Schübeler HST Series Manual

Manual of Instruction
for Partially and Fully Assembled
Ducted Fans from the Schübeler
®
HST and HDS Series
composite

Table of Contents
Safety Instructions p. 1
Intended Use p. 1
User Groups p. 1
Transport & Shipping p. 1
Delivery Contents p. 2
Installation & Assembly pp. 3-12
Installation Instructions pp. 4-7
Assembly Instructions pp. 8-11
Dimensional Drawings p. 12
Techincal Data pp. 13-18
Duct-Cross-Sections and Weights of the
HDS-Setups p. 14
Duct-Cross-Sections and Weights of the
®
HST -Setups p. 15
Overviews of the Controller-Settings (HDS) p. 16
Overviews of the Controller-Settings
®
(HST ) p. 17
®
Technical Data (HDS&HST -Setups) p. 18
First Run, Operation, Maintenance, Disposal pp. 19-22
First Run p. 20
Operation p. 21
Malefunction During Commissioning,
Error Search, Fault Clearance p. 21
Maintenance and Cleaning p. 21
Decommissioning and Disposal p. 22
EU Conformity Declaration p. 23
03/14, MK

Table of Contents
Safety Instructions p. 1
Intended Use p. 1
User Groups p. 1
Transport & Shipping p. 1
Delivery Contents p. 2
Installation & Assembly pp. 3-12
Installation Instructions pp. 4-7
Assembly Instructions pp. 8-11
Dimensional Drawings p. 12
Techincal Data pp. 13-18
Duct-Cross-Sections and Weights of the
HDS-Setups p. 14
Duct-Cross-Sections and Weights of the
®
HST -Setups p. 15
Overviews of the Controller-Settings (HDS) p. 16
Overviews of the Controller-Settings
®
(HST ) p. 17
®
Technical Data (HDS&HST -Setups) p. 18
First Run, Operation, Maintenance, Disposal pp. 19-22
First Run p. 20
Operation p. 21
Malefunction During Commissioning,
Error Search, Fault Clearance p. 21
Maintenance and Cleaning p. 21
Decommissioning and Disposal p. 22
EU Conformity Declaration p. 23
03/14, MK

Transport and Shipping
After completed dispatch, the package and especially the product have to
be checked for apparent damage, which could possibly result in the
rupture of the rotor.
-1-
Safety Instructions
Intended Use
The ducted fans are only suitable for air conveying for cooling purposes,
simulation purposes and propulsion purposes. It is not allowed to convey
any other mediums. The chaffing of hard substances must be avoided.
The ducted fan systems must not be hold in your hands during operation.
The ducted fan system isn't a drive system for man-carrying aircraft or
vehicles.
Before working with the ducted fan system it must be disconnected from
the supply voltage.
The installation circumstances, as they are shown in drawing #6, have to
be satisfied.
User Groups
At private usage commissioning is only allowed to experienced hobby
area users and youths of 14 years and above.
At commercial usage commissioning should only be performed by
professionals, like mechanical technicians and mechanical engineers.
The ducted fan systems are not to be used by persons with pacemakers.

Transport and Shipping
After completed dispatch, the package and especially the product have to
be checked for apparent damage, which could possibly result in the
rupture of the rotor.
-1-
Safety Instructions
Intended Use
The ducted fans are only suitable for air conveying for cooling purposes,
simulation purposes and propulsion purposes. It is not allowed to convey
any other mediums. The chaffing of hard substances must be avoided.
The ducted fan systems must not be hold in your hands during operation.
The ducted fan system isn't a drive system for man-carrying aircraft or
vehicles.
Before working with the ducted fan system it must be disconnected from
the supply voltage.
The installation circumstances, as they are shown in drawing #6, have to
be satisfied.
User Groups
At private usage commissioning is only allowed to experienced hobby
area users and youths of 14 years and above.
At commercial usage commissioning should only be performed by
professionals, like mechanical technicians and mechanical engineers.
The ducted fan systems are not to be used by persons with pacemakers.

