COOK Lo-Pro User Manual

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Lo-Pro

Low Profile Centrifugal Exhaust Fans

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

This publication contains the installation, operation and maintenance procedures for standard units of the “Lo-Pro” (LPD & LPB) Low Profile Centrifugal Exhaust Fans.

Carefully read this publication and any supplemental documents prior to any installation or maintenance procedure.

Loren Cook Company LC catalog 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 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 [email protected].

For information and instructions on special equipment, contact Loren Cook Company at (417)869-6474.

Receiving and Inspection

Carefully inspect the fan and accessories for any damage and shortage immediately upon receipt of the fan.

• 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 base or by the shipping carton.

NOTICE! Never lift by the shaft, motor or housing.

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.

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 field-installed wiring must be completed by qualified personnel. All fieldinstalled 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.

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

The attachment of roof mounted fans to the roof curb as well as the attachment of roof curbs to the building structure must exceed the structural requirements based on the environmental loading derived from the applicable building code for the site. The local code official may require variations from the recognized code based on local data. The licensed engineer of record will be responsible for prescribing the correct attachment based on construction materials, code requirements and environmental effects specific to the installation.

Failure to follow these instructions could result in death or serious injury.

To prevent damage to the fan during shipping, motors 5 HP and larger, and extremely heavy motors (cast iron or severe duty) are shipped loose and must be field mounted by bolting the motor on the motor mounting plate in the existing mounting slots.

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. Ensure the damper

will open freely for the correct direction of the airflow. b. Secure to curb at the damper shelf. c. Drill a hole in the curb shelf for conduit needed for

motor wiring. d. Operate the dampers manually to ensure the baldes

move freely. e. Install ventilator over curb.

Lo-Pro

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Conduit Nipple

Diverter

Terminator Lid

Sealing Nut

Terminator

Roof Top Installation Shown

Figure 4

Wall Installation

1 foot

1/4 inch

a. Position unit so that hinge on topcap is facing down.

Belt and Pulley Installation

Figure 1

Belt tension is determined by the sound of the belts when the fan is first started. The belts will produce a loud squeal, which dissipates after the fan is operating at full capacity . If belt tension is too tight or too loose, lost efficiency and damage can occur.

Do not change the pulley pitch diameter to change tension. The change will result in a different fan speed. )

a. Loosen the motor plate adjustment nuts on motor

base and move motor plate in order that the belts can easily slip into the grooves on the pulleys. Never pry, roll, or force the belts over the rim of the pulley.

b. Adjust the motor plate until proper tension is reached.

For proper tension, a deflection of approximately 1/4” per foot of center distance should be obtained by

firmly pressing the belt. Refer to Figure 1. c. Lock the motor plate adjustment nuts in place. d. Ensure pulleys are properly aligned. Refer to Figure 2.

Tolerance

Center Distance

Up thru 12” 1/16”

12” up through 48 1/8”

Over 48” 1/4”

Figure 2

Maximum

Gap

OFFSET ANGULAR OFFSET/ANGULAR

CENTER

DISTANCE

(CD)

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, next page.

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.

NOTICE! 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).

Optional Diverter

a. Position diverter so that air flow is directed up. b. Seal between diverter flange and unit side panel with

RTV 400 silicone. (RTV Silicone is NOT supplied.)

c. Use screws provided to secure diverter to unit.

Optional Grease Terminator Installation

a. Attach hardware to drain hole in the diverter. See Figure 4. b. Screw new canister into lid.

Roof Top Installation Shown

Conduit Nipple

Diverter

Terminator Lid

Sealing Nut

Terminator

Pulley Alignment

Pulley alignment is adjusted by loosening the motor pulley

setscrew and by moving the motor pulley on the motor shaft.

Figure 2 indicates where to measure

GAP

the allowable gap for the drive alignment tolerance. All contact points (indicated by WXYZ) are to have a cap less than the tolerance shown in the table. When the pulleys are not the same width, the allowable gap must be adjusted by half of the difference in width. Figure 3 illustrates using a carpenter’s square to adjust the position of the motor pulley until the belt

Figure 3

is parallel to the longer leg of the square.

Terminator

Figure 4

Terminator

Final Installation Steps

a. Inspect fasteners and setscrews, particularly fan

mounting and bearing fasteners, and tighten according to the recommended torque shown in the table on page 4, Recommended Torque for Setscrews/Bolts.

b. Inspect for correct amperage and voltage with an

ammeter and voltmeter. c. Ensure all accessories are installed. d. Check wheel-to-inlet clearance on power roof fans. e. Test the fan to be sure the rotation is the same as indi-

cated by the arrow marked ‘Rotation’.

NOTICE! Do not allow the fan to run in the wrong

direction. This will overheat the motor and cause serious damage. For 3-phase motors, if the fan is running

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Wiring Diagrams

Single Speed, Single Phase Motor

Ground A

T-1

T-4

Ground B

When ground is required, attach to ground A or B with no. 6 thread forming

Line

Wiring Diagrams

3 Phase, 9 Lead Motor Y-Connection

Low Voltage

208/230 Volts

728

L2L

To reverse, interchange any 2 line leads.

High Voltage

460 Volts

456

789

L2L

208/230 Volts

3 Phase, 9 Lead Motor Delta-Connection

Low Voltage

screw. To reverse, interchange T-1 and T-4.

2 Speed, 2 Winding, Single Phase Motor 2 Speed, 1 Winding, 3 Phase Motor

Ground A

High Speed

T-1

T-4

Line

Low Speed

Ground B

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

Together

Motor

Line

Single Speed, Single Phase, Dual Voltage 2 Speed, 2 Winding, 3 Phase

Ground A

T-5

J-10

Link A

Link B

Low Voltage

Ground B

Line

T-5

J-10

Ground B

When ground required, attach to ground A or B with No. 6 thread forming screw. To reverse, interchange T-5 and J-10 leads.

Ground A

Link A & B

Line

To reverse: High Speed-interchange leads T11 and T12. Low Speed-interchange leads T1 and T2. Both Speeds-interchange any 2 line leads.

Typical Damper Motor Schematic

9 5 3

3L2

Low Speed

1 2 3

4 5

High Voltage

460 Volts

789

456

L1L

Line

Open

Fan

Motor

Transformer**

Damper

Motor*

Second Damper

Motor

L3 L2 L1

Transformer**

For 3 phase, damper motor voltage should be the same between L1 and L2. For single phase application, disregard L3. *Damper motors may be available in 115, 230 and 460 volt models. The damper motor nameplate voltage should be verified prior to connection. **A transfomer may be provided in some installations to correct the damper motor voltage to the specified voltage.

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wrong direction, check the control switch. If is possible to interchange two leads at this location so that the fan is operating in the correct direction.

Fan Installation

Place fan over roof opening. Secure the fan with lag

screws, anchor bolts, or other suitable fasteners.

Operation

Pre-Start Checks

a. Lock out all the primary and secondary power sources. b. Inspect fasteners and setscrews, particularly those

used for mounting the fan, and tighten if necessary.

c. Inspect belt tension and pulley alignment. (Remember,

if belt tension is correct, a loud squeal occurs as the

fan increases to full power.) d. Inspect motor wiring. e. Ensure the belt touches only the pulleys. f. Ensure fan and ductwork are clean and free of debris. g. Test the fan to ensure the rotation of the wheel is the

same as indicated by the rotation label. h. Close and secure all access doors. i. Restore power to unit.

Recommended Torque for Setscrews/Bolts (IN/LB.)

Setscrews

Size

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” 348 384 7/8”-9 2040

1/2” 1/4” 504 600 1”-8 3000 5/8” 5/16” 1104 1200 1-1/8”-7 4200 3/4” 3/8” 1440 1800 1-1/4”-7 6000

Key Hex

Across

Flats

Recommended

Torque

Min. Max. Size

Hold Down Bolts

Wrench

Torque

Start Up

Turn the fan on. 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 a continuous squealing noise)

• Improper motor amperage or voltage

NOTICE! 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 Troubleshooting, page 6.

Inspection

Inspection of the fan should be conducted at the first 30

minute, 8 hour and 24 hour intervals of satisfactory opera-

tion. During the inspections, stop the fan and inspect as per the chart below.

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.

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 (airborne abrasives) should be inspected every three months. Clean the wheel and air inlets if material build-up is excessive. Excessive build-up can cause imbalance and failure of the wheel.

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 Terminator 2 should be changed every 30 to 45 days to ensure proper operation.

