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Installation, Maintenance, and Operating Instructions

for

Electric Motor Drive Units

Air-x-changers has prepared this manual for the care and up keep of your
cooler. With these simple instructions and a few tools, the owner can perform many
maintenance and light repair procedures such as tightening the V-belts, checking fan
blade angle, greasing bearings, setting the vibration switch, and cleaning fins and
tubes. If more information is needed about a specific component we recommend
that you refer to the attached specific manufactures maintenance instructions i.e.
(motors, fans, and bearings).

Because this manual covers several cooler styles and sizes, the instructions
outlined are general in nature. This should be noted when looking at any illustration
or parts of the manual that may not apply to your cooler.

Good judgement should be used when purchasing either replacement parts or


products to be used in your repair or maintenance work. Some products may cause
a decrease in performance. All replacement parts should be equivalent to the
manufacture’s original parts. Replacement parts ordered from the factory always
carry our required high level of quality. DO NOT take a chance with products that
might not do the job.
EQUIPMENT SITING AND INSTALLATION
Setting of cooler(s) is the responsibility of the purchaser who must insure that
cooler intake areas are free from obstruction to airflow and sources of hot air
(including other air coolers). Spacing of air coolers should be adequate to avoid hot
air recirculation. Raising and or separating units should compensate for the effects
of grouping coolers together.

ON ARRIVAL AT SITE SHIPPING DAMAGE


The cooler should be thoroughly inspected for damage by receiving
personnel. Damage in transit can be result of dropping or being struck by heavy
objects, any damage should be described on receiving documents presented by
carrier. Prompt claim filing will expedite early compensation from the offending
carrier.

Loose Parts
The parts list should be checked to see that all parts shipped with the cooler
are present. These parts may be secured to the skid base (if so designed) or inside
the plenum area. Basically this cooler is completely shop assembled and no
assembly at the job-site is required,
but occasionally special accessory devices will be required which must be shipped
disassembled to meet height or width limitations.

UNLOADING COOLER
Spreader bars are to be used
for lifting when the cooler is eight (8)
feet. The cooler is supplied with lifting
points to be used for off loading from
carrier. Lifting by any other point may
cause damage to the cooler.
Following are some suggested ways of
lifting. Locate the picture which
resembles the type of unit you have
and use as a guide on how to unload
and handle the cooler properly. (See
unit name plate for unit type i.e. EH, H,
FI, etc.)

TUBE BUNDLES
H-UNITS

HI-UNITS

Z-UNITS
TURN OFF AND LOCK OUT DRIVER BEFORE ENTERING COOLER
PRIOR TO RUN-IN
NOTE: Check all nuts and bolts for tightness, bolting will loosen during
shipment.
Fans
Check fan blade bolts and hub set screws for tightness. Rotate fan by hand to
insure that shaft, speed reducer, and driver turn freely. The fan should be checked
for adequate tip clearance and blade pitch angle. Slight adjustment of the tip
clearance can be made by loosening the fan shaft bearing bolts and moving the
complete fan and fan shaft assembly until it is centered in the ring. To check the fan
blade angle, use a level bubble protractor (this can be obtained from the factory).
Loosen the nuts on the bolts and place the protractor on the angle setting mark or
the clevis (refer to fan manufactures information for proper location). Using a mallet
tap on the shank end of the blade to adjust the angle. Tighten fan blade bolts to the
proper torque (refer to manufactures maintenance instructions) making sure to
tighten evenly. Recheck blade angle. Some coolers are equipped with an automatic
fan. These fans have blade angles controlled by varying the air supply pressure. Air
pressure should be applied by to the fan before starting to check for proper
operation. Before starting, the motor should be bumped to check for proper direction
of fan rotation.

Bearings
Bearing mounting bolts and set screws should be checked for
tightness. The manufacturer lubricates the bearings and no additional grease is
necessary to start. When remote lube lines are provided check to insure they are
full by loosening at the bearing end, then fill with grease from fitting end. This will
insure that the grease lines are full of grease. During high-speed operation too
much grease will cause over heating. To protect bearings against entrance of
foreign material when dust and water are present the bearings should contain as
much grease as speed will allow. Daily lubrication may be required to maintain a
slight leakage at the seals. Under normal conditions use the following table as a
guide. However, certain conditions may require a change of lubrication periods such
as the ones described above.
Read preceding page before establishing lubrication
schedule

LUBRICATION
GUIDE
Suggested Lubrication Period in
Weeks
HOURS 1 TO 251 TO 501 TO 751 TO 1001 TO 1501 TO 2001 TO 2501 TO
PER 250 500 750 1000 1500 2000 2500 3000
DAY RPM RPM RPM RPM RPM RPM RPM RPM

8 12 12 10 7 5 4 3 2
16 12 7 5 4 2 2 1 1
24 10 5 3 2 1 1 1 1
V-Belts
On coolers with an idler or electric motor, the belts should be adjusted
before run-in. First, loosen the four (4) bolts, which clamp the motor to the slide
member, or the four (4) bolts, which secure the motor to the slide base. Then,
using the adjustment screw, take the slack out of the belts. Following the
instructions below on using the tension tester to properly tension the belts.

USING THE V-BELT TENSION TESTER

1. Measure the span length (t). (See sketch on page 8)

2. Position the lower of the two O-rings using either of the following methods:
a. On the scale reading ‘Deflection Inches’, set the o-ring to show a
deflection equal to 1/64” per inch of span length (t).
b. On the scale reading ‘Inches of Span Length’, set the O-ring to show a
deflection equal to the inches of measured span length (t).
NOTE: Read scales at bottom edge of O-ring in maximum up position.

3. At center of span (t) apply force, with tension tester perpendicular to the span,
large enough to deflect one belt on the drive until the bottom edge of the lower O-
ring is even with the tops of the remaining belts. A straight edge across the tops
of the belts will insure accuracy of positioning.

4. Find the amount of deflection force on upper scale of tension tester. The
Sliding Rubber O-ring “slides down scale as tool compresses”—stays down for
accurate readings of pounds pressure. Read at top edge of ring. (Sliding ring up
before re-using).

5. Compare the deflection force with range of forces in table on


page 8. If less than minimum recommended deflection force, belts should be
tightened. If more than maximum deflection force, drive is tighter than
necessary.
NOTE: there will normally be a rapid drop in tension during the “run-in” period.
Tension new drives with a 1/3 greater deflection force than the maximum force
recommended.
V-BELT TENSION TESTER

DEFLECTION FORCE TABLE


V-BELT SMALL SHEAVE SMALL SHEAVE SPEED RECOMMENDED DEFLECT
CROSS DIA. RANGE RPM RANGE RATIO
SECT. (INCHES) RANGE DEFLECTION FORCE (Pd)
MINIMUM MAXIMUM
3VX 2.20 1200-3600 2.8 4.1
2.35-2.50 1200-3600 3.2 4.7
2.65-2.80 1200-3600 2.0 3.5 5.1
3.00-315 1200-3600 to 3.8 5.5
3.35-3.65 1200-3600 4.0 4.1 6.0
4.12-5.00 900-3600 4.8 7.1
5.30-6.90 900-3600 5.8 8.6
5VX 4.40-4.65 1200-3600 9.0 13
4.90-5.50 1200-3600 10 15
5.90-6.70 1200-3600 2.0 11 17
7.10-8.00 600-1800 to 13 19
8.50-10.90 600-1800 4.0 14 20
11.80-16.00 400-1200 15 23
HTD Drives
Place belt on sprockets and adjust take-up so that belt teeth mesh
securely with sprocket grooves. Measure belt span (t). Then tighten belt so that
it deflects 1/64th / inch of belt span when a force is applied as specified in the
table below.

Gear Drives
Gears are shipped with or without oil depending on the manufacture and
must be checked before start-up. Some gears are shipped ‘over-filled’ and the
oil must be drained to the proper level. Fill gear with approved grade oil (refer to
manufactures information for listings of recommended oils).

Measure the span length (t) as shown


in sketch above.
HTD DEFLECTION FORCE TABLE
BELT BELT FORCE
PITCH WIDTH (lbs)
20mm 4
30mm 6
8mm 50mm 11
85mm
140mm 11
55mm 16
14mm 85mm 26
115mm 37
170mm 58

NOTE: For belts wider than 2 inch, it is


suggested that a 1inch strip of metal
be placed across the belt between the
tension tester and the belt to prevent
belt distortion.
Louvers
Check all mounting brackets and bolts for tightness. On manually
operated louvers, to insure that the linkage is adjusted properly, operate blades
from a fully open position to a fully closed position. On automatic air motor
(optional) operated louvers, air should be applied to actuator to check for proper
linkage adjustment, free operation, and sufficient air supply. See manufacturer
maintenance instructions for further information on air motors.

DO NOT WALK ON LOUVERS


OR USE AS A LADDER!!
RUN-IN
Vibration Switch (optional) (Murphy & Nelson)
After the switch has been installed, adjust by turning the adjustment screw
in a clockwise direction until the starting torque does not trip the vibration switch.
For other brands see manufactures information.

V-Belts
Run fan and check the tension frequently during the first twenty-four (24)
hours of operation. Thereafter, check the belt tension periodically. Excessive
tension shortens belt and bearing life. Keep belts and sheaves clean of ant
foreign material, which may cause slippage. For instructions on proper belt
tension see V-BELTS page 7.

Gear Drives
Change the original oil after two weeks of operation by draining the
original oil and filling to operating level with flushing oil. Start the fan and shut it
immediately after it reaches operating speed. Drain flushing oil and fill with the
recommended type and amount of oil. Normally the oil should be changed every
six (6) months unless subjected to unusual operating conditions. Check the oil
level once a week. Level is accurate only when drive is stopped. Grease the
vertical and horizontal shafts annually under normal operating conditions. For
more information refer to manufactures maintenance instructions.

Process Start-up
The process start-up should be conducted in a manner that will minimize
thermal shock of the tube bundles. Over cooling of fluids during periods of low
ambient temperature and low heat loads should also be avoided during start up.

Plugs
Header plugs are installed at room temperature in our plant. To correct
any minor leaking, it may be necessary to tighten the plugs when the bundle is at
operating temperature. WARNING: Do not tighten plugs while the bundle is
under pressure. If any plugs are removed, the gasket (for shoulder plugs only)
should always be replaced. Replacement gaskets should be ordered from the
factory. When installing the plugs, a thread lubricant and antigalling compound
should be used.
LONG TERM
Fin Cleaning
Fins should be kept free of dirt and lint, which can be removed by directing
compressed air perpendicular to the tubes in a direction opposite to the normal
airflow. Do not use steam or chemicals to clean fins.

Tube Cleaning
The internal cleaning of tubes can be done three different ways:

1. Mechanical Cleaning:
This consists of using drills, (or wire brushes), on long rods. And rotating
them with air or electric motors. This is normally followed by a water wash or air
purge.

2. Chemical Cleaning:
This consists of circulating hot chemical solution through the tubes. The
solution contains inhibitors to avoid corrosion of the tube walls.

3. High Pressure Water Sprays:


This consists of placing a high-pressure water jet head at the end of the
hollow rods and pushing through the individual tubes.

NOTE: The last two processes will not work on tubes that are plugged, they
must be drilled out mechanically.

Leaking Tubes
Tube leaks can be two types: (1) leaks through the tube wall and (2) leaks
in the tube attachment. In the first case it is most practical to plug both ends of
the tube. Only a limited number of tubes can be sealed off in this manner before
performance is affected. When performance drops below acceptable limits, tube
bundle must be retubed. If leaks develop in the tube end attachment, rerolling of
the tube will be necessary. Care must be taken in selecting the proper tube
expander for the size and gauge of tube to be rolled. When rolling a tube, over-
rolling must be avoided. Consult the factory for information on taper pins to plug
the tubes and roller tube sizes.
INSTRUCTIONS FOR USING TAPER PINS FOR SEALING
LEAKING TUBES
1. Remove plug from one end of leaking tube (do not switch plugs in holes).
2. Insert taper pin through plug hole into tube and tap lightly with hammer until
seated firmly, but not too tight to be removed.
3. Measure plug for depth it was originally screwed into the plug sheet.
4. Measure the distance that the tape pin protrudes from the plug sheet in
seated position.
5. Add the distance measured in Steps 3 and 4 then subtract 1/8”. This will be
the length which should be cut off the large end of the taper pin

6. Remove the taper pin from the end of the tube.


7. Saw a piece off the large end of the taper pin, the length figured in Step 5. Be
careful not to cut the pin too short.
8. Re-insert the taper pin in the tube and drive well into place.
9. Lubricate plug (see PLUGS page 12) and replace in plug sheet. Run up
tightly. The plug should now seat and help hold the taper pin in place.
10. Repeat operation on opposite end of tube.

NOTE: If the plug removed does not seal replace it and the gasket if so
equipped.
Recommended Spare Parts
We suggest that one each of the parts, which are designated by an
asterisk (*) on the parts list be carried in your stock of spare parts. The down
time caused by waiting for delivery of a spare part usually cost more in lost
production or service than the cost of the part itself.

Spare parts orders should be specified in accordance with the parts list
description and the Job number of the unit.