-2-
Delivery Contents
HDS:
1x rotor unit incl. setscrews
1x stator unit
1x clamp ring at buyer's option
2x M3x5 hexagon bolt DIN 912
2x M3 washer DIN 125
1x manual of instruction
1x Allen wrench
HDS incl. motor:
1x ducted fan unit incl. motor at buyer's option
1x Allen wrench
®
HST :
1x fully assembled ducted fan unit
3x connection cable incl. ring terminal
3x M5x8 hexagon bolt DIN 912 8.8
3x M5 washer DIN 433
3x M5 tooth washer DIN 6797
1x manual of instruction
Installation
and
Assembly
-3-

-2-
Delivery Contents
HDS:
1x rotor unit incl. setscrews
1x stator unit
1x clamp ring at buyer's option
2x M3x5 hexagon bolt DIN 912
2x M3 washer DIN 125
1x manual of instruction
1x Allen wrench
HDS incl. motor:
1x ducted fan unit incl. motor at buyer's option
1x Allen wrench
®
HST :
1x fully assembled ducted fan unit
3x connection cable incl. ring terminal
3x M5x8 hexagon bolt DIN 912 8.8
3x M5 washer DIN 433
3x M5 tooth washer DIN 6797
1x manual of instruction
Installation
and
Assembly
-3-

-4-
Installation Instructions
Drawing #1 (Assembly):
DS-30-AXI HDS:
DS-51-AXI HDS:
Information on Drawing #1:
• Prepare the motor according to drawing #3 and the
corresponding instructions (p.7).
• Insert the motor into the stator.
• Before, please apply some copper paste on the wrapped part of
the motor, so that a proper heat conduction between the motor
case and the stator unit can be guaranteed.
• Screw the motor and the stator together according to drawing #1.
• The gap between stator and rotor is adjusted by appropriate
spacers, which will be removed after screwing (e.g. feeler gauge
stock).
•Put the rotor on the motor shaft according to drawing #1 and fix it
with 3 setscrews (pos. 3, drawing #1). In order to do this, please
put the appropriateAllen wrench in the existing bore.
• When fixing the screws, take care that the rotor and the motor
shaft don't stick together because of the screw lock.
• Don't tighten all setscrews at once, but build up fixture step-by-
step all round until you tighten all setscrews in the last round. By
doing this, a central position of the rotor on the motor shaft can be
guaranteed.
• Pay attention to the distance between rotor and stator, and also
to the position of a setscrew above the flat spot of the motor
shaft.
• Please rotate the integrated rotor by hand once. The rotor should
run smoothly (except for the cogging of the motor) and should not
exhibit any grinding noise.
• Please check the evenness of the gap between the rotorblades in
the backlight.
-5-
Drawing #2:

-4-
Installation Instructions
Drawing #1 (Assembly):
DS-30-AXI HDS:
DS-51-AXI HDS:
Information on Drawing #1:
• Prepare the motor according to drawing #3 and the
corresponding instructions (p.7).
• Insert the motor into the stator.
• Before, please apply some copper paste on the wrapped part of
the motor, so that a proper heat conduction between the motor
case and the stator unit can be guaranteed.
• Screw the motor and the stator together according to drawing #1.
• The gap between stator and rotor is adjusted by appropriate
spacers, which will be removed after screwing (e.g. feeler gauge
stock).
•Put the rotor on the motor shaft according to drawing #1 and fix it
with 3 setscrews (pos. 3, drawing #1). In order to do this, please
put the appropriateAllen wrench in the existing bore.
• When fixing the screws, take care that the rotor and the motor
shaft don't stick together because of the screw lock.
• Don't tighten all setscrews at once, but build up fixture step-by-
step all round until you tighten all setscrews in the last round. By
doing this, a central position of the rotor on the motor shaft can be
guaranteed.
• Pay attention to the distance between rotor and stator, and also
to the position of a setscrew above the flat spot of the motor
shaft.
• Please rotate the integrated rotor by hand once. The rotor should
run smoothly (except for the cogging of the motor) and should not
exhibit any grinding noise.
• Please check the evenness of the gap between the rotorblades in
the backlight.
-5-
Drawing #2:

Drawing #3 (Asemmbly of the clamp ring and
preparation of the motor):
DS-51-AXI HDS:
DS-30-AXI HDS:
-6-
Information on Drawing #3:
• Before the material removing process on the motor you have to
seal the motor front- and back-plate, as well as the motor
bearings, so that an intrusion of metal dust during the process
can be avoided.
• Mark the position of the flat spot for the setscrew on the motor
shaft and prepare it with an appropriate tool (e.g. Dremel +
cutting disc).
• Mark the position of the clamp ring on the motor.
• Roughen the marked area carefully and degrease it afterwards.
• Roughen the inside of the clamp ring carefully and degrease it
afterwards.
• Enlarge the front side of the motor by 0,15-0,20 mm (2 layers
crepe tape) and insert the motor in the stator.
• Stick the clamp ring and the motor together by using two-
component construction adhesive (e.g. Hysol 9492AB).
• Pay attention to a central position of the clamp ring and an even
layer within the stator-cone.
• Leave the clamp ring to cure at least for 6h at 50°C or for 24h at
20°C.
• Detach the motor from the stator and remove the thickening at
the front side.
• Wrap the area on the motor, which is marked in the drawing, with
thermal conductive material (e.g. 3M Alutape 425) until you reach
the required diameter ø.
-7-

Drawing #3 (Asemmbly of the clamp ring and
preparation of the motor):
DS-51-AXI HDS:
DS-30-AXI HDS:
-6-
Information on Drawing #3:
• Before the material removing process on the motor you have to
seal the motor front- and back-plate, as well as the motor
bearings, so that an intrusion of metal dust during the process
can be avoided.
• Mark the position of the flat spot for the setscrew on the motor
shaft and prepare it with an appropriate tool (e.g. Dremel +
cutting disc).
• Mark the position of the clamp ring on the motor.
• Roughen the marked area carefully and degrease it afterwards.
• Roughen the inside of the clamp ring carefully and degrease it
afterwards.
• Enlarge the front side of the motor by 0,15-0,20 mm (2 layers
crepe tape) and insert the motor in the stator.
• Stick the clamp ring and the motor together by using two-
component construction adhesive (e.g. Hysol 9492AB).
• Pay attention to a central position of the clamp ring and an even
layer within the stator-cone.
• Leave the clamp ring to cure at least for 6h at 50°C or for 24h at
20°C.
• Detach the motor from the stator and remove the thickening at
the front side.
• Wrap the area on the motor, which is marked in the drawing, with
thermal conductive material (e.g. 3M Alutape 425) until you reach
the required diameter ø.
-7-

Drawing #4 (Secure Fan Fix-optional accessories):
DS-30-AXI HDS:
DS-51-AXI HDS:
-8-
Assembly Instructions Information on Drawing #4:
• Roughen the strut and flange at the adhesive area carefully and
degrease it afterwards.
• Stick the strut with the 2 flanges by using superglue.
To guarantee the parallism of the flanges, please lay them plane
on a flat surface and slot the strut in the notch of the flanges from
above.
• Now fix the flanges in this position by using a drop of superglue.
• Lay the strut with the stuck flanges on the stator unit and align
them to each other.
• Mark the position of the strut and the flanges on the stator unit.
• Roughen the marked position carefully and degrease it
afterwards.
• Once again please position the strut and flanges on the stator unit
exactly and fix it with superglue afterwards.
• Form a fillet of glue at the hatched positions (UHU+Endfest).
• Let the glue cure according to manufacturer's data.
• Thread the rubber damper into the bores of the flanges.
• Remove the positioner of the strut by using an appropriate
clamp.
In Fuse Intake (Optional Accessories):
• Put the In Fuse Intake on the suction side of the impeller.
• Fix the In Fuse Intake by using appropriate adhesive tape
(e.g. 3M Alutape 425).
-9-
Drawing #5:

Drawing #4 (Secure Fan Fix-optional accessories):
DS-30-AXI HDS:
DS-51-AXI HDS:
-8-
Assembly Instructions Information on Drawing #4:
• Roughen the strut and flange at the adhesive area carefully and
degrease it afterwards.
• Stick the strut with the 2 flanges by using superglue.
To guarantee the parallism of the flanges, please lay them plane
on a flat surface and slot the strut in the notch of the flanges from
above.
• Now fix the flanges in this position by using a drop of superglue.
• Lay the strut with the stuck flanges on the stator unit and align
them to each other.
• Mark the position of the strut and the flanges on the stator unit.
• Roughen the marked position carefully and degrease it
afterwards.
• Once again please position the strut and flanges on the stator unit
exactly and fix it with superglue afterwards.
• Form a fillet of glue at the hatched positions (UHU+Endfest).
• Let the glue cure according to manufacturer's data.
• Thread the rubber damper into the bores of the flanges.
• Remove the positioner of the strut by using an appropriate
clamp.
In Fuse Intake (Optional Accessories):
• Put the In Fuse Intake on the suction side of the impeller.
• Fix the In Fuse Intake by using appropriate adhesive tape
(e.g. 3M Alutape 425).
-9-
Drawing #5:

Drawing #6a (Installation of the ducted fan):
-10-
Information on Drawing #6:
• The ducted fan should be fixed with the 4 position points of the
Secure Fan Fix and the recommended screws (table #1, p. 12) in
your model or on the testbed. Alternatively you can fix the
ducted fan differently but alternative mountings should always be
fixed on the casing only in the area of the stator and not in the area
of the rotor.
• Attached thrust tubes and inlet ducts in a closed-duct system
must not brace the ducted fan.
• During assembly, pay attention that the ducted fan has enough
tolerance to all sides, so that a forced position and therefore
upcoming bracing of the components can be avoided.
Bracings inside the system can lead to a rubbing of the rotor!
• The ducted fan has always to be operated with a mounted duct or
an appropriate Intake to lead the air to the rotor cleanly.
Drawing #6b (Installation of the ducted fan):
-11-
Open Duct:
Closed Duct:

Drawing #6a (Installation of the ducted fan):
-10-
Information on Drawing #6:
• The ducted fan should be fixed with the 4 position points of the
Secure Fan Fix and the recommended screws (table #1, p. 12) in
your model or on the testbed. Alternatively you can fix the
ducted fan differently but alternative mountings should always be
fixed on the casing only in the area of the stator and not in the area
of the rotor.
• Attached thrust tubes and inlet ducts in a closed-duct system
must not brace the ducted fan.
• During assembly, pay attention that the ducted fan has enough
tolerance to all sides, so that a forced position and therefore
upcoming bracing of the components can be avoided.
Bracings inside the system can lead to a rubbing of the rotor!
• The ducted fan has always to be operated with a mounted duct or
an appropriate Intake to lead the air to the rotor cleanly.
Drawing #6b (Installation of the ducted fan):
-11-
Open Duct:
Closed Duct:

-12-
Drawing #7 (Dimensions of the Impeller):
Table #1:
Technical
Data
-13-

-12-
Drawing #7 (Dimensions of the Impeller):
Table #1:
Technical
Data
-13-

-14-
Table #2:
Cross-Sections and Weights of the HDS-Setups ®
Cross-Sections and Weights of the HST -Setups:
-15-
Table #3:

-14-
Table #2:
Cross-Sections and Weights of the HDS-Setups ®
Cross-Sections and Weights of the HST -Setups:
-15-
Table #3:

Overviews of the Controller-Settings (HDS):
-16-
Table #4:
®
Overviews of the Controller-Settings (HST ):
-17-
Table #5: