Kruger TDA Series User manual

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Axial fans
Installation and Operating instructions

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Contents
1 INTRODUCTION 6
1.1 Purpose of this manual 6
1.2 Safety symbols used in this manual 6
1.3 Safety symbols used on fans 7
2 GENERAL INFORMATION 8
2.1 Definitions, basic principles, terminology used and correlated documents 8
2.2 Construction details of axial fans 8
2.2.1 Versions and motor positions 8
2.2.2 Flow indications 9
2.3 Fan name plate 10
2.4 Fan Temperature types 12
2.5 Description of fan 11
2.6 Envisaged use and foreseeable uses according to experience, and prohibited uses 17
2.7 Life cycle of fan 18
3 WARNINGS AND MAIN SAFETY INDICATIONS 19
3.1 Installation instructions: general information 19
3.2 Installation type A: Instructions for assembly, installation and connections 20
3.3 Installation type B: Instructions for assembly, installation and connections 20
3.4 Installation type C: Instructions for assembly, installation and connections 21
3.5 Installation type D: Instructions for assembly, installation and connections 21
3.6 Risks involved in foreseeable incorrect handling and/or abnormal uses based on
experience 22
3.7 Other risks related to fans pursuant to UNI EN ISO 12499 23
3.7.1 Specific risks with fans during installation 23
3.7.2 Specific risks with fans during maintenance 24
3.7.3 Environmental risks 24
3.7.4 Vibration risks 24
3.7.5 Operating speed risks 25
3.7.6 Noise emission risks 27
3.7.7 General information on noise emission data 28
4 TRANSPORT, MOVEMENT AND STORAGE 30
4.1 Lifting and movement 30
4.2 General warnings for lifting separate fan parts 30
4.3 Fan lifting instructions 30

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4.3.1 Lifting version 1 and 9 axial fans 30
4.3.2 Lifting version 4 axial fans 31
4.3.3 Lifting fans packed in crate 32
4.4 Storage 33
5 INSTALLATION 34
5.1 General information 34
5.1.1 Minimum installation distances 35
5.2 Assembly of axial fans 36
5.2.1 Version 4 axial fans 36
5.2.2 Version 1 axial fans 37
5.2.3 Version 9 axial fans 38
5.3 Mounting Configuration 39
5.4 Installing and adjusting drive belts and final checks 40
5.5 Vibration Isolator Installation 41
5.6 Blade adjustment 41
5.7 Electrical connections 42
5.8 Connection to ducts 44
6 CHECKS TO BE MADE BEFORE AND AFTER STARTING 45
6.1 Preliminary checks 45
6.2 Checks to be made with fan fully operating 46
6.2.1 Visual checks on protection net 46
6.2.2 Checking and cleaning parts in contact with fluids 47
6.2.3 Visual checks on impeller and casing 47
6.2.4 Dimensional checks 48
7 AXIAL FAN OPERATING MALFUNCTIONS 49
7.1 Most frequent malfunctions 49
8 MAINTENANCE 51
8.1 Bearing lubrication 52
8.2 Adjusting drive belt tension and cleaning belts 54
8.3 Checking and cleaning parts in contact with fluids 55
9 DISMANTLING AND REASSEMBLING ESSENTIAL COMPONENTS 56
9.1 Fan impellers with hub 56
9.2 Replacing drive belts 56
9.2.1 Assembling and dismantling pulleys 56
9.2.2 Assembling and dismantling drive belts 61

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10 FINAL DISMANTLING AND DISPOSAL OF FANS 63
10.1 Version 4 axial fans 64
10.2 Version 1 and 9 axial fans 65
11 TECHNICAL APPENDICES 66
11.1 Tightening torques for nuts and bolts 66
11.2 Checklist before starting fans 68
11.3 Programmed maintenance intervals 69
12 INDEX 70