P.O. QTY. DESCRIPTION OF COMPONENTS


__ SECTIONS IN ACCORDANCE WITH SPECIFICATION SHEET DATED: ________
__ ____ STRUCTURE(S): ______________________________________________
__ SET(S) SHUTTERS: _________________________________________________
__ SET(S) TURNING VANES: ____________________________________________
*__ FAN (S) __” DIA. __ BLADES _____ HAND _______ MAKE ___° ANGLE AT ___
_____ “ BORE WITH ___” X___” KEYWAY. __________________________
*__ FAN SHAFT(S): ____” DIA. X __” LONG WITH ___” SQ. KEYS ____ END,
KEYWAY LENGTH __”
*__ ____” FAN BEARING(S): ____________________________________________
*__ ____” IDLER BEARING(S): ___________________________________________
*__ IDLER SHAFT(S) ___” DIA. X ___” LONG WITH ___” SQ. KEY _____” LONG ONE END.
*__ IDLER PIVOT SHAFT(S) ___” DIA. X ___” LONG, CRS, WITH ONE HOLE DRILLED FOR ¼”
COTTER PIN ¼” FROM THE END.
__ SET(S) ______ TYPE IDLER FRAME PARTS; PULLROD LENGTH ____”, MINIMUM
THREAD LENGTH__________
__ VIBRATION SWICHES ____ MAKE ______ MODEL
*__ V-BELTS: ______ TYPE, ___” CENTER DISTANCE, ___ HP EACH, MATCHED SETS OF __
__ SHEAVE SET(S):________________________
__ GROOVES, FAN SHEAVE: ___” OD, _____” BORE WITH ___” X ___” KEYWAY
__ PITCH, MOTOR SHEAVE: ____” OD, ____” BORE WITH ___” X ___” KEYWAY
*__ MOTOR (S): _______ HP, ___ RPM, __ PHASE, __ HZ, __ VOLTS, ___ ENCL., VARIABLE
TORQUE, SINGLE WINDING, _____ SHAFT, ___ MOUNTING, ____ FRAME, ____ SLIDEBASE,
CUST. SPECIFICATIONS __ , MOTOR DATA REQUIRED __ , WIRING DIAGRAMS ___

* RECOMMENDED SPARE PARTS


INSPECTION

Tubes
Tubes are to be inspected for internal and external corrosion and/or
erosion periodically. This depends on the severity of service and atmosphere
that the tubes are in. Inspection of the tubes should be performed every six
months. Tube wall thickness can be checked externally using the ultrasonic
technique.

Fans
Fans should be inspected for wear (pitting, cracks and corrosion) on all
surfaces. These inspections should be preformed every six months. In addition
to surface inspections, all bolts and nuts must be checked for proper torque.

Motors
The motors should be kept free of oil, dust, dirt, water and chemicals. It is
particularly important to keep the air intake openings free of foreign material. Do
not block air outlet or inlet. The following
maintenance procedures should be performed regularly:
1. Bearing lubrication
2. Insulation resistance check
3. Cleaning
These inspections should be done at least every six (6) months.

Bearings
In addition to bearing checks as recommended by the manufacture; the
mounting bolts should be checked for proper torque and alignment. These
checks should be done at least every six (6) months.

Structure
A general inspection of the structure should be performed every six (6)
months. This inspection should include checks for corrosion, damaged members
and sheeting, and for loose bolting.

Headers
Headers should be inspected for corrosion. This corrosion should not be
allowed to proceed past the stated corrosion allowance as stated on the
specification sheet.
Harsco Industrial Air-X- Changers
(Division of Harsco)
("Seller")
TERMS AND CONDITIONS OF SALE
1. Acceptance of Terms and Conditions:
Buyer and Seller have mutually negotiated and agreed upon the terms and conditions contained herein which will apply to the sale of products by Seller to Buyer, unless mutually agreed otherwise. Any
terms contained in a purchase order, invoice or other document provided by one of the parties to the other at any point in the sale process shall not apply unless specifically agreed to in writing by both
parties hereto.
2. Express Warranty:
Seller warrants that the products sold hereunder will conform to specifications Seller has provided to Buyer (or if the product being sold by Seller is a custom built product for Buyer, to the specifications
provided by Buyer to Seller) and will be free from defects in materials and workmanship when operated in accordance with all applicable operating conditions, for a period of one (1) year after start-up, not
to exceed 18 months from shipment (the “Warranty Period”). Such warranty shall not apply to any equipment, whose structural integrity or functionality has been altered or repaired by other than the
company’s personnel or by personnel expressly approved by the Company. Seller shall, during the Warranty Period, repair or replace any products or parts or components of products found to be
defective. In the event Seller cannot repair or replace the product, Seller shall refund, or credit to Buyer, the price of such product.. Buyer agrees to provide Seller prompt written notice of any defect
immediately after the defect is discovered.. Seller makes no warranties covering deterioration or failure due to improper installation or operation.
3. WARRANTY DISCLAIMER:
EXCEPT AS SET FORTH ABOVE, THERE ARE NO WARRANTIES, EXPRESS OR IMPLIED, WITH RESPECT TO THE PRODUCTS SOLD HEREUNDER. SELLER EXPRESSLY EXCLUDES AND
DISCLAIMS ANY IMPLIED WARRANTY OF MERCHANTABILITY AND ANY WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE, APPLICATION OR USE. UNDER NO CIRCUMSTANCES
WILL EITHER PARTY BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES, WHETHER SUCH DAMAGES ARE SOUGHT IN CONTRACT, IN TORT (INCLUDING
BUT NOT LIMITED TO NEGLIGENCE AND STRICT LIABILITY) OR OTHERWISE.
4. Delivery:
Delivery terms shall be mutually agreed upon by the parties and shall be set forth on the confirmation issued by Seller for the product. Seller will exercise its reasonable efforts to meet the shipment dates
as specified in Seller’s confirmation.
5. Prices:
Pricing for the product purchased shall be agreed upon by the parties and specified on the confirmation issued by Seller. No contract shall have been formed until the pricing has been agreed upon by the
parties and specified in Seller’s confirmation issued for the product.
6. Taxes:
Unless otherwise agreed upon by the parties and stated in Seller’s confirmation, prices specified in the Seller’s confirmation do not include sales, use, excise or similar taxes. Buyer shall be responsible
for payment of the amount of any present or future sales, use, excise, value added or other similar tax applicable to the sale of products hereunder.
7. Title and Risk of Loss:
Unless otherwise agreed upon by the parties and stated in Seller’s confirmation, title and risk of loss shall pass to Buyer at the time of Seller’s delivery of the product to the carrier for delivery to Buyer,
even though the carrier may be selected by Seller.
8. Transportation:
Unless otherwise agreed upon by the parties and stated in Seller’s confirmation, delivery hereunder shall be made F.O.B. Seller’s plant, with transportation expenses paid by Buyer.
9. Terms of Payment:
Unless otherwise agreed upon by the parties and stated in Seller’s confirmation, terms of payment for shipments are net cash within thirty (30) days from the date of invoice. Failure to make timely
payment of invoices covering final or partial shipments entitles Seller at its option to withhold delivery of products ordered without liability. In addition, if this invoice or any part hereof is not paid when due,
Seller may assess a late payment charge of 1% per month (or such lesser amount as may be the maximum permitted by applicable law) on such past due amount.
10. Cancellation:
No accepted terms stated in a confirmation issued by Seller may be modified except with the prior mutual written consent of the parties.
11. Compliance with Laws:
Seller warrants that the product, to the extent based on Seller’s specifications, shall comply with all Federal, State and local laws, regulations and ordinances affecting the product. Buyer warrants that its
purchase and use of the product, as well as any specifications provided by Buyer to Seller for the product, shall comply with all Federal, State and local laws, regulations and ordinances affecting the
products.
12. Insurance:
Seller shall, at Seller’s own cost and expense, maintain appropriate insurance coverages for the manufacture and sale of the product, including Comprehensive General Liability Insurance, Worker’s
Compensation Insurance, Automobile Liability Insurance and any other insurance that may be required under applicable statute, regulation or ordinance. If Buyer requests, Seller shall provide to Buyer
certificates of insurance substantiating such coverage.
13. Indemnification:
Seller agrees to defend, indemnify and hold Buyer harmless from any and all liability, loss, damage, cost and expense, including actual attorney's fees, which Buyer may suffer or incur as a result of a third
party claim that the product violates their intellectual property or other proprietary rights. This indemnity shall not apply to the extent Buyer may have altered the product. Buyer agrees to defend,
indemnify and hold Seller harmless from any and all liability, loss, damage, cost and expense, including actual attorney's fees, which Seller may suffer or incur arising from compliance with Buyer's
drawings or specifications, including but not limited to, actual or alleged patent, trademark or copyright infringement.
14. Termination
In the event that either party hereto breaches a material obligation imposed upon it by this agreement, the non-breaching party may give the breaching party notice of such breach and the breaching party
shall have 15 business days to remedy such breach. In the event the breaching party does not remedy such breach in the time frame provided, the non-breaching party may immediately terminate this
agreement by giving notice of such termination to the breaching party. The right to terminate this agreement is in addition to any other right the non-breaching party may have at law or in equity regarding
such breach. Notwithstanding the above, either party may immediately terminate this agreement if the other party becomes insolvent, enters into bankruptcy or a receiver is appointed in respect to any of
its business or an assignment is made for the benefit of creditors.
15. Confidentiality:
Each party agrees to hold in confidence and not disclose to any third party or use for its own benefits, other than as may be approved by the disclosing party, any confidential or proprietary information
supplied to it by the other party hereto pursuant to this agreement. Confidential information shall not include information which (i) is within or becomes part of the public domain, (ii) is disclosed by a third
party not under an obligation of confidentiality with respect to such information, (iii) was already within the party’s possession prior to its disclosure by the disclosing party and (iv) is independently
developed without use of the disclosing party’s confidential information.
16. Assignment:
Either party may freely assign this contract (without further obligation for performance on the part of such party) to any successor to all or substantially all of its business, provided all rights and
responsibilities are assumed by the assignee. In all other events, neither party may assign this contract or any of its rights or obligations hereunder without the prior written consent of the other party.
17. Force Majeure:
Neither party shall be liable for its failure to perform its obligations under this agreement when such failure results from any cause beyond such party's reasonable control, including but not limited to fire,
flood or other act of God, strike or labor difficulty or disagreement, accidents at Seller's facilities, acts or requirements of government or civil authority, riot, war, embargo, truck or car shortage or other
transportation delay or difficulty. In the event of such delay, the date of delivery shall be extended for a period equal to the time loss by reason of such delay. If such force majeure event continues for a
period of 60 days, the party not impacted by the force majeure event shall be entitled to terminate this agreement upon notice to the other party. In the event of termination, Buyer shall reimburse Seller for
all reasonable costs incurred to the date of the force majeure event and Buyer shall be entitled to take control of the product or any part of the product for which it has compensated Seller.
18. Effect of Invalidity:
The invalidity in whole or in part of any provision hereof shall not affect the validity of any other provision.
19. Waiver:
No waiver by either party of the other party’s breach of contract shall be deemed to be a waiver of any other or subsequent breach. All rights and remedies available to the parties hereunder shall be
cumulative and in addition to any other rights and remedies provided herein or by law.
20. Governing Law, Jurisdiction and Venue:
The contract between the parties hereto shall be governed by and construed in accordance with the laws of the State of Oklahoma and shall be deemed entered into at Seller's place of business.
21. Siting/Installation:
Siting of cooler(s) is the responsibility of the purchaser. Purchaser must insure that cooler air intake areas are free from obstruction to air flow and sources of hot air (including other air coolers). Spacing of
air coolers should be adequate to avoid hot air recirculation. Effects of grouping coolers together should be compensated for by raising units.
22. Changes/Revisions:
The Purchaser may change the specification of its order only upon written notice and mutual agreement of the parties to such change. Any additional charges accrued as a result of such change, will be for
Purchaser's account.
23. Complete Agreement:
This agreement, along with the terms which are to be specified on the front of the applicable confirmation issued by Seller, represents the entire agreement of the parties for the sale of the products by
Seller to Buyer.
(This page intentionally left blank)
CLASS 10000 FANS
OWNER'S MANUAL
INSTALLATION
MAINTENANCE
OPERATION

Contents
2.0 INSTALLATION .......................................................................................................................... 2
2.2A INSTALL HUB AND AIR SEAL ................................................................................................ 3
2.2B INSTALL HUB AND AIR SEAL ................................................................................................ 4
2.3 INSTALL AND ADJUST BLADES .............................................................................................. 5
2.4 START-UP PROCEDURES .......................................................................................................... 6
3.0 MAINTENANCE ........................................................................................................................ 7
3.2 ANNUAL INSPECTION .................................................................................................................... 8
3.4 WARRANTY ....................................................................................................................................... 9
3.5A PARTS LIST ....................................................................................................................................10
3.5B PARTS LIST .................................................................................................................................... 11
4.0 OPERATION .............................................................................................................................. 12
4.2 BLADE OVERLOAD ......................................................................................................................13
4.3 CAUSES OF IMPROPER BLADE LOADING ..........................................................................14
4.4 CHECKING BLADE LOAD .........................................................................................................15
4.4.1 SAMPLE GRAPH of BLADE ANGLE IN DEGREES ......................................................16
4.5 DAMAGING OPERATING CONDITIONS .................................................................................17
4.5.3 OBSTRUCTIONS ....................................................................................................................18

MOORE FANS LLC, MARCELINE, MO 64658 PHONE (660) 376-3575 FAX (660) 376-2909 E-MAIL info@moorefans.com
INSTALLATION
ABOUT THIS MANUAL ....... before or after unpacking, the delivering carrier
Moore is as interested as are its customers that Moore should be promptly notified so that an inspection
fans operate at top efficiency for many, many years. This
manual has been written to achieve that result and is based may be made by the claims adjustor. It is the
on more than 50 years of experience as a manufacturer of responsibility of the consignee to file damage
axial flow fans. claims w ith the carrier. A lthough Moore w ill not
Moore fans represent the highest degree of axial fan be responsible for shipping damage, it is requested
development and are in all respects, regardless of price, the
finest obtainable for their intended purpose. As for any fine that any damage, even of a minor nature, be re-
equipment, certain precautions are necessary and certain ported to the factory at once.
abuses must be avoided in order to insure the best perform-
ance over the longest period of time If you have any
questions regarding the installation or operation of your
ID ENTIFY YO UR FA N’ S FEA TURES
Moore fan(s), please contact the Company for assistance. Section 1 consisting of your unit’ s specifica-
tions will be found on the Order Information Sheet
INSPECTION attached. Section 2 Getting Started should be
All Moore units are carefully balanced, inspected read carefully before installation begins. Moore
and packed at the factory. If any damage is evident fans have several unique features.

