Gemini
6
s
atte
G
Ceiling and cabinet fans
®
INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
This publication contains the installation, operation and
maintenance procedures for standard units of the Gemini:
Ceiling and Cabinet Fans.
Carefully read this publication and any
supplemental documents prior to any
installation or maintenance procedure.
Loren Cook Company’s Gemini catalog provides
additional information describing the equipment, fan
performance, available accessories and specication
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 above can be obtained
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.
Rotating Parts & Electrical Shock Hazard:
Disconnect electric power before working on unit.
Follow proper lockout / tagout procedures to ensure
the unit cannot be energized while being installed or
serviced.
Receiving and Inspection
Carefully inspect the fan and accessories for any
damage and shortage immediately upon receipt of fan.
• Turn the wheel by hand to ensure it turns freely and
does not bind.
• Inspect dampers (if included) for free operation of
all moving parts.
• Remove mounting brackets from packing insert &
install mounting brackets (Gemini 100 only).
• Remove shipping tape.
• Record on the Delivery Receipt any visible sign of
damage.
Handling
Lift fan by the outside housing (box) or by the blower
mounting brace. Never lift by the shaft or motor.
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.
Installation
Motor Installation
All Gemini units are shipped with motors mounted at
the factory.
A disconnect switch should be placed 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.
Grounding is required. All eld-installed wiring
must be completed by qualied personnel. All eld
installed wiring must comply with National Electric
Code (NFPA 70) and all applicable local codes.
Failure to follow these instructions could result in
death or serious injury.
Gemini 100 Inline to Ceiling Conversion
The Gemini 100 series can be converted from inline
to ceiling by ordering the Inline to Ceiling Conversion Kit
from Loren Cook Company (Part Number 797180). The
kit includes all parts required, plus detail instructions on
how to convert the Gemini 100.
Gemini 100 Ceiling to Inline Conversion
The Gemini 100 series can be eld converted from
ceiling to inline by following these steps:
1. Remove and discard the inlet box end plate.
2. Install the inline cover panel with sheet metal
screws as shown on the following page. Ceiling to
Inline Conversion Kit can be ordered from Loren
Cook Company (Part Number 797181), or fabricate
the required part using the following two sketches.
a. Galvanized Steel
16-3/4
13-15/16
Bend up at 90o
18
1-3/8
11-15/16
14-1/16
12
13-5/16
Gemini 100
1-7/1
1
Flat P
rn
(Inches)
Finished View
Figure 1
Use foil tape on the joints
Start
Outlet
Inlet
Remove Parts
Inline
Cover
Panel
Direction of Discharge (200-900 Series)
Discharge direction can be converted from right angle to
straight line, without a kit, by swapping outer panel and
the inlet/grille: See Figure 1.
1. Remove the side panel, mounting brackets (2) and
grille (if present).
2. Place the side panel where the inlet/grille had
been. Place the mounting brackets on the edge
where the side panel had been. Holes are
prepunched for this procedure.
3. Rotate unit so that the outlet is on top.
Typical Installation
Roof
Roof jack with damper
or roof cap
x2
Replace Parts
Outlet
Inlet
Fan Installation
1. Use the mounting bracket slots to lower the
unit housing by a distance equal to the ceiling
thickness. Refer to gure 2.
2. Raise the unit, as needed to accommodate
accessories and options: If lter present, raise
Exterior
Wall
6” round duct. Insulated duct will help
absorb vibration. Use the shortest runs
Joists
Power
cord
Seal around the
unit with caulk.
Insulation around unit.
Also, cover the fan with insulation.
to ensure a good seal.
possible & long radius elbows.
Wall cap
with damper
or
Short (1’) piece of flexible duct
will absorb vibration & noise.
2
unit 3/8”. If lter and deluxe aluminum grille are
Mounting
Filter (optional)
Ceiling
Grille
both present, raise unit 7/8”, due to the 1/2” grate
protrusion on the aluminum grille. If lter is not
present: the grate on the aluminum grille will t inside
of the unit (except sizes 160 & 180). Other grilles have
no protrusion and t ush with the fan.
3. Fasten duct work to the outside of the duct collar
(damper frame) using sheet metal screws and foil
tape. Make sure sheet metal screws are placed
where they do not interfere with damper operation.
4. Fasten the housing to the bottom of the joists
through the holes provided in the mounting bracket.
