Minimizing Risk Through Proper Axial Fan Selection

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Fan Application A technical bulletin for engineers, contractors and students in the air movement and control industry.Minimizing Risk Through Proper Axial Fan SelectionSelecting an axial fan is easy, right? You only need toknow the performance point, sound requirements,and size restrictions. The only thing left is to requirecertifications in order to assure those criteria are met.Unfortunately, it is not so easy.Subtleties in the catalogs, certifications andperformance of axial fans, combined with a relativelyhigh number of corresponding certifications andstandards, make it easy to select the wrong fan orincorrectly compare two performance points.Improper fan selection and procurement leads toincreased cost and project delays due to highercommissioning, expensive returns and inefficientoperation.Read on to better understand the following:expected soundlevels can leadto costly projectdelays and must beavoided wheneverpossible. AMCAoffers solutions tosuch problems byoffering the AMCACertified RatingsProgram (AMCAGreenheck Axial Fan Model RACRP). AMCACRP serves asthe global standard in air and sound performancetesting. A brief introduction of the axial fan relatedAMCA certifications will be provided and additionalinformation can be found in the references below. Relevant certifications High temperature certifications and derating(EN12101-3 and UL) Challenges of completing a “full-product”certificationThe AMCA CRP program has two sets ofdocumentation: publications and test standards.Publications are high-level descriptions defining thesteps required for a product series to be certified. Thepublications then reference specific test standardswhich further define test procedures. Common pitfalls.The two main publications for axial fans are:Minimize your risk by understanding the importanceand challenges associated with proper certification andfan selection. AMCA Publication 211, Fan Air Performance AMCA Publication 311, Fan Sound Performance.Relevant CertificationsThe AMCA CRP test standards are shown under TestStandards in this document. A specifying engineeror consultant may choose to reference both thepublication and the test standard in order to increasetheir confidence that the product is AMCA certified.Air and Sound Certification — AMCAThe most important part of the fan is its air andsound performance. Improper airflow or higher thanP.O. Box 410 Schofield, WI 54476 715.359.6171 Fax 715.355.2399Copyright 2016 Greenheck Fan Corp.

Greenheck Product Application GuideTest Standards ANSI / AMCA Standard 210, LaboratoryMethods of Testing Fans for CertifiedAerodynamic Performance Rating ANSI / AMCA Standard 250, LaboratoryMethods of Testing Jet Tunnel Fans forPerformance ANSI / AMCA Standard 300, Reverberant RoomMethod for Sound Testing of Fans ISO 5801, Industrial Fans — Performance TestingUsing Standardized Airways ANSI / AMCA Standard 320, LaboratoryMethods of Sound Testing of Fans using SoundIntensity ANSI/AMCA Standard205, Energy EfficiencyClassification for FansIn order for a product to qualifyas an AMCA Certified Productit must meet all of the followingcriteria: Tested at AMCA Accreditedlaboratory Tested to the appropriatetest standard Published catalog or electronic selection softwarethat is reviewed and approved by AMCA All certified models are listed at www.amca.orgwith a reference to the certified catalog and/orelectronic selection software Periodic check test performed on schedule.If any of the above criteria are not met, then the productis not certified and should not bear the AMCA seal. Anuncertified product could lead to low performing air andsound, and costly commissioning.AMCA is a third-party, independent entity thatverifies air and sound performance and ensures thatall manufacturers use the same methods for collectingthe data. When comparing fan performance between2manufacturers, it is critical that you compare AMCAdata to AMCA data. If a manufacturer’s data is notAMCA certified, it may not be independently verified.High Temperature CertificationsSimilar to the air and sound performance, the motormake and origin selected for the high temperatureapplication should exactly match the testedcombination of fans and motors. A manufacturerloses the certification and assurance that the fan willperform if they use a motor from a different countryor different brand name.Common certifications are the following: UL Power Ventilators for Smoke Control Systems:572 F / 2 hours, 752 F / 2 hours EN12101-3 Specification for Powered Smoke andHeat Exhaust Ventilators: 300 C for two hours,400 C for two hours.EN12101-3 is a European-based standard whichcertifies ventilators to be used for smoke controlapplications. It requires that the units be fullyimmersed in the hot air as opposed to just the airflow through the prop. In addition, the worst caseconditions must be tested along with all accessories.The high temperature testing also must occur in theproper mounting position or else the certificationis invalid. Matching the EN12101-3 requires beingtested by a third party company which is an officialnotified body. The manufacturer can then display theCE mark.UL requires that one fan size be tested to qualify aspecific motor manufacturer. The test process, as wellas the motor size and power, is defined and chosenby the manufacturer and subsequently confirmed bythe UL inspector. Any test temperature and durationis selected by the manufacturer because UL doesnot have a test standard. The time and temperatureis typically selected based on other standards orcodes such as NFPA and IBC. However, the time,temperature, and test methodology can vary fromcompany to company and even across product lineswithin the same company.Fan Application