2.0 INSTALLATION
2.1 GETTING STARTED

2.1.1 FAN IDENTIFICATION Moore keeps records indexed by serial and job
Every fan, or group of identical fans, is assigned a Job numbers of all fans produced for at least forty years in
Number. This number will be found on the Order Informa- order to provide proper maintenance advice and infor-
tion Sheet showing fan specifications. A copy is attached to mation on spare parts and replacements.
this manual. If non-identical fans are shipped together, a Job
Number is assigned to each fan or group and a set of 2.1.2 PLA NNING THE INSTA LLA TIO N
Information Sheets will be included for each Job Number. The sequence given for the installation may be
The Job Number is written in semi-permanent ink on changed if the conditions w arrant. For example, the
each blade, hub and air seal. All fan parts bearing the same air seal may be installed on the hub before the hub is
Job Number are entirely interchangeable. (Blades of the installed on the drive shaft. (In fact, for inverted fans,
same Series and Diameter are also interchangeable between it is necessary to install the air seal first.) The instal-
Job Numbers.) lation should be planned before beginning so that the
Fan components covered by more than one Job Num- steps required are taken in the most convenient order.
ber may be crated together. The Job Number that is written If you need information not found here, please contact
on each part, however, will make sorting simple. Mo o re.
Each individual fan produced by Moore is assigned a Class 10000 fans are suitable for horizontal or vertical
Serial Number. This Serial Number is embossed on a perma- mounting, for electric motor or engine drive and may be
nent metal tag and attached to each fan hub. The Fan designed for clockwise (right hand) or counterclockwise (left
Information Sheet provided for each Job Number lists all of hand) rotation. Some drawings illustrating the installation
the individual Serial Numbers of the identical fans assume vertical mounting and need to be mentally rotated
covered by that Job Number so that, in future years, for horizontal mounting. Be sure to refer to the dimensional
reference to the fan specifications provided w ill iden- drawing(s) provided. These will illustrate the proper orien-
tify the characteristics of each individual fan. tation of the fan and the rotation direction.

Page 2 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
Q D TYPE HUB (CAST IRON BUSHING) INSTALLATION

2.2A INSTALL HUB AND AIR SEAL

Hub Only Without Air Seal


Air Seal Installed on Hub
On orders consisting of more than a small number of fans, the To install the hub:
air seals are crated separately and must be installed in the Install the three hub studs in the hub. Hand-tighten
field. When field installed, the air seal may be installed on only.
the fan hub before the hub is installed on the bushing if it is Slip the bushing onto the shaft and check the key for
more convenient to do so. The air seal, however, must not proper fit. Be sure the shaft is completely through the
be used to lift the hub. MAXIMUM bushing.
BUSHING TORQUE
SIZE Carefully clean the bore of the hub and the outside of
FT-LBS M-KGS
the bushing with a clean, dry cloth. Use no lubricants in this
SF 20 2.77
E installation. Use of lubricants can cause hub breakage.
40 5.53
J 90 12.44 Do not clean or alter the lubricant coating on the hex
BLADE M 150 20.75 nuts.
TUBE
Lift the hub by grasping the hub tubes. Do not lift the
hub by grasping the air seal.
FAN Install the fan hub on the bushing with the studs
HUB
extending through the bushing flange. Place the stud nuts on
STAINLESSSTEEL the studs and tighten the nuts alternately, keeping the pull on
BUSHING STUD STAINLESS NUT
(Specially Coated)
all of them as nearly equal as possible while drawing the hub
onto the bushing until the bushing tightly grips the shaft.
Caution should be used to prevent the hub from cocking on
Q D BUSHING the bushing.
Tighten the nuts to the torque shown in the table at left.
SHAFT Do not over-torque. Excessive torque can cause hub or
bushing breakage.
HUB INSTALLATION ON Q D BUSHING
To install the airseal:
If the airseal is to be installed on the shaft side of the fan,
ROD END cut out the center to provide clearance for the bushing.
Locate the air seal installation hardware in the plastic
AIR SEAL bag taped to one of the hub tubes. Install the air seal studs on
the appropriate side of the hub tube. Finger tighten.
RESILIENT Place one resilient washer on each stud as shown in the
HUBTUBE
WASHER drawings at left. Place the air seal onto the studs and install
the remaining hardware, following the sequence shown in
the drawings. Do not lubricate this end of the studs.
Note that the diameter of the resilient washers, before
they are compressed, is slightly less than the diameter of the
aluminum washer. Tighten each nut until the resilient
washer's diameter is the same as the aluminum washer. Do
ALUMINUM NUT not overtighten. Overtighteness exists when the resilient
ALUMINUM washer has expanded in diameter larger than the diameter of
WASHER the aluminum washer.
RESILIENT Note: Some air seals are provided with more mounting
WASHER holes than may be required. This is done intentionally to
AIR SEALSTUD
make the air seals more interchangeable between units.
AIR SEAL INSTALLATION ON HUB For example, an air seal with 8 mounting holes can be
used with either a 4-blade or an 8-blade unit.

TMC-704 Rev F- 03/03 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 Page 3
HT BUSHING HUB (ALUMINUM BUSHING) INSTALLATION

2.2B INSTALL HUB AND AIR SEAL

Hub Only Without Air Seal Air Seal Installed on Hub

Hub installation instructions DO NOT apply lubricant between the bushing bore and the
shaft.
Some Moore Class 10000 hubs are shipped with Moore Installation:
Hi-Torque (HT) Aluminum Bushings. The following Install the bushing in the hub by aligning the threaded
paragraph details the installation procedure for these holes on the I.D. of the hub with the slots on the OD of the
hubs. bushing with the cap screws captured between the bush-
ing and the hub. Insert the bushing in the hub. Using a
Lubrication: hex key wrench, sequentially tighten the socket head cap
If the bushing was pre-installed in the hub at the factory, screws until the bushing is almost fully engaged in the
no further lubrication is required prior to installation. hub. Leave slight play between the bushing and hub to
If the bushing was not installed in the hub at the factory, facilitate installation on the shaft.
it is imperative to apply high quality grease to the Place the hub/ bushing on the shaft. (Preferably cap
following surfaces: screw heads will be towards free end of shaft.) Insert the
key, and tighten the setscrew to secure the hub and key to
1. The cap screw threads the shaft. Now begin sequentially tightening the socket
2. The underside of the cap screw heads head cap screws (approximately 2-3 turns per cap screw
3. The bushing taper / hub bore initially) to firmly engage the bushing in the hub and seat
Bushing
the bushing on the shaft. Once the bushing/ hub is firmly
Bushing OD Allen Head Hex Key
FAN TYPE Required Torque seated on the shaft, continue tightening the cap screws
Bold Size
HUB sequentially until the specified torque, shown in the
U 4" 12 mm 10 mm 50 ft-lb (6.9m-kg)
W 5.5" 16 mm 14 mm 90 ft-lb (12.5m-kg) following table, is reached. DO NOT over-tighten cap
X 5.5 " Long 16 mm 14 mm 135 ft-lb (18.7m-kg) screws as this could cause damage to the hub.
Z 7" 16 mm 14 mm 135 ft-lb (18.7m-kg)

Caution:
If bushing is expected to see frequent oscillating loads (Greater
Bushing than 50% of nominal expected Static Torque), Fan should be
operated for approximately 15 minutes and then re-torque
bushing cap screws.
Cap Screws
To install the airseal:
If the airseal is to be installed on the shaft side of the fan,
ROD END cut out the center to provide clearance for the bushing.
Locate the air seal installation hardware in the plastic bag
AIR SEAL
taped to one of the hub tubes. Install the air seal studs on the
appropriate side of the hub tube. Finger tighten.
RESILIENT HUBTUBE Place one resilient washer on each stud as shown in the
WASHER drawings at left. Place the air seal onto the studs and install the
remaining hardware, following the sequence shown in the
drawings. Do not lubricate this end of the studs.
Note that the diameter of the resilient washers, before
they are compressed, is slightly less than the diameter of the
aluminum washer. Tighten each nut until the resilient washer's
ALUMINUM NUT
diameter is the same as the aluminum washer. Do not
overtighten. Overtighteness exists when the resilient washer
ALUMINUM has expanded in diameter larger than the diameter of the
WASHER aluminum washer.
RESILIENT Note: Some air seals are provided with more mounting
WASHER holes than may be required. This is done intentionally to
AIR SEALSTUD
make the air seals more interchangeable between units.
AIR SEAL INSTALLATION ON HUB For example, an air seal with 8 mounting holes can be used
with either a 4-blade or an 8-blade unit.
Page 4 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
INSTALLATION

2.3 INSTALL AND ADJUST BLADES


2.3.1 INSTALL BLADES

CLAMP

ROD
END

HUB
TUBE

R ES I LI EN T
M O UN T

BLADE BOLT

NO TE: M O UNTING BO LT
SUPPLIED WITH G REA SE
O N THREA D S A ND
CO NICA L FA CE
BLADE

the bolt into the second resilient mount lightly. A 3/ 4" drive
BEFOREINSTALLING BLADES. . . . torque wrench with a short extension may be used. The blade
Check to see thatthe hub islevel. If the drive shaftisnot mounting bolt is supplied from the factory with grease on the
truly horizontal (orvertical), causing the hub to be cocked, it threads and conical face. D o NO T clean the grease f ro m
willbedifficultto adjustbladeanglesaccurately. Eccentric ro- the bolt.
tation of the fan can also cause serious vibration problems. Complete the installation of one blade by holding the
If misalignment,vibrationorunbalance inthe system is blade so that the blade extends straight out from the hub tube.
present, itwill be more easily identified and corrected atthis Holding the blade in this position, tighten the bolt using a
time. torque wrench set to 200 ft-lb (28 m-kg) making sure the
ro d end and the resilient mo unts seat.
After installing the first blade, manually rotate the fan
Moore fan bladesare carefully balanced to the same momentatthe while moving the blade tip in and out to be sure the blade
factory. Any Class10000bladeof thesameseriesand diametermay clears the ring or throat at all points. When the blade is held
be installed on any hub furnished on the job. They are completely in alignment with the blade tube (that is, straight outward
interchangeable. from the hub), it should clear the fan ring by a distance
M o o re Class 10000 Fans are designed f o r engine adequate to provide for any relative motion between the fan
drive and o ther applicatio ns w ith the mo re severe re- wheel and the ring. Excess clearance between the blade tips
q uirements o f this service. Pro per installatio n, w ith and the ring, however, should be avoided to prevent backflow
particular attentio n to tightening nuts to the specif ied which seriously reduces fan efficiency. If clearance is exces-
to rq ue, is essential to maintain the design integrity o f sive, the diameter may be adjusted at this time. See Section
these units. 2.3.2.
Installoneblade:Cleanany dirtorgreasefromtherod end and Install the rest of the blades so that they are identical
the surfacesof the resilientmounts. Align the rod end hole with w ith the first blade. To rq ue all b o lts to 200 f t-lb s (28 m-
the holes in the resilient mounts and insert the blade mount- kg). If blades are installed properly, they will return to their
ing bolt first through the resilient mount with the recess to undisturbed position if the tips are pressed in the axial
accept the bolt head, then through the rod end hole and screw direction with moderate force (10 to 20 lb).

TMC-704 Rev F- 03/03 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 Page 5
INSTALLATION

2.3.2 ADJUST BLADE ANGLE

Hubs are shipped from the factory with the rod end set
for the blade angle indicated by the design performance. A
HEAVY DOTTED LINE
change in blade angle is sometimes necessary, however, to
INDICATES LOCATION FOR
adjust to actual site conditions. Failure to adjust the blade angle MEASURING BLADE ANGLE
when required may result in blade overload. The causes of
improper blade loading are explained in Section 4.3 of this
manual. Section 4.4 "Checking Blade Load" provides a simple
method of determining the maximum blade angle allowable
in terms of static pressure vs blade angle. Please refer to these
sections before increasing blade angle.
To adjust, loosen the Clamp Nut just enough to allow
the blade to be turned. Place a inclinometer on the flat surface
of the mounts end as shown in the illustration at right. Turn
the blade until the desired angle is achieved.. Make a
permanent record of the final angle selected and take care
that all blades on the fan are set at the same angle. A typical
adjustment may be +/ - 3o. The maximum recommended
blade angle is 30o .
Retighten the Clamp Nut to 18 ft-lbs (2.5 m-kg).
Recheck each blade angle before tightening.

WARNING: The fan is designed to consume the


horsepower stated on the Fan Specification Sheet. The
engine drive typically produces far more power than
the fan can absorb. Too great an increase in blade angle
can cause serious blade overload which will stall the
blades. In this condition, the fan will actually deliver less
air and blade life may be shortened. Blade load consid-
erations are discussed in Section 4.0 Operation in this
manual.

