Acme Engineering PV100 Installation Manual

FORM 613097

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INSTALLATION & MAINTENANCE INSTRUCTIONS

Models PV (including PVH hurricane option) and USPV

For the PV Model with hurricane construction that complies with Florida Building Code including High Velocity Hurricane Zones (HVHZ) see the ADDITIONAL INSTALLATION AND MAINTENANCE INSTRUCTIONS on page 4.

RECEIVING AND INSPECTION

Immediately upon receipt of a shipment, carefully inspect for damage and shortage. Turn the impeller by hand to see that it turns freely and does not bind. If any damage and/or shortage is detected or suspected, the carrier must be asked to conduct an inspection. The consignee’s representative should not accept a shipment without a notation on the delivery receipt indicating items not delivered or the apparent extent of damage.

When a shipment is opened and damage is found which was not evident externally (concealed damage), it is mandatory that the consignee request an immediate inspection by the carrier. Report any damage to the carrier within 15 days. Failure to report damage within the above time limit will result in rejection of a claim.

HANDLING

When handling fans and their accessories, always use equipment and methods that will not cause damage. Fans should be lifted using slings and padding or spreaders to avoid damage.

CAUTION! Always make sure that all lifting and handling equipment and techniques conform to current safety standards.

Avoid lifting fans in a way that will bend or distort fan parts. Never pass slings or timbers through the fan orifice.

CAUTION! Do not lift by the fan hood. Fans with special coatings or paints must be protected in handling to prevent damage.

STORAGE

Fans are protected against damage during shipment. If they cannot be installed and put into operation immediately upon receipt certain precautions are necessary to prevent deterioration during storage. Responsibility for integrity of fans and accessories during storage must be assumed by the user. The manufacturer will not be responsible for damage during storage. These suggestions are provided solely as a convenience to the user, who shall make his own decision as to whether to use any or all of them.

INDOOR: The ideal storage environment for fans and accessories is indoors, above grade, in a low humidity atmosphere which is sealed to prevent the entry of blowing dust, rain, or snow. Temperatures should be evenly maintained between 70°F and 105°F (wide temperature swings may cause condensation and "sweating" of metal parts). Windows should be covered to prevent temperature variations caused by sunlight. Provide thermometers and humidity indicators at several points and maintain the atmosphere at 40% relative humidity, or lower.

It may be necessary to use trays of renewable desiccant or portable dehumidifier to remove moisture from the air in the storage enclosure.

Thermostatically controlled portable heaters (vented to outdoors) may be required to maintain even temperatures inside the enclosure.

CAUTION! Provide fire extinguishers, or fire alarms, or emergency response communication to protect building and

equipment against fire damage. Be sure that building and storage practices meet all local, state and federal fire and safety codes.

The following fans or accessories must be stored indoors, in a clean dry atmosphere:

a. Propeller wall fans not in wall housings. b. Any fan protected by a cardboard carton. c. Motors dismounted from fans. d. Spare wheels or propellers. e. Belts, sheaves, bushings and other parts when not

mounted on fan. f. Boxes, bags or cartons of hardware. g. Curbs h. Dampers

Remove any accumulations of dirt, water, ice or snow and wipe dry before moving to indoor storage. Allow cold parts to reach room temperature to avoid “sweating” of metal parts. Open boxes or cartons. Remove any accumulated moisture; if necessary use portable electric heaters to dry parts and packages. Leave coverings loose to permit air circulation and to permit periodic inspection.

Rotate wheels or propellers by hand to distribute bearing grease over the entire bearing surfaces.

Store at least 3 ½” off the floor on wooden blocks covered with moisture proof paper or polyethylene sheathing. Provide aisles between parts and along all walls, to permit air circulation and space for inspection.

OUTDOOR: Fans designed for outdoor use may be stored outdoors, if absolutely necessary. The storage area should be reasonably level and drained or ditched to prevent accumulation of water. Fencing and lighting for security are desirable. Roads or aisles for portable cranes and hauling equipment are needed. Consider the use of drift fencing to minimize accumulation of blowing snow or dirt.

The following fans may be stored outdoors, if dry indoor storage space is not available:

a. Fans intended for outdoor use that are crated in wood. b. Wall fans installed in wall housings.

All fans must be supported on wooden blocks or timbers above water or normal snow levels. Provide enough blocking to prevent settling into soft ground. Fans should be set in place using the directional arrow markings on the crate as a guide.

Locate pieces far enough apart to permit air circulation, sunlight, and space for periodic inspection. Place all parts on their supports so that rain water will run off, or to minimize water accumulation. Do not cover parts with plastic film or tarps-these cause condensation of moisture from the air passing through heating and cooling cycles.

Fan wheels and propellers should be blocked to prevent spinning caused by strong winds.

