRUGER for lifting
and moving the fan.

Hot surfaces >60 °C.

Danger of burns or scalding. Hot surfaces – Emission of hot fluids.
This symbol is applied if the fan is used to move hot fluids.

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2 GENERAL INFORMATION

2.1 Definitions, basic principles, terminology used and correlated documents

 Point 3.1 of the UNI EN ISO 13349 standard defines a fan as “rotary-bladed machine which receives
mechanical energy and utilizes it by means of one or more impellers fitted with blades to maintain a
continuous flow of air or other gas passing through it and whose work per unit mass does not normally
exceed 25 kJ/kg.”
 Point 3.6.1 of the UNI EN ISO 13349 standard defines an axial-flow fan as “a fan in which the air enters
and leaves the impeller along essentially cylindrical surfaces with the fan.”
 The blades may have the following shapes: flat (obtained directly by pressing sheet steel) or more
frequently a wing profile (obtained with aluminium).

The fundamental dimensions that define a fan are as follows:

 Volumetric flow: this is the volume of fluid passing through the fan in a certain period of time - one second
(m3/s), one minute (m3/min) or one hour (m3/h);
 Static pressure: this is the energy imparted by the impeller to overcome the resistance offered by the
system to the passage of fluid (measured in mm of water column = mm w.c. or Pascal = Pa);
 Dynamic pressure: this is the energy possessed by the fluid as a result of the speed imparted by the
impeller at the output opening of the fan (measured in mm w.c. or Pa);
 Total pressure: this is the arithmetical total of static pressure and dynamic pressure (measured in mm
w.c. or Pa);
 Flow: two directions for the fluid moved are identified for an axial fan, either from the motor towards the
impeller (flow A) or from the impeller towards the motor (flow B), see Fig. 2-2;
 Rotation speed: this is the rotation speed of the impeller, and is measured in revolutions per minute (RPM);
 Efficiency: this is the percentage ratio between the energy that the fan manages to transmit to the fluid
and the energy supplied by the motor to the impeller; it depends on impeller characteristics, and has no
measurement units;
 Power absorbed: this is the power needed (provided by the motor) by the fan for correct operation, and is
measured in kW;
 Name plate motor power: this is the nominal power that the motor can provide; it must always be greater
than the power absorbed by the fan, and is measured in kW;
 Sound pressure level: this is the energy propagated into the channel of the external ear and that generates
vibrations of the ear drum, namely the level of noise emitted by the fan; it is measured in decibels using
scale A (a scale that allows the impact of noise on the human ear to be assessed, according to the
frequency of the noise);
 Sound power: this is the index of emission of sound power, and constitutes an intrinsic and constant
characteristic of a sound source; it is expressed in watts.

The following documents are correlated to this manual:

 Kruger fan selection sheet for the fan, which lists dimensions, weights, rotation speeds, fluid types and
data on flexible couplings and vibration dampeners.
 Kruger Product Traveller and Finished Goods Card, which indicates the characteristics of the
transmission installed on the fan.
 The instruction and warnings manual of the manufacturer of the electric motor (if supplied together
with the fan).

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2.2 Construction details of axial fans
2.2.1 Versions and motor position

VERSION 1 VERSION 4 VERSION 8

VERSION 9 VERSION 12 Standard position with motor at 0°

Fig. 2-1 Axial fan versions

2.2.2 Flow indications

The diagram refers to version 4,

but is valid for all construction
versions:

A = Flow from motor to impeller

B = Flow from impeller to motor
U = Flow upwards
D = Flow downwards

Fig. 2-2 Flow indications

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2.3 Fan name plate
The name plate is the only means of fan identification recognized by the manufacturer. It must not be modified,
and must not be removed or damaged. Fig. 2-3 shows the plate fitted to the fan.

Fig. 2-3 Name plate of fan described by this manual

Fan model / Fan series / Blade type / Hub diameter / Blade number / Tip angle

Fan tag

Fan item code

Serial number

Air flowrate / Static pressure

Fan speed / Total pressure

Motor technical data

Maximum fan speed /

Maximum fan installed power

Manufacturer site

Fig. 2-4 Key to reading fan name plate

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2.4 Fan Temperature types

Range General Ff250 F300 Ff300 F400

Fan Series (mm) Ventilation 250°C / 300°C / 300°C / 400°C /
20°C to +55°C 2 hrs 1 hr 2 hrs 2 hrs
TDA 315-2000     
TDA-V 315-2000     
TDC 450-2000    
TDD 450-2000     
TDB-II 315-1400  - - - -
TBE 315-2000  - - - -
MXA 450-2000     
TRC 1250-2240     
MXC* 315-2000     
Please consult KRUGER for fan series other than specified.
* MXC series is designed for kitchen exhaust application and comply with UL 762

Table 2-1 Types of fans

2.5 Description of fan

2.5.1 TDA series

Taking the fan shown in Fig. 2-5, TDA fan is generally constituted by the following components:
 Protection Net (1); ● Motor Base Reinforce (7);
 Impeller (2); ● Motor Base (8);
 Motor Support (3); ● Mounting Feet (9);
 Motor (4); ● Hanger (10);
 Tube Casing (5); ● Terminal Box (11)
 View Port (6);

Fig. 2-5 TDA fan components indicated

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2.5.2 TDA-V series

Taking the fan shown in Fig. 2-6, TDA-V fan is generally constituted by the following components:
 Protection Net (1); ● Terminal Box (7);
 Impeller (2); ● Terminal Support (8);
 Motor (3); ● Outlet Vane (9);
 Tube Casing (4); ● Hanger (10);
 View Port (5); ● Mounting Feet (11);
 Motor cover (6); ● Motor Base (12)

Fig. 2-6 TDA-V fan components indicated

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2.5.3 TDB-II series

Taking the fan shown in Fig. 2-7, TDB-II fan is generally constituted by the following components:
 Protection Net (1); ● Motor cover Plate (Front) (9);
 Motor cover Plate (Rear) (2); ● Hub (10);
 Motor cover Rong 1 (3); ● Impeller (11);
 Motor Support (4); ● View Port (12);
 Motor Base (5); ● Terminal Box (13);
 Mounting Feet (6); ● Motor (14);
 Hanger Bar (7); ● Motor cover (15)
 Tube Casing (8);

Fig. 2-7 TDB-II fan components indicated

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2.5.4 MXA series

Taking the fan shown in Fig. 2-8, MXA fan is generally constituted by the following components:
 Pod Cover (1); ● Motor cover (8);
 Impeller (2); ● Outlet Vane (9);
 Hub (3); ● Motor Base (10);
 Tube casing (4); ● Terminal Box (11);
 View Port (5); ● Hanger (12);
 Terminal Box (6); ● Mounting Feet (13)
 Motor (7);

Fig. 2-8 MXA fan components indicated

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2.5.5 TBE series

Taking the fan shown in Fig. 2-9, TBE fan is generally constituted by the following components:
 Protection Net (1); ● Shaft (11);
 Upper Belt Back Cover (2); ● Hub (12);
 Upper Belt Casing (3); ● Impeller (13);
 Upper Belt Front Cover (4); ● Bearing Base (14);
 Motor (5); ● Mounting Feet (15);
 Motor Base (6); ● Drive Set (16);
 Lip Channel (7); ● Lower Belt Back Cover (17);
 Hanger Bar (8); ● Lower Belt Casing (18);
 Bearing Support (9); ● Lower Belt Front Cover (19);
 Bearing (10); ● Access Door (20)

Fig. 2-9 TBE fan components indicated

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2.5.6 MXC series

Taking the fan shown in Fig. 2-10, MXC fan is generally constituted by the following components:
 Protection Net (1); ● Motor Base (8);
 Inlet Cone (2); ● Motor (9);
 Wheel (3); ● Bearing Base (10);
 Outlet Vane (4); ● Bearing (11);
 Tube Casing (5); ● Shaft (12);
 Hanger Bar (6); ● Drive Set (13);
 Mounting Feet (7); ● Belt Cover (14);

Fig. 2-10 MXC fan components indicated

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2.6 Envisaged use and foreseeable uses according to experience, and prohibited uses
The envisaged use for the fan with the name plate as shown in Fig. 2-3 is as follows:
A commercial axial fan is a machine that serves to move a gaseous fluid inside a fluid movement system to
which the fan is connected by means of ducts and technical chambers provided for this purpose. The flow of
the fluid moved by the machine enters and leaves the fan in an axial direction.
The energy required to move the volumes of fluid entering the system from the suction inlet is transferred by
the rotation of the impeller inside the casing. Impeller rotation is obtained in most cases by the energy supplied
by an electric motor, as indicated earlier in paragraph 2.4 of this manual.
The fan must be used in the flow range specified in the performance diagrams. Use of the fan with flows lower
than the minimum value indicated in the diagrams may cause unstable fluid dynamic operation and vibrations.
Axial fans are used in many applications associated prevalently with the development of industrial processes.
Here is a list of some possible industrial sectors with application examples:
 Textile sector (air conditioning and treatment, drying)
 Food processing sector (drying, cooking, circulation)
 Steel sector (extraction of fumes)
 Painting sector (filtration, dust removal)
 Transport sector such as maritime and railways (conditioning, motor cooling)
 Other applications not listed but agreed with our Engineering and/or Research & Development Area.
Some categories of use other than those described above are excluded, and more specifically:
 Operation of the fan with non-gaseous fluids or with fluids with characteristics different from those
defined in the technical information sheet accompanying the fan, since structural damage may be
caused to the fan with the possible risk of injury to persons and/or damage to things;
 Operation of the fan in all types of system with pressures (present or even partially generated by the
fan) greater than 1.05 times standard atmospheric pressure, since structural damage may be caused
to the fan with the possible risk of injury to persons and/or damage to things;
 Operation of the fan in all types of system classified in accordance with the ATEX 2014/34/EC Directive
and that move potentially explosive fluids, since risks of ignition/explosion may occur with possible
injury to persons and/or damage to things. Fans that are specifically constructed, classified and
marked for ATEX conformity for a suitable category for the installation location are excluded, and these
must be accompanied by the legally required documentation;
 Operation of the fan in industrial chemical plants where the fluid moved is highly corrosive for the
materials used in fan construction, or in the presence of highly toxic fluids where the construction
methods of casings and the types of seal used are not suitable for this specific application, since
structural damage may be caused to the fan with the possible risk of injury to persons and/or damage
to things;
 Operation of the fan in mining industry plants and with underground installations, since additional risks
not considered in the use of the fan above ground may arise, with possible injury to persons and/or
damage to things.

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2.7 Life cycle of fan
The reliability of all components is guaranteed by a production process with ISO 9001 certification and by compliance
with the programmed maintenance intervals indicated in paragraph 11.3 of this manual.
The components normally subject to wear are the following:

 bearings, calculated for a theoretical duration normally of 40,000 hours

 drive belts, calculated for a theoretical duration of 25,000 hours

For safety reasons, protection net in electro welded wire must be replaced every 2–3 years.

In the hypothesis of use of the fan at constant speed for two work shifts every day equivalent to 16 hours, calculated
for 250 days per year, the expected life cycle for the impeller is equivalent to 40,000 hours.
In case of use in conditions of particularly difficult operation (medium, high), this limit must be reduced. Any
such reduction must be assessed in collaboration with the KRUGER Technical Office. In the specific case of
operation at variable speeds, the impeller life cycle must be assessed on a case-by-case basis, and must also
be agreed with the KRUGER Technical Office.

CAUTION:
 Do not exceed the maximum rotation speed indicated by KRUGER.
 Do not use ON-OFF operating cycles unless expressly approved by KRUGER.
 Do not use variable-speed cycles unless expressly approved by KRUGER.
 Do not subject the fan to thermal gradients greater than 3°C/minute.

Even if it has never operated, an impeller that has been stored for more than ten years must be checked by
KRUGER for possible defects before it can be used.

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3 WARNINGS AND MAIN SAFETY INDICATIONS
3.1 Installation instructions: general information

Fans can be installed in four different ways, in conformity with the AMCA 201 standard:
 Type A: Free Inlet, Free Outlet;
 Type B: Free Inlet, Ducted Outlet;
 Type C: Ducted Inlet, Free Outlet;
 Type D: Ducted Inlet, Ducted Outlet.

Generally, KRUGER does not and cannot know which of the above installation types will be chosen
and applied by the user, and unless otherwise specified by contract, the fan is supplied for installation
types B, C or D according to the fan series and flow. The person responsible for designing the system,
together with the final user, must conduct an analysis of risks for the specific installation type chosen.
Depending on the way that it is intended to install and insert the fan in the fluid movement system, the
following protection net must be installed, according to installation type:
 Type A installation: fixed KRUGER protection net installed on inlet and outlet;
 Type B installation: fixed KRUGER protection net installed only on inlet;
 Type C installation: fixed KRUGER protection net installed only on outlet;
 Type D installation: no fixed protection net installed on inlet and outlet.
The system designer and the user must ensure that ducting systems are fitted with conformant protection net
for the duct connections made, as follows:
 Type A installation: no protection net (no ducts are connected);
 Type B installation: fixed protection net fitted on outlet duct;
 Type C installation: fixed protection net fitted on inlet duct;
 Type D installation: fixed protection net fitted both on inlet and outlet ducts.

CAUTION:
Unless otherwise specified by contract, fans are supplied for installation types B, C or D in
conformity with the AMCA 201 standard and according to fan series and flow.

Always verify all safety aspects of the installation type chosen.

With regard to protection net to be fitted to ducts, in compliance with the design project, they must prevent
access to parts of the fan and its accessories that could cause injuries. They must also be sufficiently robustly
constructed to resist the stresses generated by the machine and environmental conditions.
KRUGER invites users and/or system designers to design, construct and install protection net in conformity
with the criteria of the UNI EN ISO 12499 standard.

CAUTION:
Even with protection net installed (regardless of the conditions of supply or installation), the
fan may be dangerous due to the effects of indrawn or moved air.
Depending on the dimensions of the fan, this type of danger may even CAUSE DEATH.
The risk of being crushed against the inlet grille may be fatal or may cause serious injuries
(crushing of body parts, unconsciousness).

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CAUTION:
It is advisable to adopt precautions that prevent access to the room containing the fan while it
is operating, or to keep persons away with fixed protection net that maintain a safe distance
from the inlet opening.

WARNING:
Check the efficiency of all protection net every month. In case of wear, damage or breakage,
replace them immediately.

Protection net must be fixed securely in position using fixings that are not slackened by vibrations, and that
require the use of a tool for their removal.

CAUTION:
On starting and in compliance with programmed maintenance intervals, check that nuts and
bolts are correctly tightened. Monitor vibration levels with a vibrometer, and establish an alarm
threshold (see paragraph 12.3).

It is always the responsibility of the installer to guarantee that there is an adequate level of protection against
the risk of accidental contact with moving parts.
The installer and the user must also take other types of risk into consideration, and in particular those deriving
from the entry of foreign bodies and the inlet of explosive, inflammable or toxic gases or gases at a high
temperature.
The risks involved in maintenance operations must also be taken into consideration. It must be possible to
perform these operations in conditions of maximum safety, by isolating the fan from the motor or by taking
other suitable precautions.

CAUTION:
A safety procedure for access to the fan must be compiled, taking into consideration the
indications provided by the manufacturer, information deriving from the analysis of risks at the
installation point and safety requirements in workplaces.

3.2 Installation type A: Instructions for assembly, installation and connections

In case of type A installations, since neither the inlet nor outlet of the fan are connected to ducts, protection net
must be fitted on both the inlet and the outlet.
Protection net dimensions can be obtained from the dimensional drawing given in catalogues, from scale and
non- scale drawing programs downloadable from the reserved area of the website, or from any dimensional
drawings provided as documentation together with the products supplied.

3.3 Installation type B: Instructions for assembly, installation and connections

In case of type B installations, since the fan inlet is free and the outlet is connected to a duct, a protection net
must be fitted on the inlet.
Protection net dimensions can be obtained from the dimensional drawings given in catalogues, from scale and
non- scale drawing programs downloadable from the reserved area of the website, or from any dimensional
drawings provided as documentation together with the products supplied.

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3.4 Installation type C: Instructions for assembly, installation and connections
In case of type C installations, since the fan inlet is connected to a duct and the outlet is free, a protection net
must be fitted on the outlet.
Protection net dimensions can be obtained from the dimensional drawings given in catalogues, from scale and
non- scale drawing programs downloadable from the reserved area of the website, or from any dimensional
drawings provided as documentation together with the products supplied.

CAUTION:
Protection net are designed to protect against accidental contacts and to resist the pressures
generated only by the fan to which they are fitted.
Each protection net, if supplied individually, can be used only on the fan for which it was
designed. If therefore a protection net is ordered individually, it is compulsory to provide the
reference details of the fan to which it will be fitted (serial number).

3.5 Installation type D: Instructions for assembly, installation and connections

In case of type D installations, since both the fan inlet and outlet are connected to ducts, no protection net
need to be installed on either the inlet or outlet of the fan.

CAUTION:
The system designer must assess the need to fit any necessary protection net at the inlet and
outlet ends of the system.

For installation types B, C and D, it is advisable to insert flexible duct between the fan and ducts
so as to compensate for any misalignments that may be present, to prevent the transmission of
vibrations and to avoid structural stress.

The choice of a standard flexible duct for applications that are not particularly difficult depends on two
fundamental factors:
 dust content of the fluid moved
 fluid temperature

CAUTION:
Flexible ducts are suitable for installation on a single-stage fan, and must not be subjected to
effects of fluid dynamics caused by other machines installed in the same fluid movement
system.

For special applications, such as for example the movement of fluids at a high temperature or that are
particularly corrosive, or to guarantee perfect sealing of the joint, special joints must be used.
In this case the user and/or system designer must contact the KRUGER Technical Office.

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3.6 Risks involved in foreseeable incorrect handling and/or abnormal uses based on
experience

 When moving, lifting and installing the fan, always follow the instructions provided in this manual.
 It is absolutely prohibited to use the fan in conditions other than those indicated by the data on the name
plate.
 It is absolutely prohibited to deactivate, remove, modify or in any other way render inoperative safety
devices, protection net or control devices, either of individual components or of the fan itself.
 Do not position the hands, arms or any other part of the body near moving parts, even by forcing the
opening of apertures.
 It is forbidden to extend parts of the body beyond protection structures. It is forbidden to use aids that
may increase normal accessibility.
 It is forbidden to use fans in atmospheres or environments with the risk of explosions, with the exception
of fans that are in conformity with the ATEX 2014/34/EC Directive.
 It is forbidden for unauthorized operators to work on any fan defects or malfunctions or to alter the type
of operation or installation.
 Great care must be taken to ensure that fluids with characteristics other than those defined in this manual
(technical information sheet) are not introduced into fans.
 After all repair work involving the removals of protection net, barriers or other protection devices, these
must be replaced and checked for correct positioning and efficiency before the fan is started again.
 All protection net and safety devices must be maintained in conditions of perfect and constant efficiency.
Warning signs, safety symbols and danger warnings must be also maintained in perfect efficiency and in
their correct position.
 When tracing the causes of any faults or malfunctions with fans, take all the precautions described in this
manual, intended to prevent all and any kind of injury to persons or damage to things.
 Remember to tighten all bolts, nuts and fixing rings on all mechanical components that are adjusted or
serviced, following the indications given in Table.
 Before starting the fan, check that all protection net and safety devices are installed and in perfect
operating condition. If they are not, it is absolutely prohibited to start the fan. The person responsible for
plant safety or the department head must be informed immediately.
 Operators must be provided with Personal Protection Equipment (PPE) in conformity with legal
requirements. Bulky garments and various accessories (ties, wide sleeves, etc.) are prohibited.














 22 of 71 IGB010.E8 – December 2020

3.7 The fluid moved by the fan must be adequately checked for the possible presence of toxic and/or
inflammable substances, even if their presence is not envisaged in the use of the fan. Other risks
related to fans pursuant to UNI EN ISO 12499
The specific risks defined below are those deriving from mechanical aspects of the fan.

A person may be injured as a result of:

a) being dragged between a moving part and a fixed part, for example an impeller and the
casing or some other fixed part of the fan;
b) being dragged between two moving parts, for example a drive belt and a pulley;
c) being dragged into the fan through the air inlet, with consequent contact with the shaft or
impeller;
d) contact with a moving part, such as the impeller;
e) ejection from the fan outlet of fragments deriving from the introduction of residual solids or
liquids extraneous to the process, or deriving from the suction environment;
f) an object drawn into the fan mouth and ejected at high speed from the fan inlet or outlet;
g) structural defects of fan components;
h) contact with fan surfaces at dangerous temperatures, for example below -20°C or higher
than +50°C;
i) when working with hot fluids, there may be losses of jets of hot fluid from the transmission
shaft hole that may cause burns or scalds.
l) the potential harmfulness of the fluid being moved or the presence of substances that in
case of leaks may be hazardous;
m) a hazard deriving from motor overspeed, which may cause the breakage of machine parts;
n) the inlet of air at abnormal temperatures higher than those recommended may cause
structural deformations, malfunctions and hazards.

