Flexxaire TAC2000-P Series Manual

Printed in Canada
INSTALLATION AND SERVICE MANUAL
FOR THE
TAC2000-P & TAC3000-P FAN SERIES
(PNEUMATIC CONTROL)
TAC2000-H & TAC3000-H FAN SERIES
(HYDRAULIC CONTROL)
PUBLICATION No. 01524
Revision 10
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Printed In Canada 01524r10.doc TAC2000/TAC3000 Manual 12/03/2009Page 1
1.1. INTRODUCTION
This manual (P/N 01524) is produced to assist in
the installation, operation and maintenance of
Flexxaire®TAC2000-P, TAC3000-P, TAC2000-H and
TAC3000-H Series Fan Systems.
Flexxaire has made every effort to ensure that the
information contained in this manual is correct and
complete at the time of printing. Flexxaire will
assume no responsibility for any errors or omissions.
If you have any questions regarding this manual or
any other document provided with your fan system,
please contact:
Flexxaire
Product Support Department
10430-180 Street
Edmonton, Alberta, Canada
T5S-1C3
Phone: [phone]
Fax: [phone]
Toll Free: 866-489-3267
1.2. IMPORTANT SAFETY
INFORMATION
The safety information in this publication is to be
used in conjunction with the safety information
supplied from the original machine manufacturer.
Please refer to all safety information supplied, prior
to doing any work on the fan assembly or any other
component to assure safety.
Improper operation, maintenance or repair of
this product can be dangerous and could
result in injury or death.
Always use Flexxaire parts and components or
Flexxaire approved parts and components. The use
of unapproved parts and/or components will void
the 1-year warranty.
Do not operate or perform any maintenance
on this product until you have read and
understand the operation and maintenance
information. Please contact Flexxaire or an
approved dealer for any information that you
may require.
The person(s) servicing the product may be
unfamiliar with many of the systems or
components on the product. This makes it
important to use caution when performing
any type of service work. A knowledge of the
product and/or its components is important
before the removal or disassembly of any
component.
1.2.1. PROTECTIVE EQUIPMENT
Always wear protective glasses, protective shoes
and any other protective equipment as required by
job conditions when working around this product.
1.2.2. PRESSURIZED FAN HUB
The hub assembly is spring loaded. If disassembly
of the hub is required, take caution that you are well
protected from the hub’s release which may be
sudden and pose an impact related injury.
Also make sure that the internal pressure is
released. Consult the pneumatic or hydraulic control
instructions.
1.2.3. HOT FLUIDS AND PARTS
To avoid burns, be alert for hot parts on the
assembly or the machine that have just been
stopped and have hot fluid in lines, tubes and
compartments.
1.3. PRODUCT SUPPORT
The Flexxaire Product Support Department provides
technical support, information on fan installation and
maintenance, parts, instruction manuals, and is
responsible for warranty administration. Contact the
Product Support Department for any problems that
this technical manual does not address.
Phone: [phone] or 780-930-6836
Monday to Friday 8:00 am to 4:00 pmMST
1.4. FAN SPECIFICATIONS
The following needs to be considered prior to the
installation of the Flexxaire Fan System. If your
situation is listed in this section, DO NOT INSTALL
THE FAN. Damage and/or injury may occur.
1.4.1. MOUNTING
WARNING: This fan is not designed to be
mounted onto a crank shaft or crank shaft pulley.
Torsional vibration from crankshafts will damage the
fan and could result in machine damage and serious
injury.
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Printed In Canada 01524r10.doc TAC2000/TAC3000 Manual 12/03/2009Page 2
1.4.2. FAN BLADE TIP SPEED
WARNING: The fan system must not exceed a
blade tip speed of 20,000 feet/minute. Exceeding
this speed may cause damage to and/or failure of
the fan, which in turn may cause injury or death, or
damage to the radiator and surrounding equipment.
To calculate the blade tip speed, use the following
formula:
Fan Diameter (Inches) X 3.14 X Fan RPM
12
If your calculated tip speed exceeds 20,000 ft/min,
contact Flexxaire directly, prior to installation. It is
important to use Fan RPM and NOT engine
RPM.
1.5. FAN OVERVIEW
Flexxaire’s TAC2000/TAC3000 fan systems are
designed to minimize overheating caused by debris
plugged radiators, screens and guards, and reduce
overcooling in low ambient temperatures. The
blades of the TAC2000/TAC3000 vary pitch, not
speed, to control air flow volume and direction.
How your TAC2000/TAC3000 works:
The TAC2000-P/TAC3000-P is a pneumatically
actuated variable pitch fan. The TAC2000-
H/TAC3000-H is a hydraulically actuated variable
pitch fan. The blades are held in full pitch by a
heavy spring. As pneumatic (or hydraulic) pressure
is applied to the control line, the pitch of the blade is
reduced and then reversed. When the pressure is
released, the fan blades return to their default
position. The TAC2000/TAC3000 has a number of
important features:
1. Fail Safe Operation: The blades are spring
loaded into the default full pitch position. If
the fan losespressure, the fan will default to
full pitch and act like a fixed pitch fan giving
maximum cooling.
