Air UCP206-103D3 Guide

Blower
Maintenance
TB
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33
, Rev. 01
Date:
08
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FO
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eng.com / (706)364
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0010 / 1765 Tobacco Rd., 30906 Augusta,GA USA
This section contains general maintenance instructions for your Blower unit. For specific information about
maintenance of components, particularly for special application blowers, contact AIR.
Contents
1. General Motor Maintenance ..............................................................................................................................2
2. Drive Maintenance .............................................................................................................................................2
2.1. Belt Tension Adjustment ............................................................................................................................3
2.2. Sheave Aligment .........................................................................................................................................4
3. Bearing Maintenance .........................................................................................................................................7
3.1. Bearings NTN ..............................................................................................................................................7
3.2. Bearings - DODGE .......................................................................................................................................7
4. Blower Wheel and Shaft Maintenance ...............................................................................................................9
5. Structural Maintenance ......................................................................................................................................9
6. Troubleshooting Guidelines ............................................................................................................................ 10
6.1. Troubleshooting Performance Problems ................................................................................................ 10
6.1.1. Air Capacity Problems ...................................................................................................................... 10
6.1.2. Noise ................................................................................................................................................ 10
6.1.3. Vibration .......................................................................................................................................... 10
6.1.4. Motor Problems............................................................................................................................... 11
6.1.5. Drive Problems ................................................................................................................................ 11
6.1.6. Bearing Problems............................................................................................................................. 11
7. Lubrication (Only applies to DODGE bearings): ............................................................................................... 12

Blower
Maintenance
TB
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33
, Rev. 01
Date:
08
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14
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Written By:
FO
Page
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0010 / 1765 Tobacco Rd., 30906 Augusta,GA USA
1. General Motor Maintenance
The three basic rules of motor maintenance are:
a) Keep the motor clean
Keeping motors and windings clean is important because dirt and dust serve as thermal insulators.
Heat normally dissipated by the motor is trapped causing overheating and/or premature failure.
Blow dust and dirt out of windings and off the motor periodically. Use low pressure (50 psig)
airstream so that winding damage does not occur. Keep the area surrounding the motor open so the
air can circulate through the motor cooling fan.
b) Keep the motor dry
Motors should be kept dry to avoid electrical short circuit. Motors kept in storage for a long time can
have moisture condensate on the windings. Be certain the motor is dry before use.
c) Keep the motor properly lubricated
Some smaller motors are lubricated for life (typically motors less than 10HP). Motor bearing
lubrication, if required, must follow a rigorous schedule. Lubrication interval, type, and the amount
of grease will be indicated on the motor nameplate.
It must be emphasized that excessive lubrication, i.e. a quantity of grease greater than that
recommended on the motor nameplate, can result in the increase of bearing temperatures leading
to reduced operating hours.
Grounding rings should be considered for motors controlled by variable frequency drives (VFDs).
They can be installed by the end user or purchased with Unit.
2. Drive Maintenance
V-belt drives need periodic inspection and occasional belt replacement. When inspecting drives, look for
dirt buildup, burrs or obstructions which can cause premature belt or drive replacement. If burrs are
found, use fine emery cloth or a stone to remove the burr. Be careful that dust does not enter the
bearings.
Check the sheaves for wear. Excessive slippage of belts on sheaves can cause wear and vibration.
Replace worn sheaves with new ones. Carefully align sheaves to avoid premature sheave failure.
Observe belts for wear. If fraying or other wear is observed to be mostly on one side of the belts, the
drives may be misaligned. Reinstall the drives according to instructions bellow. Never use belt dressing
on any belts.
When replacing belts, replace the entire set. After initial replacement and tensioning, recheck belt
tension after a few days to adjust belt tension again. New belts require a break-in period of operation.

Blower
Maintenance
TB
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33
, Rev. 01
Date:
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2.1. Belt Tension Adjustment
Follow steps 1 to 8 and record data.
Required equipment: tensiometer, tape measure, straight edge.
1. Make sure the motor is de-energized.
2. Measure the span length of the belt. Span length is the distance the belt spans between the
sheaves. The desired belt deflection is 1/64 of an inch for every inch of belt span. For example, if the
span length is 32 inches, the desired belt deflection is ½ inch.
3. Set the large “O” ring on the tensiometer to the desired deflection determined in Step 2.
4. Set the small “O” ring on the tensiometer to the zero mark.
5. Holding the tensiometer, press the opposing end of the tensiometer to the midpoint of the belt
span as indicated in Figure 1. Press down on the tensiometer (deflecting the belt) until the large “O”
ring is even with the original location of the belt. For a single belt drive, the tensiometer should be
depressed until the large “O” ring is lined up with the bottom of the straight edge placed on the
outside rims of the two sheaves. For a multiple belt drive, depress the tensiometer until the large
“O” ring is even with the top of the next belt. Take a reading from each belt for an average.
6. The small “O” ring now indicates the force (lbs) required to get the desired belt deflection. Check
this reading against the recommended range of belt deflection force in the table at the end of this
document.
7. Tighten or loosen the belt accordingly to achieve the recommended belt deflection force for initial
installation. Tightening the belt will increase the force; loosening the belt will decrease the belt
deflection force.
8. Inspect the belt drive after 24-48 hours of run time. The initial stretch is taken out of the belts and
the belts seat lower in the sheaves. Check belt tension to assure it fall between the maximum and
minim values show in the table.