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Index of Diagrams
Fig. 2-1 Axial fan versions 9
Fig. 2-2 Flow indications 9
Fig. 2-3 Name plate of fan described by this manual 10
Fig. 2-4 Key to reading fan name plate 10
Fig. 2-5 TDA fan components indicated 11
Fig. 2-6 TDA-V fan components indicated 12
Fig. 2-7 TDB-II fan components indicated 13
Fig. 2-8 MXA fan components indicated 14
Fig. 2-9 TBE fan components indicated 15
Fig. 2-10 MXC fan components indicated 16
Fig. 4-1 Example of lifting version 1 and 9 axial fans 32
Fig. 4-2 Example of lifting version 4 EF axial fans 33
Fig. 4-3 Example of lifting fans packed in crate 34
Fig. 5-1 Minimum installation distances with inlet duct 36
Fig. 5-2 Minimum installation distances with free inlet 36
Fig. 5-3 Assembly of version 4 axial fans 37
Fig. 5-4 Assembly of version 1 axial fans 38
Fig. 5-5 Assembly of version 9 axial fans 39
Fig. 5-6 Vibration Isolator setup 41
Fig. 5-7 Diagram of electrical connections for single-speed and two-speed motors 43
Fig. 5-8 Example of positioning of external terminal box 43
Fig. 5-9 Assembly tolerances for flexible joints 44
Fig. 5-10 Minimum installation distances with inlet duct 44
Fig. 8-1 Checking drive belt tension 53
Fig. 9.1 Pulley holes 56
Fig. 9.2 Angular misalignment 58
Fig. 9.3 Parallel misalignment 58
Fig. 10-1 Exploded view of version 4 fan 63
Fig. 10-2 Exploded view of version 1 and 9 fan 64
Index of Tables
Table 2-1 Types of fans 11
Table 8-1 Bearing Grease Weight Standard of TACBECON SGHT 200S (Class F)/ 600 (Class H) 52
Table 8-2 Relubrication intervals and quantity of grease according to fan rotation speed 53
Table 8-3 Setting drive belt tension: test load and deflection 54
Table 9-1 Tightening torques 60
Table 11-1 Tightening torques M for bolts with ISO metric threads 66
Table 11-2 Tightening torques for blade fixing bolts on fans with steel hub 67

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1 INTRODUCTION
1.1 Purpose of this manual
This manual contains instructions and warnings, and constitutes documentation that must compulsorily
accompany the product. Otherwise the product is lacking one of its essential safety requisites.
The manual must be kept with care, and must be made available to all persons involved with the product.
The warnings are intended to safeguard the safety of persons exposed to residual risks.
The instructions provide indications for the most appropriate conduct for the correct use of fans as intended
by the manufacturer.
WARNING:
The safety precautions used for the fan must also be adapted to its specific destination
of use.
The safety precautions differ according to the type of fan installation, as specified in
paragraph 3.1 below.
The information given in this manual is therefore indispensable for the use of fans in
conformity with the destination of use of the product and without risks.
In this manual the letters “KRUGER” stand for Kruger Ventilation Industries Asia Co., Ltd.
No part of this manual may be copied, reproduced or transmitted in any form whatsoever and by any
electronic, mechanical or photographic means without the express authorization of KRUGER.
The KRUGER Technical Office is fully at your disposal for all information required.
1.2 Safety symbols used in this manual
Certain items of particular interest in this manual may be preceded by one of the following symbols:
DANGER: Indicates situations that might cause personal injuries.
DANGER: Live electrical components.
WARNING: Indicates important information of particular general interest

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1.3 Safety symbols used on fans
The following safety symbols are used on KRUGER fans:
Prohibited to lubricate and/or adjust moving parts.
Prohibited to remove protection net.
Hazard due to presence of moving parts.
This symbol is applied near the inspection hatches provided on fans.
It is permitted to open inspection hatches only when all moving parts
have reached a complete standstill.
Indication of a lifting point.
This symbol is applied near the points identified by KRUGER for lifting
and moving the fan.
Hot surfaces >60 °C.
Danger of burns or scalding. Hot surfaces – Emission of hot fluids.
This symbol is applied if the fan is used to move hot fluids.

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2 GENERAL INFORMATION
2.1 Definitions, basic principles, terminology used and correlated documents
 Point 3.1 of the UNI EN ISO 13349 standard defines a fan as “rotary-bladed machine which receives
mechanical energy and utilizes it by means of one or more impellers fitted with blades to maintain a
continuous flow of air or other gas passing through it and whose work per unit mass does not normally
exceed 25 kJ/kg.”
 Point 3.6.1 of the UNI EN ISO 13349 standard defines an axial-flow fan as “a fan in which the air enters
and leaves the impeller along essentially cylindrical surfaces with the fan.”
 The blades may have the following shapes: flat (obtained directly by pressing sheet steel) or more
frequently a wing profile (obtained with aluminium).
The fundamental dimensions that define a fan are as follows:
 Volumetric flow: this is the volume of fluid passing through the fan in a certain period of time - one second
(m3/s), one minute (m3/min) or one hour (m3/h);
 Static pressure: this is the energy imparted by the impeller to overcome the resistance offered by the
system to the passage of fluid (measured in mm of water column = mm w.c. or Pascal = Pa);
 Dynamic pressure: this is the energy possessed by the fluid as a result of the speed imparted by the
impeller at the output opening of the fan (measured in mm w.c. or Pa);
 Total pressure: this is the arithmetical total of static pressure and dynamic pressure (measured in mm
w.c. or Pa);
 Flow: two directions for the fluid moved are identified for an axial fan, either from the motor towards the
impeller (flow A) or from the impeller towards the motor (flow B), see Fig. 2-2;
 Rotation speed: this is the rotation speed of the impeller, and is measured in revolutions per minute (RPM);
 Efficiency: this is the percentage ratio between the energy that the fan manages to transmit to the fluid
and the energy supplied by the motor to the impeller; it depends on impeller characteristics, and has no
measurement units;
 Power absorbed: this is the power needed (provided by the motor) by the fan for correct operation, and is
measured in kW;
 Name plate motor power: this is the nominal power that the motor can provide; it must always be greater
than the power absorbed by the fan, and is measured in kW;
 Sound pressure level: this is the energy propagated into the channel of the external ear and that generates
vibrations of the ear drum, namely the level of noise emitted by the fan; it is measured in decibels using
scale A (a scale that allows the impact of noise on the human ear to be assessed, according to the
frequency of the noise);
 Sound power: this is the index of emission of sound power, and constitutes an intrinsic and constant
characteristic of a sound source; it is expressed in watts.
The following documents are correlated to this manual:
 Kruger fan selection sheet for the fan, which lists dimensions, weights, rotation speeds, fluid types and
data on flexible couplings and vibration dampeners.
 Kruger Product Traveller and Finished Goods Card, which indicates the characteristics of the
transmission installed on the fan.
 The instruction and warnings manual of the manufacturer of the electric motor (if supplied together
with the fan).