2. Depending on the control kit ordered(see
Section 2.0), the fan can be run in a neutral
pitch (or any pitch in between) to solve
overcooling problems and save horsepower
and fuel.
3. When purging, there are no horsepower
spikes,in fact,the horsepower drops off as
you pass through neutral pitch, then slowly
builds as pitch increases.
2.0. CONTROL KITS
Due to the variability of machines that the TAC2000/
TAC3000 fan may be installed on, the fan does not
include any control components. Flexxaire has a
number of different control kits available to suit a
wide range of applications:
PNEUMATIC CONTROL:
-2 Position kit (Manual Purge)
-2 Position kit with timer (Manual and Auto Purge)
-3 Position kit (Manual Purge with neutral capability)
-3 Position kit with timer (Manual and Auto Purge
with neutral capability
-Full Variable Pitch Controller (Full fan control)
-Each kit is available with or without an air
compressor.
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Printed In Canada 01524r10.doc TAC2000/TAC3000 Manual 12/03/2009Page 3
HYDRAULIC CONTROL:
-2 Position kit (Manual Purge)
-2 Position kit with timer (Manual and Auto Purge)
-Full Variable Pitch Controller (Full fan control)
All of these pneumatic and hydraulic kits are
available in 12V and 24V configurations. Contact
Flexxaire or your dealer for details and availability.
2.1. MAJOR COMPONENTS
The TAC2000/TAC3000 Fan Assembly can be identified by several external components as shown in Figure 1.
Use this diagram for terminology andmajor component identification.(This figure is of a TAC2000-H, but all the
major components are the same between the TAC2000 and TAC3000 fans.)
Figure 1: Fan Components
MAJOR COMPONENTS:
1. Blade Assembly
2. Rotary Union
3. Hub Assembly
4. Mounting Adapter Bolts
5. Mounting Adapter
6. Hub Mounting Bolts
7. Blade Counter Weight
8. Blade Mounting Shaft
9. Fan Pilot
2.2. EXISTING FAN REMOVAL
The following is a general description for the
removal of an existing fan and the installation of a
Flexxaire TAC2000/TAC3000 Fan.
A. Remove fan guards and safety equipment to
gain access to the existing fan.
B. Loosen belt(s) and remove existing fan
hardware as required.
C. Clean mounting surface of the fan drive.
2.3. INSTALLATION
Mounting Adapters
The TAC2000/TAC3000 fan is supplied with either a
pre-machined mounting adapter or a generic
mounting adapter. Pre-machined mounting
adapters are machined for your pilot and bolt circle.
Generic mounting adapters require a pilot and bolt
circle machined into them to match the pilot and
bolt circle of your fan drive. Contact Flexxaire for
machining instructions if you are using a generic
mounting adapter. For some applications, a wider 2-
piece adapter may be used, and the necessary
hardware for assembling the 2 parts together will be
included. This 2-piece adapter may be pre-
assembled.
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Printed In Canada 01524r10.doc TAC2000/TAC3000 Manual 12/03/2009 Page 4
Fan Position
Ideally the fan should be centered in the shroud
(30-70% immersion isacceptable). This may
require modification or removal of the fan spacer or
modification of the shroud. See Figure 2.
Figure 2
A. Install the Flexxaire supplied mounting
adapter using bolts from the original fan. If
the bolt length needs to be changed, use an
equivalent or better grade of bolt. Follow
original equipment manufacturer’s torque and
thread locking specifications when installing
the mounting adapter to the fan drive. Refer
to Figure 3.
Figure 3: Adapter Plate Mounting
B. Set up dial gauge to measure axial deviation
of the mounting adapter on the fan mounting
surface. Deviation should not exceed 0.005”.
Refer to Figure 3.
C. Set up dial gauge to measure radial deviation
of the mounting adapter on the 1” pilot hole
surface. Deviation should not exceed 0.005”.
Refer to Figure 3.
D. Remove the silicon shipping plugsfrom the
rear of the fan. Place the TAC2000/ TAC3000
fan onto the mounting adapter, and torque
the 3/8” bolts to 40 Ft-Lbs (54 N.m). Do not
use loctite. Refer to Figure 4.
Figure 4
3.0. ATTACHING THE BLADES
Your Flexxaire fan shipped with the fan blades
unattached. Care must be taken to ensure the
blades are attached correctly. If the primary
operation of the fan is to “pull” air towards the
engine, the blades must be mounted with the
concave surface towards the engine (assuming the
fan rotates counter clockwise, as viewed from the
engine towards the fan). If the primary operation of
the fan is to “push” air away from the engine, the
blades must be mounted with the concave surface
away from the engine. Refer to Figure 6
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