Greenheck APH Installation Manual

Document 475405

Model HPA, Model PLG,

Model APM, Model APH

Installation, Operation and Maintenance Manual

Please read and save these instructions for future reference. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage!

General Safety Information

Only qualiﬁed personnel should install this fan. Personnel should have a clear understanding of these instructions and should be aware of general safety precautions. Improper installation can result in electric shock, possible injury due to coming in contact with moving parts, as well as other potential hazards. Other

Model HPA - Housed Plenum Array

Model PLG - Plug

Model APM - Advanced Plenum Medium Pressure

considerations may be required if high winds or seismic activity are present. If more information is needed, contact a licensed professional engineer before moving forward.

1. Follow all local electrical and safety codes, as well as the National Electrical Code (NEC), the National Fire Protection Agency (NFPA), where applicable. Follow the Canadian Electric Code (CEC) in Canada.

2. The rotation of the wheel is critical. It must be free to rotate without striking or rubbing any stationary objects.

3. Motor must be securely and adequately grounded.

4. Do not spin fan wheel faster than max cataloged fan rpm. Adjustments to fan speed signiﬁcantly effects motor load. If the fan RPM is changed, the motor current should be checked to make sure it is not exceeding the motor nameplate amps.

5. Do not allow the power cable to kink or come in contact with oil, grease, hot surfaces or chemicals. Replace cord immediately if damaged.

6. Verify that the power source is compatible with the equipment.

7. Never open access doors to a duct while the fan is running.

DANGER

Always disconnect power before working on or near a fan. Lock and tag the disconnect switch or breaker to prevent accidental power up.

Model APH - Advanced Plenum High Pressure

CAUTION

When servicing the fan, motor may be hot enough to cause pain or injury. Allow motor to cool before servicing.

CAUTION

Precaution should be taken in explosive atmospheres.

Housed Plenum Array, Plug and Plenum

Table of Contents

General Safety Information . . . . . . . . . . . . . . . . . . . . . 1

Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Handling..................................2

Storage................................. 2-3

Inspection and Maintenance during Storage......3

Removing from Storage...................... 3

General Information

Unit and System Identiﬁcation Tags . . . . . . . . . . . . 3

Pre-Installation Information ...................3

Electrical Disconnects .......................3

Moving Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Belt Guards ...............................3

Air Pressure and Suction . . . . . . . . . . . . . . . . . . . . . 4

Fans - Rigging and Lifting ......................4

Installation - Housed Plenum Array ............... 5

Installation - Plenum and Plug................... 5

Unhoused Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Belt Guards ...............................6

Bases (Foundation and Isolation)............... 6

V-Belt Drives

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Alignment of Pulleys and Belts . . . . . . . . . . . . . . . . 7

Radial Gap, Overlap and Wheel Alignment .........8

Field Coating Touch-Up Procedure ...............9

Electrical Connections.........................9

Unit Start-Up

Visual Inspection of Equipment ...............10

Check...................................10

Additional Steps for Initial Start-Up ............10

Vibration...................................11

Routine Maintenance

Fan Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Motors ..................................11

Belt Drive Maintenance . . . . . . . . . . . . . . . . . . . . . 12

Variable Frequency Drive Operation . . . . . . . . . . . 12

Shaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Parts List ..................................13

Troubleshooting............................. 14

Maintenance Log............................ 15

Our Commitment ............................ 16

Receiving

Upon receiving the product check to ensure all items are accounted for by referencing the delivery receipt or packing list. Inspect each crate or carton for shipping damage before accepting delivery. Alert the carrier of any damage detected. The customer will make a notation of damage (or shortage of items) on the delivery receipt and all copies of the bill of lading which is countersigned by the delivering carrier. If damaged, immediately contact your Greenheck Representative. Any physical damage to the unit after acceptance is not the responsibility of Greenheck Fan Corporation.

Unpacking

Verify that all required parts and the correct quantity of each item have been received. If any items are missing report shortages to your local representative to arrange for obtaining missing parts. Sometimes it is not possible that all items for the unit be shipped together due to availability of transportation and truck space. Conﬁrmation of shipment(s) must be limited to only items on the bill of lading.

