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TCF TXP 1016-140, Operating And Assembly Instructions Manual, Page: 63 / 63

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Summary of Contents for TXP 1016-140

Page 1: ...xtreme Pressure Blowers Operating and Assembly Instructions TXP 1016 140 TXP 1212 120 TXP 1313 120 TXP 1414 120 TXP 1614 110 For proper and safe use follow this guide Store for later look up IM 825 Version June 2021 ...

Page 2: ...20 2 7 7 Hazards when Operating Multiple Fans 20 2 8 Safety and Surveillance Equipment 21 2 8 1 General 21 2 8 2 Existing Safety Devices 22 2 8 3 Safety Instructions on the Fan 23 2 9 Emergency Information 24 3 PRODUCTCT DESCRIPTION STRUCTURE AND FUNCTION 24 3 1 Specifications 24 3 2 Equipment and Accessories 24 3 3 Construction 24 3 3 1 General Overview 24 3 3 2 Power Supply 25 3 3 3 Frequency 26...

Page 3: ...ductory Notes on Safety 46 6 2 Behavior in the Event of Disturbances 47 6 3 Fault Table 47 7 MAINTENANCE AND REPAIR47 7 1 Introductory Notes on Safety 47 7 2 Measures Before Maintenance and Repair Work 49 7 3 Notes on Maintenance and Repair Work 49 7 4 Review and Control 49 7 5 Cleaning IK Devices 50 7 6 Ball Bearings 50 7 7 Fine Filter 50 7 8 Seals and Radial Shaft Seals 51 7 9 Structural Mainten...

Page 4: ...standard ver sion Residual Risks The operating manual informs and warns the user of residual risks that are not fully removed through design and protective measures Orientation in the Operating Instructions Presentation of general information symbols This operating manual contains the fol lowing general information symbols which guide you as a reader through the operating instructions and gives yo...

Page 5: ...ormation about the warnings in the operating instructions Observe all warnings on the product and in the documentation and be extra careful in these cases Also share all warnings with other users Warnings as well as command ments and prohibitions are for your personal protection Design of Warnings in the Operating In structions DANGER Indicates an imminent threat that leads to serious bodily injur...

Page 6: ...oduct Identification Aluminum Extreme Pressure Blowers Product Model TXP Model Designation TXP 1016 140 TXP 1212 120 TXP 1313 120 TXP 1414 120 TXP 1614 110 1 2 Contact Information Twin City Fan Blower 5959 Trenton Lane Minneapolis MN 55328 Phone 763 551 7600 Fax 763 551 7601 E Mail tcf_sales tcf com Internet www tcf com Tab 2 Manufacturer s Details 1 3 Copyright This document is copyrighted and in...

Page 7: ...cal building codes or in the ab sence of local codes the National Electric Code ANSI NFPA 70 Lat est Edition In Canada wiring must comply with CSA C22 1 Part 1 Electrical Code Kostal Quick Start Guide UL Notes Kostal Omron Quick Start Guide For special versions Observe addi tional documents 1 5 Rating Plate The fan is clearly marked by signs It has a motor shield and a device shield Use the inform...

Page 8: ... plate The information there must be complied with The power shield is located on the frequency in verter Fig 5 Position of the power plate on the Fre quency Inverter Omron Fig 6 Performance plate frequency inverter Omron Fig 7 Position performance plate on the fre quency inverter Kostal Fig 8 Performance plate frequency inverter Kostal ...

Page 9: ...The operator must check during the en tire operating period of the product whether the operating instructions he has issued comply with the current state of the regulations and if necessary adapt them Technical Condition of the Product The following requirements are made for the technical condition of the product and must be ensured by the operator The product may only be used as intended The prod...

Page 10: ...reliably are authorized as staff Persons whose responsiveness is affected e g by drugs alcohol or medi cation are not approved When selecting personnel observe the age and occupational regulations appli cable at the place of employment 2 2 2 Unauthorized Person In addition to qualified personnel third parties and or insufficiently qualified per sons may reside with the product or its surroundings ...

Page 11: ...ar protective goggles The goggles are used to protect the eyes from flying parts Wear head protection hair pro tection Head protection hair protection is a hairnet a cap a hairband or any other measure for covering or tying together long open hair It is used to protect against grasping or pulling in long hair by moving e g also rotating parts Wear protective gloves The protective gloves are used t...

Page 12: ...personal injury and property dam age resulting from the improper use Predictable misuse also includes The promotion of Aggressive media Abrasive media Adhesive media Toxic media Explosive media very humid with drop for mation media Installation in an explosive atmos phere Series or parallel connection of sev eral fans Outdoor installation without special measures Conversion and modification 2 6 Co...