For Ceiling Radiation Damper Installation
see separate document “Gemini/CRD
Installation Supplement.”
Figure 2
Unit Housing
Joists
Bracket
Grate Protrusion (aluminum grille only)
Wiring Diagrams
Gemini 100 Series:
Cap off wire that is not in use.
Red Wire (Low Speed)
Black Wire (High Speed)
Green Wire
(Ground by COOK)
White Wire
(Common)
For fan power supply connection use 4-wire cable
provided in eld wiring box shown above. Connect eld
ground wire to green ground screw located inside fan
electrical box. Connect one supply line to white wire.
Depending on fan speed requirements connect other
supply line to Red wire for Low Speed or Black wire
for High Speed. Insulate unused Red or Black wire.
Replace electrical box cover. Model 126, 146, 166, 186
are Low Speed. Models 128, 148, 168, 188 are High
Speed.
Gemini 200, 300, 500, 600 and 700 Series:
White Line
Ground Screw for
Field Grounding
Notice! Do not install above or around
cooking equipment (shaded area)
O
45
O
Cooking
Equipment
45
Floor
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 Wiring Diagrams.
Lock out all power sources before unit is wired to power
source.
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).
Note: Insulate Unused Leads. Fan plug box is designed
for single speed operation, using an FSC to vary speed if
required. Do not wire to more than two leads.
Black (High)
Red (Low)
Line
Electrical Shock & Fire Hazard:
Insulate Unused Lead
Failure to follow these instructions could result in
death or serious injury.
Gemini 400 Series:
White Line
Black Line
Wiring continued on the next page.
3
Gemini 800 - 900 Series:
2
3
2
3
2
1
3
e
e
e
White Line
Black (High)
Blue (Medium)
Red (Low)
Line
1 PH / 60 HZ / 115 V
LEESON 10.2 AMPS
P1
P2
T3
T2
T4
T5 T5
Line 1
Insulate
Line 2
P1
P2
T3
T2
T4
1 PH / 60 HZ / 208-230 V
LEESON 5.2 AMPS
Insulate
Insulate
Line 1
Line 2
Electrical Shock & Fire Hazard:
Insulate Unused Leads Separately
Failure to follow these instructions could result in
death or serious injury.
Gemini 1000:
1 PH / 60 HZ / 115V
MARATHON 6.0 AMPS
Purple
White
Yellow
Orange
Brown
1 PH / 60 HZ / 115V
MAGNETEK 8.0 AMPS
Black
White
Red
Blue
Orange
T4
P4
T5
P6
T6
P6
T4
T7
T6
T9
T5
T8
Gemini 2000:
1 PH / 60 HZ / 115V
MARATHON 10.8 AMPS
Purple
Brown
Blue
White
Black
Line 1
Line 2
Insulate
Line 1
Line 2
Insulate
3 PH / 60 HZ / 208-230 V
MARATHON 2.2-2.0 AMPS
MAGNETEK 2.2-2.0 AMPS
Insulate
Insulate
Insulate
3 PH / 60 HZ / 460 V
MARATHON 1.0 AMP
MAGNETEK 1.0 AMP
Insulate
Insulate
Insulate
Line 1
Insulate
Line 2
1 PH / 60 HZ / 208-230 V
MARATHON 2.8-3.0 AMPS
Purple
Yellow
Brown
Orange
White
1 PH / 60 HZ / 208-230 V
MAGNETEK 4.1 AMPS
Purple
Yellow
Blue
Orange
White
T1
T7
T2
T8
T3
T9
T1
T2
T3
P4
P5
P6
1 PH / 60 HZ / 208-230 V
MARATHON 6.0-5.4 AMPS
Orange
Brown
Blue
White
Black
Insulate
Insulate
Insulate
Insulate
Insulate
Insulate
Insulate
Insulate
Line 1
Line 2
Line 2
Line 1
Line 1
Line
Line
Line 1
Line
Line
Line 1
Line 2
3 PH / 60 HZ / 208-230 V
MARATHON 4.1-4.2 AMPS
T4
P4
T5
P6
T6
P6
LEESON 3.4 AMPS
Insulate
Insulate
Insulate
T1
T7
T2
T8
T3
T9
Line 1
Line 2
Line 3
3 PH / 60 HZ / 460 V
MARATHON 2.1 AMPS
T4
T7
T6
T9
T5
T8
LEESON 1.7 AMPS
Insulate
Insulate
Insulate
T1
T2
T3
P4
P5
T6
Line
Line
Line
Insulat
Insulat
Insulat
FSC:
Fan
FSC
White
Black
Time Delay Switch:
light
Final Installation Steps
1. Inspect fasteners and setscrews, particularly fan
mounting fasteners, and tighten as required.
2. Inspect for correct amperage and voltage with an
ammeter and voltmeter.
3. Ensure blower is secured to duct work.
4. Ensure all accessories are installed.
5. Inspect wheel-to-inlet clearance. Make sure wheel
does not rub against the inlet.
6. Test the fan to be sure the rotation is the same as
indicated by the arrow marked Rotation.
Grille installation is described after the operation
and inspection sections.
4
Fan
Red
Blue
Switch
White
Black
Operation
Pre-Start Checks
1. Lock out all the primary and secondary power
sources.
2. Inspect fasteners and setscrews, particularly those
used for mounting the fan, and tighten if necessary.
3. Inspect motor wiring.
4. Ensure fan and ductwork are clean and free of
debris.
5. Test the fan to ensure the rotation of the wheel is
the same as indicated by the rotation label.
6. Restore power to unit.
Start Up
Before attaching the grille, turn the fan on and inspect
for the following:
• Direction of rotation.
• Excessive vibration.
• Unusual noise.
• Motor noise.
• Improper motor amperage or voltage.
If a problem is discovered, immediately shut off the fan.
Lock out all electrical power and check for the cause of
the trouble — refer to the ‘Troubleshooting’ section.
Inspection
Inspection of the fan should be conducted at the rst
30 minute interval of satisfactory operation. During the
inspection, stop the fan and inspect as per directions
below.
• Inspect bolts, setscrews, and motor mounting bolts.
• Adjust and tighten as necessary.
Grille Installation
Attach the grille by hand-tightening the grille screws.
When the unit is furnished with a lter, place the screws
through the hole in the grille. Install the lter through the
holes provided in the lter frame. See gure 2.
1. Disconnect the motor from electrical supply
2. Remove the mounting bolts on the inlet plate
assembly and remove the motor/wheel assembly
3. Remove the blower wheel with an allen wrench
Electrical Supply
Grill Mount Holes
Gemini 200 - 700 series
To inspect, clean, or repair, refer to the follow diagram
and follow these steps:
1. Remove grille.
2. Remove blower assembly from housing:
1. Disconnect the motor from electrical supply.
2. Remove mounting bolts.
3. Slide discharge ange out of spring clip and
remove motor/blower assembly from box.
3. Remove inlet ring from blower housing.
4. Remove blower wheel with an allen wrench.
Blower Mounting Brace
Mounting Bolts
Junction Box & Cover
Wheel
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.
Fans exhausting contaminated air (airborne abrasives)
should be inspected every three months.
Regular inspections are recommended for fans
exhausting non-contaminated air.
It is recommended the following inspections be
conducted twice per year.
• Inspect bolts and setscrews for tightness. Tighten
as necessary.
• Inspect for cleanliness. Clean exterior surfaces
only. Removing dust and grease on motor housing
assures proper motor cooling.
Access
Gemini 100:
To inspect, clean or repair refer to the diagram below
and follow these steps:
1. Remove grille.
2. Remove blower assembly from housing:
Unit
Mounting
Bracket
Adjustment
Wiring
Box
Duct Collar
Bolts
Motor
Damper
Blade
Gemini 800 - 2000 series:
To inspect, clean, or repair, refer to the diagram below
and follow these steps:
1. Remove grille.
2. Remove blower assembly from housing:
5
1. Disconnect the motor from the electrical supply.
2. Remove motor plate bolts.
3. Slide motor plate and remove motor/blower
assembly from box.
3. Remove inlet rings from blower housing (both
sides).
4. Mark the wheel and housing to ensure correct
replacement of blower wheels (one is clockwise
and the other is counter-clockwise), then remove
the blower wheels with an allen wrench.
Wheel
Blower Housing
Mo tor Plate
Motor Plat e Bolts
Motor
Inlet Ring
(Ensure proper clearance between wheel and inlet ring)
damper operation.
Excessive Vibration and Noise
1. Damaged or unbalanced wheel.
2. Speed too high.
3. Incorrect direction of rotation. Make sure the fan
rotates in same direction as the arrows on the
motor or belt drive assembly.