Blower
Maintenance
TB
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, Rev. 01
Date:
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V-Belt
Cross
Section
Small Sheave
Diameter Range
(Inches)
Recommended Deflection Force (Lbs)
Initial
Installation
Retensioning
Maximum Minimum
A
- 3 3.6 3.1 2.4
3.1 - 4.0 4.2 3.6 2.8
4.1 - 5.0 5.2 4.6 3.5
5.1 - 6.1 5.3 4.1
B
- 4.6 7.3 6.4 4.9
4.7 - 5.6 8.7 7.5 5.8
5.7 - 7.0 9.3 8.1 6.2
7.1 - 10.0 8.8 6.8
AX
- 3 5.1 4.4 3.4
3.1 - 4.0 5.5 4.8 3.7
4.1 - 5.0 6.0 5.2 4.0
5.1 - 6.7 5.9 4.5
BX
- 4.6 10.0 8.7 6.7
4.7 - 5.6 11.0 9.5 7.3
5.7 - 7.0 11.5 9.9 7.6
7.1 - 12.0 10.1 7.8
5V
7.1 - 10.3 16.5 14.3 11.0
10.9 - 11.8 19.5 16.9 13.0
12.5 - 16.0 21.0 18.2 14.0
5VX
- 5.5 15.0 13.0 10.0
5.9 - 8.0 19.0 16.9 13.0
8.5 - 10.9 21.0 18.2 14.0
11.8 - 22.0 19.5 15.0
2.2. Sheave Aligment
Precise alignment of belt driven machinery is essential to increase belt and pulley life, reduce vibration,
and reduce energy costs.
It is possible to determine the type of misalignment and how to correct it by using this document:

Blower
Maintenance
TB
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Follow steps 1 to 6.
Required equipment: TKBA 40 Belt alignment tool or similar
(consists of two units and four sizes of V-guides that attach
magnetically to the grooves of each pulley).
1. Make sure the motor is de-energized.
2. Four sizes of V-guides are supplied with the TKBA 40 to fit
pulley grooves of most widths and types. Select and attach
the appropriate V-guides as shown in figure 2.
3. The units are provided with strong magnets and V-guides.
Place the V-guides of the first unit in the groove of the first
pulley and press the unit firmly until the magnet secures it to
the pulley. Place the second unit in the opposite groove of
the second pulley. Position both units facing each other as
shown in Figure 4.
4. Switch on the laser unit by pressing the ON/OFF button.
5. The laser line emitted from the laser unit will now appear on
the receiver unit so that the type of misalignment can be
determined. The pattern will vary depending on the type of
misalignment, as shown in figure 5, 6, 7 and 8.

Blower
Maintenance
TB
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33
, Rev. 01
Date:
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6. Before aligning the pulleys, it is important that the pulleys are mounted correctly on the shafts and that the
shafts are straight. Buckled pulleys will have a detrimental effect on the alignment quality. Adjust one (or
both) pulley machines(s) step by step until the laser line hit the three reference lines of the receiver unit.
6.1. Elimination of vertical angle misalignment: Place shims beneath the front or rear feet of the moveable
machine until the laser line is parallel to the reference lines (as per figure 11).
6.2. Elimination of horizontal angle misalignment: Move the machine until the laser line is positioned
equidistantly from the three reference lines, the top line and the two bottom reference lines (as per
figure 13).
6.3. Elimination of parallel misalignment: Move one of the pulleys on its shaft unit the laser line exactly
matches the three reference lines (as per figure 15).
The pulleys are now successfully aligned!
*NOTE: When tightening the belt, check the horizontal angle alignment and adjust if necessary.
WARNING: Switch OFF THE LASER UNIT AND REMOVE BOTH UNITS before starting machinery.