2.3.3 ADJUST DIAMETER IF REQUIRED


At times it may be necessary to adjust the fan changed as discussed in the previous section. A match
diameter to suit a particular ring. To do so, loosen the mark may be made at a point on the threads and the tube
clamp nut so that the rod end can be rotated in the hub before turning to assure that exactly one revolution is
tube. One complete revolution will increase or de- made. Tighten the clamp nut to 18 ft-lbs (2.5m-kg).
crease the radius of the fan by .059" (1.5 mm). Take care Maximum adjustment possible is about +/ - 0.75" (19
that the clevis is returned to exactly the factory-set mm). At least 1.0" (25 mm) of rod end threads must remain
angle unless it is intended that the blade loading be in the tube.

2.4 START-UP PROCEDURES


Before starting the fan, manually check all bolts or stop the fan and observe the blades as the fan comes
nuts to see if they are tightened. Take care not to exceed to rest. All of the blades should return to their origi-
the stated torque limits. nal position at the same rate.
Manually rotate the fan while checking each blade for Inspect the inner surface of the fan ring and
proper clearance. the blade tips for any indication of scoring.
Start the fan and watch it in operation. All blades The horsepower given on the Fan Specifications
should move to the same operating position, indicating that is the calculated horsepower (at the fan shaft) that is
the blade angles are properly set and that all blades are required for the specified performance. Consult the
equally loaded. If vibration or unbalance is evident, see factory or the fan curve before increasing the blade
Section 3.3. angle for the fan to consume more than the speci-
After the fan has been operating for several minutes, fied horsepower.

Page 6 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
MAINTENANCE

3.0 MAINTENANCE
3.1 PERIODIC INSPECTION

3.1.1 PURPOSE 3.1.4 CRACKS, DENTS AND CORROSION


Fan failure is mo st likely the result o f d estruc- Skin cracking may be caused by the tips d ragging
tive repetitive stress acting o ver a perio d o f time. o n the fan ring, o r it may be the result o f lo ng-term
These stresses may be caused by mechanical abuse, fatigue d ue to co ntinued o peratio n und er co nd itio ns o f
e.g. ro ugh gears o r d rive shaft imbalance, o r by vibratio n o r unbalance as discussed in Sectio n 3.3 w hich
aero d ynamic abuse such as blad e o verlo ad o r abno r- fo llo w s. Skin cracking can also be caused by co ntinued
mal flo w co nditio ns. Fo rtunately, these stresses mani- o peratio n und er o verlo ad co nd itio ns as d iscussed in
fest themselves in typical w ays that may easily be Sectio n 4.3 Causes o f Blad e Overlo ad .
d etected o n inspectio n if o ne kno w s w hat to lo o k fo r. Cracking in air seals can o ccur if the airseal has
The purpo se o f this sectio n o f this manual is to been impro perly installed . See Sectio n 2.2. Check to be
d escribe the sympto ms o f po tentially d amaging me- sure the resilient w ashers are present and the nuts
chanical pro blems and ho w they can be co rrected . pro perly tightened .
A ero d ynamic abuses are co vered in Sectio n 4.0 Op- The fatigue strength o f materials, w hether metal
eratio n. o r plastic, may be lo w ered by lo ng-term expo sure to
w ater.
3.1.2 FREQUENCY OF INSPECTION Dents in blad es are caused by o bjects falling into
The frequency o f inspectio n varies w id ely in the fan o r the fan striking so me o bstacle. Mino r d ents
acco rd ance w ith the severity o f service and a suitable may so metimes be repaired by d rilling a small ho le in
inspectio n sched ule sho uld be d evelo ped w ith expe- the center o f the d ent and pulling o utw ard o n the blad e
rience o ver time. During the first w eek o f o peratio n, skin. Blad es may be o rd ered fro m the facto ry fo r re-
at least o ne inspectio n sho uld be mad e. A t these placement. If there is any evid ence o f this type o f
initial inspectio ns, in ad d itio n to the items listed d amage, the hub sho uld be carefully inspected as d is-
belo w , check all nuts fo r tightness to make certain cussed in Sectio n 3.1.6 w hich fo llo w s.
that all w ere tightened pro perly at installatio n. Take The Type 5052 aluminum, a marine allo y, used as
care no t to exceed the stated to rque limits. Fo llo w ing the blade material o n Mo o re fans w o rks w ell w ith either
the first w eek, it is pro bable that inspectio ns o f the fresh o r sea w ater. Waters that are acid , alkaline, o r
fan need be mad e no mo re freqently than inspectio n co ntain co pper salts, ho w ever, sho uld be avo ided fo r all
o f the d rive. aluminum allo ys. If yo u have questio ns regard ing the
suitability o f the fan materials und er certain w ater
3.1.3 BLADE ANGLE AND RUNNING POSITION co nd itio ns, please co ntact the facto ry.
Turn o ff the unit and w atch the blad e tips. A
lo o seness in the clamp bo lt w ill permit a blad e to
flatten in angle. This usually can be d etected by 3.1.5 HUB INSPECTIO N
lo o king at the tips o f the blad es w hile the fan is If damage to the fan has occurred, the hub should be
slo w ing d o w n. A t the same time, befo re the unit carefully inspected since subtle damage may have been
co mes to a co mplete sto p, w atch the track o f the caused that is not readily apparent. Check the hub for any
blad e tips to see that all blad es mo ve to the same sign of bending or twisting of the hub tubes. Hub tubes
o perating po sitio n. If o ne o r mo re blad es is at a cannot be replaced in the field on manual fans and a new
substantially different po sitio n than the o ther blades, hub should be ordered.
o r if all o f the blad es are at a d ifferent po sitio n than Bushings are frequently cracked during a fan wreck
at the last inspectio n, investigate further. This co nd i- and should be carefully inspected. Damage may occur to
tio n may be caused by a d amaged resilient mo unt, the studs that attach the hub to the bushing. It is a good idea
requiring blad e replacement. to replace the studs when replacing a damaged fan blade.

As with any industrial equipment, before entry into fan chamber, strict adherence to ALL Lock-
out /Tag-out procedures is well advised!

TMC-704 Rev F- 03/03 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 Page 7
MAINTENANCE

3.2 ANNUAL INSPECTION


3.2.1 CLEAN BLADES IF INDICATED 3.2.3 CLOSE INSPECTION
A smo o th blad e surface is essential fo r efficient The yearly inspection should be a very thorough
fan perfo rmance. If an incrustatio n fo rms o n the blades one. All nuts and bolts should be checked and careful
it sho uld be remo ved . Use steel w o o l as an abrasive scrutiny given to all highly stressed areas.
alo ng w ith a mild d etergent o r a very mild fo rm o f Inspect the resilient mounts as follows: With the
so lvent. Lye must no t be used because it attacks fan turned off, grasp each blade and feel for looseness at
aluminum read ily. the mount. If in doubt, the blade should be removed and
the mount assembly visually inspected. Wear is indi-
cated by a fretting effect and the resilient mount material
3.2.2 CHECK SYSTEM PRESSURE will show signs of extruding from the cavity. If these
Rad iato r sectio ns may be effected by the accu- indications are not apparent, replace the blade and con-
mulatio n o f d ust and d irt in so me atmo spheres. (Co t- tinue normal operations.
to nw o o d seed s are particularly tro ubling.) These ac- Inspect the blade tips for any signs of cracking and
cumulatio ns may significantly increase the static pres- the fan ring for any scoring that might indicate that the
sure. A d just the blad e angle if necessary as d escribed blades have been striking or rubbing against the fan
in Sectio n 4.4 Checking Blad e Lo ad . ring.

3.3 VIBRATION AND UNBALANCE


3.3.1 GENERAL are negligible. A rotating centrifugal load of 100 pounds,
No piece of rotating equipment is perfectly bal- due to unbalance, would be extremely objectionable
anced. It is always possible that the minute unbalances and possibly even damage the structure on which the
of the various components may combine to provide a drive was mounted. By contrast, it would be unlikely that
noticeable lack of balance. This rarely occurs, since it is the drive shaft of a fan, of perhaps 25 HP, would be
unlikely that all unbalanced components will become supported on bearings rated less than 2000 or 3000 pounds
assembled with their heavy sides in the same direction. radial load. For higher horsepowers, the bearing capacity
Nevertheless, if unbalance is noted, the various compo- would be correspondingly increased. From this it is evi-
nents should be rotated into different positions to see if dent that speed reducer or drive shaft bearing failure could
this might cure the unbalanced condition. never be caused by moderate or even objectionable fan
If vibration or unbalance occur, either at the time unbalance.
of installation or later during the operation of the unit,
its cause may be determined by following the directions 3.3.3 BELT DRIVE UNITS
belo w . The more common causes of vibration in belt drive
units are not the drives themselves but the result of shafts
3.3.2 FAN UNBALANCE that are too flexible or non-rigid supporting members.
Vibration is most likely to be caused by the fan if Vibration can be caused by misalignment of the sheaves or
the blades are not set at the same angle. If the blades are poorly adjusted belt tension. Consult the manufacturer of
properly set, the fan is the least likely cause of vibration. the drives for information. The quickest way to identify the
All fan components are balanced to within ±0.2 ft-lbs. cause of vibration in belt drive units is to operate the fan
If the fan is in an unbalanced condition, the fre- with the blades removed.
quency of vibration of the structure will be that of the
RPM of the fan and is quite low. In the case of large fans, 3.3.4 RO UG H G EA RS
the frequency is often low enough to be mentally counted Continued operation on rough gears and bearings is
along with the rotation of the fan. A vibration of 500 RPM almost certain to develop cracks in the blade skins. Rough
or less will be felt as a weave in the structure rather than gears may be of two types:
a vibration. Below 400 RPM, the vibration may be men- 1. Rough or failed bearings in the drives or gears will
tally counted and above that point may be read with a result in a high frequency vibration being transmitted into
frequency meter. the fan where some areas of the skin will respond to the
Before assuming fan unbalance, check for loose frequencies applied. Cracks will appear in the blade skin and
bearing seats or bearings journaling the shaft on which eventually, in some areas, the skin may actually fall away.
the fan is mounted. This condition will cause the shaft to 2. The other type of rough gear occurs when the output
rotate eccentrically, throwing the weight of the fan off- shaft accelerates and decelerates with each pinion tooth
center, resulting in unbalance of the frequency of the fan engagement. With a six tooth pinion and a motor speed of
RPM. 1800 RPM, or 30 cycles per second, this gear misalignment
After all checks have been made and the fan is still impresses upon the fan a vibrating frequency of 30 x 6 = 180
determined to be unbalanced, field balancing may be cycles per second. If the engagement of teeth is also included,
accomplished as described below in Section 3.3.6. the frequency is 360 cycles per second. This type of high
It should be noted that the loads imposed on the frequency vibration is at least as serious as that caused by bad
drive shaft and its supporting bearings by fan unbalance bearings.

Page 8 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
MAINTENANCE
3.3.5 THRO A T FLUTTER If in d o ubt that thro at flutter is the cause o f
A ny fan that is effectively mo ving air at the tips vibratio n, red uce the angle o f the blad es until the
o f the blad es w ill d evelo p a red uced pressure area (o r fan is d o ing little o r no w o rk. If the vibratio n ceases
suctio n) o n the fan thro at o r ring at the tip o f the und er this co nd itio n, it is certain that thro at flutter
blad e. This suctio n tend s to d raw the thro at to w ard is present w hen the blad es are lo ad ed .
the tip o f each blad e, w hich means that a fo ur blad e
fan w o uld tend to d raw the thro at into so mething 3.3.6 FIELD BA LA NCING
appro aching a square w hile a six blad e fan w o uld Unbalance in o ld er fans may d evelo p because
d raw it into so mething resembling a hexago n, etc. o f so me structural change o r by installing o ne new
Since the fan is ro tating, the effect o n the thro at is that blad e o n an o ld fan w here the existing blad es had
o f co ntinually d raw ing it into a ro tating po lygo n. changed in w eight in the co urse o f o peratio n.
The resulting thro at flutter is frequently mistaken Use w ire to attach a small w eight in succes-
fo r fan unbalance. sio n to each o f the air seal stud s until the best
A substantial thro at o r ring w ill be sufficiently lo catio n fo r the w eight is fo und . The w eight sho uld
rigid that flutter w ill no t exist. A w eak o r flexible then be increased o r d ecreased until the best bal-
thro at, particularly w hen used w ith a fan o f a lo w ance is achieved . The permanent w eight may then
number o f blad es, w ill be greatly affected by this be secured to the stud o r hub tube, w hichever is the
type o f vibratio n. Thro at flutter is easily d etected d ue mo st co nvenient fo r the type and shape o f w eight
to the fact that it is invariably o f a frequency o f the fan to be used . One o r mo re pieces o f metal shaped like
RPM times the number o f blad es o n the fan. a washer could be placed over the stud, on the hub
Thro at flutter w ill cause no d amage to the fan so tube, behind the stud, or over the threaded portion of
lo ng as the thro at d o es no t d isintegrate and fall into the rod end. Aluminum or stainless weights should be
the fan blad es. It may be eliminated by stiffening o r used and weights should not be attached to the blade
bracing the thro at. skin.