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VERSION 1 VERSION 4 VERSION 8
VERSION 9 VERSION 12 Standard position with motor at 0°
2.2 Construction details of axial fans
2.2.1 Versions and motor position
Fig. 2-1 Axial fan versions
2.2.2 Flow indications
The diagram refers to version 4,
but is valid for all construction
versions:
A = Flow from motor to impeller
B = Flow from impeller to motor
U = Flow upwards
D = Flow downwards
Fig. 2-2 Flow indications

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Fan item code
Serial number
Air flowrate / Static pressure
Fan speed / Total pressure
Motor technical data
Maximum fan speed /
Maximum fan installed power
Manufacturer site
Fan tag
2.3 Fan name plate
The name plate is the only means of fan identification recognized by the manufacturer. It must not be modified,
and must not be removed or damaged. Fig. 2-3 shows the plate fitted to the fan.
Fig. 2-3 Name plate of fan described by this manual
Fig. 2-4 Key to reading fan name plate
Fan model / Fan series / Blade type / Hub diameter / Blade number / Tip angle

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2.4 Fan Temperature types
Fan Series
Range
(mm)
General
Ventilation
20°C to +55°C
Ff250
250°C /
2 hrs
F300
300°C /
1 hr
Ff300
300°C /
2 hrs
F400
400°C /
2 hrs
TDA 315-2000     
TDA-V 315-2000     
TDC 450-2000    
TDD 450-2000     
TDB-II 315-1400 
- - - -
TBE 315-2000  - - - -
MXA 450-2000 
   
TRC 1250-2240     
MXC* 315-2000     
Please consult KRUGER for fan series other than specified.
* MXC series is designed for kitchen exhaust application and comply with UL 762
Table 2-1 Types of fans
2.5 Description of fan
2.5.1 TDA series
Taking the fan shown in Fig. 2-5, TDA fan is generally constituted by the following components:
 Protection Net (1); ● Motor Base Reinforce (7);
 Impeller (2); ● Motor Base (8);
 Motor Support (3); ● Mounting Feet (9);
 Motor (4); ● Hanger (10);
 Tube Casing (5); ● Terminal Box (11)
 View Port (6);
Fig. 2-5 TDA fan components indicated

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

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

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

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

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

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

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2.7 Life cycle of fan
The reliability of all components is guaranteed by a production process with ISO 9001 certification and by compliance
with the programmed maintenance intervals indicated in paragraph 11.3 of this manual.
The components normally subject to wear are the following:
 bearings, calculated for a theoretical duration normally of 40,000 hours
 drive belts, calculated for a theoretical duration of 25,000 hours
For safety reasons, protection net in electro welded wire must be replaced every 2–3 years.
In the hypothesis of use of the fan at constant speed for two work shifts every day equivalent to 16 hours, calculated
for 250 days per year, the expected life cycle for the impeller is equivalent to 40,000 hours.
In case of use in conditions of particularly difficult operation (medium, high), this limit must be reduced. Any
such reduction must be assessed in collaboration with the KRUGER Technical Office. In the specific case of
operation at variable speeds, the impeller life cycle must be assessed on a case-by-case basis, and must also
be agreed with the KRUGER Technical Office.
CAUTION:
 Do not exceed the maximum rotation speed indicated by KRUGER.
 Do not use ON-OFF operating cycles unless expressly approved by KRUGER.
 Do not use variable-speed cycles unless expressly approved by KRUGER.
 Do not subject the fan to thermal gradients greater than 3°C/minute.
Even if it has never operated, an impeller that has been stored for more than ten years must be checked by
KRUGER for possible defects before it can be used.