3.7.1 Specific risks with fans during installation

 The user must provide a well-levelled fixing surface. Incorrect levelling may cause abnormal fan vibrations
that over time could cause deformation and/or breakage, with the detachment of fan parts, representing a
hazard for exposed persons that may even be fatal.
 The user must also arrange electrical connections for the fan casing or structure to the main electrical
grounding system of the place of use, to prevent any formation and accumulation of static electricity.
 All protection net installed must remain correctly connected to the fan with all relative fasteners (bolts, nuts,
etc.). The removal of one or more fixing points may impair the functionality and solid fixing of the protection
net.
 Fans supplied as standard versions are not intended for use in potentially explosive environments.
 The place of installation of the fan must be kept clean. Any spills of oil or water not due to the fan must be
cleaned away as quickly as possible.
 The minimum installation distances defined in this manual must always be respected to guarantee correct
operation and the absence of additional risks. Incorrect positioning could impair the correct operation of
the fan.

IGB010.E8 – December 2020  23 of 71

3.7.2 Specific risks with fans during maintenance
 During maintenance and cleaning operations on the impeller, take great care with rotations of the impeller,
which could cause trapping or cutting injuries against fixed parts of the casing.
 A programmed maintenance schedule for the fan must be prepared and applied, so as to prevent
mechanical failures or breakages caused by wear or inadequate maintenance (see paragraph 12.3).

CAUTION: IT IS ABSOLUTELY PROHIBITED TO:

 Carry out any type of maintenance operation without having first checked that the fan
impeller is effectively at a standstill.
 Proceed with any type of maintenance operation on the fan (including lubrication) without
having first disconnected it from the mains powers supply.
 Clean the fan while it is operating.
 Open fan protection net or inspection hatches while it is operating.

CAUTION:
Even when the power supply to a fan is interrupted, its rotating parts may still move, due to air
passing through the fan, either naturally or from fluid currents generated by a fan located in
other parts of the system of linked ducts, or due to the inertia of the impeller after the machine
has been switched off. In this case as well, there may be the risk of trapping or cutting injuries
against fixed parts of the casing.

3.7.3 Environmental risks

KRUGER fans are designed to operate in and to withstand ordinary conditions of working environments. The
presence of:
 Vibrations
 Corrosive agents (dust, gas, fumes, mist)
 High temperatures
 Condensation
 Solid bodies
 Abnormal turbulence
 Currents of air
 Voltage differences due to installation
can affect the lifespan of components, causing premature deterioration, above all with respect to protection
net.
Since it is impossible to establish all-inclusive criteria that can take into account all the possible combinations
of these effects, it is advisable to implement a plan of periodical checks according to the effective deterioration
noted, so that any variations in structural characteristics can be detected in subsequent checks.

3.7.4 Vibration risks

Vibrations are the main factor affecting the operational life and safety of fans, and for this reason it is essential
to accurately monitor their level during fan operation and work cycles.
The ISO 1940/1 and ISO 2372 international standards establish the field of acceptability and the classification
of rotating machines, and more specifically, the ISO 14694 standard establishes values for commercial fans.

The reference values for KRUGER products are established by category BV4 of AMCA 204 standard.

 24 of 71 IGB010.E8 – December 2020

If ignored, vibrations can:
 Cause the formation of cracks serious enough to cause structural failure, which may even be sudden
 Cause difficult operating conditions for bearings, with malfunctions that may even include seizing (with
dangerous overheating effects)
 Cause slackening of tightening and fixing components (nuts and bolts)
 Generate greater noise.

KRUGER strongly recommends the use of a control and monitoring system for the fan, with continuous
monitoring of vibrations and bearing temperatures.
Depending on the specific application and use of the fan, it is advisable to define an "alarm threshold" for fan
vibration levels and bearing operating temperatures.

The monitoring of vibrations and temperatures makes it easier to take preventive actions
against accidents.

3.7.5 Operating speed risks

Operating speeds greater than those envisaged by the fan design can create conditions of risk due to the
reduction of the operative lifespan of moving parts.
In case of faults or malfunctions, overspeed conditions may be created due to:
 Errors in the control system
 Short circuits on monitoring components
 Driver or inverter malfunctions
 Mechanical breakage of components, and in particular on shafts.

CAUTION:
 Do not exceed the maximum rotation speed indicated by KRUGER.
 Do not use ON-OFF operating cycles unless expressly approved by KRUGER.
 Do not use variable-speed cycles unless expressly approved by KRUGER.
 Do not subject the fan to thermal gradients greater than 3°C/minute.

CAUTION:
A condition of overspeed, even for a limited time, may cause irreversible damage and create
situations of extreme risk hazards.

During normal operation, conditions of overspeed attributable to the drive system or motor may occur, in
particular if the fan is supplied "with shaft only" or with motor "without drive system".

In these cases, it is the responsibility of the user to verify and guarantee the correctness of additional
installations.
The construction of the transmission by the user or installer is a critical point for safety.
The transmission is an integral part of the machine, and its construction requires a design process and
awareness of the design parameters developed by KRUGER.

IGB010.E8 – December 2020  25 of 71

CAUTION:
To construct the entire transmission and/or install the motor only, the user and/or installer must
always request the transmission specifications document. It is absolutely prohibited to construct
transmissions with the use of couplings, drive belts and pulleys of types other than those
indicated by the transmission specifications document.

CAUTION:
If no inverter is used for gradual starting of the fan, it is absolutely prohibited to use toothed
pulleys, as these can cause irreversible damage to fan structures. Consult the KRUGER
Technical Office.

CAUTION:
Conditions of overspeed can be caused by drive system faults on fans with direct
transmissions.

In the case of directly-coupled fans of high power, starting is a moment of particular stress for rotating
mechanical organs.

In the case of fans supplied without an electric motor, incorrect electrical connections to the motor or the wrong
motor choice could be the cause of operation at speeds in excess of the original design speed, given that the
rotation speed of an asynchronous motor depends on the frequency and the number of poles.

The use of a supply frequency different from the original design frequency affects all fan characteristics. The
modification of conditions of use requires a complete revision of the technical information sheet of the fan.

In the case of use at varying fan speeds or with frequent starting and stopping during operation, rotating organs
are subject to mechanical stresses that may affect their operative lifespan.

CAUTION:
Fan operation within a very broad range of operating speeds may lead to increased vibration in
correspondence with a specific resonance frequency of the system of which the fan is only a
single component.
Avoid working at speeds coinciding with structural resonance frequencies, and if this is not
possible, modify some variable that can change the resonance frequency of the system, for
example by using vibration dampers of a different type.

If the rotation direction of a fan must be inverted, or if it must be restarted, this must be done only when the
impeller is in the rest position (total standstill).

CAUTION:
Inverting the fan rotation direction or starting it with the impeller turning in the opposite direction
may cause breakage of the blades and/or the impeller hub, with the risk of ejection of metal
parts.

The replacement of moving parts with non-original spare parts may be the cause of different operating
conditions with respect to the original design condition (e.g. AISI 304 stainless steel, or AISI 316L stainless
steel).

 26 of 71 IGB010.E8 – December 2020

CAUTION:
Respect the maximum speeds indicated in the catalogue for the applicable temperature. For
transmission shafts in stainless steel, these speeds must be reduced by 20%. Comply with the
information given on the transmission specifications document supplied with the fan.

Operation at a speed significantly lower than up to 40% of nominal speed (unless otherwise specified by
KRUGER) may affect the cooling of the motor and bearings, with possible malfunctions due to higher
temperatures. For electrical components, the user and installer are advised to provide adequate protection for
the drive system or motor, with the use of heat detection capsules if possible, and also using a servo-ventilated
motor if necessary.
Resonance phenomena in the structure must be avoided. These may emerge at specific rotation speeds, and
may cause damage to the structure.

CAUTION:
Resonance phenomena at low frequencies may cause damage to the structure.

3.7.6 Noise emission risks

KRUGER designs its fans dedicating attention to the elimination of the noise that they generate. Nevertheless,
during normal operation fans act as a sound source.
The spectrum of frequencies of Sound emission depends on the dimensional and structural characteristics of
the fan, and also on its application of use (rotation speed, fluid moved, etc.).

KRUGER, in collaboration with AMCA, has measured the Sound emissions of its fans in its own test laboratory
in accordance with the AMCA 300 standards.

CAUTION:
Vibrations and noise emission are directly correlated. Compliance with the instructions given for
correct installation so as to reduce vibrations to a minimum is of equivalent importance for noise
reduction.

Since the noise emitted by a fan can be influenced by external factors that can affect the overall noise level,
such as:
 The dimensions of the environment in which the fan is installed
 The presence of static elements near the fan (e.g. walls)
 The presence of other machines that are also sources of noise emission
KRUGER invites the user to measure ambient noise levels. It should be noted that the presence of other
operating machines generates a "superimposition of effects" and resonance that multiply ambient noise.
In addition, in cases of restricted environments, or if the fan is installed against walls, the effect of reverberation
and resonance on structures (walls and ceiling) is "exponential".

CAUTION:
Avoid positioning fans in areas that could increase the noise risk.

The definition of the risks to workers of exposure to noise is not the responsibility of KRUGER, which limits
itself to indications of values, levels of uncertainty, standards or criteria used for noise emission
measurements.
IGB010.E8 – December 2020  27 of 71
As envisaged by applicable legislation, it is the user that must assess the level of exposure of operatives to
noise emissions using its own specific procedures, identifying:
 Sources of noise and their relative importance
 Average exposure times for each operative
 The level of direct and reflected noise
 The noise transmitted by structures and not through the air

CAUTION:
Avoid working positions that increase the noise risk for operatives.

CAUTION:
Reducing exposure times and the use of Personal Protection Equipment will reduce the risks
caused by exposure to noise emissions.

If exposure to noise, in terms of Sound pressure, exceeds 80 dBA, the employer must provide operatives with
Personal Protection Equipment for hearing. If exposure is equal to or higher than 85 dBA, the employer must
take all possible action to ensure that Personal Protection Equipment for hearing is effectively used.

CAUTION:
With sound pressures higher than 100 dBA, operatives may approach the fan only if it is not
operating, even if wearing Personal Protection Equipment.

3.7.7 General information on noise emission data

Level of Sound power – LwA

This is the average value of Sound power expressed in dBA (value weighted according to scale A) emitted
into the environment by a fan with ducting on both the inlet and outlet sides.
The value refers to channelled air with a density of 1.2 kg/m3, at the maximum permitted rotation speed of the
impeller and with operation at the optimum point on the curve.
It is assumed that the fan is positioned in a free space, or in an area of dimensions such as to not cause
significant reflection, and resting on a flat and rigid surface.
The possible contribution to the overall noise level of the noise caused by the motor, the transmission system
and any accessories that may be present is not considered.
In addition, the value of background noise of the installation environment is not considered to be significant.

Level of Sound pressure – LpA

This is the average of the average temporal values of Sound pressure emitted into the environment by a fan
with ducting on both the inlet and outlet sides.
Pressure values are recorded on the measurement surface surrounding the fan (parallelepiped measurement
surface).
The pressure value is expressed in dBA (value weighted according to scale A).
The value refers to channelled air with a density of 1.2 kg/m3, at the maximum permitted rotation speed of the
impeller and with operation at the optimum point on the performance curve.
The measured values refer to a measurement distance of one meter.
It is assumed that the fan is positioned in a free space, or in an area of dimensions such as to not cause
significant reflection, and resting on a flat and rigid surface.