Handling

Fans are to be rigged and moved by the lifting brackets provided or by the skid when a forklift is used. Location of brackets varies by model and size. Handle in such a manner as to keep from scratching or chipping the coating. Damaged ﬁnish may reduce the ability of the fan to resist corrosion. Fans should never be lifted by the shaft, fan housing, motor, belt guard, windband or accessories.

Storage

• Rotate fan wheel monthly and purge bearings once every three months

• Energize fan motor once every three months

• Store belts ﬂat to keep them from warping & stretching

• Store unit in location which does not have vibration

• After storage period, purge grease before putting fan into service

If storage of fan is in a humid, dusty or corrosive atmosphere, rotate the fan and purge the bearings once a month. Improper storage which results in damage to the fan will void the warranty.

Fans are protected against damage during shipment. If the unit cannot be installed and operated immediately, precautions need to be taken to prevent deterioration of the unit during storage. The user assumes responsibility of the fan and accessories while in storage. The manufacturer will not be responsible for damage during storage. These suggestions are provided solely as a convenience to the user.

The ideal environment for the storage of 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 30°F (-1°C) and

Housed Plenum Array, Plug and Plenum

110°F (43°C) (wide temperature swings may cause condensation and “sweating” of metal parts). All accessories must be stored indoors in a clean, dry atmosphere.

Remove any accumulations of dirt, water, ice or snow and wipe dry before moving to indoor storage. To avoid “sweating” of metal parts allow cold parts to reach room temperature. To dry parts and packages use a portable electric heater to get rid of any moisture build up. Leave coverings loose to permit air circulation and to allow for periodic inspection.

The unit should be stored at least 3½ in. (89 mm) off the ﬂoor on wooden blocks covered with moisture proof paper or polyethylene sheathing. Aisles between parts and along all walls should be provided to permit air circulation and space for inspection.

Inspection & Maintenance during Storage

While in storage, inspect fans once per month. Keep a record of inspection and maintenance performed.

If moisture or dirt accumulations are found on parts, the source should be located and eliminated. At each inspection, rotate the wheel by hand ten to ﬁfteen revolutions to distribute lubricant on motor. 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. Immediately remove the original rust preventive coating with petroleum solvent and clean with lint-free cloths. Polish any remaining rust from surface with crocus cloth or ﬁne emery paper and oil. Do not destroy the continuity of the surfaces. Wipe clean thoroughly with Tectyl® 506 (Ashland Inc.) or the equivalent. For hard to reach internal surfaces or for occasional use, consider using Tectyl® 511M Rust Preventive or WD-40® or the equivalent.

Removing from Storage

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

Prior to fully assembling and installing the fan and system components, inspect the fan assembly to make sure it is in working order.

1. Check all fasteners, set screws, wheel, bearings, drive, motor base and accessories for tightness.

2. Rotate the fan wheel by hand and assure no parts are rubbing. Access to the wheel is obtained through an access panel located on the side of the fan housing.

3. Ensure proper wheel settings for radial gap and alignment. See below.

General Information

To ensure a successful installation, the instructions in this manual should be read and adhered to. Failure to comply with proper installation procedures may void the warranty.

Unit and System Identiﬁcation Tags

Each fan has a permanently afﬁxed manufacturer’s engraved metal nameplate containing the model number and individual serial number.

The tag shown is an example of an identiﬁcation nameplate on the fan. The information provides general details about the fan, as well as containing speciﬁc information unique to the unit. When contacting your Greenheck representative with future needs or questions, please have the information on this label available. Tags are mounted in an area which is clearly visible, usually on the side of the fan cabinet.

Pre-Installation Information

Before installation, it is important to be certain the mounting surface will bear the operating weight of the unit. For proper unit operation, it is also important that it be operated in a completely level position.

For further details on safety practices involving industrial and commercial fans, please refer to AMCA Publication410.

Electrical Disconnects

All fan motors should have disconnects located in close visual proximity to turn off electrical service. Service disconnects shall be locked-out when maintenance is being performed.

Moving Parts

All moving parts must have guards to protect personnel. Refer to local codes for requirements as to the number, type and design. Fully secure fan wheel before performing any maintenance. The fan wheel may start “free wheeling” even if all electrical power has been disconnected. Before the initial start-up or any restart, check the following items to make sure that they are installed and secure.

• Do not spin fan wheel faster than the maximum cataloged fan rpm.

• Adjustments to fan speed signiﬁcantly affects motor load. If the fan RPM is changed, the motor current should be checked to make sure it is not exceeding the motor nameplate amps.

Belt Guards

Do not operate fans without proper protective devices in place. Failure to do so may result in serious bodily injury and property damage. Check local codes to ensure compliance for all protective devices.

Housed Plenum Array, Plug and Plenum

General Information - continued

Fans – Rigging and Lifting

Air Pressure and Suction

In addition to the usual hazards associated with rotating machinery, fans also create a dangerous suction at the inlet. Special caution needs to be used when moving around a fan, whether it is in operation or not. Before start-up, make sure the inlet area is clear of personnel and loose objects.

CAUTION

Fans should never be lifted by the shaft, motor, motor cover or accessories.

Fans are to be rigged and moved by the lifting brackets and/or lifting points provided or by the skid when a forklift is used. Location of brackets varies by model and size. Handle in such a manner as to keep from scratching or chipping the coating. Damaged ﬁnish may reduce ability of fan to resist corrosion. See coating repair section of this manual for details involving touchup of damaged surfaces.

• Use standard lifting and rigging practices.

• ALL lifting brackets on each component must be utilized at the same time.

• Fan to be kept level during lifting and installation.

APM

Lifting Point

APH

Lifting Point

Housed Plenum Array, Plug and Plenum

Installation - Housed Plenum Array

Installation - Plenum and Plug Fans

1. Carefully remove any crate and packing materials.

2. Place the fan onto the mounting structure using the recommended lifting points and hooking

Unhoused Wheels

Adjacent Walls - The distance between the fan and

walls or ceilings will effect the performance of the fan. The recommended distance between the fan wheel and any wall is a minimum of one-half wheel diameter. Multiple walls reduce the performance even more.

method as shown. Lift each fan individually into it’s proper position.

One-half

wheel

Recommended

Lifting Points

diameter

Side by Side - When two or more plenum fans are in parallel, there should be at least one fan diameter spacing between the wheels. Applications with less

spacing will experience performance losses.

One-half

wheel

diameter

One

wheel

diameter

One-half

wheel

diameter

3. Bolt the fan to the ﬂoor and adjacent fans using the inlet and outlet mounting ﬂanges. The ﬁrst layer of fans should be securely installed before installing the second layer of fans.

4. Thin gasket material or caulk between fans is recommended to prevent unwanted noise of air.

5. Do not exceed the maximum number of stacked modules (refer to table).

Standard Housing

Wheel

Size

W H D^

15 29.00 29.00 32.06 16 31.50 31.50 37.00 256T 250 18 34.38 34.38 38.19 20 37.25 37.25 39.56 256T 340 22 41.00 41.00 42.19 286T 380 24 44.75 44.75 43.75 286T 425 27 48.94 48.94 47.56 30 53.81 53.81 48.94 326T 820 33 58.81 58.81 51.06 326T 960

36 64.56 64.56 51.06 326T 1100

Dimensions are in inches. ^Does not account for motors or accessories. *Weight is less motor and drives.

Maximum

Stacked

Modules

Maximum

Motor

Frame

215T 215

256T 290

286T 680

Weight*

CAUTION

When installing a fan, ensure the proper protective devices are used to protect personnel from moving parts and other hazards. A complete line of protective accessories are available from Greenheck including inlet guards, outlet guards, belt guards, shaft guards, protective cages, and electrical disconnects.

(lbs.)

Housed Plenum Array, Plug and Plenum

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