Carnes AC Installation Manual
WARNING
This unit has rotating parts. Safety precautions
should be exercised at all times during installation,
operation, and maintenance.
ALWAYS disconnect power prior to working on fan.
Personal Safety
Disconnect switches are recommended. Place
the disconnect switch near the fan in order that
the power can be swiftly cut off in case of an
emergency, and in order that maintenance personnel are provided complete control of the
power source.
AC
Centrifugal Roof and Wall Exhausters
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
This publication contains the installation, operation
and maintenance instructions for st andard units of the
AC-Centrifugal Roof and Wall Exhausters.
• ACE-D/ACE-B
• ACW-D/ACW-B/ACW-HP/ACW-XP
• ACRU-D/ACRU-B/ACRU-HP/ACRU-XP
Carefully read this publication prior to any installation or maintenance procedure.
Loren Cook catalog, AC, provides additional information
describing the equipment, fan performance, available
accessories, and specification data.
For additional safety information, refer to AMCA publication 410-96, Safety Practices for Users and Installers of
Industrial and Commercial Fans.
All of the publications listed ab ove ca n be o btained from
Loren Cook Company by phoning 417.869.6474, extension 166; by FAX at 417.832.9431; or by e-mail at
info@lorencook.com.
For information and instructions on special equipment,
contact Loren Cook Company at 417.869-6474.
Receiving and Inspection
Immediately upon receipt of an AC fan, carefully inspect
the fan and accessories for damage and shortage.
• Turn the wheel by hand to ensure it turns freely and
does not bind.
• Check dampers (if included) for free operation of all
moving parts.
• Record on the Delivery Receipt any visible sign of
damage.
Handling
Lift the fan by the shipping carton or lifting lugs provided under
top cap. Never lift by the shaft,
motor or housing.
Storage
If the fan is stored for any length
of time prior to installation, store it
in its original shipping crate and
protect it from dust, debris and
the weather.
Lifting Lugs
grease terminator or grease trough was not purcha sed, a 1 1/16 inch diameter drain hole should be drilled at the bottom
side of the fan for drainage.
Wall Exhauster Installation
If your fan is a wall exhauster, a mounting template is
shipped with the fan. Use the template to locate the necessary lag screws or anchor bolts on the wall. The fa n can then
be lifted and attached easily. Secure with lag screws, anchor
bolts, or other suitable fasteners.
Damper Installation
If your fan is supplied with dampers, follow the directions
below. If your fan does not include dampers, proceed to Belt
and Pulley Installation.
a. Place the damper inside the curb or inside the duct
work. Ensure the damper will open freely for the correct
direction of the airflow.
b. Secure to curb at the damper shelf.
c. Drill hole in the curb shelf for conduit needed for motor
wiring.
d. Operate the dampers manually to ensure the blades
move freely.
e. Install fan over curb while aligning the conduit location
with the conduit hole in the curb.
Wiring Installation
All wiring should be in accordance with local ordinances
and the National Electrical Code, NFPA 70. Ensure the
power supply (voltage, frequency, and current carrying
capacity of wires) is in accordance with the motor nameplate. Refer to the Wiring Diagrams, page 3.
Upblast units have two wiring conduits. The vertical con-
duit comes plugged. The horizontal conduit is directly
above the vertical conduit.
Installation
If the fan was delivered with the motor unmounted, see
the maintenance section for belt and pulley installation.
If the fan was purchased as a wall mount unit and a
ACE-B
For Units Without A Juncti on Box
Personal Safety
Disconnect switches are recommended. Place
the disconnect switch near the fan in order that
the power can be swiftly cut off in case of an
emergency, and in order that maintenance personnel are provided complete control of the
power source.
Recommended Torque for Setscrews/Bolts (IN/LB)
Setscrews
Hold Down Bolts
Size
Key Hex
Across
Flats
Recommended
Torque
Min. Max. Size
Wrench
Torque
No.10 3/32” 28 33 3/8”-16 240
1/4” 1/8” 66 80 1/2”-13 600
5/16” 5/32” 126 156 5/8”-11 1200
3/8” 3/16” 228 275 3/4”-10 2100
7/16” 7/32” 29 348 7/8”-9 2040
1/2” 1/4” 42 504
5/8” 5/16” 92 1104
3/4” 3/8” 120 1440
An approved metal field wiring compartment must be
secured to the unit with two screws in order that the box
does not rotate. All wires must be protected from abrasion
where they enter and exit the wiring compartment. The
green ground wire from the motor must be secured under
the green ground screws inside the field wiring compartment using a closed loop connector . Complete connections
in accordance with the wiring diagram on the motor.
For Units With A Junction Box
Pull wires through the appropriate conduit. Protect wires
from abrasion where they enter the field wiring compartment
and complete connections in accordance with the diagram
on the motor.
Lock off all power sources before the fan is wired to
power source.
Leave enough slack in the wiring to allow for motor movement when adjusting belt tension. Some fractional motors
have to be removed in order to make the connection with
the terminal box at the end of the motor.
Follow the wiring diagram in the disconnect switch
and the wiring diagram provided with the motor. Correctly label the circuit on the main power box and
always identify a closed switch to promote safety (i.e.,
red tape over a closed switch).
a. Remove the top cap which covers the motor assembly
by unlatching the snap clips.
b. For internal wiring, run the electrical wire and conduit
through the opening drilled in the damper shelf (refer to
Damper Installation), then through the wiring conduit in
the ventilator base to the motor compartment. For
external wiring, run the wires through the horizontal
conduit on upblast units, or under top cap in downblast
units.
c. Pull the wires through and complete the wiring. For fur-
ther information. Refer to Wiring Diagrams on page 3.
Final Installation Steps
a. Ensure fasteners and set screws, particularly fan
mounting and bearing fasteners are tightened according to the recommended torque shown in the table on
page 2, Recommended Torque for Setscrews/Bolts.
b. Inspect for correct amperage with an amme ter and cor-
rect voltage with a voltmeter.
c. Ensure that all accessories are installed.
d. Test the fan to be sure the rotation is the same as indi-
will overheat the motor and cause serious damage. For
3-phase motors, if the fan is running in the wrong direction, check the control switch. It is possible to interchange two leads at this location so that the fan is
cated by the arrow marked Rotation.
Do not allow the fan to run in the wrong direction . This
operating in the correct direction.
e. Inspect wheel-to-inlet clearance. Wheels may shift in
shipment. To realign wheel-to-inlet, shift upper bearing
so there is an equal radial clearance between the wheel
and inlet. Refer to wheel to inlet clearance on page 5.
Operation
Pre-Start Checks
a. Lock out all the primary and secondary power sources.
b. Inspect and tighten fasteners and setscrews, particu-
larly fan mounting and bearing fasteners Refer to
Torque chart.
c. Inspect belt tension and pulley alignment. Refer to Belt
and Pulley Installation, page 4.
d. Inspect motor wiring. Refer to Wiring Installation.
e. Ensure belt touches only the pulleys.
f. Rotate the wheel to ensure it rotates freely.
g. Ensure fan and ductwork are clean and free of debris.
h. Close and secure all access doors.
i. Restore power to fan.
Start-up
Turn on the fan. In variable speed units, set the fan to its
lowest speed. Inspect for the following:
• Direction of rotation
• Excessive vibration
• Unusual noise
• Bearing noise
• Improper belt alignment or tension (listen for squealing)
• Improper motor amperage or voltage
If a problem is discovered, immediately shut the fan
off. Lock out all electrical power and check f or the cause
of the trouble. Refer to Troubleshooting on page 6.
Inspection
Inspection of the fan should be conducted at the first 30
minute, 8 hour and 24 hour intervals of satisfacto ry oper a-
tion. During the inspections, stop the fan and inspect as
instructed.
30 Minute Interval
Inspect bolts, setscrews, and motor mounting bolts. Adjust
and tighten as necessary.
8 Hour Interval
Inspect belt alignment and tension. Adjust and tighten as
necessary.
24 Hour Interval
Inspect belt tension. Adjust and tighten as necessary.