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3 WARNINGS AND MAIN SAFETY INDICATIONS
3.1 Installation instructions: general information
Fans can be installed in four different ways, in conformity with the AMCA 201 standard:
 Type A: Free Inlet, Free Outlet;
 Type B: Free Inlet, Ducted Outlet;
 Type C: Ducted Inlet, Free Outlet;
 Type D: Ducted Inlet, Ducted Outlet.
Generally, KRUGER does not and cannot know which of the above installation types will be chosen
and applied by the user, and unless otherwise specified by contract, the fan is supplied for installation
types B, C or D according to the fan series and flow. The person responsible for designing the system,
together with the final user, must conduct an analysis of risks for the specific installation type chosen.
Depending on the way that it is intended to install and insert the fan in the fluid movement system, the
following protection net must be installed, according to installation type:
 Type A installation: fixed KRUGER protection net installed on inlet and outlet;
 Type B installation: fixed KRUGER protection net installed only on inlet;
 Type C installation: fixed KRUGER protection net installed only on outlet;
 Type D installation: no fixed protection net installed on inlet and outlet.
The system designer and the user must ensure that ducting systems are fitted with conformant protection net
for the duct connections made, as follows:
 Type A installation: no protection net (no ducts are connected);
 Type B installation: fixed protection net fitted on outlet duct;
 Type C installation: fixed protection net fitted on inlet duct;
 Type D installation: fixed protection net fitted both on inlet and outlet ducts.
CAUTION:
Unless otherwise specified by contract, fans are supplied for installation types B, C or D in
conformity with the AMCA 201 standard and according to fan series and flow.
Always verify all safety aspects of the installation type chosen.
With regard to protection net to be fitted to ducts, in compliance with the design project, they must prevent
access to parts of the fan and its accessories that could cause injuries. They must also be sufficiently robustly
constructed to resist the stresses generated by the machine and environmental conditions.
KRUGER invites users and/or system designers to design, construct and install protection net in conformity
with the criteria of the UNI EN ISO 12499 standard.
CAUTION:
Even with protection net installed (regardless of the conditions of supply or installation), the
fan may be dangerous due to the effects of indrawn or moved air.
Depending on the dimensions of the fan, this type of danger may even CAUSE DEATH.
The risk of being crushed against the inlet grille may be fatal or may cause serious injuries
(crushing of body parts, unconsciousness).

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CAUTION:
It is advisable to adopt precautions that prevent access to the room containing the fan while it
is operating, or to keep persons away with fixed protection net that maintain a safe distance
from the inlet opening.
WARNING:
Check the efficiency of all protection net every month. In case of wear, damage or breakage,
replace them immediately.
Protection net must be fixed securely in position using fixings that are not slackened by vibrations, and that
require the use of a tool for their removal.
CAUTION:
On starting and in compliance with programmed maintenance intervals, check that nuts and
bolts are correctly tightened. Monitor vibration levels with a vibrometer, and establish an alarm
threshold (see paragraph 12.3).
It is always the responsibility of the installer to guarantee that there is an adequate level of protection against
the risk of accidental contact with moving parts.
The installer and the user must also take other types of risk into consideration, and in particular those deriving
from the entry of foreign bodies and the inlet of explosive, inflammable or toxic gases or gases at a high
temperature.
The risks involved in maintenance operations must also be taken into consideration. It must be possible to
perform these operations in conditions of maximum safety, by isolating the fan from the motor or by taking
other suitable precautions.
CAUTION:
A safety procedure for access to the fan must be compiled, taking into consideration the
indications provided by the manufacturer, information deriving from the analysis of risks at the
installation point and safety requirements in workplaces.
3.2 Installation type A: Instructions for assembly, installation and connections
In case of type A installations, since neither the inlet nor outlet of the fan are connected to ducts, protection net
must be fitted on both the inlet and the outlet.
Protection net dimensions can be obtained from the dimensional drawing given in catalogues, from scale and
non- scale drawing programs downloadable from the reserved area of the website, or from any dimensional
drawings provided as documentation together with the products supplied.
3.3 Installation type B: Instructions for assembly, installation and connections
In case of type B installations, since the fan inlet is free and the outlet is connected to a duct, a protection net
must be fitted on the inlet.
Protection net dimensions can be obtained from the dimensional drawings given in catalogues, from scale and
non- scale drawing programs downloadable from the reserved area of the website, or from any dimensional
drawings provided as documentation together with the products supplied.