Page 13: ...s Fan in gen eral Exposure to noise Danger from envi ronment Danger due to speed and resonances Danger due to weight and safe standing Table 3 Assignment of residual hazards For more information see the following chapters 2 7 1 Hazards from Fans Many residual hazards come from the fan itself and are due to its intended use During operation the impeller ro tates inside the fan and this can lead to ...

Page 14: ...ntenance and repair work In these situations unexpected start up of the fan carries a great risk Therefore the product must be discon nected from the power supply before these works and secured against re en try Then wait for all moving parts to stop Only then can work on the product be carried out Unexpected start up can cause hazards due to being drawn in if the fan starts unexpectedly hair clot...

Page 15: ...o the rotat ing impeller fingers or limbs can be severed Do not reach into the inside of the fan during operation Check regularly whether the necessary protective grilles are present at the open ings and are intact Replace missing or damaged protective grilles immediately Wait until the impeller stops before removing protective grilles for maintenance After completion of maintenance work in stall ...

Page 16: ... lead to breakage of the impeller Fragments are thrown out of the fan and can injure by standers Observe the switching cycles specified in chap ter 2 4 Appropriate Use The impeller of the fan is designed for high loads Nevertheless it can be damaged by repeated impermissible rapid starting and braking This breaks the impeller and parts of it are thrown out of the discharge side People hit with fra...

Page 17: ...danger Check the condition of these protective measures regularly and replace them in the event of damage Hazards due to the weight of the fans During transport or installation of the fan there is a risk of the fan tipping over or falling In these situations the fan is not yet firmly screwed and its own weight can injure people Secure the fan with suitable fasteners during transport or installatio...

Page 18: ...wer supply 2 Secure against re entry 3 Detect freedom of tension 4 Earth and short circuit 5 Cover or barriers to adjacent tense parts 2 7 3 Exposure to noise The fan causes noise during operation This residual hazard cannot be elimi nated as it is the result of the function of the fan Increased noise exposure can lead to hearing damage or other health damage Therefore always wear a hearing protec...

Page 19: ...empera ture of the conveying medium during op eration If this is above 122 F 50 C the fan must be protected by the opera tor from direct contact Touching hot surfaces can lead to burns When conveying from the intake side to the blow out side the temperature in the conveyed medium can be increased Depending on the operating conditions this temperature difference can be in a range of up to 176 F 80 ...

Page 20: ...frequencies These can be ex cited by certain speeds of the fan which leads to a possible resonance opera tion The resonance operation can lead to mechanical destruction of the fan and the associated personal injury There is danger to life The fan must not be oper ated in resonance mode The fans are designated in such a way that reso nances usually do not occur If the speed changes during operation...

Page 21: ...ch has been built in accordance with applicable legal regulations and is safe to operate Dangerous hazards that cannot be ruled out are provided with protective devices and if necessary are marked with warning signs on the product and in structions for occupational safety in the operating instructions The product may only be operated if all safety and safety related equipment is in place and funct...

Page 22: ...e and volume flow Warning signs and pictograms Warning signs are placed at danger ous areas that can not be ruled out in the constructive way warning staff of dangers Motor circuit breakers Protects the elec tric motor from overload overload protection function is usually part of the frequency con verter Safety Function Fan Cover Mo tor Intervention protec tion for cooling fan wings motor Protecti...

Page 23: ...TXP Inst Maint Manual IM 825 23 2 8 3 Safety instructions on the Fan Fig 10 Safety instructions on the housing 1 2 Fig 11 Safety instr on the device base 1 2 ...

Page 24: ...emature re energizing Before switching back on make sure that no one is in the danger zone Check the fan before recommis sioning Make sure that all security devices are installed and functional Shutdown in case of emergency is complete 3 PRODUCT DESCRIPTION STRUCTURE AND FUNCTION 3 1 Specifications The technical data can be found in the appendix 3 2 Equipment and accessories The equipment and acce...

Page 25: ...on in the control cabinet IV Kostal for installation with adapter plate on a wall Information on the frequency converter The frequency inverters are de scribed in the enclosed operating instructions of the respective manufacturer Therefore please note the documents supplied Version IK Fig 13 Structure of the fan with frequency converter 1 Frequency 2 Motor 3 Isolator 4 Console 5 Fan Housing 6 Prot...

Page 26: ...e fan hous ing The heat shield constructively separates the motor from the fan housing Fig 14 Heat Shield 1 Heat Shield Temperatursperre 3 4 Description The electric motor drives the impeller in side the fan Through the rotating impel ler the fan sucks in the conveying me dium e g air via the intake opening and transports it to the outlet via the fan housing Fig 15 Functional description The fan i...

Page 27: ... qualification The following personnel are ap proved for transport and stor age Transport companies with appropriate expertise Manufacturer s staff Trained Personnel Important information about your safety You are responsible In any case the safety instruc tions in Chapter 2 Safety and the local safety regulations must be observed and complied with Wear the following protective equip ment Safety s...

Page 28: ... ble means of transport Transport can be carried out by the fol lowing means of transport and means of transport Transport with min 2 people for fans up to 40 kg 88 18 lbs Transport with lifting device such as forklift Transport with load crane 4 4 2 Transport Information DANGER Danger to life due to float ing loads Falling loads can lead to seri ous injuries and even death Never step under float ...

Page 29: ...ng area of the hoist Secure the transport routes 4 4 3 Transport of pallets by crane Packed fans on the pallet can be trans ported by crane Fig 17 Transport of the Pallet by Crane To transport the packages by crane proceed as follows 1 Attach ropes straps or multi point hangings to the pallet 2 Check that the packages are dam aged by the stopper The stopper must not damage the packages or the pack...

Page 30: ...tween the tie bars of the pallet The forks must be retracted un til they protrude on the other side 2 Check the center of gravity of the pallet and package The package must not tip over when lifting 3 Transport the packages to their destination The transport is complete 4 4 5 Transporting the Unpacked Fan If the fan is to be lifted and or trans ported floating the load carrying device can be posit...

Page 31: ...le in original packag ing in a closed room store dry dust free and vibra tion free Suction and pressure connection must be closed Storage temperature range from 20 C 4 F to 60 C 140 F After a storage period of 12 months or more the motor bearings must be checked before the fan installa tion During commissioning with 50 of the frequency let the fan run for 2 minutes so that the ball bearing grease ...

Page 32: ...tion and maintenance The fan is equipped with isolators between the engine and the con sole Do not strain the isolators on shear or pull Screw the fan tightly at the place of use with the console on a level solid and sufficiently stable surface without vibration transmission load We recommend the suction and pressure side connection of the system via compensators The console is designed only for t...

Page 33: ...e gloves work clothes safety shoes safety helmet Fan is unpacked and set up To mount the fan proceed as fol lows 1 Check the clearance around the drive motor s ventilation system The minimum distances must be maintained Power Minimum dis tance to the fan hood 2 HP 1 5 kW 1 34 in 34 mm 2 HP 1 5 kW 2 09 in 53 mm Table 6 Clearances to fan hood 2 Check the clearance to walls or sur rounding systems on...

Page 34: ...ARNING Risk of fire and electric shock due to loose or in correctly tightened connec tions Incorrectly tightened or loose connections can cause elec tric shocks fires property damage and personal dam age Check the connections for looseness and tighten them according to the tightening torques of the following table Threaded Bolt Tightening Torque M4 0 88 ft lb 1 2 Nm M5 1 48 ft lb 2 0 Nm M6 2 21 ft...

Page 35: ...rcuit breakers In order to comply with the EN 61800 5 1 standard the protective conductor connection must be double cut carried out via separate terminals or a protec tive conductor cross section of at least 10 mm2 Cu Fig 22 Proective connection for Kostal 5 5 1 Connection IK Fans Preconditions Supply voltage must be consistent with the information on the name plate of the frequency inverter The f...

Page 36: ...ted a ca ble break in the protective conduc tor of the power supply may result in an error The housing of the fan is then put under tension and can lead to serious injury or death on contact Therefore use a second protective conductor The electrical connection of fans with frequency inverter is completed 5 5 2 Connection IV Fans Preconditions Frequency inverters Omron and Kostal can be operated at...

Page 37: ...t 20m IV Kostal close to the motor with wall adapter plate max 9 feet 3m In the case of inverter supply volt ages 400 V longer cables see above and or exceeding the pulse voltages max 1000 Vpk for drive motors up to 0 75 kW max 1300 Vpk for drive motors greater than 0 75 kW on the motor terminals suitable measures such as a motor filter to protect the motor must be installed Please contact the in ...

Page 38: ...verter corresponds to the volt age on the motor power plate To perform the electrical connection in the terminal box proceed as fol lows Make sure that the above points are true Insert the electrical connection ca ble into the terminal box Connect the protective conductor connection in the terminal box to a suitable protective conductor sys tem Connect the existing temperature sensor PTC thermisto...

Page 39: ...ired for the following fans Indication of the interconnection on the power plate e g with the specification on the rating plate 230 400V or the motor may only be used for the lower voltage 230V 3 phase cur rent in the be connected Circuit Fig 26 Star Circuit If the main s phase L1 is connected to U1 and to W1 the mains phase L3 the impeller rotates to the left counter clockwise If the main s phase...

Page 40: ... motor current Output voltage of the inverter equal to the motor rated voltage Supply voltage max 480V includ ing 5 voltage tolerance The pulse rate of the inverter should be 8 kHz as a lower pulse frequency produces strong motor noises The frequency converter must con tain an overload protection The values for the maximum mini mum frequencies must be observed see Tab 4 page 17 The inverter must h...

Page 41: ...d malfunctions in inverter operation the following times ap ply for the respective device en gine power class see name plate in the event of a ramp run as well as a change in speed for the respective device engine power class see nameplate Device engine power Accelera tion Time s Deceler ation Time s 0 34 HP power 4 0 HP 10 20 4 0 HP engine 20 40 Device engine power Accelera tion Time s Deceler at...

Page 42: ...ons of the frequency inverter manufac turer and the information in this operat ing instructions See 5 5 2 Connection of Frequency Converter Fans in order to meet the requirements of the EC Di rective Electromagnetic Compatibility 2014 30 EU Frequency inverters Omron and Kostal provided that all instructions in the oper ating instructions are complied with comply with the following US standard 47 C...

Page 43: ...missioning therefore a measurement must be carried out on the flange bearing of the fan The vibra tion values detected must be within the following limits Maximum permissible vibration velocity Limit values according to ISO 14694 2003 E category BV 3 Effective Value r m s mm s in s In Installation Maximum permissible vibration velocity Limit values according to ISO 14694 2003 E category BV 3 Start ...

Page 44: ...an on briefly and then off again The fan starts briefly the fan impeller rotates a bit 2 Check the running direction of the fan using the arrow on the fan housing 3 If the direction of rotation is re versed swap the polarity L1 for L3 The rotational direction check is complete 5 7 3 Commissioning of the Fans To put the fan into operation pro ceed as follows 1 Make sure there are no foreign ob ject...

Page 45: ...rations 11 Measure the vibration levels 12 Check the cooling air supply for the electric motor 13 Check the seal only for sealed fans Once everything is in order commissioning is complete and the blower gate can be used 5 7 4 Surge Stall Unstable Operations When the fan is operated to the left of the maximum pressure of the character istic curve pumping effects can occur in the interaction between...

Page 46: ...oltage carrying parts results in an electric shock Damage to compo nents or insulation material can be life threatening Work on electrical in stallations equipment may only be carried out by electrical profes sionals If the insulation mate rial is damaged switch off the power supply immediately and se cure the fan against re engagement Have the damage rectified im mediately Keep moisture away from...

Page 47: ... ap pendix 7 MAINTENANCE AND REPAIR 7 1 Introductory notes on safety Personnel qualification The following personnel are ap proved for maintenance and re pair Manufacturer s staff Trained staff with regular training in the handling of fans All electrical work may only be carried out by trained and authorized electricians Important information about your safety You are responsible In any case the s...

Page 48: ... connec tions Incorrectly tightened or loose connections can cause elec tric shocks fires property damage and personal dam age Check the connections on loose seat and tighten them after the tightening torques of the following table WARNING Risk of injury and or de struction of the fan If the fan continues to be used in an unsuitable operat ing state components can be damaged and destroyed De stroy...

Page 49: ...re starting maintenance check the following points The fan is switched off The fan is secured against re ener gizing and disconnected from the mains The impeller of the fan stands still The fan has cooled down Required tools and spare parts are available Discontinued operating states or control settings are noted Note our hints in the guidelines to the frequncy converter 7 3 Notes on maintenance a...

Page 50: ...he fans are equipped with sealed ball bearings which do not require relubrica tion Check the ball bearings during mainte nance and before each recommission ing Operation is only permitted with flawless ball bearings To do this turn the impeller by hand and check it for smoothness Important information about the ball bearings In case of frequent start up and departure an early replacement of the be...

Page 51: ... NOTE Damage to property due to incorrect spare parts Incorrect or faulty replace ment and components from third party manufacturers can cause serious damage When using unapproved spare parts all warranty and service claims will be for feited Use only original spare parts For spare parts orders you provide the following information from the service plate Model Serial Number 7 11 Measures after mai...

Page 52: ... safety instruc tions in Chapter 2 Safety and the local safety regulations must be observed and complied with Wear the following protective equip ment Hearing protectors Safety shoes Gloves Work clothes Goggles Hairnet 8 2 Dismantling and disposal DANGER Danger to life from electric ity and other energies Serious bodily injury or death due to electric shock or other energies on the fan Disconnect ...

Page 53: ...e all operating and auxiliary materials and remove processing materials Dispose of everything in an environmentally friendly manner 6 Disassemble all assemblies and components professionally and comply with applicable local occu pational health and safety and envi ronmental regulations 7 Recycle recyclable material such as aluminum stainless steel steel copper and plastic Some compo nents require ...

Page 54: ...rent con sumption speci fied on the motor shield is ex ceeded Fan runs outside the character istic line system resistance too low Adjust the working point with throttle valve or by reducing the frequency Impeller rotation direction wrong Control the direction of rotation One or two phases not con nected correctly Connect missing phases Motor not properly connected in star or triangle Connect motor...

Page 55: ...uency inverter wrong corner frequency max frequency set Set the corner fre quency max fre quency correctly For fans with customer owned frequency inverter frequency in verter is not properly parameter ized Frequency inverter is correct parameterizing Impeller runs rest less Contaminated impeller Clean the impeller and avoid contamination in the future install filters Impeller defective Replacing t...

Page 56: ... lb db A TXP 1016 140 4 0 536 34 1 8275 400 140 6 3 4 0 64 83 86 6205 TXP 1016 140 5 5 918 34 5 8310 400 140 8 5 5 4 73 83 89 6205 TXP 1016 140 7 5 1405 34 5 8300 400 140 9 5 7 4 73 83 89 6205 TXP 1212 120 5 5 639 36 8 7093 400 120 8 1 5 4 77 89 96 6205 TXP 1212 120 7 5 1179 36 9 7090 400 120 11 3 7 4 93 89 96 6206 TXP 1212 120 8 5 1391 36 8 7079 400 120 12 3 8 4 95 89 96 6206 TXP 1313 120 10 1176...

Page 57: ...20 20 2659 48 6 7185 400 120 21 7 20 1 181 94 103 6208 TXP 1614 110 20 1642 54 9 6500 400 110 28 0 20 1 196 93 95 6208 TXP 1614 110 25 2366 54 9 6510 400 110 34 0 24 8 212 93 95 6208 TXP 1614 110 30 3189 54 9 6505 400 110 37 3 29 5 225 93 99 6208 Table 12 Specifications The values in the table apply only to motors of Twin City Fan Blower other brands may vary 1 min value max value of the character...

Page 58: ...58 TXP Inst Maint Manual IM 825 10 3 Declaration Abb 32 Declaration of Conformity ...

Page 59: ...TXP Inst Maint Manual IM 825 59 10 4 Exploded View Abb 33 Exploded View ...

Page 60: ... Bolt ISO 4017 7 Fan Housing 8 Impeller 9 Disc 10 Cylinder Head Screw DIN 7984 11 Cover 12 Protective Grille 13 Hex Bolt ISO4017 14 Hexagon Nut ISO 4032 15 Disc DIN125 16 Isolator 17 Console Table 13 Spare Parts Contact Twin City Fan Blower for an individual spare parts list To do this you need the serial number see performance plate of the device ...

Page 61: ... 61 Housing Positions The housing position of the fan is crucial for ordering some spare parts Order spare parts to suit the direction of rotation Fig 34 Housing position left hand running Fig 35 Housing position right hand drive ...

Page 62: ...the fan with frequency converter 25 Fig 14 Heat Shield 26 Fig 15 Functional description 26 Fig 16 Possible transport packaging 28 Fig 17 Transport of the Pallet by Crane 29 Fig 18 Transport of the Pallet by lifting vehicle 30 Fig 19 Load carrying equipment between the motor and the fan flange 30 Fig 20 List 33 Fig 21 Attach the fan to the foundation 34 Fig 22 Proective connection for Kostal 35 Fig...

Page 63: ...ible Frequencies 17 Tab 5 Safety Devies 22 Tab 6 Distances from Fan Hood 33 Tab 7 Tightening Torques for threads in the motor terminal box IV IV Omron IV Kostal 34 Tab 8 Acceleration and Deceleration Times 41 Tab 9 Maximum Permissible Vibration Speed 43 Tab 10 Maintenance Intervals Ball Bearings 50 Tab 11 Troubleshooting 55 Tab 12 Specifications 57 Tab 13 Spare Parts 60 10 7 Updates ...

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