2
Wiring Diagrams
Fan
Motor
Damper
Motor*
Second
Damper
Motor
T
ransformer**
Transformer**
L3
L2
L1
T-1
T-4
Ground B
L
2
L
1
Ground A
Line
Ground B
J-10
T-5
Ground A
Link A
Link B
Low Voltage
Line
L
2
L
1
Ground A
Link A & B
L
1
L
2
Line
Ground B
T-5
J-10
Single Speed, Single Phase Motor
When ground is required, attach to ground A or B with no. 6 thread forming
screw. To reverse, interchange T-1 and T-4.
Wiring Diagrams
3 Phase, 9 Lead Motor
Y-Connection
Low Voltage
208/230 Volts
4
5
6
3
1
9
728
L2L
L
1
To reverse, interchange any 2 line leads.
3
High Voltage
460 Volts
456
789
3
12
L2L
L
3
1
3 Phase, 9 Lead Motor
Delta-Connection
Low Voltage
208/230 Volts
7
6
1
L
L
1
2 Speed, 2 Winding, Single Phase Motor 2 Speed, 1 Winding, 3 Phase Motor
Ground A
T-1
T-4
Ground B
High Speed
Low Speed
L
1
Line
L
2
When ground required, attach to ground A or B with No. 6 thread forming
screw. To reverse, interchange T-1 and T-4 leads.
Motor
To reverse, interchange any 2 line leads. Motors require magnetic control.
High Speed
1
Together
2
3
L
4
1
L
5
6
L
Motor
2
Line
3
Single Speed, Single Phase, Dual Voltage 2 Speed, 2 Winding, 3 Phase
9
8
5
4
3
2
L
3
2
Low Speed
High Voltage
1
2
3
4
5
6
460 Volts
789
456
12
L1L
L
2
L
1
L
2
Line
L
3
Open
3
3
When ground required, attach to ground A or B with No. 6 thread forming
screw. To reverse, interchange T-5 and J-10 leads.
Typical Damper Motor Schematic
For 3 phase, damper motor voltage should be the same between L1 and
. For single phase application, disregard L3. *Damper motors may be
L
2
available in 115, 230 and 460 volt models. The damper motor nameplate
voltage should be verified prior to connection. ** A transformer may be
provided in some installations to correct the damper motor voltage to the
specified voltage.
Maintenance
Establish a schedule for inspecting all parts of the fan. The
frequency of inspection depends on the operating conditions and location of the fan.
Inspect fans exhausting corrosive or contaminated air
within the first month of operation. Fans exhausting contaminated air should be inspected every three months.
Regular inspections are recommended for fans exhausting non-contaminated air.
Regular inspections of the Grease Terminator 2 are recommended. Depending on the amount of grease discharged through the fan, the Grease Terminator 2 should
be changed every 30 to 45 days to ensure proper operation. Any buildup of grease is easily seen during a visual
inspection of the clear canister. However, if the Grease Ter-
To reverse: High Speed-interchange leads T11 and T12.
Low Speed-interchange leads T
line leads.
and T2. Both Speeds-interchange any 2
1
minator 2 becomes saturated, grease will no longer be
absorbed.
It is recommended the following inspections be conducted
twice per year.
• Inspect bolts and setscrews for tightness. Tighten as necessary. Refer to Torque chart.
• Inspect belt wear and alignment. Replace worn belts with
new belts and adjust alignment as needed. Refer to Belt
and Pulley Installation, page 4.
• Bearings should be inspected as recommended in the
Conditions Chart.
• Inspect for cleanliness. Clean exterior surfaces only.
Removing dust and grease on motor housing assures
proper motor cooling.
3
Fan Bearings
Relubrication Intervals
Service
Conditions
NEMA Frame Size
Up to and
including 184T
213T-365T 404T and larger
1800 RPM
and less
Over 1800
RPM
1800 RPM
and less
Over 1800
RPM
1800 RPM
and less
Over 1800
RPM
Standard 3 yrs. 6 months 2 yrs. 6 months 1 yr. 3 months
Severe 1 yr. 3 months 1 yr. 3 months 6 months 1 months
The fan bearings are provided prelubricated. Any specialized lubrication instructions on fan labels supersedes information provided herein. Bearing grease is a petroleum
lubricant in a lithium base conforming to a NLGI #2 consistency . If user desires to utilize another type of lubricant, they
take responsibility for flushing bearings and lines, and
maintaining a lubricant that is compatible with the installation.