3.4 WARRANTY
MOORE FANS LLC (the Seller) warrants only to Buyer, damage on account of misuse, neglect or accident or
as its purchaser for resale, that the fans manufactured shipping damage, or if repairs or part replacements have
and sold by Seller to Buyer under this Agreement will been made or attempted without Seller's prior written
be free from all defects in material and workmanship authorization. SELLER SHALL NOT BE LIABLE IN ANY EVENT FOR ANY
under ordinary use for a period of two (2) years from INCIDENTAL OR CONSEQUENTIAL DAMAGESFOR BREACH OFTHIS OR ANY
the date of shipment or one (1) year from the date the WARRANTY. THIS WARRANTY IS IN LIEU OF ALL OTHER GUARANTEES OR
fan is installed on a customer's premises, whichever EXPRESSED WARRANTIES AND ALL IMPLIED WARRANTIES, INCLUDING
occurs first. This warranty period shall apply only if THE IMPLIED WARRANTIES OF MERCHANTABILITY AND OF FITNESS FOR
Seller receives written notice of any defect within the A PARTICULAR PURPOSE. DUE TO THE VARIETY OF CONDITIONS UNDER
warranty period. Upon receipt of such notice, Seller, at WHICH THE FANS MAY BE USED, RISKS OF RESULTS OBTAINED FROM USE
its option, may require Buyer to return the fan at OF THE FANS, WHETHER USED ALONE OR IN COMBINATION WITH OTHER
Buyer's cost to Seller for inspection by Seller. If the fan PRODUCTS, IS ENTIRELY BUYER'S. THE ABOVE LIMITATIONS ON DAMAGE
is found to be defective on inspection by Seller, as a sole AND EXCLUSION OR LIMITATION OF IMPLIED WARRANTIES ARE NOT
and exclusive remedy, Seller will, at its option, either APPLICABLE TO THE EXTENT PROHIBITED BY STATE LAW .
repair or replace the fan. This warranty shall not apply to

TMC-704 Rev F- 03/03 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 Page 9
MAINTENANCE

3.5A PARTS LIST


NOT TO SCALE: SOME DIMENSIONS
AND ANGLES HAVE BEEN
EXAGGERATED FOR CLARITY
2

1
5

8
3
6
4
7

9 SHOP
DWG. PA RT
NO. NO. DESCRIPTION

15
1 2883 ROD END CLASS 10000 HEAVY DUTY
10 1 4269 ROD END CLASS 10000 STANDARD DUTY

13 2 2871 RESILIENT MOUNT, THREADED


11
3 2867 RESILIENT MOUNT, RECESSED

4 2886 24MM ALUMINUM BLADE MOUNTING BOLT


12
5 3028 8MM X 50MM SS CLAMP BOLT

14 6 3029 8MM SS CLAMP NUT

7 3081 SS LOCK WASHER

8 3073 ROD END CLAMP

9 52 5/ 8" RESILIENT WASHER

10 169 16MM ALUMINUM NUT

11 151 5/ 8" ALUMINUM FLAT WASHER


12 3033 16MM AIR SEAL STUD

13 1345 10MM SS STUD FOR QDSF BUSHING (3)


1347 12MM SS STUD FOR QDE BUSHING (3)
1558 16MM SS STUD FOR QDJ BUSHING (3)
2728 18MM SS STUD FOR QDM BUSHING (3)

14 QDSF, QDE,QDJ OR QDM TYPE BUSHING

15 1346 10MM SS NUT FOR QDSF BUSHING (3)


1348 12 MM SS NUT FOR QDE BUSHING (3)
1559 16 MM SS NUT FOR QDJ BUSHING (3)
2729 18 MM SS NUT FOR QDM BUSHING (3)

Page 10 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
MAINTENANCE

3.5B PARTS LIST


NOT TO SCALE: SOME DIMENSIONS
AND ANGLES HAVE BEEN
2 EXAGGERATED FOR CLARITY

8 3

5 6 4

7
12
9 SHOP
DWG. PA RT
NO. NO. DESCRIPTION
10
1 2883 ROD END CLASS 10000 HEAVY DUTY
1 4269 ROD END CLASS 10000 STANDARD DUTY
11
2 2871 RESILIENT MOUNT, THREADED

3 2867 RESILIENT MOUNT, RECESSED


13
4 2886 24MM ALUMINUM BLADE MOUNTING BOLT

5 3028 8MM X 50MM SS CLAMP BOLT

6 3029 8MM SS CLAMP NUT

7 3081 SS LOCK WASHER


14 8 3073 ROD END CLAMP

9 52 5/ 8" RESILIENT WASHER

10 169 16MM ALUMINUM NUT

11 151 5/ 8" ALUMINUM FLAT WASHER

12 3033 16MM AIR SEAL STUD

13 4153 12MM HEX BOLT FOR U BUSHING (4)


4154 16MM HEX BOLT FOR W BUSHING (4)
4159 16MM HEX BOLT FOR X BUSHING (4)
4159 16MM HEX BOLT FOR Z BUSHING (8)

14 U BUSHING (4" )
W BUSHING (5.5")
X BUSHING LONG (5.5")
Z BUSHING (7")

TMC-704 Rev F- 03/03 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 Page 11
OPERATION

4.0 OPERATION
4.1 AERODYNAMIC ABUSE

4.1.1 ABOUT THIS SECTION . . . . Under such conditions, the unit stresses in the blades
It is widely acknowledged that the kinds of mechanical would not be expected to vary more than plus or minus
abuse described on the preceding pages are destructive for 50%. Fan design based on such assumptions is entirely
all types of operating equipment. It is less well recognized reasonable and, with proper drives and installation con-
that — for fans — aerodynamic stresses are an even more ditions, has proven highly successful.
serious hazard. This section deals with the causes of destruc-
tive aerodynamic stresses and how they can be avoided.
Although this information is given primarily for the
4.1.3 ABNORMAL CONDITIONS
benefit of operators of Moore equipment, it may be applied
Abnormal operating conditions result in destructive
to fans of any manufacture.
repetitive stresses that can seriously shorten fan life. The
Unlike smaller fans, which are typically furnished
aerodynamic abuses discussed in this section can cause
complete with their surroundings, the large fan wheel is
repeated flexing of the fan blades and hub. Violent displace-
supplied as an unprotected component of the system and is
ment of the resiliently mounted Moore fan blades may
installed in innumerable types of surroundings. Not only do
occur — a greater displacement than would occur in rigidly
the types and conditions of the drives for these fan wheels
mounted blades. The resilient mounting, of course, mini-
vary widely, but the entrance and exit conditions and the
mizes the structural unit stresses which would be transmit-
enclosure for the wheel assume a myriad of possible com-
ted to the root of the blade and into the hub and drive.
binations. In designing his product, the manufacturer of fan
Although Moore units may be expected to resist greater
wheels must anticipate the operating conditions based upon
stress than units of conventional design, such repetitive
his knowledge of what is reasonable and customary for the
stresses may exceed the capability of the resilient mounts
industry. He may over-design for abnormal stresses only
to absorb them. If so, fatigue of the mounts and metal may
until the practical limit is reached to avoid excessive weight,
develop, adjusting linkages may wear, and ultimate failure
cost and inefficiency.
becomes a possibility.
Some of the abuses set out in the following text are
4.1.2 NORMAL OPERATING CONDITIONS far less important than others. All of them may occur in
The fan manufacturer assumes a fairly reasonable atmo- varying degrees.
sphere for the operation of his product, including the follow- Specifically, abuse due to serious repetitive stresses
ing: can lead to mount failure and, if carried to extremes, can
The fan selection will be reasonably in line with the require blade replacement. In units of other manufacture
performance the unit is expected to maintain, with an with rigidly mounted blades, repetitive stresses of this type
adequate blade area for the pressure required at the
given RPM. Blades will not be loaded beyond their may lead to blade breakage, probably near the root or at
capacity to maintain air flow. the point of attachment to the hub where stresses are
highest, or may lead to failure of the hub itself. The resilient
A fan ring will be provided that is round, rigid and of mount design, unique with Moore fans, dampens these
a depth at least sufficient to cover the tips of the blades. vibrational forces and results in a fan that is far less
Tip clearances will be uniform and controlled. vulnerable to failure from these conditions than other units
with rigidly mounted blades. Even so, extreme conditions
The approach air will represent a relatively uniform
and axial flow with, of course, some unavoidable can cause damage.
turbulence expected. Adequate open area will be pro- A well-designed fan can be expected to operate for
vided at the inlet of the fan. many years without trouble under normal operation as
described above. The extreme repetitive stresses de-
Major obstructions will not be present at either the scribed below, however, will certainly reduce the life of
inlet or discharge of the fan. the fan, causing failure many years sooner than would
occur if the fan were operated as intended. Fortunately,
The RPM of the fan will be within the design limits.
these destructive conditions are readily observable to
The relative direction and velocity of approaching air someone who is knowledgeable about them, and they
to the blades will be fairly constant and protection will can be corrected with reasonable effort and expense
be provided from extreme wind conditions. once they are observed.

Page 12 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
OPERATION

4.2 BLADE OVERLOAD


Of all the aerodynamic abuses to be avoided in the operation A fan blade is no different than an airplane wing except
of a fan, the most important is that of overloading the fan that the air usually is being deflected upward rather than
blades. Blade overload occurs because of insufficient blade downward, the convex side of the blade being the lower
area: In other words, when there is an inadequacy in the surface rather than the upper surface as in the case of an
number of blades on the fan selected. airplane. The result of blade overload is identical: When
The Moore system of rating is based upon the pressure blade load exceeds that allowable, a violent vibration will
that each blade will produce at a given RPM with good take place in the blade as the laminar, or uniform, flow makes
efficiency. This pressure is called 100% blade load. When blade and breaks perhaps many times a second.
load exceeds 110%, the fan will not only operate at lower Another way of looking at this problem is to
efficiency, it may be subject to structural damage as well. consider that the available number of blades are set at
In selecting a fan, the total pressure divided by the too steep an angle to be able to move air at the axial
pressure to be produced by one blade determines the number velocity which is necessary to maintain a smooth flow
of blades required for the anticipated performance. When- over the convex surface. In other words, to move air at
ever information is available, The Moore Company checks the the velocity necessary for this blade angle, plus over-
selection. Even so, underestimation of the pressure require- coming the static resistance of the system, the total
ments by the system designer, or changes in the operating pressure which would have to be maintained for an air
conditions over time, may result in overload conditions. flow corresponding to this angle is greater than the
Why is a blade overload condition of such concern? We
total pressure capability of the given number of blades
are all aware of the fact that an airplane traveling at a given
at this RPM. Such a condition can only be corrected by
speed can carry only a certain load. If the speed of the airplane
decreasing the blade angle until smooth flow is ob-
is decreased or the load increased, stalling flow over the wing
tained or by increasing the number of blades and the
will occur. In the case of an airplane, approximately two-thirds
total pressure potential of the fan until the fan’ s pres-
of the lift provided by the wing is the result of the air flow over
sure potential equals the pressure necessary to move
the top or convex portion of the wing. Lift is provided as a
the specified quantity of air through the system.
reaction to the flow of air being accelerated and deflected
Continued operation under conditions of stalling
downward as it passes over the wing. A negative pressure
flow, or blade overload, will significantly shorten the
area is thus formed on the top surface of the wing which tends
to lift it upward. life of the fan. Operation under these conditions will
So long as air flow over the wing is smooth and clings also reduce efficiency to a ridiculously low figure. See
to the surface of the wing, little turbulence is present. When the chart under Section 4.4 Checking Blade Load which
the load is increased, or the speed decreased, the angle of the follows. Note that although air flow remains constant
wing to the air stream must be increased to a point where the or decreases, horsepower continues to increase with
air flow breaks away from the upper surface of the wing. This increased blade angle.
is known as stalling or burbling flow, since the air, instead of In conclusion, if a given fan, in a given installation,
clinging to the wing, breaks away near the leading edge and can only absorb forty horsepower, for example, the
leaves what might be called a turbulent void above the upper blades may be pitched up to consume fifty horsepower
wing surface, nullifying the accelerated flow which was re- without any increase in air delivery, and possibly with a
sponsible for the greater part of the lift of the wing. decrease. As a result, the extra ten horsepower is totally
When this occurs, the wing loses a large portion of its wasted -- perhaps worse than wasted. It is good practice
lift. Flow, however, will re-establish briefly and break again, to select a sufficient number of blades so that blade load
the cycle being repeated continuously, resulting in a severe will amount to slightly less than 100% of full blade load when
vibration throughout the aircraft as the flow alternately consuming 100% of the rated fan horsepower. There are
makes and breaks. Anyone who has experienced a stall in an a number of reasons for allowing this safety factor which
airplane will be familiar with this violent phenomenon. are set out in detail below.

AIRFLOW IN NORMAL FLOW AIRFLOW IN STALLING FLOW


Downward flow provides lift to the wing Note lack of air deflection downward.