 28 of 71 IGB010.E8 – December 2020

The possible contribution to the overall noise level of the noise caused by the motor, the transmission system
and any accessories that may be present is not considered.
In addition, the value of background noise of the installation environment is not considered to be significant.
The point at which maximum Sound pressure is found normally corresponds to the outlet duct (external to the
ducting), and its value is 3–4% higher than the average value.

IGB010.E8 – December 2020  29 of 71

4 TRANSPORT, MOVEMENT AND STORAGE

Lifting and movement operations with the fan may create hazardous situations for exposed persons. It is
therefore advisable to follow the instructions provided by KRUGER and to use suitable equipment.

4.1 Lifting and movement

It is advisable to carry out all lifting and movement operations on the fan and its components with extreme
care, avoiding impacts that may affect its correct operation or damage covered parts.
Use only the points indicated to lift the fan, distributing the load in a uniform manner.

Lifting points are identified with this symbol.

CAUTION:
The user assumes liability for the choice of the lifting equipment and ropes, straps or chains
considered to be most suitable both for the purpose and for their lifting capacity. For lifting and
movement, do not use zones or points other than those marked by a symbol.

4.2 General warnings for lifting separate fan parts

For reasons of transport, some fan parts may be delivered disassembled.

CAUTION:
 All transport operations must be carried out solely by qualified personnel.
 The movement of separate or disassembled parts of the machine must be carried out with
suitable means of transport.
 For the correct movement of these parts, respect the indications on weight provided by
KRUGER.

Generally, special or specific equipment is not necessary for the lifting of fan parts.

4.3 Fan lifting instructions

4.3.1 Lifting version 1 and 9 axial fans
Version 1 fans are supplied without motor. Version 9 fans are supplied with the motor supported by the casing.
Version 12 fans have the motor fixed to the base. To lift them, the specific holes provided in the structure must
be used (as shown in Fig. 4-1). These holes are located on opposite sides above the center of gravity, and are
indicated by specific symbols.

In this case it is advisable to use a chain sling with two arms, the choice of which by the user must be
compatible with the weight of the fan. In particular, the user must ensure that the weight load limit (WLL) of the
sling is equal to or greater than the load to be lifted.

Slings with several arms (3 or 4) used with a number of arms that is less than the total number of arms
composing the sling must be used with a lower WLL than the WLL marked on the sling, applying the factors
indicated by standard UNI EN ISO 818-6 - A.1.3.7. It is advisable for unused arms to be gathered and hooked
together, to reduce the risk of them swinging freely or being caught up during movement of the load.

 30 of 71 IGB010.E8 – December 2020

Every time that a sling is used, it must be inspected beforehand for possible damage or evident signs of wear.

To connect the sling to the load, it is preferable to use the method with straight arms. In this case, the lower
ends are connected directly to the attachment point. The hooks must be chosen so as to ensure that the load
settles at the center of the hook, preventing the tip of the hook from being loaded. The hook tips must also be
oriented outwards, unless the hooks have been specifically designed for being used otherwise.

Before operating the lifting equipment, it is advisable to check that the load is free to move, and that it is not
blocked by connection components or other obstacles to movement.

It is advisable to keep the hands and other body parts away from the chains, to prevent injuries when they are
put under load. When lifting operations are ready to start, any slack must be taken up before lifting itself can
start. The load must be lifted slowly, checking that it is firmly secured and that it moves into the required
position. Reference must also be made to standard ISO 12480-1 to plan and manage lifting operations and to
ensure that a safe working system is used.

Fig. 4-1 Example of lifting version 1 and 9 axial fans

4.3.2 Lifting version 4 axial fans

Version 4 fans have the impeller fitted directly on top the motor shaft, and to lift them only the holes provided
in the structure must be used (as shown in Fig. 4-2). These holes are located on opposite sides above the
center of gravity, and are indicated by specific symbols.

For the criteria to be applied in lifting operations the instructions provided in paragraph 4.3.1 must be followed.

IGB010.E8 – December 2020  31 of 71

Fig. 4-2 Example of lifting version 4 axial fans

CAUTION:
The lifting lugs on motors must never be used to lift the fan.

4.3.3 Lifting fans packed in crate

The weight and center of gravity of the crate are indicated on the outside of the package.
The lifting points for lifting the crate with a forklift truck are identified by two black triangles with the tip pointing
downwards.
KRUGER ensures the stability of the fan or of fan components inside the case by means of rigid connections
linked directly to the packing, so as to prevent any possible sudden movements of crate contents.
Nevertheless, while moving a crate with a forklift truck, the risk of instability or of the loss of stability caused
by unforeseen movements of the forklift remains. To avoid this risk caused by unforeseen movements, care
must be taken to carry out movement operations on a flat surface without projections or holes that could affect
the stability of the loaded forklift truck. The speed of the forklift truck must also be reduced to a minimum, with
the load at the minimum possible height.
Since the stability of the load is ensured when the position of the center of gravity is located at a lower height
vertically than the lifting point, whenever possible it is preferable to lift crates using lifting straps and/or chains.

CAUTION:
Before lifting check:
 that the capacity of the lifting equipment is compatible with the load
 that the lifting equipment is in good condition
 that the load has been correctly hooked up in safety
 that the lifting point is vertically above the center of gravity of the load
 that the operator who carried out hooking up operations has moved away from the
lifting areas

CAUTION:
Positioning of the lifting point at a significant distance from the vertical of the center of gravity
of the load can generate dangerous oscillations of the load when lifted.

 32 of 71 IGB010.E8 – December 2020

The load must be lifted away from the support surface with a very slow initial movement, so as to be able to
identify any potential oscillations of the load. If residual oscillations of a nature that could be a hazard for
persons or things during transport of the load are present after lifting it away from the support surface, it is
advisable to wait for these oscillations to stop before starting transport operations.

Fig. 4-3 Example of lifting fans packed in crate

4.4 Storage
If the fan is to be stored, it must be protected against weather conditions and damp, dust and the effects of
atmospheric and environmental agents.

CAUTION:
Close inlet and outlet openings during storage.

It is advisable to periodically check the satisfactory state of conservation of the fan, and to manually rotate the
impeller about once a month to prevent deformations to bearings.

IGB010.E8 – December 2020  33 of 71

5 INSTALLATION
5.1 General information

CAUTION:
All assembly operations must be carried out only by qualified personnel.

Generally, special or specific equipment is not necessary for the assembly of fan parts.
In the case of assembly of parts requiring a specific procedure, KRUGER will provide the
additional information necessary for carrying out the operations correctly.

Special foundations are not necessary for positioning the fan. A well-levelled concrete support surface is
sufficient, suitable to withstand the weight load of the fan and the dynamic stresses generated by its normal
operation.

KRUGER designs and constructs its fans dedicating the greatest possible attention to the elimination of
vibrations at their source. During installation, the user and/or installer must take the necessary measures to
reduce vibrations from the overall system (fan and ducts).

It is advisable to use Spring vibration isolators and flexible ducts to reduce to a minimum the
transmission of vibrations during fan operation.

The support surface must be flat and horizontal, to prevent the bending and misalignment of supports. If
necessary, suitable metal spacers must be placed between the fan base and the support surface to ensure
perfect adherence. Use the fixing points provided, ensuring that the tightening of nuts and bolts does not
deform fan structures.
The support surface must be sufficiently rigid to withstand normal fan vibrations, and must not be subject to
phenomena of structural resonance.
If the fan is mounted on a structure raised above floor level, the vibration characteristics of this structure must
be verified.
The necessary and sufficient parameters for the definition of the technical characteristics of the support
structure to be used for fan installation are as follows:
 static load of the fan
 dynamic load of the fan
 position of the center of gravity of the fan

KRUGER does not consider fixing by means of welding the fan structure to foundation plates
to be an acceptable fixing method.

Ducting connected to the fan must be supported separately, and must be coaxial with respect to the inlet and
outlet openings, so as to prevent deformation caused by the tightening of nuts and bolts.

 34 of 71 IGB010.E8 – December 2020

CAUTION:
All installation operations must be carried out solely by qualified personnel, authorized and
using suitable equipment.

CAUTION:
During installation, the conservation of the minimum access spaces requested for
maintenance operations must be verified.

CAUTION:
The use of flow regulation devices connected directly to the fan inlet may generate unstable
operation.

5.1.1 Minimum installation distances

If possible in the available space, to guarantee correct entry of the fluid into the inlet opening it is advisable on
fans connected to ducting to leave a straight section of duct with a length about 2.5 times the fan size (given
on the name plate). The result of this calculation divided by 1000 gives the recommended length (in meters).

Fig. 5-1 Minimum installation distances with inlet duct

If the fan is installed with a free inlet opening, it must be positioned at a minimum distance from walls or other
machinery of 1.5 times the fan size (given on the name plate). The result of this calculation divided by 1000
gives the recommended minimum distance (in meters).

Fig. 5-2 Minimum installation distances with free inlet

IGB010.E8 – December 2020  35 of 71

5.2 Assembly of axial fans
The main steps of the assembly of axial fans in the various versions supplied are illustrated below.
5.2.1 Version 4 axial fans
3

Fig. 5-3 Assembly of version 4 axial fans

Step Operation Description

1 Positioning of motor [1] The motor must be positioned on its base without fully tightening its
fixing fasteners.

2 Fitting of impeller [2] on

motor shaft IMPORTANT:
If necessary, reduce the diameter of the motor shaft until its nominal
size is reached with a tolerance of +0/+5 microns. Assembly with
excessive play can cause vibrations. Forced assembly creates
deformations and vibrations, also making it more difficult to remove
the impeller.
After the impeller has been fitted to the projection on the motor shaft
and the head washer has been fully fixed, a check must be made to
ensure that the clearance between the impeller and the casing (3) is
constant around the entire circumference. If clearance
is not constant, correct the position of the motor support base.

3 Fixing of motor Fully tighten the motor fixing nuts.

Table 5-1 Sequence of operations for assembly of version 4 fans

(refer to Fig. 5-3 for the identification of components)

 36 of 71 IGB010.E8 – December 2020

5.2.2 Version 1 axial fans

Fig. 5-4 Assembly of version 1 axial fans

Step Operation Description

1 Positioning of support [1] The bearing support must be positioned on its base without fully
tightening its fixing fasteners.

2 Fitting of impeller [2] on

support IMPORTANT:
If necessary, reduce the diameter of the motor shaft until its nominal
size is reached with a tolerance of +0/+5 microns. Assembly with
excessive play can cause vibrations. Forced assembly creates
deformations and vibrations, also making it more difficult to remove
the impeller.

After the impeller has been fitted to the projection on the support
shaft and the head washer has been fully fixed, a check must be
made to ensure that the clearance between the impeller and the
casing (3) is constant around the entire circumference. If clearance
is not constant, insert shim (spacer) beneath the support feet.

3 Fixing of support Fully tighten the support fixing.

4 Fitting of protection net [4] Protect all moving parts with the envisaged protection net.

Table 5-2 Sequence of operations for assembly of version 1 fans

(refer to Fig. 5-4 for the identification of components)

IGB010.E8 – December 2020  37 of 71

5.2.3 Version 9 axial fans

Fig. 5-5 Assembly of version 9 axial fans

After completing steps 1-2-3 indicated in paragraph 5.2.2, proceed with the installation of the transmission.

Step Operation Description

1 Installation of motor [1] Position the motor on its base [2] complete with stays.

2 Fitting of pulleys with tapered Pulleys must be fitted so as to ensure their correct alignment and
bush and fitting and tightening. To do this, regulate motor position (see paragraphs 5.3
positioning of V-belts [3] and 8.2 for fitting and tightening of drive belts). After identifying the
correct position, motor fixing fasteners must be fully tightened.

3 Fitting of protection net (4) Protect all moving parts with the envisaged protection net.

Table 5-3 Sequence of operations for assembly of version 9 fans

(refer to Fig. 5-5 for the identification of components)

 38 of 71 IGB010.E8 – December 2020

5.3 Mounting Configuration
Horizontal mounting configurations are provided with a standard support for both ceiling and floor applications.
The mounting configurations and the motor position can be changed in the field. Lifting lugs are provided to
assist in the installation.

Version 4 Version 9

IGB010.E8 – December 2020  39 of 71

5.4 Installing and adjusting drive belts and final checks
If the fan is fitted with a V-belt drive, the transmission is assembled as follows:
 Carefully clean tapered parts and the bush hole before fitting it onto the pulley.
 Fit the bush onto the pulley, taking care to align the threaded half-holes on the pulley with the
unthreaded half-holes on the bush.
 Screw in the grub screws by hand without fully tightening them.
 Fit the assembly onto the shaft, after carefully cleaning it.
 Position the pulleys and check their alignment with a straight edge.
 Lock in place, tightening screws alternately.
 Fit the belts.
 Do not force the belts with a lever, to avoid damaging the fibers of the internal reinforcement.
 Before tensioning the belts, mark a known length on the taut side (e.g. 100 mm) and, rotating the
transmission, gradually tension the belts (as described in paragraph 8.2) until a relative increase in
length is obtained of:
0.8% for uniform torque;

1% for irregular torque.

Excessive belt tension may damage bearings and cause shaft breakage.

 40 of 71 IGB010.E8 – December 2020

5.5 Vibration Isolator Installation
 Choose proper isolator
 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.
 25 mm deflection type for SBA / SHA series and 50 mm deflection type for SBB / SHB series.

Deflection

Fig. 5-6 Vibration Isolator setup

5.6 Blade adjustment

If the working point of the fan has to be changed and it is necessary to adjust the blade angle, please contact
KRUGER Technical Office.

IGB010.E8 – December 2020  41 of 71

5.7 Electrical connections

CAUTION:
The fan is supplied in conformity with Directive 2014/30/EC on electromagnetic compatibility. In
particular, the electric motor, if supplied with the fan, is guaranteed by its manufacturer to be
conformant to this directive. It is the responsibility of the installer to check that the system in
which the fan is inserted is conformant to the directive. If the motor is not supplied with the fan
but is fitted by the customer, it is compulsory for the customer to check that it is conformant to
the directive.

The mains power supply line to the fan must be able to deliver sufficient power.
Connections to the mains power supply must be made by qualified personnel, remembering that the customer
is always responsible for the electrical power supply through to the motor connection terminals.
Customers are reminded of the need to ensure all safety conditions for the grounding of the fan.
The grounding system must be conformant with applicable legislation in the country of installation, and must
be regularly checked by qualified personnel.
Make the connection to the grounding connector before making all other connections.
Check that the connection layout (see Fig. 5.7) is suitable for the power supply voltage.
Standard electric motors can normally operate indifferently in both rotation directions. To invert the rotation
direction, it is sufficient to exchange any two of the power supply cables directly on the terminal board.

CAUTION:
It is the responsibility of the installer to provide an electrical power supply system for the fan in
conformity with the EN 60204-1 standard.
In particular, an electrical cut-off switch must be provided near the fan, so that maintenance
personnel have direct control over power supply to the fan (see points [Link] Enabling Control
and 10.7 Emergency Stop Devices of the EN 60204-1 standard).

In addition, the designer of the electrical system must provide controls for starting, normal stopping and
emergency stopping, in conformity with Annex I of MACHINERY DIRECTIVE 2006/42/EC.

CAUTION:
It is the responsibility of the customer and/or electrical installer to choose the correct size and
type of the device and of cables used for electrical connections to the fan, depending on the
motor installed and the mains power supply system.

Work may be done on electrical components only with the fan at a standstill and disconnected from the
electrical power supply.
Before installation and starting, check that the data on the motor name plate are in conformity with the
characteristics of the electrical power supply system.

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The layouts shown are merely indicative. Consult the connection layout provided by the motor manufacturer.

Three-phase single-speed motors Three-phase motors Three-phase motors

Single winding Two separate windings
Single voltage Single voltage

Delta connection Dahlander connection for high speed Connection for high speed

Star connection Dahlander connection for low speed Connection for low speed

Fig. 5-7 Diagram of electrical connections for single-speed and two-speed motors

Openings for cable entries must be made in a way that prevents the cables from coming into contact with
sharp edges or moving parts, and in particular the impeller. If openings for cable entries must be made in the
casing, the openings must be fitted with suitable protective devices (grommets). In this case, consult the
KRUGER Technical Office. These precautions are applicable in particular if an external terminal box is fitted.

Fig. 5-8 Example of positioning of external terminal box

IGB010.E8 – December 2020  43 of 71

5.8 Connection to ducts
The fan must be connected to ducting with all parts correctly aligned, without obstructions to air flow from
gaskets or flexible components. The weight of ducting must not be supported by the fan, and deformations of
parts of the machine by ducting connections must be avoided. Any flexible joints between the fan and inlet
and/or outlet ducts must be installed in a way that prevents stress on flexible components, and that avoids
contacts between metallic parts of the joints (see fig. 5-9 for assembly tolerances).

10° max.
Operating range 40 mm max.
130-200 mm

10 mm max.

Theoretical Parallel misalignment Axial compression Angular misalignment

Fig. 5-9 Assembly tolerances for flexible joints

If possible in the available space, to guarantee correct entry of the fluid into the inlet opening it is advisable on
fans connected to ducting to leave a straight section of duct with a length about 2.5 times the fan size (given
on the name plate). The result of this calculation divided by 1000 gives the recommended length (in meters).

Fig. 5-10 Minimum installation distances with inlet duct

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6 CHECKS TO BE MADE BEFORE AND AFTER STARTING
6.1 Preliminary checks

CAUTION:
Checks before the first starting must be made only with the fan at a standstill and disconnected
from the electrical power supply.

Before the fan is started for the first time a number of preliminary checks are necessary:
 Verify the compatibility of the fan for its intended application.
 In case of completion of the transmission by the installer, verify the compatibility of the fan name plate with
the transmission specifications document.
 Check that all protection nets are present.
 Check that all nuts, bolts and other fasteners envisaged by KRUGER are present.
 Check that all nuts, bolts and other fasteners (impeller, supports, foundation, transmission if present) are
correctly tightened.
 Check the correct lubrication of the fan and motor bearings, and if necessary replace the grease (see chapter
8 MAINTENANCE).
 Check that all rotating parts can turn freely.
 Check for the absence of objects or foreign bodies inside the fan.
 Check that the rotation direction is correct. A short burst of electrical power is sufficient to check that the
rotation direction is the same as that indicated on the fan casing. If necessary invert the rotation direction
(see Electrical connections).

KRUGER recommends the use of the checklist given in paragraph 11.2 to record the necessary checks for
safety conditions.

CAUTION:
Operating trials must not be permitted before the checks of the checklist have been made (see
paragraph 11.2 ).

CAUTION:
Axial fans must never operate with their openings completely closed.

IGB010.E8 – December 2020  45 of 71

6.2 Checks to be made with fan fully operating
Check that power absorption does not exceed the value indicated on the motor name plate. If it does,
immediately halt the fan and contact the manufacturer.
Fan operation must be free from excessive vibrations and abnormal noise.
With the fan at a standstill, check that the temperature of the bearings does not exceed the limits of tolerance
(with an ambient temperature of 20°C, the temperature of supports must be no higher than 70°C). It must be
taken into consideration that in the first hours of operation, a higher temperature than that indicated may be
normal, if it then falls to a lower value. In case of abnormal overheating of bearings, consult the KRUGER
technical service.
After 3–4 hours of operation, with the fan at a standstill and disconnected from the power supply, repeat the
checks on the tightness of nuts and bolts, bearing temperatures, and for fans with transmission, the temperature
and tension of drive belts.
With regard to vibrations, the criterion for the verification of conditions of safety refers to standard ANSI/AMCA
204:2005, which recommends the following limits for mechanical vibrations (vibration speed in mm/s RMS),
measured in installation conditions:

 alarm: 4.5 (rigid), 7.1 (flexible);

 stop: 7.1 (rigid), 11.2 (flexible);

These limits are considered to be valid by KRUGER in general, with the exception of specific indications for
individual applications.
Measurement point and direction: on fan supports or motor, in a direction perpendicular to the rotation axis,
on the horizontal or vertical plane.
The use of the definition of rigid and flexible refers to the fact that the structure reaches its first critical speed
higher or lower respectively than operating speed. KRUGER fans normally have a rigid structure with regard
to this definition.
The type of vibration damper used affects the value of the first critical speed.
The reference limits for temperature on supports, measurable on the external bearing ring regardless of
ambient temperature, are as follows:

 alarm 100 °C;

 stop 120 °C;

6.2.1 Visual checks on protection net

For protection net, checks must be made for the following:
 Corrosion or dullness of galvanized surfaces
 Detachment of rivets/welds
 Evidence of noises typical of loose protection net
 Impacts and permanent deformation of components
 Breakage of wires
 Corrosion of fasteners
 Slackening of fixing elements

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CAUTION:
All protection net must be inspected every month and replaced if necessary.

CAUTION:
In case of doubts, carry out checks more frequently or replace the protection net.

6.2.2 Checking and cleaning parts in contact with fluids

The periodical cleaning of the impeller prevents vibrations that might be caused by any dust deposits that
accumulate while the fan is running.
If the fan is used for the movement of even slightly dusty fluids, the Impeller must by inspected
periodically for cleanness and/or wear.
Deposits of material or wear on impeller parts may cause abnormal fan vibrations.

6.2.3 Visual checks on impeller and casing

Periodical visual checks must be made for wear on impeller blades, given that deterioration of these parts can
create a condition of extreme risk, due to the ejection of the blade or the failure of structural components, with
consequences that may even be fatal.