Greenheck Product Application GuideIn the case of both UL and EN12101-3, if the fan isinstalled or configured in a way that is different fromthe way it was tested and certified, then it is no longercertified to work in the intended high temperatureenvironment.High Temperature – Derating PerformanceA high temperature rated fan is less efficient than astandard temperature fan. This is primarily because asthe temperature of the fan increases, the blade and thehousing have different rates of thermal expansion. Inorder to prevent the blades of the fan from touchingthe fan housing, the distance between the bladesand fan housing (tip clearance) must be increased.Depending on the performance point, the differencein efficiency could result in 1-10% difference in powerconsumption, and in some cases may also require alarger motor.There is no standard method for derating thehigh temperature performance to the standard fanperformance. However, if you encounter a manufacturerthat has the same performance for the standard and hightemperature fans, it is strongly suggested that you ask themanufacturer why there are no performance degradationspublished.Challenges of Completing A “Full-Product”CertificationEvery performance point must be certified across allof these construction combinations which typicallyrequires that a high number of fans be tested. AMCAallows propellers to be tested with blades at variousdegree increments. That initial data can then beused to interpolate the performance across the otherpoints which have not been tested. Accessory lossescan also be subtracted from the AMCA certified data.However, only the base unit data is actually AMCAcertified and published because the fan performancewill be maximized.As an example, please refer to Greenheck’s RA productline. This product has the entire product line certifiedto bear the AMCA Air and Sound seal.Figure 1 shows the breakdown of the RA modelnomenclature and all the potential combinations. Itis a significant cost to test the product across all thevarious combinations, which is motivation for themanufacturers to be tempted to not validate the entireline.To further illustrate, Figure 2 shows an excerpt fromthe AMCA certified performance catalog showingvarious pitch angles on a single fan size, hub, prop, andmotor speed combination. These catalogs are requiredto be available on the AMCA website. In order forthe RA product line to be completely certified, over1,000 tests (air and sound) were submitted to AMCA.These tests accounted for all the data shown in theGreenheck Model RA performance catalog, as well asin our Computer Aided Product Selection program,With advances in manufacturing processes of axialfans, each product has a high degree of configurationwhich makes certifying the product difficult, andmaking sure the product you are selecting is certifiedequally difficult. Review thecertification documents to ensure themodel being purchased matches themodel offered.RA - Round AxialThe standard design components ofan axial fan are: Fan size diameter Hub diameter Number of blades Pitch angle of blades.Model Number CodeRA - 500 - 225 - 4 - 40-20 - 4Fan ub Diameter190400225533275Motor Speed2 - 2 Pole4 - 4 Pole6 - 6 Pole8 - 8 PoleBlade Pitch(degrees)Number of Blades3, 4, 6, 8, 9, 12Figure 1 - RA Fan Model NomenclatureFan Application3