TMC-704 Rev F- 03/03 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 Page 13
OPERATION

4.3 CAUSES OF IMPROPER BLADE LOADING


4.3.1 VARIATION FROM PREDICTED blad e w ill flo w aro und the tip and nullify the negative
CONDITIONS pressure o n the und ersid e o f the blad e fo r so me d is-
Although those who design air coolers and cooling tance in fro m the tip. Fo r a fan o f, say, 12-ft d iameter,
towers undoubtedly do their best to accurately state the the last 12 to 18 inches o f the blad e co uld be pro d ucing
calculated static resistance of the system, a number of no pressure w hatever and perfo rming no useful func-
factors may cause the actual co nd itio ns to vary fro m tio n. The balance o f the fan blad e to w ard the hub then
the d esign co nd itio ns. When a variatio n o ccurs, it must pro d uce a higher pressure to co mpensate fo r the
may be fo und , upo n testing, that the static pressure po rtio n near the tip.
fo r a given vo lume thro ugh the system is higher Excessive tip clearance also leaves an unsw ept
than anticipated . In this case, the number o f blad es area betw een the tip o f the blad e and the fan ring. A ir
pro vid ed may be inad equate to meet the perfo r- that has been pumped by the fan w ill return d o w nw ard
mance. On the o ther hand , the static pressure may thro ugh this unsw ept area at a velo city greater than
have been o verestimated and excess blad e area pro - that at w hich it passed thro ugh the fan in the d esired
vid ed , resulting in a fan w ith unutilized capacity d irectio n. This co nd itio n ad d s even further to the
o perating at lo w efficiency. requirements o f the po rtio n o f the blad e w hich is d o ing
Inad eq uate Blad e A rea: The blad e angle is the w o rk and efficiency w ill be greatly red uced .
selected to mo ve the anticipated vo lume o f air and With the lo ss o f a fo o t at the tips o f the blad es,
the number o f blad es is selected to maintain the plus the back flo w betw een the tips and the ring, the 12-
to tal anticipated pressure required to mo ve this ft fan in this example might be co nsid ered an effective
vo lume at a given RPM. If the static pressure turns 10-ft fan. It w o uld have to d eliver sufficient air to
o ut d o be higher than pred icted , the fan may then be satisfy the perfo rmance requirements o f the installa-
o perating in an o verlo ad co nd itio n. If the RPM tio n, plus the amo unt o f air w hich is returning in the
canno t be increased , the o nly so lutio n to this co nd i- v o id betw een the tip s and the thro at. Und er such
tio n is to red uce the blad e angle until the fan can circumstances, excessive blad e lo ad ing co uld o ccur
carry the then red uced vo lume at the o riginally ev en tho ug h the required sy stem p ressure is no t
anticipated pressure. Since red ucing the vo lume, achieved .
w hile ho ld ing the to tal pressure as o riginally an-
ticipated , can o nly red uce the ho rsepo w er, it is then 4.3.3 PO O R ENTRA NCE CO ND ITIO NS
impo ssible to co nsume the ho rsepo w er o riginally A ir w ill appro ach the fan fro m all po ssible d irec-
intend ed w itho ut o verlo ad ing the fan. This is o ne o f tio ns, increasing in velo city as it nears the o pening,
a number o f reaso ns fo r p ro v id ing so me safety then accelerating rapid ly as it enters. The air appro ach-
facto r in blad e lo ad ing at the time o f o riginal fan ing fro m the sid e must be turned thro ugh 90O to enter
selectio n. a ring w ho se entrance terminates in a flat plate. If the
Excessive Blad e A rea: Occasio nally, an exces- inlet end o f the ring pro jects so me d istance o ut, w ith
sive number o f blad es may be specified in the inter- appro ach po ssible fro m all d irectio ns, a po rtio n o f the
est o f making a co nservative selectio n. If the static air must be turned thro ugh 180O . The inertia o f the
pressure has been o verstated , the theo retical num- appro aching air prevents it fro m turning sharply and
ber o f blad es w ill be greater than need ed . This ad vancing parallel to the d esired flo w . It co nsequently
theo retical number o f blad es is usually a fractio nal sw o o ps to w ard the center, leaving the o uter area o f the
number and the actual number o f blad es used must, fan w ith red uced flo w o r even reverse flo w near the
o f co urse, be the next larger integer, resulting in ring .
so me "safety facto r" in the selectio n. If, in ad d itio n, The effect o f po o r entrance co nd itio ns is similar
a blad e o r tw o is ad d ed as a "safety facto r" o r in to that previo usly d escribed fo r excessive tip clearance
anticipatio n o f increased future requirements, it in that the effective d iameter has been red uced and
may be imp o ssible to meet the o riginal p erfo r- excessive blad e lo ad ing co uld o ccur even tho ugh the
mance requirement efficiently. The o nly w ay to required system pressure is no t achieved . Efficiency
pro vid e the o riginal perfo rmance and d raw no mo re w ill be greatly red uced .
than the o riginal ho rsepo w er is to flatten the blad e
angle. There is a limit, ho w ever, in ho w far the 4.3.4 EXCESSIVE DEFLECTION
blad e angle may be red uced befo re further red uc- The pressure which the fan can achieve is dependent upon
tio n w ill d ecrease airflo w w itho ut a further red uc- the square of the velocity of the blades relative to the air. If the
tio n in ho rsepo w er. Fo r belt d rive units, the mo st air could be moved into the fan in an axial direction and passed
practical so lutio n to this pro blem is to red uce the through the fan into the discharge without changing direction,
RPM o f the fan. the relative velocity of the blades to the air stream would be the
true velocity of the blades at any point. This, of course, is not
4.3.2 EXCESSIV E TIP CLEA RA NCE the case. For the blades to accomplish work upon the air, they
Unless the fan ring is very clo se to the tip o f the must also deflect the air in the direction of rotation of the fan.
blad e, air fro m the high pressure surface o f the The air when rotated with the fan is moving with a certain

Page 14 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
OPERATION

velocity in the same direction as the rotation of the fan, which the fan, even though it does not reach the full rated pressure.
reduces the relative velocity between the fan blades and the
air by some portion of this rotational velocity. 4.3.5 CONCLUSION
Moore fans are designed in contemplation of a maxi- As can be seen by the various points discussed in this
mum deflection of 50o at the hub, decreasing to a very small section, there are a number of complex factors which tend to
value at the tip. This deflection is considered in the determi- cause fans to be operated in a condition of improper blade
nation of the pressure which may be provided by each blade loading which can shorten fan life or lower efficiency. When
over its full length. If fans are selected, or if conditions exist, blade angles are set to consume the specified horsepower (at
which cause the deflection to exceed 50o at the hub, the velocity the fan shaft), the resulting performance should be very close
of the blades relative to the air is less than anticipated and the to the specified performance. If this is not the case and the
blades will not provide the rated pressure. The test below, problem cannot be identified or corrected, please contact
however, will show the full allowable pressure capability of Moore for assistance.

4.4 CHECKING BLADE LOAD


One metho d o f checking blad e lo ad is to run a ings. Keep increasing the angle and fo llo w ing this
co mplete field test o n the fan. A ltho ugh labo rio us, pro ced ure until the mo to r is fully lo ad ed , in w hich
this metho d w ill pro vid e ample pro o f so lo ng as case the fan is able to co nsume full rated fan ho rse-
neither excessive tip clearance no r po o r entrance po w er w itho ut o verlo ad OR until the curve w hich w ill
co nd itio ns are present. If either are present, ho w - have started o n a definite slo pe begins to appro ach the
ever, the co nd itio ns set o ut abo ve und er Sectio n ho rizo ntal. It w ill be no ted that the static pressure w ill
4.3.3 w o uld apply and the fan co uld be o verlo ad ed be co nsistently increasing w ith increased blad e angle
even tho ugh the to tal pressure ind icated by the test until the blad e lo ad ing reaches maximum, at w hich
w as w ithin the allo w able blad e lo ad ing. po int it w ill level o ff.
A better, mo re co nvenient and simpler metho d Subsequent increases in blad e angle may have
o f d etecting blad e o verlo ad , o r d etermining maxi- quite d ifferent effects, d epend ing o n the ind ivid ual
mum allo w able blad e angle, is set o ut belo w . The installatio n. The static pressure curve may merely
equipment need ed is a w rench, a to rque w rench, a stay level o r may d ro p o ff sharply. In rare cases, it
pro tracto r and a draft gauge (or manometer). may level o ff and again start rising as the fan begins
All fans are shipped with the blade angle set for o perating as a centrifugal blo w er.
the anticipated performance requirements furnished Typical examples are sho w n in d o tted lines o n
to The Moore Company by the purchaser. This blade the chart o ppo site. Operatio n beyo nd the first po int
angle is called out on the Fan Specification Sheet. This o f levelling, o r in the area o f the d o tted lines, is
angle refers to the angle measured at the location ind icative o f blad e o verlo ad . No te that po w er co n-
shown in Section 2.3.3. Hubs are shipped with the sumptio n lo ad w ill co ntinue to increase even tho ugh
clevises set at this angle. the fan has passed into o verlo ad co nd itio n. The maxi-
To start the test, ad just the blad es to an angle mum blad e angle allo w able is that w hich pro d uces a
o f appro ximately half that called o ut o n the speci- static pressure abo ut 5% belo w the po int w here the
ficatio ns o r measured o n the units. Co nnect the curve beco mes level. This represents a safe lo ad ing,
d raft gauge to as quiescent a spo t in the plenum as and the blad es may be set and left at this angle regard -
po ssible, preferably in the co rner o f the plenum and less o f the lo catio n o n the chart, assuming the mo to r
either ahead o f o r fo llo w ing the fan, d epend ing is no t o verlo ad ed .
upo n w hether the applicatio n is ind uced o r fo rced The po int so selected w ill also appro ximate the
d raft. Since the figures o btained are purely rela- po int o f the mo st efficient o peratio n o f the fan. Due
tive, it is no t necessary that accurate static pressure to po ssible erro r in static pressure pred ictio ns, o r in
read ings be o btained , but rather that the read ings read ings w hich are intend ed o nly to be relative, as
taken represent a co nsistent series o f pressures at w ell as o ther variables, the final blad e setting cho sen
the po int o f read ing cho sen. may fall belo w o r abo ve the specified static pressure.
Start the fan and reco rd o n the chart pro vid ed A typical perfo rmance chart is sho w n o ppo site
the blad e angle and he static pressure ind icated . fo r a fan capable o f a higher blad e lo ad ing than
A d vance the blad e angle by o ne o r tw o d egrees and o rigianally specified . A blank chart is also pro vid ed
repeat the perfo rmance, reco rd ing again these read - fo r yo ur use.

TMC-704 Rev F- 03/03 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 Page 15
OPERATION

1.2 120
SELECTED BLADE ANGLE
1.1 110

1.0 FULL LOAD AMPERES 100

% RATED FAN HORSEPOWER


FACTORY-SET BLADE ANGLE
STATIC PRESSURE

.9 90
.8 80
STATIC
.7 PRESSURE 70
FINAL % RATED FAN HP
.6 60
.5 50

.4 40
BLADE ANGLE VS % RATED FAN HP
.3 30
.2 20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

4.4.1 SAMPLE GRAPH of BLADE ANGLE IN DEGREES

Note in the chart above that static pressure (and air flow) has angle is 5% below the point where the static pressure curve
reached its maximum at an 11 degree blade setting and blade becomes level. The horsepower curve has been added to illus-
overload is beginning. With further increase in blade angle, trate the point that in an overload condition, horsepower will
anything may happen, as indicated by the dotted extensions increase without increased performance.
into the shaded overload area. Note that the final selected blade
STATIC PRESSURE

BLADE ANGLE IN DEGREES

BLANK CHART FOR CUSTOMER USE

Page 16 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
OPERATION

4.5 DAMAGING OPERATING CONDITIONS


4.5.1 GENERAL
In the case of a fan blowing inward in a short ring,
Any condition which causes repeated blade loading
the condition is even more critical. In such an installa-
and unloading is detrimental to fan performance, both in
tion, the air on the inlet side of the fan has a horizontal
terms of efficiency and structural durability. Normal
velocity which may be quite high. It is necessary for the
obstructions, of course, must be expected in the air stream.
fan to pick up this air and direct it inward. In a strong
There are certain conditions, however, which may be
wind, the angle of air moving through the fan may be
avoided by reasonable attention to the points briefly dis-
increased more than 45O.
cussed in this section. Additional information on the
The illustration above assumes a fan operating with
importance of inlet and discharge conditions can be found
a tip speed (VB) of 10,000 feet per minute (114 miles per
in Moore's General Catalog.
Ideally, air should approach a fan in an axial direc-
tion and at a uniform velocity over the area of the fan. Air
approaching a fan at an angle tends to increase the relative
velocity of the blades to the air on one side of the fan and
decrease the relative velocity on the other side. This
means that the fan blade during one-half of its revolution
is picking up a heavier air load due to the higher relative
velocity and, through the other half of its revolution, a
lower air load as it goes "down wind". The net result is a
repetitive loading and unloading of the blades at each
revolution of the fan. This condition can be quite serious
if the velocities are high and the angle of approach devi-
ates considerably from axial.

4.5.2 WIND
With a vertically mounted fan blowing outward
into the wind and surrounded by a short fan ring or stack,
high winds may cause some concern. The farther the ring
extends beyond the fan, the less effect would be expected
from wind. It is a fact, however, that wind across the face
of the ring will affect the direction of air flow well down
into the ring. In the case of a fan installed near the outlet hour) with a horizontal component of wind velocity (VW)
of the ring, the direction from axial of the fan discharge of 20 miles per hour. Note that the velocity (VR) of the fan
may be increased by as much as 45O under high wind blade relative to the air varies by a factor of 1.43. The
conditions. blade load varies as the square of this velocity, or 2.05.