A NLGI #2 grease is a light viscosity, low-torque, rustinhibiting lubricant that is water resistant. Its temperature
range is from -30°F to 200°F and capable of inte rmittent
highs of 250°F.
Bearings should be relubricated in accordance with the
condition chart below.
For best results, lubricate the bearing while the fan is in
operation. Pump grease in slowly until a slight bead forms
around the bearing seals. Excessive grease can damage
seal and reduce life through excess contamination an d/or
loss of lubricant.
In the event that the bearing cannot be seen, use no
more than three injections with a hand operated grease
gun.
ditions. However, it is advisable to add lubricant after 3
years. Use only LIGHT grade mineral oil or SAE 10W oil up
to 30 drops. If the unit has been stored for a year or more it
is advisable to lubricate as directed above. For VCR direct
drive units and other units in severe conditions, lubrication
intervals should be reduced to half.
Motors without sleeve bearings (as described above) will
have grease lubricated ball or roller bearings. Motor bearings without provisions for relubrication will operate up to 10
years under normal conditions with no maintenance. In
severe applications, high temperatures or excessive contaminates, it is advisable to have the maintenance department disassemble and lubricate the bearings after 3 years
of operation to prevent interruption of service.
For motors with provisions for relubrication, follow intervals of the table below.
Conditions Chart
RPM Temp °F Greasing Interval
Up to 1000
1000 to 3000
Over 3000
Any Speed < -30 Consult Factory
Any Speed > 200 1 week
For moist or otherwise contaminated installations; divide the interval by a
factor of 3. For vertical shaft installations divide the interval by a factor of 2.
-30 to 120 6 months
120 to 200 2 months
-30 to 120 3 months
120 to 200 1 month
-30 to 120 1 month
120 to 200 2 weeks
Lubricants
Loren Cook Company uses petroleum lubricant in a lithium
base conforming to NLGI grade 2 consistency. Other grades
of grease should not be used unless the bearings and lines
have been flushed clean. If another grade of grease is used,
it should be lithium-based.
A NLGI grade 2 grease is a light viscosity, low-torque, rustinhibiting lubricant that is water resistant. Its temperature
range is from -30°F to +200°F and capable of intermittent
highs of +250° F.
Motor Bearings
Motors are provided with prelubricated bearings. Any
lubrication instructions shown on the motor nameplate
supersede instructions below.
Direct Drive 1050/1075,1200,1300 &1500 rp m units use a
prelubricated sleeve bearing that has a oil saturated wicking material surrounding it. The initial factory lubrication is
adequate for up to 10 years of operation under normal con-
Motors are provided with a polyurea mineral oil NGLI #2
grease. All additions to the motor bearings are to be with a
compatable grease such as Exxon Mobil Polyrex EM and
Chevron SRI.
The above intervals should be reduced to half for vertical
shaft installations.
Motor Services
Should the motor prove defective within a one-year pe riod,
contact your local Loren Cook representative or your nearest
authorized electric motor service repres en ta tive .
Changing Shaft Speed
All belt driven ventilators (5HP or less) are equipped with
variable pitch pulleys. To change fan speed, perform th e following:
a. Loosen setscrew on driver (motor) pulley and remove
key, if equipped.
b. Turn the pulley rim to open or close the groove facing. If
the pulley has multiple grooves, all must be adjusted to
the same width.
c. After adjustment, inspect for proper belt tension.
Speed Reduction
Open the pulley in order that the belt rides deeper in the
groove (smaller pitch diameter).
Speed Increase
Close the pulley in order that the belt rides higher in the
groove (larger pitch diameter). Ensure that the RPM limits of
the fan and the horsepower limits of the motor are maintained.
4
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