INSPECTION AND MAINTENANCE

DURING STORAGE

Inspect fans and accessories at least once per month, while in storage. Log results of inspection and maintenance per formed. A typical log entry should include the following:

a. Date b. Inspector’s Name c. Name of Fan

d. Location e. Condition of Paint or Coating f. Is moisture present? g. Is dirt accumulated? h. Corrective steps taken?

If moisture or dirt accumulations are found on parts, the source should be located and eliminated. Fans should be rotated at each inspection by hand ten to fifteen revolutions to redistribute the motor and bearing lubricant.

If paint deterioration begins, consideration should be given to touch-up or repainting. Fans with special coatings may require special techniques for touch-up or repair.

Machined parts coated with rust preventive should be restored to good condition promptly if signs of rust occur. The most critical items are pulleys, shafts and bearing locking collars. At the first sign of rusting on any of the above parts, remove the original rust preventive coating with petroleum solvent and clean lint-free cloths. Polish any remaining rust from surfaces with crocus cloth or fine emery paper and oil. Do not destroy the continuity of the surfaces. Wipe clean with lint-free cloths and recoat surfaces evenly and thoroughly with Tectly 506 (Ashland Oil Company) or equal. For hard to reach internal surfaces or for occasional use, consider using Tectly 511M Rust Preventive or WD40 or equal.

REMOVING FROM STORAGE

As fans are removed from storage to be installed in their final location, they should be protected and maintained in similar fashion, until the fan equipment goes into operation.

INSTALLATION

CAUTION! This unit has rotating parts and safety precautions should be exercised during installation, operation and maintenance.

WARNING! Do not use in hazardous environments where fan’s electrical system could provide ignition to combustible or flammable materials, unless unit is specifically built for hazardous environments.

WARNING! If gases, other than clean air, are to be exhausted using the fan, then the user bears the responsibility of determining that the fan is appropriate and safe for the application.

4. If the fan manufacturers prefab curb is used, a flange is provided for mounting the damper. Damper should be installed before setting exhauster.

5. If damper box is being used, assemble box and mount in curb before setting exhauster. Damper may be installed at this time if desired. Damper should be fastened to the bottom of the damper box, curb flanges or nailing strips in curb.

6. Remove motor compartment cover and mount motor onto drive base. (Larger motors are shipped not mounted because of the possibility of shipping damage.)

Refer to Figure 3 for sizes 75-240 and Figure 2 for Hurricane model). The motor is mounted directly to the slots on the drive base using the four motor mount bolts with their nuts. For sizes 75-135, motors with 1 (38mm) shaft length use upper set of slots on the drive base. For motors with shaft longer than 1 lower set of slots on the drive base. Belt tensioning is

" (38mm) use

brought about by sliding the motor away from the fan pulley and then tightening the motor mount bolts and nuts.

Belt should depress its width when pressed firmly inward at midway point between the pulleys. Connect the wiring

and conduit, if used, from the disconnect switch to the motor.

For fan sizes 260 through 300, refer to Figure 4, for size 365 refer to Figure 5 and for size 425 through 543 refer to Figure 6. Motor adjustment rails are provided. Most motors for these sizes are shipped separately. The motor is to be bolted to the motor adjustment rails using the motor mount bolts, nuts and washers. Install belt(s) and check for tension. Belt tensioning is accomplished by loosening the motor adjustment rail bolts and nuts, and also the belt jack locknut. The two (2) belt jack bolts are then turned clockwise to tighten the belt. After proper belt tension is reached, the motor adjustment rail bolts and nuts and belt jack locknuts must be tightened. The proper belt tension is described above. The electrical wiring connections can now be made and the flexible steel conduit (where used) may be connected to the motor.

7. Turn impeller by hand to make sure it rotates freely. If impeller hits orifice, adjust as follows:

For fans with duplex split pillow block bearings, 3-dimensional adjustment is provided. Horizontal movement for adjustment is allowed by four (4) bolts in the separator pan. Loosen the four nuts in the outer edge (one in each quadrant) of the separator pan for adjustment in all horizontal positions, re-tighten the four nuts. Vertical movement for adjustment is allowed by two (2) slots in the motor base bearing housing at the top and bottom. The set screws can be loosened and the shaft can be raised or lowered. Then the set screws must be re-tightened following the set screw tightening procedure in Table 1.

Fans with unitary pillow block bearings have the same adjustment capability and is accomplished in the same manner as described above with one exception. The vertical adjustment is carried out by loosening the bearing set screws and carefully sliding the fan shaft to a new location. Tighten all bearing set screws (see Table 1 for torque recommendations) into the fan shaft when complete.

WARNING! Do not damage the orifice when adjusting the wheel.

CAUTION! Guards must be installed when fan is within reach of personnel or within eight (8) feet (2.5m) of working level or when deemed advisable for safety.

CAUTION! Before proceeding, make sure electrical service to fan is locked in “OFF” position.

10. All wiring should be in accordance with local ordinances and the National Electric Code.

11.