Any buildup of grease is easily seen during a visual inspec-

tion of the clear canister. However, if the Terminator 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.

• Inspect belt wear and alignment. Replace worn belts

with new belts and adjust alignment as needed. See Belt and Pulley Installation, page 2.

• Bearings should be inspected as recommended in the

Conditions Chart, page 5.

• Inspect for cleanliness. Clean exterior surfaces only.

Removing dust and grease on motor housing assures proper motor cooling.

Fan Bearings

The fan bearings are provided prelubricated. Any specialized lubrication instructions on fan labels supercedes 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 intermittent 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 and/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.

Motor Bearings

Motors are provided with prelubricated bearings. Any lubrication instructions shown on the motor nameplate supersede instructions below.

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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

Direct Drive 1050/1075,1200,1300 &1500 rpm 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 conditions. 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.

Relubrication Intervals

Service

Conditions

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

Up to and

including 184T

1800 RPM

and less

Over 1800

RPM

NEMA Frame Size

213T-365T 404T and larger

1800 RPM

and less

Over 1800

RPM

1800 RPM

and less

Over 1800

RPM

Motors are provided with a polyurea mineral oil NGLI #2 grease. All additions to the motor bearings are to be with a compatible grease such as Exxon Mobil Polyrex EM and Chevron SRI.

The above intervals should be reduced to half for vertical shaft installations.

Maximum RPM

LPB

Size

100 3320 - 245 1011 1335 120 2755 - 270 871 1154 135 2481 - 300 835 1121 150 2051 - 330 713 963 165 1832 1971 365 623 884 180 1608 1754 402 538 746 195 1428 1758 445 462 739 210 1270 1507 490 357 682 225 1143 1319 540 345 581

Maximum RPM

Standard Reinforced Standard Reinforced

LPB Size

Maximum RPM

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.

Changing Shaft Speed

All belt driven H-Series fans with motors up to and including 5HP are equipped with variable pitch pulleys. To change the fan speed, perform the 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.

Replacing Pulleys and Belts

a. Clean the motor and fan shafts. b. Loosen the motor plate mounting bolts to relieve the

belt tension. Remove the belt.

c. Loosen the pulley setscrews and remove the pulleys

from the shaft.

If excessive force is required to remove the pulleys, a three-jaw puller can be used. This tool, however , can easily warp a pulley. If the puller is used, inspect the trueness of the pulley after it is removed from the shaft. The pulley will need replacement if it is more than 0.020 inch out of true.

d. Clean the bores of the pulleys and place a light coat of oil on the bores.

e. Remove grease, rust and burrs from the shaft.

f. Place fan pulley on the fan shaft and the motor pulley

on the motor shaft. Damage to the pulleys can occur when excessive force is used in placing the pulleys on their respective shafts.

g. After the pulleys have been correctly placed back onto their shafts, tighten the pulley setscrews.

h. Install the belts on the pulleys. Align and adjust the belts to the proper tension as described in Belt and Pulley Instal- lation, page 2.

Replacing Grease Terminator

Set up a regular schedule for changing the Grease Terminator. Depending on the amount of grease going through the fan, the Grease Terminator should be changed every 30 to 45 days. To replace the Grease Terminator, simply unscrew the used canister and screw on a new one.

Notice! If the Grease T erminator becomes completely saturated, grease will no longer be absorbed and will run through to the roof.

Bearing Replacement

The fan bearings are pillow block ball bearings.

a. Loosen screws on bearing cover.

b. Push bearing cover toward the wheel. As the bearing cover moves toward the wheel it will slide down to reveal the bearings and shaft.

c. Remove the old bearing. d. Remove any burrs from the shaft by sanding.

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e. Slide new bearings onto the shaft to the desired loca-

tion and loosely mount bearings onto the bearing support. Bearing bolts and setscrews should be loose enough to allow shaft positioning.

f. Correctly position the wheel and tighten the bearing

bolts securely to the bearing support.

g. Align setscrews bearing to bearing and secure tightly

to the shaft.

NOTICE! Never tighten both pairs of setscrews

before securing bearing mounting bolts. This may damage the shaft.

h. Inspect the wheel position again. If necessary , readjust

by loosening the bearing bolts and setscrews and repeat from step e.