THE EFFECT OF AIR LOAD ON HUB AND DRIVE In conventional fans with rigidly attached blades,
Moore fan blades are attached to the hub by a pivot. the bending moment at the shaft due to the air load is equal
As the fan rotates, centrifugal force causes the blades to rise to the load (FA ) multiplied by the distance from the fan
(as do the blades of a helicopter). The air load (FA ) is centerline to the point of application of the force on the
uniform over the blade, but there is a point (shown on the blade (RF). This moment will be from 2 to 4 times as great
blade in the drawing below) where, if the total load were as that produced by the Moore fan under the same condi-
applied at that point, the effect would be the same. The
resultant of the air load (FA ), assumed in this example to
be downward, and the horizontal centrifugal force (FC) is
the force on the blade (FB). The blade automatically posi-

tions.
Also of concern with the conventional fan is the
tions itself in the direction of this force with the result that bending moment due to the air load at the point of
the force is translated inward to the pivot point, as illus- attachment of the blades to the hub since this is usually the
trated by the dotted line. The effect of this arrangement is structurally weakest area of the fan. The moment due to
exactly as if the total air load (FA ) were applied at the pivot the air load at this point is the load (FA ) times the distance
point rather than at the point outward on the blade. The (D). For the Moore fan, this moment is zero since the
maximum bending moment applied to the shaft by the air blades are attached at the pivot point.
load is equal to the load (FA ) multiplied by the distance A more complete discussion of the Moore fan design
from the fan centerline to the pivot point (RP). can be found in The Moore Company’s General Catalog.

TMC-704 Rev F- 03/03 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 Page 17
OPERATION

In this rather common wind condition, then, it can be through the fan. This area should be distributed reasonably
seen that the blade load on the side where the blade is going uniformly. It would be unwise to attempt to operate a fan
against the wind will be double the load on the side where with one-half or one-third of the fan area completely blanked
the blade is going with the wind. In a 40 mile per hour wind, off. Such a condition would cause stalling of the fan blade
the blade load would vary by a factor greater than 4. In a 60 through one-half the revolution but create a condition of
mile per hour wind, the load would vary by a factor of more overload in the half which was not blocked off. Excessive
than 10! It is obvious that operation under such conditions vibration would result. Any condition which forces the air to
will impose tremendous repetitive loadings on the fan approach the fan in a non-axial direction should be avoided.
blades.
In areas of unusually high wind velocities, it may be 4.5.4 UNEVEN TIP CLEARANCE
advisable to shield the fan in some manner. Where fan rings are out of round or not centered with
the fan, the tip clearance of each blade will vary as it makes
4.5.3 OBSTRUCTIONS a revolution. If tip clearance is tight at one point and excessive
Obstructions of one type or another in the air stream, at another, proper flow will establish itself at the tight point,
ahead of or beind the fan, are to be expected. In fact, it would loading the blade to the very tip, while at the loose point the
be virtually impossible to eliminate all obstructions. Struc- air will flow from the high pressure side of the blade through
tural supporting members, foundations and the like, need the opening between the blade tip and the ring and nullify the
not be of serious concern although all obstructions, even negative pressure on the under side of the blade. This will
small ones, will increase the static pressure and must be unload the blade near the tip within the area of excessive
taken into consideration by the system designer in specify- tip clearance. Under this condition, the blade will load and
ing the fan performance. unload near the tip one or more times per revolution,
The total free area from which the fan can draw air resulting in an undesirable repetitive vibration. Every
should be twice the net area of the fan (fan area minus hub effort should be made to keep the tip clearance to a
area). In other words, the air approaching the inlet of the fan minimum and to have this clearance as constant as pos-
should have no more than half the velocity of the air passing sible around the entire ring.

Page 18 MOORE FANS LLC, Marceline, MO 64658 Phone (660) 376-3575 FAX (660) 376-2909 TMC-704 Rev F- 03/03
(This page intentionally left blank)
VS-7037N
Revised 11-03

Shock/Vibration Control Switches Section 20


(00-02-0185)

Installation Instructions
Models: VS2, VS2C, VS2EX, VS2EXR, VS2EXRB and VS94
Please read the following instructions before installing. A visual inspection of this product for damage during shipping is recommended before
mounting. It is your responsibility to have a qualified person install the unit, and make sure installation conforms with NEC and local codes.

GENERAL INFORMATION

WARNING LISTED*

BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT


✔ Disconnect all electrical power to the machine.
✔ Make sure the machine cannot operate during installation.
✔ Follow all safety warnings of the machine manufacturer.
✔ Read and follow all installation instructions.
Model VS2EX

Description Remote Reset Option (VS2EXR,


The Murphy shock and vibration switches are available in a variety of VS2EXRB and VS94 only)
models for applications on machinery or equipment where excessive Includes built-in electric solenoid which allows reset of tripped unit from a
vibration or shock can damage the equipment or otherwise poses a remote location. Standard on VS2EXR and VS2EXRB. Optional on
threat to safe operation. A set of contacts is held in a latched position VS94 (options listed below).
through a mechanical latch and magnet mechanism. As the level of -R15: Remote reset for 115 VAC
vibration or shock increases an inertia mass exerts force against the -R24: Remote reset for 24 VDC
latch arm and forces it away from the magnetic latch causing the latch
arm to operate the contacts. Sensitivity is obtained by adjusting the Time Delay Option (VS94 only)
amount of the air gap between the magnet and the latch arm plate. Overrides trip operation on start-up. For VS94 series models, the delay
Applications include all types of rotating or reciprocating machinery time is field-adjustable from 5 seconds up to 6-1/2 minutes with a 20-
such as cooling fans, engines, pumps, compressors, pump jacks, etc. turn potentiometer (15 seconds per turn approximately). Options listed
below:
Models -T15: Time delay for 115 VAC
VS2: Base mount; non hazardous locations. -T24: Time delay for 24 VDC
VS2C: C-clamp mount; non hazardous locations.
Space Heater Options (VS94 only)
VS2EX: Explosion-proof; Class I, Div. 1, This optional space heater board prevents moisture from condensing
Groups C and D*. inside the VS94 Series case. Options listed below:
VS2EXR: Explosion-proof with remote reset. -H15: Space heater for 115 VAC
VS2EXRB: Explosion-proof; Class I, Div. 1, Group B* ; with -H24: Space heater for 24 VDC
remote reset.
VS94: Base mount; non hazardous locations, NEMA 4X/IP66. Warranty
A limited warranty on materials and workmanship is given with this
FWMurphy product. A copy of the warranty may be viewed or printed by
going to www.fwmurphy.com/warranty.asp.

VS-7037N page 1 of 8
DIMENSIONS

VS2 VS2C
3 in. 4-3/4 in.
(76 mm) (121 mm) 3 in. 4-3/4 in.
Slotted (76 mm) (121 mm)
Sensitivity Slotted
Reset Adjustment Sensitivity
Push Reset Adjustment
4-19/32 in. Button Push
(116 mm) Plug 5-7/16 in.
(138 mm) Button Weatherproof
Strain Relief
Bushing

5-1/8 in. 1/4 x 1/2 in.


2-1/4 in. (130 mm) 27/32 in.
(6 mm x 13 mm) (21 mm)
(57 mm) Mounting Holes Slot 2 places
C-Clamp

VS2EX and VS2EXR


5-5/8 in.
(143 mm)
Reset
Push
1/2 NPT Button
Conduit 4-7/8 in.
Slotted (124 mm)
Sensitivity
1-3/4 in. Adjustment
(44 mm)
5-1/4 in.
3/8 in. 3 in. (133 mm)
(10 mm) (76 mm)
4 places Mounting Holes 6-3/8 in. Mounting Holes
(162 mm)

VS2EXRB

10-5/8 in. 8-5/8 in.


(270 mm) (219 mm)

6 in.
(152 mm)
1/2 NPT
Conduit
2-1/2 in.
(64 mm)
4-1/2 in. 9-1/8 in.
(114 mm) (232 mm)
Mounting Centers 10-3/16 in. Mounting Centers
(259 mm)

VS94
6-29/32 in.
(176 mm)

Manual
7-9/64 in. Reset
(181 mm) Push-button 4-5/8 in.
(118 mm)

6-1/2 in.
(165 mm) 3/4 NPT
1-5/8 in. conduit fitting
(41 mm)

4 in.
(102 mm)
Mounting slot
5/16 x 9/16 in. 4 in. 6-1/2 in.
(8 x 14 mm) (102 mm) (165 mm)
4-places.

VS-7037N page 2 of 8
SPECIFICATIONS
VS2 and VS2C additional SPDT switch); 5A @ 480 VAC; 2A resistive, 1A inductive,
• Case: Weatherproof (equal to NEMA 3R) suitable for non-hazardous areas. up to 30 VDC.
VS2: Base mount • Remote Reset:(optional):
VS2C: C-clamp mount. Includes 45 feet (13.7 meters), 2-conductor 16 Option Operating Current
AWG, 30 strands/0.25 mm strand dia. (1.5 mm2) cable, and five cable -R15: 350 mA @ 115 VAC
hold down clamps. -R24: 350 mA @ 24 VDC
• Contacts: SPDT double make leaf contacts, 5A @ 480 VAC. • Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement.
• Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement.
VS94
VS2EX • Case: Polyester fiberglass reinforced; NEMA type 4 and 4X; IP66; CSA
• Case: Explosion-proof and weatherproof aluminum alloy housing; types 4 and 12.
meets NEMA 7/IP50 specifications; Class I, Division 1, Groups C & • Conduit Fitting: 3/4 NPT conduit fitting connection.
D; UL and CSA listed.* • Normal Operating Ambient Temperature:
VS2EX: base mount. 0 to 140°F (-18 to 60°C).
• Snap-switches: 2-SPDT snap-switches; 5A @ 480 VAC;* • Snap-switches: 2-SPDT snap acting switches; 5A @ 480 VAC; 2A
2A resistive, 1A inductive, up to 30 VDC. resistive, 1A inductive, up to 30 VDC.
• Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement. • Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement.
• Normal Operating Temperature: -40 to 140°F (-40 to 60°C). • Heater (optional):
Option Operating Current
VS2EXR H15 .023 A @ 115 VAC
• Case: Same as VS2EX. H24 .12 A @ 24 VDC
• Snap-switch: 1-SPDT snap-switch and reset coil; 5A @ 480 VAC;* 2A • Remote Reset (optional):
resistive, 1A inductive, up to 30 VDC. Option Operating Current
• Remote Reset (optional): R15 .17 A @ 115 VAC
Option Operating Current R24 .36 A @ 24 VDC
-R15: 350 mA @ 115 VAC • Time Delay (optional):
-R24: 350 mA @ 24 VDC Option Operating Current Standby Current
• Range adjustment: 0 - 7 G’s; 0 - 100 Hz /0.100 in. displacement. T15 .360 A @ 115 VAC .01 A @ 115 VAC
• Normal Operating Temperature: -40 to 140°F (-40 to 60°C). T24 1.15 A @ 24 VDC .01 A @ 24 VDC
VS2EXRB • Time Delay/Remote Reset: Adjustable 20-turn potentiometer from
• Case: Explosion-proof aluminum alloy housing; rated Class I, 5 seconds to 6-1/2 minutes (15 seconds per turn approximately).
Division 1, Group B hazardous areas.
• Snap-switch: 1-SPDT snap-switch with reset coil (option available for *CSA and UL listed with 480 VAC rating.

INSTALLATION
orientation should be on a horizontal plane or with the sensitivity adjustment
WARNING: STOP THE MACHINE AND DISCONNECT ALL pointing down. Sensitivity adjustment for model VS2 is covered by a plug.
ELECTRICAL POWER BEFORE BEGINNING INSTALLATION.
The plug must be in place and tight to prevent moisture or dust intrusion.
The VS2 and VS94 series shock switches are sensitive to shock and C-Clamp Installation (VS2C model only)
vibration in all three planes of motion - up/down, front/back and side/side.
Front/back is the most sensitive (The reset pushbutton is located on the A C-Clamp is supplied with the VS2C model only.
“front” of the unit). For maximum sensitivity mount the unit so that the The C-Clamp is shipped installed on the VS2C
front faces into the direction of rotation of the machine. (See Dimensions on but must be installed on the VS2EX and
page 2 for sensitivity adjustment location). VS2EXR switches.
The VS2 and VS94 Series must be firmly attached/mounted to the machine 1. The C-Clamp (B) will already be installed on C
so that all mounting surfaces are in rigid contact with the mounting surface a 1/4 in. (6 mm) thick steel mounting plate
of the machine. For best results, mount the instrument in-line with the (A). Bolt the VS2 switch to the mounting A
direction of rotating shafts and/or near bearings. In other words, the reset plate as illustrated — with four 5/16 in.
bolts, nuts, and washers. B
push button should be mounted pointing into the direction of shaft rotation
(see page 5). It may be necessary to provide a mounting plate or bracket to 2. The mounting location should provide
attach the VS2 and VS94 Series to the machine. The mounting bracket convenient access to the TATTLETALE® D
should be thick enough to prevent induced acceleration/vibration upon the push button (C).
VS2 or VS94 Series. Typically 1/2 in. (13mm) thick plate is sufficient. See 3. The hardened set screw and nuts (D) are used to tighten
illustrations on page 5 for typical mounting locations. the switch to an I-Beam or cross member such as a Sampson post of an
oilwell pumpjack.
CAUTION: A dust boot is provided on the reset pushbutton
for all series to prevent moisture or dust intrusion. The sensitivity
adjustment for model VS2EX is not sealed; therefore, mounting
Continued on next page.

VS-7037N page 3 of 8
INSTALLATION Continued

All Models allow the machine to stop. Turn the sensitivity adjustment 1/4 turn
clockwise, (adjustment for VS94 and VS2EXRB models is located within
WARNING: STOP THE MACHINE AND DISCONNECT ALL
the box, see DETAIL “B”).
ELECTRICAL POWER BEFORE BEGINNING INSTALLATION.
WARNING: MAKE THE AREA NON-HAZARDOUS BEFORE
1. Firmly secure the unit to the equipment using the base foot mount or OPENING THE EXPLOSION-PROOF (-EX) ENCLOSURES.
C-Clamp if applicable. See C-Clamp Installation page 3.
For oilwell pumpjacks attach the VS2 and VS94 Series to the Sampson Depress the reset button and restart the machine.
post or walking beam. See Typical Mounting Locations page 5. Repeat this process until the unit does not trip DETAIL “B”
on start-up.
2. Make the necessary electrical connections to the vibration switch. See
Less Sensitivity
Internal Switches, page 6 for electrical terminal locations and page 7 for 5. If the instrument does NOT trip on start-up, Sensitive adjustment
typical wiring diagrams. DO NOT EXCEED VOLTAGE OR CURRENT stop the machine. Turn the sensitivity
RATINGS OF THE CONTACTS. Follow appropriate electrical adjustment 1/4 turn counter-clockwise.
codes/methods when making electrical connections. Be sure that the run of Repeat the start-up/stop process until the
electrical cable is secured to the machine and is well insulated from instrument trips on start-up. Turn the
electrical shorting. Use of conduit is recommended. sensitivity adjustment 1/4 turn clockwise (less
NOTE: If the electrical cable crosses a pivot point such as at the pivot of sensitive). Restart the machine to verify that the More Sensitive

the walking beam, be sure to allow enough slack in the cable so that no instrument will not trip on start-up.
stress is placed on the cable when the beam moves. 6. Verify that the unit will trip when abnormal shock/vibration exists.
If conduit is not used for the entire length of wiring, conduit should be
used from the electrical supply box to a height above ground level that VS94 Time Delay Adjustment
prevents damage to the exposed cable from the elements, rodents, etc. or WARNING: REMOVE ALL POWER BEFORE OPENING
as otherwise required by applicable electrical codes. If conduit is not ACCESS DOOR. IT IS YOUR RESPONSIBILITY TO HAVE A
attached directly to the VS2 and VS94 Series switch, use a strain relief QUALIFIED PERSON ADJUST THE UNIT, AND MAKE SURE
bushing and a weatherproof cap on the exposed end of the conduit. A IT CONFORMS WITH NEC AND LOCAL CODES.

“drip loop” should be provided in the cable to prevent moisture from 1. Apply power to the time delay circuit. (see
draining down the cable into the conduit should the weathercap fail. page 7 for time delay circuit). The time delay DETAIL “C”
Sensitivity Adjustment function will be initiated.
2. Time the length of the delay with a watch.
WARNING: REMOVE ALL POWER BEFORE OPENING
Let time delay expire. After it expires, the
THE ENCLOSURE. IT IS YOUR RESPONSIBILITY TO HAVE A
QUALIFIED PERSON PERFORM ADJUSTMENTS, AND MAKE
override circuit will de-energize the Turn to
decrease
SURE IT CONFORMS WITH NEC AND LOCAL CODES. DO solenoid, allowing the latch arm to trip. A
NOT ADJUST SENSITIVITY WHILE THE MACHINE IS RUNNING. STAND clicking noise is heard.
CLEAR OF THE MACHINE AT ALL TIMES WHEN IT IS OPERATING. 3. TURN THE POWER OFF TO RESET Pot
Turn to
THE TIME DELAY CIRCUIT. increase
All models of the VS2 and VS94 Series cover a wide range of sensitivity.
NOTE: Allow 30 seconds bleed-time between
Each model is adjusted to the specific piece of machinery on which it is
turning the power “OFF” and “ON”.
installed. After the switch has been installed in a satisfactory location (see
page 5) the sensitivity adjustment will be increased or decreased so that the 4. Locate the time adjustment pot (DETAIL “C”). The time is factory-set at the
switch does not trip during start-up or under normal operating conditions. lowest setting (5 seconds approximately). To increase time, rotate the
This is typically done as follows: 20-turn pot clockwise as needed (15 seconds per turn approximately).
5. Repeat the above steps as necessary to obtain desired time delay.
1. REPLACE ALL COVERS, LIDS, AND
ELECTRICAL ENCLOSURES. NOTE: An external time delay can be used with the remote reset feature
2. Press the reset push button to engage the magnetic latch. To be sure the of the VS2EXR series to provide a remote reset and override of the trip
magnetic latch has engaged, observe latch operation on start-up. Time delay must automatically disconnect after
through the window on the VS2 and DETAIL “A”
VS2C (see DETAIL “A”). On the
VS2EX, VS94 series the reset button Reset Push button

will remain depressed meaning the


magnetic latch has engaged.
3. Start the machine.
4. If the instrument trips on start-up,
Sensitivity
Adjustment

VS-7037N page 4 of 8
TYPICAL MOUNTING LOCATIONS

These are typical mounting locations for best operation. Other mountings are possible.
NOTE: See Installation section on page 3.
2-Throw Balance-Opposed Compressor Pumping Unit

Reset

NOTE: If installing on
cylinders, 2 vibration/shock Reset
switches are recommended-
1 for each cylinder.

Engine Reset “Y” Type


and Reciprocating
Vertical Compressor
Shaft
Pump
Reset

Reset

Generator Cooling Tower Fan or


Sets Reset Heat Exchanger

Reset

Engine Compressor
Turbine Centrifugal Reset
Compressor

Reset

VS-7037N page 5 of 8
INTERNAL SWITCHES

VS2 and VS2C VS2EXR


Remote Reset
Terminal
Sensitivity
Sensitivity Adjustment
Adjustment

NC NO COM
Ground
NO1 NC COM NO2 Terminal
SPDT Snap-Switch
SPDT Switch Terminals

VS2EX VS2EXB and VS2EXRB


Remote Reset
SPDT Snap-Switch Terminal
Sensitivity Sensitivity
Adjustment Adjustment
NC NO COM

NC NO COM NC NO COM
Ground
Ground Terminal
Terminal SPDT NC NO COM
SPDT Snap-Switch Snap-Switch Optional SPDT
Snap-Switch
(VS2EXRB only)

VS94
Time Delay and/or
Remote Reset
SPDT Terminal (Optional)
Snap-Switch

NC NO COM Ground
Terminal

NC NO COM Sensitivity
Adjustment

SPDT
Snap-Switch
Heater Board
Terminal (Optional)

VS-7037N page 6 of 8
ELECTRICAL

WARNING: REMOVE POWER BEFORE OPENING THE UNIT (ACCESS DOOR). STOP THE MACHINE AND DISCONNECT ALL
ELECTRICAL POWER BEFORE BEGINNING THE WIRING OPERATION. IT IS YOUR RESPONSIBILITY TO HAVE A QUALIFIED
PERSON INSTALL AND WIRE THE UNIT, AND MAKE SURE IT CONFORMS WITH NEC AND APPLICABLE CODES.

VS2 and VS2C VS2EX


Typical Wiring Diagram for Single or Dual CD Ignition Typical Wiring Diagram for Single or Dual CD Ignitions
SPDT Switch SPDT Switch
Contacts shown in the RESET position. (Optional 2-SPDT [DPDT])†
Contacts shown in the
RESET position
To good
NO1 NC COM NO2 CD Ignition engine
2 N.O. N.C. COM ground

CD Ignition Resistor
2 To good (100 Ω, 3 Watt)
Resistor engine ground
(100 Ω, 3 Watt)
CD Ignition
N.O. N.C. COM
1
CD Ignition
1
To good
engine ground

VS2EXR and VS2EXRB VS94


Typical Wiring Diagram for Single or Dual CD Ignitions Typical Wiring Diagram for Single or Dual CD Ignitions
SPDT Switch Time Delay or 2-SPDT
(Optional 2-SPDT [DPDT])† Remote Reset Switches (DPDT)
Contacts shown in the Momentary
Remote Reset Contact for (Optional) Contacts shown in the
RESET position 115 VAC or 24 VDC* RESET position
Remote
To good Reset only
Momentary engine To good
Push Button ground engine
N.O. N.C. COM
Maintained Time N.O. N.C. COM ground
†Additional Contact for Delay
Time Delay
Switch
115 VAC or Optional
24 VDC (Voltage on VS2EXRB
is specified N.O. N.C. COM only 115 VAC or
when ordered). 24 VDC* N.O. N.C. COM

*Voltage is specified Heater Board


CD Ignition To good (Optional) To good
2 engine ground when ordered.
engine ground
Resistor
(100 Ω, 3 Watt)
CD Ignition CD Ignition
CD Ignition 1 2
Resistor
1 (100 Ω, 3 Watt)

VS2, VS2C, VS2EX, VS2EXR, VS2EXRB and VS94 VS2, VS2C, VS2EX, VS2EXR, VS2EXRB and VS94
Typical Wiring Diagram for Electric Motors Typical Wiring Diagram for Distributor Ignition or Diesel
Contacts shown Switch Terminals Contacts shown
Switch Terminals in the RESET position NOTE: Terminal N.O. is in the RESET position
NOTE: Terminal N.O. is N.O. N.C. COM
N.O. N.C. COM terminal NO1 on models
terminal NO1 on models (see Note)
(see Note) VS2 and VS2C.
VS2 and VS2C.
Ignition
Switch
L1 L2 L3 Push-button
Station

Ammeter

HC

Diesel Fuel
Shutoff Valve Ignition Coil Distributor Battery
H A

MOTOR Hand Off


Automatic
Selector
HC

VS-7037N page 7 of 8
SERVICE PARTS

PART NO. DESCRIPTION PART NO. DESCRIPTION


VS2 VS2EXRB
20000030 Movement assembly 20010090 Snap-switch and insulator kit (1 switch per kit)
20000031 Glass and gasket assembly prior to September 1, 1995.*
20000032 Reset push button assembly 20000288 Snap-switch and insulator kit (1 switch per kit) for models
manufactured on September 1, 1995 or later.*
VS2C 20000057 Inside snap-switch and insulator kit (1 switch per kit) for
20000030 Movement assembly model VS2EXRB-D prior to September 1, 1995.*
20000031 Glass and gasket assembly 20000058 Outside snap-switch and insulator kit (1 switch per kit) for
20000032 Reset push button assembly model VS2EXRB-D prior to September 1, 1995.*
20050021 Mounting clamp 20000287 Inside snap-switch and insulator kit (1 switch per kit) for model
20000185 VS2C 5-clamp hardware package assembly. VS2EXRB-D manufactured on September 1, 1995 or later.*
20050465 2-Conductor electrical cable, 45 feet (13.7 meters) 20000290 Outside snap-switch and insulator kit (1 switch per kit) for model
VS2EXRB-D manufactured on September 1, 1995 or later.*
VS2EX 20050077 Adjustment shaft
20010091 Movement assembly 20000262 Movement assembly
20050087 Cover 20000049 Reset solenoid assembly (115 VAC)
00000309 Cover gasket 20000234 Reset solenoid assembly (24 VDC)
20010090 Snap-switch and insulator kit (1 switch per kit)
prior to September 1, 1995.*
VS94 Series
20000288 Snap-switch and insulator kit (1 switch per kit) for models
manufactured on September 1, 1995 or later.* 25050506 Dust boot
20000289 C-clamp conversion mounting kit 00000232 Conduit fitting
20010090 Snap-switch and insulator kit (1 switch per assembly)
VS2EXR prior to September 1, 1995.**
20000262 Movement assembly 20000288 Snap-switch and insulator kit (1 switch per assembly)
for models manufactured on September 1, 1995 or later.***
20050087 Cover
00000309 Cover gasket
* If no date code is found, refer to the old switch. Models with date 0895 and before use old switch.
20010090 Snap-switch and insulator kit (1 switch per kit) Dated 0995 after, use straight snap-switch arm, no rollers.
prior to September 1, 1995.* ** Models dated Q1 thru Q8 (formed snap-switch arm and rollers).
20000288 Snap-switch and insulator kit (1 switch per kit) for models ***Models date coded Q9 thru Q12 and R1 thru R12 (straight snap-switch arm, no rollers).
manufactured on September 1, 1995 or later.*
20000049 Reset solenoid assembly (115 VAC)
20000234 Reset solenoid assembly (24 VDC)
20000289 C-clamp conversion mounting kit

CONTROL SYSTEMS & SERVICES DIVISION FRANK W. MURPHY, LTD. MACQUARRIE CORPORATION
P.O. Box 1819; Rosenberg, Texas 77471; USA Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K. 1620 Hume Highway
+1 281 633 4500 fax +1 281 633 4588 +44 1722 410055 fax +44 1722 410088 Campbellfield, Vic 3061; Australia
FWMurphy e-mail sales@fwmurphy.com e-mail sales@fwmurphy.co.uk +61 3 9358 5555 fax +61 3 9358 5558
P.O. Box 470248 MURPHY DE MEXICO, S.A. DE C.V. www.fwmurphy.co.uk e-mail murphy@macquarrie.com.au
Tulsa, Oklahoma 74147 USA Blvd. Antonio Rocha Cordero 300, Fracción del Aguaje MURPHY SWITCH OF CALIFORNIA
+1 918 317 4100 San Luis Potosí, S.L.P.; México 78384 41343 12th Street West
fax +1 918 317 4266 +52 444 8206264 fax +52 444 8206336 Palmdale, California 93551-1442; USA
D
RE

GI
E

e-mail sales@fwmurphy.com Villahermosa Office +52 993 3162117 +1 661 272 4700 fax +1 661 947 7570
STER

USA–ISO 9001:2000 FM 28221

www.fwmurphy.com e-mail ventas@murphymex.com.mx e-mail sales@murphyswitch.com UK–ISO 9001:2000 FM 29422

www.murphymex.com.mx www.murphyswitch.com
In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time.
Printed in U.S.A.

078792

VS-7037N page 8 of 8

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