WARNING! Check voltage at the fan to see if it corresponds with the motor nameplate. High or low voltage can seriously damage the motor. Extra care should be taken when wiring two speed motors since improper connections will damage motor and void motor warranty. Leave enough slack in wiring to allow for motor movement when adjusting belt tension.

12. Apply power momentarily and compare the rotation of the impeller with the directional arrow on fan. Wheel rotation is clockwise as viewed from drive side. WARNING! Operation in the wrong direction will deliver air but will

overload the motor to the extent of blowing fuses, and seriously damaging the motor. In the case of three phase motors, the direction can be changed by interchanging any two of the three motor leads. In the case of single phase motors, the reversing instructions will appear on the wiring diagram in the motor wiring compartment.

13. Using a minimum of eight (8) lag bolts - two (2) on each side near corners, securely fasten fan to curb. Fasten all bolts securely. The fan should rest on the curb as level as possible.

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MAINTENANCE

1. Under normal usage, no spare parts are recommended for one year of operation. Recommended spare parts are shown on pages 5 through 9.

CAUTION! Before proceeding, make sure electrical service to fan is locked in “OFF” position.

WINDMILLING: Even when the power supply is locked out, fans may cause injury or damage if the impeller is subject to “windmilling” which is the turning of the impeller and drive components due to a draft in the system. To guard against this hazard, the impeller should be secured to physically restrict rotational movement.

2. Impeller shaft bearings on units with duplex split pillow block housing are permanently lubricated and do not require relubrication. Units with unitary pillow block bearing have grease fittings and, under normal operation will need no relubrication for 3 to 5 years. If relubrication is required, use a grease conforming to NLGI No. 2. CAUTION! Lubricating bearings with a high pressure gun can blow bearing seals and overfill the bearing with grease. This condition can result in excessive churning and overheating. For normal operating conditions it is a standard practice to fill only 30% of the bearing void with grease. Do not over lubricate.

3. Motor bearings are prelubricated. Consult information printed on motor for lubrication instructions.

4. Check belt tension after first 48 hours of operation and thereafter annually. Belt should depress its width when pressed firmly inward at midway point between the pulleys. Too much tension will damage bearings. Belt should be tight enough to prevent slippage. When replacing worn belt, replace motor pulley if “shoulder” is worn in groove.

WARNING! Do not replace the motor pulley with a larger diameter pulley. Do not replace the fan pulley with one smaller in diameter. The pulley ratios are set so that the motor will not be overloaded. Do not operate at speeds higher than that cataloged for this equipment.

5. If impeller shaft bearings need replacement, replace with bearings comparable to the original equipment. If duplex split pillow block bearings are used, install new bearings into neoprene rings, check correct position of impeller with orifice, position bearings in die-formed recess and tighten set screws. (Minimum/maximum torque settings shown in Table 1.) Replace die-formed bearing cap and tighten four bolts.

NOTE: If locking collar type bearing is used, collar must first be positioned against inner race on the bearing nearest the impeller and turned in the direction of impeller rotation with drift pin and hammer until it locks. Locking collars must be on the inboard (facing) sides of the bearings. Secure the bearing to the shaft with torque set screw. Lock and secure the other bearing to the shaft in the same manner.

NOTE: If pillow block type bearings are used, slide bear ings onto shaft to desired location and bolt bearing block securely to support base. Slide shaft back and forth in secured bearing (do not drive with hammer) and rotate to make certain it turns freely. Check correct position of im peller with inlet orifice. Then secure bearings to shaft by tightening set screws.

SET SCREW TIGHTENING SCHEDULE

1. Before initial operation of the fan, tighten set screws according to the procedure outlined below.

2. After 500 operating hours or three months, whichever comes first, tighten set screws to the full recommended torque.

3. At least once a year, tighten set screws to the full recommended torque.

PROCEDURE FOR TIGHTENING SET SCREWS IN

BEARINGS AND HUBS

One Set Screw Application

Using a torque wrench, tighten the set screw to the torque recommended in Table 1.

Two Set Screw Application

1. Using a torque wrench, tighten one set screw to half of the torque recommended in Table 1.

2. Tighten the second set screw to the full recommended torque.

3. Tighten the first set screw to the full recommended torque.

Table 1. Recommended Tightening Torque

for Set Screws

Set Screw Diameter Torque (in-lbs)

#10 35

1/4 80

5/16 126

3/8 240

7/16 384

1/2 744

9/16 1080

5/8 1500

3/4 2580

7/8 3600

1 5400

VARIABLE FREQUENCY

DRIVES AND MOTORS

There are occasions when a Variable Frequency Drive (VFD) will cause poor motor performance and possible damage. To avoid these problems, the Company recommends the following:

1. Select compatible motor and VFD inverter; if possible, the motor and the inverter should be from the same manufacturer or at least the inverter selected should be recommended by the motor manufacturer.

2. A motor shaft grounding system should be used to

prevent motor bearing damage from eddy currents.

NOTE: The Company will not honor motor warranty claims if the customer fails to follow these recommenda

tions.

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