Blower
Maintenance
TB
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33
, Rev. 01
Date:
08
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14
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Written By:
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3. Bearing Maintenance
For instructions covering bearing assembly or disassembly, or installation details, please contact AIR
Engineering. Any bearing which is disassembled should be kept separate from other bearing parts as
components may not be interchangeable. Maintain cleanliness of components and bearings to prevent
bearing contamination.
3.1. Bearings NTN
Apply to models:
UCP206-103D3
UCP207-107D3
Inspect and tighten all bearing collar and wheel setscrews after the first 50 to 100 hours of operation
and monthly thereafter. For torque values, refer to table “Recommended Torque” on section 3.2.
This blower bearing types are permanently lubricated and require no further lubrications.
3.2. Bearings - DODGE
Apply to models:
P2B-DLMAH-103
P2B-DLMAH-107
P2B-DLMAH-111
P2B-DLMAH-115
P2B-SCAH-100
P2B-SCAH-103
P2B-SCMAH-103
P2B-DLAH-115

Blower
Maintenance
TB
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33
, Rev. 01
Date:
08
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14
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Written By:
FO
Page
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0010 / 1765 Tobacco Rd., 30906 Augusta,GA USA
For setscrew mounted bearings:
After 24 hours operation, the setscrews should be retightened to the torque as shown on
“Recommended Torque” table below to assure full locking of the inner race to the shaft. Care should
be taken that the socket key or driver is in good condition with no rounded corners and the key is
fully engaged in the setscrew and held square with the setscrew to prevent rounding out of the
setscrew socket when applying maximum torque.
Do not drill through the setscrew holes for spot drilling of the shaft. (Some inner rings have
tempered setscrew threads and can be damaged by a drill.)
NOTE: On all Setscrew Product the setscrews can be re-torqued many times without damage to the
bearing system. AIR recommends a monthly inspection and tightens of all set screws. To achieve
maximum shaft holding power it is highly recommended that setscrews be replaced with new
hardware after any disassembly operation.
For D-LOK mounted bearings:
Be sure collar is square and tight against shoulder on inner ring. Tighten cap screw to recommended
torque shown in the table below.
Recommended Torque
Setscrews D-LOK
Setscrew
Size
Key Hex
Across
Flats
Standard Ball
Bearing Insert Cap
Screw
Size
Recommended
Torque
Min Max
(in.) (in.) (in-lbs.) (in-lbs.) (in.) (in-lbs.)
#10 3/32 28 33 #8-32 58
1/4 1/8 66 80 #10-32 90
5/16 5/32 126 156 1/4-28 180
3/8 3/16 228 275 5/16-24 400
(mm) (mm) (N-m) (N-m) (mm) (N-m)
M5 2.5 3.2 3.7 M4 5.85
M6 3 6.2 7.7 M5 10.75
M8 4 14.2 17.8 M6 20.5
Proper lubrication of bearings helps assure maximum bearing life. All fans are equipped with decals
indicating relubrication intervals for normal operating conditions. However, every installation is
different and the frequency of lubrication should be established accordingly.
Relubricate while running, if safety permits, until some purging occurs at seals. Adjust lubrication
frequency depending on conditions of purged grease. Use one-half of listed interval for vertical shaft
applications or for 24-hour operation.

Blower
Maintenance
TB
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, Rev. 01
Date:
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Lubricate with a high quality NLGI No. 2 lithium-base grease having rust inhibitors and antioxidant
additives, and a minimum oil viscosity of 500 SUS at 100°F (38°C). Some greases having these properties
are:
 Shell - Gadus S2 V100 2
 Exxon - Ronex MP.
 Mobil - Mobilith SHC100
 Mobil - Mobilith SHC220
Lubricate bearings prior to extended shutdown or storage and rotate shaft monthly to aid corrosion
protection.
Observation of the condition of the grease expelled from unit ball or roller bearings at the time of
relubrication is the best guide as to whether re-greasing intervals and the amount of grease added
should be altered. This observation is particularly important when bearings operate continuously over
160°F.
Greases are made with different bases. There are synthetic base greases, lithium base, sodium base, etc.
Avoid mixing greases with different bases. They could be incompatible and result in rapid
deterioration or breakdown of the grease.
All bearings are filled with grease before leaving the factory. When the fans are started, the bearings
may discharge excess grease through the seals for a short period of time. Do not replace the initial
discharge because leakage will cease when the excess grease has worked out. Sometimes the bearing
has a tendency to run hotter during this period and one should not get alarmed unless it lasts over 48
hours or gets above 220oF.
4. Blower Wheel and Shaft Maintenance
Periodically inspect the shaft and wheel for dirt buildup, corrosion, and signs of excess stress or fatigue.
Clean the components and, when appropriate, apply new coatings. (Any addition of coatings or weld can
create an imbalance.) Check the balance of the assembly.
5. Structural Maintenance
All structural components or devices used to support or attach the blower or blower motor to a
structure should be checked at regular intervals. Vibration isolators, bolts, foundations, etc., are subject
to failure from corrosion, erosion, and other causes. Improper mounting can lead to poor operation
characteristics or fan fatigue and failure.
Check metallic components for corrosion, cracks, or other signs of stress.