4. Motor needs lubrication or replacement.
5. Fan surge.
Overheated Motor
1. Motor improperly wired.
2. Incorrect direction of rotation. Make sure the fan
rotates in same direction as the arrows on the
motor or belt drive assembly.
3. Cooling air diverted or blocked.
4. Improper inlet clearance.
5. Incorrect fan RPMs.
6. Incorrect voltage.
Reassembly
Simply reverse the disassembly instructions. Make sure
the wheel rotates in the same direction as the arrow on
the blower housing. Make sure the wheels do not rub on
the inlet rings. When replacing the motor, make sure the
motor and wheels are properly aligned with the blower
housing.
Notice! Ensure that the blower discharge ange is
secured in slot of the cabinet on Gemini 200 - 700
series.
Motor Bearings
Motor bearings are pre-lubricated and sealed.
Under normal conditions they will not require further
maintenance for a period of ten years.
Motor Services
Should the motor prove defective within a one-year
period, contact your local Loren Cook representative
or your nearest authorized electric motor service
representative
Troubleshooting
Problem and Potential Causes:
Low Capacity or Pressure
1. Incorrect direction of rotation. Make sure the fan
rotates in same direction as the arrows on the
motor or belt drive assembly.
2. Poor fan inlet conditions. There should be a straight
clear duct at the inlet.
3. Improper wheel alignment.
4. Damper held shut by tape.
5. Screw attaching duct work to collar interfering with
6
Gemini 100 Parts List
1
2
3
4
5
6
7
8
9
10
Air Flow
11
11
Diagram Part
Number
1 Inlet Box End Plate
(Ceiling only)
2 Housing/Scroll
3 Field Wiring Compartment
4 Motor
5 Tinnerman Clip (Grill) X2
6 Mounting Bracket
7 Backdraft Damper
8 Wheel
9 Motor Mount/Inlet
10 Inlet Box
11 Grille
Part Description
Gemini 200 - 900 Parts List
Diagram Part
Number
1 Backdraft Damper Backdraft Dampers
2 Damper Frame Damper Frame (2)
3 Mounting Bracket
(2)
4 Wheel Wheel (2)
5 Grille (Ceiling and
Wall)
6 Blower Housing Blower Housing (2)
7 Motor Motor
8 Insulation Insulation
9 Cabinet housing Cabinet housing
10 Housing Side
Cover
Size
200 - 700
(2)
Mounting Bracket
(2)
Grille (Ceiling and
Wall)
Housing Side
Cover
Size
800 - 900
1
67
5
2
Air Flow
3
9
8
4
10
7
Gemini 1000 - 2000 Parts List
Diagram Part
Number
1 Grille (ceiling and wall)
2 Backdraft Damper (2)
3 Wheel (2)
4 Blower Housing (2)
5 Motor
6 Insulation
7 Mount Brackets (2)
8 Cabinet housing
9 Housing Side Cover
2
Part Description
8
Limited Warranty
Loren Cook Company warrants that your Loren Cook
fan was manufactured free of defects in materials
and workmanship, to the extent stated herein. For
a period of one (1) year after date of shipment, we
will replace any parts found to be defective without
charge, except for shipping costs which will be paid
by you.
This warranty is granted only to the original
purchaser placing the fan in service.
This warranty is void if the fan or any part thereof
has been altered or modied from its original design
or has been abused, misused, damaged or is in
worn condition or if the fan has been used other
than for the uses described in the company manual.
3
This warranty does not cover defects resulting from
normal wear and tear.
9
To make a warranty claim, notify Loren Cook
Company, General Ofces, 2015 East Dale Street,
Springeld, Missouri 65803-4637, explaining in
writing, in detail, your complaint and referring to the
specic model and serial numbers of your fan. Upon
receipt by Loren Cook Company of your written
1
complaint, you will be notied, within thirty (30) days
of our receipt of your complaint, in writing, as to the
4
5
6
manner in which your claim will be handled. If you
are entitled to warranty relief, a warranty adjustment
will be completed within sixty (60) business days of
the receipt of your written complaint by Loren Cook
Company.
This warranty gives only the original purchaser
7
placing the fan in service specically the right. You
may have other legal rights which vary from state to
state.
Corporate Ofces 2015 E. Dale Street Springeld, MO 65803
Phone 417-869-6474 Fax 417-862-3820 lorencook.com
8
Gemini IOM - June 2014
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