Greenheck Product Application GuideRA-315-225-3 (2900 RPM)Common PitfallsTested “In Accordance With”Figure 2 - This excerpt from RA fan catalog performancecatalog shows certified data for the 315 mm diameterfan with a 225 mm hub. The fan certified has threeblades and was tested at ten different blade angles.CAPS. Each RA model was tested across ten differentblade angles that performed within close enoughperformance of each other to guarantee the requiredAMCA tolerance. This method of rating providesa rigorous and thorough process to ensure that thetest data provided will match what manufacturersactually produce for all fan sizes and constructioncombinations.Many manufacturers claim that aproduct is tested “in accordancewith” a particular standard. Thestandard could be AMCA, UL, ENor any other standard, but “testingin accordance with” does not meanthat the product is certified. Forexample, when a manufacturerrequires the EN12101-3certification, the testing must beconducted by a “notified body”that is a third party testing facilitywho ensures the product worksin the desired environment. Ifa manufacturer claims to haveEN12101-3 and they have notemployed the services of a notifiedbody or cannot direct the customerto a notified body’s website,then the product is not certified.Without third party certification,there is no assurance that theproducts purchased will perform inan emergency situation when thecustomer needs it the most.Similarly, a product could be tested to a particularAMCA standard, but it may only be tested bythe manufacturer on uncertified equipment. Themanufacturer may then potentially test limitedproduct variations that are not representative of theworst case conditions. AMCA may have not beeninvolved in the testing, nor in reviewing the data, yetthe manufacturer could still claim to be tested “inaccordance with” that particular standard.To ensure you are getting a certified product, it isvital to confirm that the construction details of thefan selected match the certified product. This requires Regardless of the standard, it is important to minimizerisk and maximize safety by confirming that theconfirming the fan diameter, blade size, hub size,number of blades and the pitch angle. If a competitor products being purchased are properly certified.does not submit the full product code, it is importantto request it and verify that model is certified.4Fan Application FA/

Greenheck Product Application GuideAMCA Certified Ratings Seal VersusMember LogoAnother important point to note is the differencebetween the AMCA certified ratings seal and themember logo. The member logo can be used onmarketing documentation that has no performancedata in order to demonstrate that the companyis a member of the AMCA organization. It doesindicate any certification for a particular product line.Sometimes companies may place the member logoon documentationwith performancedata. This misleadsthe audience tothink that theproduct is AMCAcertified. Theconfusion thatthis misusage cancause is why it is aviolation of AMCA.The AMCA ratings seal, on theother hand, is used to show thata particular product is certifiedto air and/or sound.Catalog Comparison Tips —Sound ComparisonsWith axial fans in particular,the sound data can be confusing.Manufacturers may choose to publish sound poweror sound pressure. Sound power is easier to comparebecause it is not affected by the environment ordistance. Sound pressure, on the other hand, will givedifferent results depending on the environment. Ifcomparing sound pressure levels, make sure to payattention to the type of sound that is tested (inlet/outlet/total sound) along with any distance referencesof published dBA ratings. It is also important to beaware of what type of sound information is publishedand certified. The sound performance could belisted as octave band sound power levels, A-weightedsound power levels or sones (either hemispherical orFan Application FA/spherical). When comparing the sound levels of twofans review their respective method of testing andconfirm that the results are comparable. Similarly,make sure that when comparing sound on products,the product is also AMCA Air and Sound Certified.ConclusionThe elements outlined in this paper are critical toensuring you get the product and performance thatyou can rely on. Understanding ways to properlyselect an axial fan and determining that it is certifiedwill minimize the risk of surprises occurring on thejob site. This will prevent costly project delays dueto extended commissioning, product returns andpotential reorders from another supplier — savingtime and money. In the case of smoke removal or othersafety applications it is vital to ensure the health andsafety of the building occupants. Specify, purchaseand install with confidence — correctly selectcertified products for your building projects.Sources AMCA Publication 11, Certified Ratings ProgramOperating Manual www.amca.org/whitepapers www.greenheck.com.in www.greenheck.com www.amca.org www.asiaamca.org www.amca.org/certified-listed/cpsearch.php5

Greenheck Product Application Guide6Fan Application FA/

Methods of Testing Fans for Certified Aerodynamic Performance Rating ANSI / AMCA Standard 250, Laboratory Methods of Testing Jet Tunnel Fans for Performance ANSI / AMCA Standard 300, Reverberant Room Method for Sound Testing of Fans ISO 5801, Industrial Fans — Performance Testing Using Standardized Airways

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