CAUTION:
Axial fans must not be used for fluids containing abrasive agents.

To monitor phenomena of accidental abrasion on impeller blades and the casing, use a portable lamp to
visually inspect components, slowly rotating the impeller to allow all blades to be seen. Blades must be totally
free from damage and must show no signs or abrasion or missing sections.
With regard to the phenomenon of corrosion on impeller blades and the casing, corrosive and acidic
environments can reduce the thickness of fan safety components.
This phenomenon must not be underestimated, also because it does not depend solely on the concentration
of aggressive agents.
Condensation may form during pauses in fan operation, and this may accelerate the phenomenon of chemical
corrosion, which in turn may alter the thickness of components, affecting their integrity.

IGB010.E8 – December 2020  47 of 71

6.2.4 Dimensional checks

CHECKLIST – DIMENSIONAL CHECKS ON COMPONENTS

COMPONENTS TO TYPE OF CRITERIA FOR

RESULT
CHECK CHECK/INSTRUMENT ACCEPTABILITY

Impeller: presence of
scratches or grooves on Visual Undamaged OK 
surfaces

Reduction of thickness no
Casing: sheeting Dimension/Caliper or
greater than 10% in an OK 
thickness equivalent
area without wear

Reduction of thickness no
Inlet: thickness (if greater than 20% in an
Dimension/Caliper OK 
present) area without wear or with
paint undamaged

Reduction of thickness no
Flexible ducts:
greater than 20% in an
thickness of anti-wear Dimension/Caliper OK 
area without wear or with
sheeting (if present)
paint undamaged

Absence of damage and

Welding (entire structure) Visual OK 
cracks

Date:

Signature:

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7 AXIAL FAN OPERATING MALFUNCTIONS
7.1 Most frequent malfunctions
The following Table lists the main problems that may be encountered:

PROBLEM CAUSE SOLUTION

Rotation speed too low Increase rotation speed
Impeller partially blocked Eliminate obstruction
Resistance pressure of system lower Check the resistance pressure value
Power absorption lower than design
than design value of the system
value
Fluid density lower than intended Check the fluid density value
value
Incorrect blade angle Increase blade angle

Rotation speed too high Reduce rotation speed

Resistance pressure of system Check the resistance pressure value
greater than design value of the system
Eliminate obstruction
Openings or ducting partially blocked Check the position of adjustment
organs
Pre-rotation of air in opposite direction Check minimum installation distances
Power absorption higher than design to fan rotation (paragraph 5.1.1)
value
Fluid density higher than intended Check the fluid density value
value
Power supply to motor with voltage Check for correct voltage of power
lower than shown on name plate supply to motor
Defects in motor windings Check for correct motor operation
Incorrect blade angle Reduce blade angle

Rotation speed too low Increase rotation speed

Fluid density lower than intended Check the fluid density value
Insufficient pressure value
Check the resistance pressure value
Air flow greater than intended value
of the system
Check operating field envisaged by
Instability of air flow
operating curve
Fluctuations in flow due to other fans Check for correct installation on
Pulsating operation
operating in parallel system
Inlet air turbulence created by Check minimum installation distances
system near inlet opening (paragraph 5.1.1)

See previous point “Pulsating

Pulsating operation
operation”
Use the inverter to avoid operation at
Structural resonance at specific
these speeds or modify frequencies of
rotation speeds
the overall system
Vibrations
Wear on impeller parts Inspect the impeller
Deposit of material on impeller Inspect the impeller
Check for correct coupling between
Friction between moving parts
moving parts

IGB010.E8 – December 2020  49 of 71

PROBLEM CAUSE SOLUTION
Intrinsic bearing defects Check condition of bearings

Bearing malfunctions due to Check condition of bearings

unbalanced impeller or excessive belt Check belt tension (see paragraph
tension 8.2)

Check for correct coupling between

Friction between moving parts
moving parts
Vibrations See previous point “Vibrations”
Pulsating operation See point “Pulsating operation”
Excessive noise Check for correct conditions of power
Electromagnetic motor malfunctions
supply to motor (inverter)
Check for presence of rounded
Presence of holes or sharp
projections in points with high air
projections speed

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8 MAINTENANCE

Read this section carefully before carrying out maintenance operations on the fan. This will
ensure greater conditions of safety for maintenance personnel and greater reliability of the work
done.

The safety rules to be respected during maintenance operations on the fan are as follows:
 Maintenance and/or lubrication operations must be carried out only by qualified and expert personnel,
authorized by the technical management of the factory, in conformity with applicable safety directives and
standards, using tools, equipment and products suitable for the purpose.
 During maintenance operations, suitable clothing must be worn, such as closely-fitting overalls and safety
footwear, absolutely avoiding garments that are bulky or with loose parts.
 During maintenance operations on the fan, it is advisable to fence it off and to identify it with signs with the
wording: "FAN UNDERGOING MAINTENANCE".

CAUTION:
The fan must be disconnected and isolated from the electrical power supply during
maintenance operations. Always check that the impeller and motor are at a standstill before
accessing the fan and its components or opening the inspection hatch.
In the case of fans that move hot fluids, wait for the fan to cool down before carrying out
maintenance operations, so as to prevent contact with surfaces at high temperatures.

In the case of maintenance operations on rotating parts or parts inside ducts, it is also necessary:
 where present, to disconnect the flexible motor coupling;
 where present, to remove drive belts from pulleys.

CAUTION:
In the case of use of a multi-stage fan, disconnect the electrical power supply from the entire
multi-stage fan and check that the impeller is at a total standstill before carrying out any
maintenance operation.

The person responsible for maintenance must use a team of persons so as to guarantee absolute coordination
between the persons and the maximum safety for persons exposed to risk. All persons preparing to carry out
maintenance operations must be in full visual contact to warn of possible hazards.

CAUTION:
Any necessary movement of parts to be removed or disassembled from the machine must be
made with suitable transport and lifting equipment.

Generally, special or specific equipment is not necessary for the fan maintenance operations.

Full systematic maintenance of the fan is necessary for its normal correct operation, and is
also a factor of safety for operatives.

IGB010.E8 – December 2020  51 of 71

To facilitate the planning of programmed maintenance, KRUGER has compiled a Table (see paragraph 11.3)
with general indications of the points to be monitored and the frequency of checks.

Periodic cleaning and maintenance, together with lubrication, are essential to ensure correct
fan operation and a longer operative lifespan of the fan.

8.1 Bearing lubrication

Maintenance should always be performed by experienced and trained personnel.
For enclosed motor, keep motor vent-pipe (inlet/outlet) from blocking for optimum cooling effect. Grease motor
bearing as recommended by motor supplier. The following is general reference for motor greasing:

Bearing Bearing Grease Weight Grease Weight

Frame
DE NDE Full (g) 100% Standard (g) 80%
56 6201ZZC3 6201ZZC3 2.5 2.0
63 6201ZZC3 6201ZZC3 2.5 2.0
71 6202ZZC3 6202ZZC3 5.0 4.0
80 6204ZZC3 6204ZZC3 6.3 5.0
90 6205ZZC3 6205ZZC3 8.8 7.0
100 6206ZZC3 6206ZZC3 11.3 9.0
112 6306ZZC3 6306ZZC3 21.3 17.0
132 6308ZZC3 6308ZZC3 26.3 21.0
160 6309C3 6309C3 65.0 52.0
180 6311C3 6311C3 106.3 85.0
200 6312C3 6312C3 128.8 103.0
225 6313C3 6313C3 150.0 120.0
280 2P 6314C3 6314C3 196.3 157.0
280 4P-8P 6316C3 6316C3
315 2P (Horizontal) 6316C3 6316C3
315 2P (Vertical) 6316C3 7316
315 4P-8P (Horizontal) NU319C3 6319C3 317.5 254.0
315 4P-8P (Vertical) NU319C3 7319 317.5 254.0
355 2P (Horizontal) 6319C3 6319C3 317.5 254.0
355 2p (Vertical) 6319C3 7319 317.5 254.0
355 4P-8P (Horizontal) NU322C3 6322C3 515.0 412.0
355 4P-8P (Vertical) NU322C3 7322 515.0 412.0

Table 8-1 Bearing Grease Weight Standard of TACBECON SGHT 200S (Class F)/ 600 (Class H)

 52 of 71 IGB010.E8 - December 2020

600 720 750 900 1000 1200 1500 1800
Bearing number
RPM RPM RPM RPM RPM RPM RPM RPM
62XX 6210
63XX 12
72XX 13
73XX 14
15
16
17 2000Hrs
18 3000Hrs
20
22
24 1500Hrs
26
28 2000Hrs 1000Hrs
30
32 500Hrs
34 1500Hrs
36
38 2000Hrs 1000Hrs

600 720 750 900 1000 1200 1500 1800

Bearing number
RPM RPM RPM RPM RPM RPM RPM RPM
NU2XX NU214
NU3XX 15 2000Hrs
16
17
18 3000Hrs 1500Hrs
20
22 1000Hrs
24 2000Hrs
26
28 500Hrs
30
32 2000Hrs
34 1000Hrs
36
38 2000Hrs
40 1000Hrs
44
48 1000Hrs
Table 8-2 Relubrication intervals and quantity of grease according to fan rotation speed

Check and lubricate bearings at the intervals recommended by the motor manufacturer. It is always advisable
to periodically substitute bearings with replacements as indicated on the motor name plate.

Use the type of grease recommended by the motor manufacturer to lubricate motor bearings.

IGB010.E8 – December 2020  53 of 71

8.2 Adjusting drive belt tension and cleaning belts
A simplified method for setting the correct tension of V-belts is as follows: Table 8-2 can be used to obtain the
value P of the load for each belt for the profile type and the diameter of the smaller pulley. The value L can
also be obtained from the same Table.
Use this formula:

to calculate the value Le, where:

Le= deflection [in mm] of the section at the center point of distance I between pulley centers L= deflection for
distance between centers of 100 mm
I = distance between centers [in mm]
Applying load P perpendicularly to the section (Fig. 8-1) the transmission must be tightened until the
calculated deflection Le is reached.

I/2
Le

Fig. 8-1 Checking drive belt tension

Profile Load on belt P Diameter of smaller pulley d Deflection for distance

[N] [mm] between centers of 100 mm L

from 63 to 71 2.45
from 75 to 90 2.20
SPZ 25
from 95 to 125 2.05
over 125 1.90

from 100 to 140 2.75

SPA 50 from 150 to 200 2.55

over 200 2.45

from 160 to 224 2.55

SPB 75 from 236 to 355 2.22

over 355 2.10

from 224 to 250 2.55

from 265 to 355 2.20
SPC 125
from 400 to 560 2.00
over 560 1.90

Table 8-3 Setting drive belt tension: test load and deflection

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Check drive belt tension at least after about the first 8 hours of operation, and then follow the indications given
for programmed maintenance (see paragraph 11.3).
Completely replace belts when worn to a degree that affects satisfactory operation of the transmission due to
an insufficient value of pre-tension or if slipping is more than 4-5%. Belt wear depends on various factors,
including environmental factors, the number of operation hours, and the number and type of start-ups.

The manufacturers of standard V-belts recommend that an ambient temperature of 80°C

should not be exceeded. For higher temperatures, special belts are necessary.

Dirty belts must not be cleaned with solvents like petrol, benzene, turpentine, etc., or with abrasive or sharp
instruments.
It is advisable to use a solution of alcohol and glycerine in a proportion of 1:10. The transmissions installed on
KRUGER fans have two or more drive belts.

In the case of breakage of one or more belts, it is advisable to replace the entire set.

8.3 Checking and cleaning parts in contact with fluids

Periodic impeller cleaning makes it possible to avoid vibrations caused by any dust deposits that accumulate
during fan operation.

If the fan is to be used to move fluids that are even slightly dusty, the impeller must be checked
periodically for cleanness and/or wear.

Deposits of material or wear on some impeller parts can produce abnormal fan vibrations.
If there are parts that are excessively worn, it is essential to replace the impeller (for this operation contact
the KRUGER Technical Service).

For all information and for any modifications to be made on our products, please contact the
KRUGER technical office in advance, specifying the machine type and serial number given on
the fan name plate.

IGB010.E8 – December 2020  55 of 71

9 DISMANTLING AND REASSEMBLING ESSENTIAL COMPONENTS

CAUTION:
All dismantling and reassembly operations described below must be carried out solely by
qualified and authorized personnel.

CAUTION:
All dismantling and reassembly operations described below must be carried out:
 With the absolute certainty that the fan is at a complete standstill (impeller stationary);
disconnect the power supply to the main control panel with the power switch and apply a lock
with key to be consigned to the person responsible for maintenance.
 After having created a work environment with all necessary equipment and free from all other
activities that could dangerously interfere with dismantling and reassembly operations.
 After carefully cleaning, degreasing or lubricating, according to use, all components
dismantled and reassembled.

9.1 Fan impellers with hub

If the working point of the fan has to be changed and it is necessary to adjust the blade angle, please contact
KRUGER Technical Office.

CAUTION:
The impeller must be moved with care, avoiding impacts that could alter its base or deform it.

9.2 Replacing drive belts

9.2.1 Assembling and dismantling pulleys

1. Check that the motor shaft and the transmission

shaft are parallel.

2. Before fitting the bush (Photo 1) into the pulley,

carefully clean tapered parts and the bush hole.

Photo 1

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3. Fit the bush into the hole in the pulley, taking care
to align the threaded half-holes on the pulley with the
unthreaded half-holes on the bush (Photo 1). There
may be 2 or 3 of these holes (Fig. 9.1), as can also
be seen in Table 9.1, depending on pulley size.

Fig. 9.1 Pulley holes

4. Screw in the grub screws by hand without fully

tightening them (Photo 2).

Photo 2

5. Check that the shaft surface is totally clean, and

insert the fixing spline into its slot (Photo 3).

Photo 3

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6. Fit the assembled bush, grub screws and pulley
onto the motor shaft with the spline inserted in the
corresponding slot in the bush hole. If necessary,
widen the bush hole by inserting a suitable tool into
the bush slit (Photos 4 and 5).

Photo 4

Photo 5

7. Always check that there is a minimum of clearance

between the spline and the corresponding slot Clearance
(Photo 6).

Photo 6

8. Repeat operations 2 to 7 to fit the pulley onto the

transmission shaft.

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9. Use a straight edge of a suitable length to check
correct alignment of the pulleys (Photo 7). Use a
rubber hammer to move pulleys axially until the
parallel misalignment has been corrected (Photo 8).

Photo 7

Photo 8

10. Adjust motor Variation

position to Variation
correct
misalignment
(Fig. 9.2 and
9.3).

Fig. 9.2 Angular misalignment Fig. 9.3 Parallel misalignment

11. Tighten the pulley grub screws alternately

Photo 9) until the tightening torque indicated in
Table 9.1 is reached.

Photo 9

IGB010.E8 – December 2020  59 of 71

12. Check correct pulley alignment again.

CAUTION:
Incorrect alignment causes excessive wear and greater friction on drive belts, higher power
absorption by the transmission, noise and vibrations that reduce the effective lifespan of the
transmission.

Generally, the tolerance in pulley alignment in V-belt drive transmissions may not be greater than 0.5 degrees
or 5 mm for each 500 mm of distance between centers (Figs. 9.2 and 9.3).

CAUTION:
To remove pulleys, unscrew the grub screws used to fix them and insert one or two of them in
the free holes, screwing them in until the bush is detached.

Type Bush Grub screws

(Max. bore
diameter Max.
Length Length Socket Tightening
[mm]) diameter N° Whitworth
[mm] [mm] size torques [Nm.]
[mm]
1008 (25) 22 35 2 1/4 13 3 5.7
1108 (28) 22 38 2 1/4 13 3 5.7
1210 (32) 25 47 2 3/8 16 5 20
1215 (32) 38 47 2 3/8 16 5 20
1310 (35) 25 52 2 3/8 16 5 20
1610 (42) 25 57 2 3/8 16 5 20
1615 (42) 38 57 2 3/8 16 5 20
2012 (50) 32 70 2 7/16 22 5 31
2517 (65) 45 85 2 1/2 25 6 49
3020 (75) 51 108 2 5/8 32 8 92
3030 (75) 76 108 2 5/8 32 8 92
3535 (90) 89 127 3 1/2 38 10 115
4040 (100) 102 146 3 5/8 44 14 172
4545 (110) 114 162 3 3/4 51 14 195
5050 (125) 127 178 3 7/8 57 17 275
Table 9-1 Tightening torques

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9.2.2 Assembling and dismantling drive belts

1. After checking correct pulley alignment, fit the

belts. Tools should not be used to force the belts
into place on the pulleys (Photos 10, 11 and 12).
If necessary, reduce the distance between pulley
centers by moving the motor closer.

Photo 10

Photo 11

Photo 12
2. Check belt tension. For this operation, see
paragraph 8.4 of this manual.

3. If the tension of belts is insufficient, the motor

must be moved to tension them correctly.

IGB010.E8 – December 2020  61 of 71

4. Check correct pulley alignment again.

5. Fit the complete system of transmission protection

devices.

CAUTION:
After the first 8 hours of operation, stop the fan and check that pulley assembly screws are still
fully tightened.

6. To remove the drive belts, repeat the previous

operations in the reverse order.

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10 FINAL DISMANTLING AND DISPOSAL OF FANS

At the end of the life cycle of the fan, the machine and its accessories must be dismantled as indicated below,
so as to allow the various components to be disposed of differently according to the type of material from which
they are made. Before demolishing the machine, the user must drain the grease present in bearing supports
and generally clean the various components.

CAUTION:
Particular attention must be dedicated to the possible presence of residues of toxic and/or
corrosive substances left by the fluid moved.

Most of the components (casing, motor pedestal, inlet, bearings, protection net, pulleys, bushes) are made of
metallic materials (steel and cast iron), and can therefore be disposed of together.
Impellers are made from the aluminium materials.
The electric motor must instead be separated and disposed of at a facility specializing in the elimination of
electrical wastes, together with any electric servomotors.
Drive belts are made for rubber, and vibration dampers are also made mainly from the same material.
Most of the accessories are also made from metals, except for flexible ducts, constituted by two metallic flanges
bolted together and separated by a textile joint in PVC or aluminumized glass fiber.
Fan dismantling operations can be carried out either in the place of installation, if the need for safe working
conditions allows this, or in some other location, after removing and transporting the fan as indicated in Chapter
4 of this manual.

CAUTION:
All dismantling operations described below must be carried out solely by qualified and
authorized personnel.

CAUTION:
All dismantling operations must be carried out
 With the absolute certainty that the fan is at a complete standstill (impeller stationary), after
the motor has been disconnected from the electrical power supply by qualified and authorized
persons.
 After having created a work environment with all necessary equipment and free from all other
activities that could dangerously interfere with dismantling operations.

Special or specific equipment is not necessary for the dismantling of fan parts.

Dismantling operations can be carried out following the detailed assembly instructions given in Chapter 10 in
the reverse order.

CAUTION:
Regardless of the installation type, all connection connected to the fan flange must be
disconnected and removed before proceeding.

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10.1 Version 4 axial fans

Fig. 10-1 Exploded view of version 4 fan

With reference to Fig. 10-1, the correct dismantling sequence for version 4 fans is as follows:

 Protection Net (1); ● Terminal Box (7);

 Impeller (2); ● Terminal Support (8);
 Motor (3); ● Outlet Vane (9);
 Tube Casing (4); ● Hanger (10);
 View Port (5); ● Mounting Feet (11);
 Motor cover (6); ● Motor Base (12)

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10.2 Version 1 and 9 axial fans

Fig. 10-2 Exploded view of version 1 and 9 fan

With reference to Fig. 10-2, the correct ducts sequence for version 1-9 fans is as follows:

 Protection Net (1); ● Shaft (11);

 Upper Belt Back Cover (2); ● Hub (12);
 Upper Belt Casing (3); ● Impeller (13);
 Upper Belt Front Cover (4); ● Bearing Base (14);
 Motor (5); ● Mounting Feet (15);
 Motor Base (6); ● Drive Set (16);
 Lip Channel (7); ● Lower Belt Back Cover (17);
 Hanger Bar (8); ● Lower Belt Casing (18);
 Bearing Support (9); ● Lower Belt Front Cover (19);
 Bearing (10); ● Access Door (20)

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11 TECHNICAL APPENDICES

11.1 Tightening torques for nuts and bolts

Tightening torques M of the Table 11-1 are valid under the following conditions:
 Type UNI 5737 bolts with hexagonal heads, type UNI 5931 and UNI 6107 screws with cylindrical head, in
normal conditions of supply.
 Tightening torques are assumed to be applied slowly with a torque wrench.

While maintaining the same pre-stressing values, tightening torques must be varied as follows in these
cases:
 increased by 5% for UNI 5712 bolts with extra-wide heads
 reduced by 10% for oiled galvanized bolts
 reduced by 20% for oiled phosphate-treated bolts
 reduced by 10% if bolts are tightened with an impact wrench.

D x pitch Sr 8.8 10.9 12.9

M M M
mm mm² Nm Nm Nm
6 x 1 20.1 10.4 15.3 17.9

7 x 1 28.9 17.2 25 30

8 x 1.25 36.6 25 37 44

10 x 1.5 58 50 73 86

12 x 1.75 84.3 86 127 148

14 x 2 115 137 201 235

16 x 2 157 214 314 368

18 x 2.5 192 306 435 509

20 x 2.5 245 432 615 719

22 x 2.5 303 592 843 987

24 x 3 353 744 1060 1240

27 x 3 459 1100 1570 1840

30 x 3.5 561 1500 2130 2500

Table 11-1 Tightening torques M for bolts with ISO metric threads

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Tightening torques valid for fixing bolts with 12.9 resistance class for aluminium blade
on fans with steel hub

Bolt Torque (Nm) Torque must be checked with a

M8 30 torque wrench.