Wheel Replacement

a. Drill two holes approximately centered between the

shaft and the edge of the hub OD with the following dimensions:

• 1/4" diameter

• 3/8" to 1/2" deep

• 180° apart in face of hub

b. Tap 1/4" holes to 5/16" thread with the 5/16" hole tap.

Do not drill or tap any larger than recommended.

c. Screw the puller arms into the tapped holes full depth

of threads (3/8" to 1/2" approximately). Align center of puller with center of shaft. Make certain all setscrews in hub (normally a quantity of two) are fully removed. Work puller slowly to back wheel off the shaft.

Recommended Puller

Lisle No. 45000 Sterling Wheel Puller. This puller is avail-

able at most automotive parts retail outlets.

Wheel-to-Inlet Clearance

The correct wheel-to-inlet clearance is critical to proper fan performance. This clearance should be verified before initial start-up since rough handling during shipment could cause a shift in fan components. Refer to wheel/inlet drawing for correct overlap.

Adjust the overlap by loosening the wheel hub and mov-

ing the wheel along the shaft to obtain the correct value.

A uniform radial gap (space between the edge of the cone and the edge of the inlet) is obtained by loosening the inlet cone bolts and repositioning the inlet cone.

Wheel/Inlet Overlap

Size Maximum Overlap

100 - 165 3/16” 180 - 245 1/4” 270 - 300 5/16” 330 - 365 3/8”

402 7/16”

445 - 490 1/2”

540 13/16”

Wheel Replacement Components

Above - Drilled Hole Location

Above - Wheel Puller

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Troubleshooting

Problem and Potential Cause Low Capacity or Pressure

•Incorrect direction of rotation. Make sure the fan rotates in same direction as the arrows on the motor or belt drive assembly.

•Poor fan inlet conditions. There should be a straight clear duct at the inlet.

•Improper wheel alignment.

Excessive Vibration and Noise

•Damaged or unbalanced wheel.

•Belts too loose; worn or oily belts.

•Speed too high.

•Incorrect direction of rotation. Make sure the fan rotates in same direction as the arrows on the motor or belt drive assembly.

•Bearings need lubrication or replacement.

•Fan surge.

Overheated Motor

•Motor improperly wired.

•Incorrect direction of rotation. Make sure the fan rotates in same direction as the arrows on the motor or belt drive assembly.

•Cooling air diverted or blocked.

•Improper inlet clearance.

•Incorrect fan RPMs.

•Incorrect voltage.

Overheated Bearings

•Improper bearing lubrication

•Excessive belt tension.

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LPD Parts List

Parts No.

1 Top Cap 2 Motor

Description

100-540

3 Wheel Hub

4 Wheel 5 Outside Housing Panel 6 Upblast Diverters (Optional) 7 Inlet Side Inner Panel 8 Inlet 9 Base

10 Wrapper

LPB Parts List

Parts No.

1 Top Cap 2 Belt Set 3 Bearing Support Channel 4 Driven Sheave 5 Bearings (2) 6 Shaft 7 Top Cap Hinge 8 Hatch 9 Wheel Hub

Description

100-540

10 Wheel 11 Upblast Diverters (Optional) 12 Outside Housing Panel 13 Inlet Side Inner Panel 14 Inlet 15 Base 16 Wrapper 17 Motor Access Panel 18 Motor Plate 19 Drive Side InnerPanel 20 Motor 21 Driven Sheave

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 modified 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. This warranty does not cover defects resulting from normal wear and tear. To make a warranty claim, notify Loren Cook Company, General Offices, 2015 East Dale Street, Springfield, Missouri 65803-4637, explaining in writing, in detail, your complaint

and referring to the specific model and serial numbers of your fan. Upon receipt by Loren Cook Company of your written complaint, you will be notified, within thirty (30) days of our receipt of your complaint, in writing, as to the 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 placing the fan in service specifically the right. You may have other legal rights which vary from state to state. For fans provided with motors, the motor manufacturer warrants motors for a designated period stated in the manufacturer’s warranty. Warranty periods vary from manufacturer

to manufacturer. Should motors furnished by Loren Cook Company prove defective during the designated period, they should be returned to the nearest authorized motor service station. Loren Cook Company will not be responsible for any removal or installation costs.

Corporate Offices: 2015 E. Dale Street Springfield, MO 65803 417.869.6474

lorencook.com

Lo-Pro IOM - December 2013