Blower
Maintenance
TB
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33
, Rev. 01
Date:
08
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14
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Written By:
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0010 / 1765 Tobacco Rd., 30906 Augusta,GA USA
6. Troubleshooting Guidelines
Use current safety practices when investigating blower or system performance problems. General safety
practices and performance troubleshooting guidelines can be found in AMCA Publications 410 and 202,
respectively. Fan application and field measurement procedures can be found in AMCA Publications 201
and 203.
6.1. Troubleshooting Performance Problems
The lists below indicate possible areas to check when air or sound values do not match expectations.
Most fan problems can be pinpointed to one of these common causes.
6.1.1. Air Capacity Problems
1. Resistance of system not at design rating. If resistance is lower than expected, both airflow and
horsepower may be up. If resistance is higher than anticipated, air volume will be down.
2. Fan speed is not at design speed.
3. Air density not at design values. Also check air performance measurement techniques and
procedures.
4. Devices for air modulation are closed or plugged. Also check filters.
5. Wheel mounted improperly or is rotating in reverse.
6. Parts of system or fan have been damaged or need cleaning.
6.1.2. Noise
1. Air performance is incorrect and fan is not at design point of operation. Fan forced to operate in an
unstable flow region.
2. Bearing failure. Check bearings (lubrication).
3. Supply voltage high or inconsistent supply frequency. Adjustable frequency controllers can generate
motor noise.
4. Objects which are installed in a high velocity airstream can generate noise. This includes flow
sensors, turning vanes, etc.
5. Poor fan inlet conditions.
6. Acoustics or sound measurement procedure incorrect.
6.1.3. Vibration
1. Misalignment of drive components.
2. Poor foundations or mounting structure (resonances).

Blower
Maintenance
TB
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, Rev. 01
Date:
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3. Foreign material attached to rotating components.
4. Damaged rotating components (bearings, shaft, fan, wheel, sheaves).
5. Broken, lose or missing setscrews.
6. Loose bolts.
7. Vibration transmitted by another source.
8. Water accumulating in airfoil blades.
9. Fan is operating in stall or unstable flow region.
6.1.4. Motor Problems
1. Incorrect wiring.
2. Speed of fan too high.
3. Parts improperly installed - binding.
4. Bearings improperly lubricated.
5. WR2 capability of motor too low for application.
6. Protection devices may be improperly sized.
7. When used with VFD, a high pitch motor noise may be associated with the harmonic natural
frequency of the motor and the switching frequency of the VFD. Changing the VFD switching
frequency parameter may solve the problem.
6.1.5. Drive Problems
1. Belts improperly tensioned.
2. Drive alignment is poor.
6.1.6. Bearing Problems
Common failure causes are:
1. Setscrews loosening and shaft turning within the bearing
2. Crowned bearing supports. Loosen one bolt and measure the clearance between the pillow block
and the support. Add shim to compensate.
3. Noise: If a bearing is increasing in noise intensity and/or vibration, it will probably result in failure.
4. Temperature: If a bearing temperature begins to gradually rise, it will generally result in failure. A
bearing can operate up to 200 degrees and operate satisfactorily if the temperature remains
constant and the bearing receives adequate lubrication.

Blower
Maintenance
TB
-
33
, Rev. 01
Date:
08
-
14
-
20
20
Written By:
FO
Page
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eng.com / (706)364
-
0010 / 1765 Tobacco Rd., 30906 Augusta,GA USA
7. Lubrication (Only applies to DODGE bearings):
The major cause of bearing failure is contamination of grease, insufficient grease, or incompatibility of
grease. If a fan is to be stored for any length of time at the job site, the bearings immediately should be
filled with grease while rotating the shaft and then the bearings should be re-greased and rotated
monthly. This will prevent moisture, which condenses within the bearing, from corroding the raceways.
Most greases used on fan pillow blocks are lithium base. Use the greases shown on the bearing decal.
Do not mix the bases without completely purging out the initial grease.
Initially, follow the lubrication instruction on the side of the fan. The frequency of lubrication should be
adjusted depending on the condition of the old grease being purged. This is the responsibility of the
user. If the grease is dirty, the lubrication frequency should be more often.
Rough handling and/or dropping a fan can result in brinelling the bearing. This appears as a clicking
noise at first, then gradually worsens until failure.
When replacing a bearing, always align the bearings first, then bolt the pillow blocks to their support,
rotate the shaft, fasten the bearings to it. If the bearing is fastened to the shaft first, tightening the
pillow block bolts may bind the shaft and preload the bearings.