M10 60 Do not use galvanized nuts or

bolts.
M12 80
M16 110

Table 11-2 Tightening torques for blade fixing bolts on fans with steel hub

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11.2 Checklist before starting fans
The checks listed below are necessary, but could be insufficient in environments with particular types of risk.

CHECKLIST BEFORE STARTING FANS

CODE SERIAL NUMBER YEAR

Identify installation type in accordance with paragraph 3.1. A B C D 

Check compatibility of fan with type of application. OK 

Check that the fan and motor name plate data are compatible with the data on
the product traveller and finished goods card (if present). OK 

Check the compatibility of the electrical data of the motor name plate with the
electrical power supply (frequency, voltage, connections); for further checks OK 
consult the motor instruction manual.

Check the efficiency of any power switch installed for the electrical power supply
to the motor and any auxiliary circuits (e.g. heaters). OK 

Check for absence of foreign bodies inside fan. OK 

Check for presence of all nuts, bolts and other fasteners envisaged. OK 

Check tightness of nuts and bolts in accordance with Table 11-1

(impeller, supports, foundations, transmission if present). OK 

Check for the efficiency of interblock on access door to room or on safety

barriers (if necessary). OK 

Check lubrication conditions of bearings (including motor bearings if these can

be lubricated) OK 

Check that all rotating parts can turn freely. OK 

Check directions of fan rotation and fluid flow. OK 

Check availability of safety procedure for access to fan. OK 

Check that personnel have been instructed and trained. OK 

Date:

Signature:

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11.3 Programmed maintenance intervals

The intervals of time suggested constitute a working basis for the customer, who must according to
circumstances make any modifications necessary for the specific operating conditions.

Programmed maintenance intervals according to intensity of use

Intensity of use

High Medium Low

For all fans

Check perfect condition of all protection net and warning symbols. See
1 paragraph 1.3 and 6.2.1 1 month 1 month 1 month

Check correct tightness of all nuts and bolts in accordance with Table 11-1, 3 6
2 above all in presence of cyclical thermal gradients
1 month
months months

Check that the impeller is free from defects due to wear and corrosion. See 3 6
3 paragraphs 6.2.2 and 6.2.3
1 month
months months

6 12
4 Check that impeller is clean 1 month
months months

6 12
5 Check for absence of dangerous vibrations. See also paragraph 3.7.4 1 month
months months

6 12
6 Check for absence of abnormal noise 1 month
months months

6 12
7 Check for correct lubrication of motor bearings. See paragraph 8.1 1 month
months months

6 12
8 Check electrical operating parameters of motor and servomotors installed 1 month
months months

6 12
9 Check perfect condition of all accessories installed 1 month
months months

Additional maintenance for fans with belt-drive transmission

3 6
10 Check tension and wear of drive belts. See paragraph 8.2 1 month
months months

See also transmission

11 Check condition of lubrication of bearings in accordance with paragraph 8.1
information card

Check temperature of bearings. After an initial increase due to running in, 3 6

12 temperature values should remain constant over time.
1 month
months months

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12 INDEX
diameter; 36; 37; 54; 60
abrasion; 47
directives; 51
accessories; 19; 22; 29; 30
dismantling; 56; 61; 63; 64
Sound; 8; 27; 28; 29
ducts; 17; 19; 20; 21; 24; 34; 44; 48; 51; 55; 63; 65
air; 8; 17; 19; 22; 23; 24; 28; 44; 49; 50
duration; 18
clean; 23; 24; 40; 56; 57; 69
dust; 17; 21; 24; 33; 47; 55
alignment; 38; 40; 59; 60; 61; 62
efficiency; 8; 20; 22; 68
angle; 41; 49; 56
energy; 8; 17
blade; 8; 26; 41; 47; 49; 56; 67
emissions; 27; 28
assembly; 20; 21; 34; 36; 37; 38; 40; 41; 43; 56; 62; 63
environment; 19; 22; 23; 24; 27; 28; 29; 33; 47; 55; 56;
ATEX; 17; 22 63; 68
balance; 50 equipment; 22; 28; 30; 31; 32; 34; 35; 51; 56; 63
base; 11; 12; 13; 14; 15; 16; 22; 30; 34; 36; 37; 38; 41;
outlet; 12; 14; 16; 19; 20; 21; 23; 28; 29; 33; 34; 44; 52;
56; 64; 65
64
bearings; 18; 24; 27; 33; 40; 45; 46; 50; 53; 63; 68;
explosion; 17; 22
69
fixing; 20; 22; 23; 25; 34; 36; 37; 38; 46; 57; 67
belts; 18; 26; 38; 40; 46; 51; 54; 55; 56; 60; 61; 62; 63;
69 flange; 63
tension; 40; 46; 50; 54; 55; 61; 69 flow; 8; 9; 17; 19; 35; 44; 49; 68
blades; 8; 26; 47 hot; 7; 23; 51
bushes; 63 friction; 49; 50; 60
casing; 11; 12; 13; 14; 15; 16; 17; 23; 24; 30; 36; 37; gaskets; 44
43; 45; 47; 48; 63; 64; 65; 66
grease; 45; 52; 53; 63
chains; 30; 31; 32
protection net; 7; 11; 12; 13; 15; 16; 18; 19; 20; 21; 22; 23;
characteristics; 8; 17; 22; 24; 26; 27; 34; 42
24; 37; 38; 45; 46; 47; 63; 64; 65; 69
checks; 24; 40; 45; 46; 47; 48; 52; 68
holes; 30; 31; 32; 40; 50; 57; 60
classification; 24
hub; 13; 14; 15; 26; 56; 65; 67
cleaning; 24; 40; 47; 52; 54; 55; 56
name plate; 8; 10; 17; 22; 35; 42; 44; 45; 46; 49; 53; 55; 68
components; 11; 12; 13; 14; 15; 16; 18; 22; 23; 24; 25;
inspection; 7; 24; 51
27; 30; 31; 32; 36; 37; 38; 42; 44; 46; 47; 48; 51; 56;
63 installation; 6; 17; 19; 20; 21; 22; 23; 24; 25; 27; 28; 29; 34;

connection; 19; 20; 21; 23; 26; 31; 32; 42; 43; 44; 45; 35; 38; 39; 41; 42; 44; 46; 49; 63; 68
63; 68 inlet; 16; 17; 19; 20; 21; 23; 28; 33; 34; 35; 44; 48; 49; 52; 63
connector; 42 inverter; 25; 26; 49; 50
grounding; 23; 42 lifting lugs; 32; 39
control; 22; 25; 42; 56 load; 20; 21; 30; 31; 32; 33; 34; 54
corrosion; 46; 47; 69 lubrication; 24; 45; 51; 52; 53; 68; 69
coupling; 49; 50; 51 interval; 18; 20; 53; 69
couplings; 8; 26 maintenance; 18; 20; 24; 35; 42; 45; 51; 52; 56; 69
flexible; 8; 21; 34; 44; 46; 48; 51; 63 materials; 17; 63
cycle; 24; 25 life cycle; 18; 63

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misalignment; 21; 34; 59 direction; 8; 17; 26; 46; 49; 68
motor pedestal; 63 safety; 6; 7; 18; 19; 20; 22; 24; 25; 32; 42; 45; 46; 47;
electric; 8; 17; 42; 63 51; 68
movement; 17; 19; 21; 30; 31; 32; 33; 47; 51 screws; 40; 57; 58; 59; 60; 66
multi-stage; 51 serial number; 21; 55; 68
noise/noisiness; 8; 25; 27; 28; 29; 46; 50; 60; 69 series; 11; 12; 13; 14; 15; 16; 19; 41
nuts and bolts; 20; 25; 34; 46; 66; 68; 69 shaft; 15; 16; 23; 25; 27; 31; 36; 37; 40; 56; 57; 58; 65
nuts; 22; 23; 36; 45; 68 slipping; 55
oil; 23; 66 spline; 57; 58
operation; 8; 17; 18; 20; 22; 23; 24; 25; 26; 27; 28; 30; standards; 24; 27; 51
31; 32; 33; 34; 35; 36; 37; 38; 46; 47; 49; 50; 51; 52; steel; 8; 17; 63; 67
55; 56; 58; 61; 62; 63 stainless steel; 26; 27
paint/painting; 17; 48 supports; 34; 45; 46; 63; 68
parts; 7; 19; 20; 22; 23; 24; 25; 26; 30; 31; 34; 37; 38; surfaces; 7; 8; 23; 46; 48; 51
40; 43; 44; 45; 47; 49; 50; 51; 55; 56; 63; 68
symbols; 6; 7; 22; 30; 31; 69
lifting equipment; 30; 31; 32; 51
system; 8; 17; 19; 21; 23; 24; 25; 26; 27; 28; 29; 31; 34; 42;
personal protective equipment (PPE); 22
49; 62
play; 36; 37
temperature; 11; 20; 21; 23; 24; 25; 27; 46; 51; 55; 69
positions; 9; 20; 22; 23; 26; 27; 28; 31; 32; 34; 35; 36;
high; 18; 20; 21; 23; 24; 26; 43; 49; 50; 51; 69
37; 38; 39; 40; 43; 49; 59
thickness; 47; 48
power supply; 24; 42; 45; 46; 49; 50; 51; 56; 63; 68
tightening torques; 60; 66; 67
voltage; 24; 42; 43; 49; 68
tightening; 25; 34; 36; 37; 38; 40; 57
power; 8; 24; 26; 28; 42; 45; 46; 49; 56; 60; 68
tools; 51; 61
absorbed; 8
transport; 17; 30; 33; 51; 63
installed; 8; 19; 21; 22; 23; 27; 35; 42; 44; 55; 68; 69
intended; 6; 19; 22; 23; 45; 49
pressure; 8; 17; 21; 28; 29; 49
washer; 34; 37
atmospheric; 17; 33
spring; 34
dynamic; 8; 17; 21; 34
wear; 18; 20; 24; 31; 47; 48; 49; 51; 55; 60; 69
resistance; 8; 49; 67
welds; 46
static; 8; 23; 27; 34
pre-tension; 55
pulleys; 26; 38; 40; 51; 56; 59; 60; 61; 63
qualified personnel; 30; 34; 35; 42
range; 17; 26
reassembly; 56
reliability; 18; 51
removal; 17; 20; 22; 23
risks; 6; 17; 19; 20; 22; 23; 24; 25; 27; 28
rotation direction; 26; 42; 45
rotation; 8; 17; 18; 24; 25; 26; 27; 28; 42; 45; 49; 53;
68

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