Greenheck FJ-M Maintenance Manual

Document 484719

Model FJ-M

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 these instructions will result in voiding of the product warranty and may result in personal injury

to comply with instructions could result in personal injury and/or property damage!

and/or property damage.

FumeJet® Fume Exhaust Fans

Model FJ-M Fume Jet Fan

Model FJ-M is a pre-engineered, factory supplied combination of a centrifugal blower with a discharge stack. Designed to follow ANSI Z9.2 standard for local exhaust systems. Fan offers extended discharge to reduce and prevent exposure to harmful fumes. Performance capabilities range up to 17,000 cmh and up to 5.8 in. wg. of static pressure.

FJ-M fans are available in 8 sizes with wheel diameters ranging from 315 710 mm. Each fan shall bear a permanently afﬁxed manufacturer’s engraved metal nameplate containing the model number and individual serial number.

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 considerations may be required if seismic activity is 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) and the National Fire Protection Agency (NFPA), where applicable.

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.

FJ-M

Belt Drive

DANGER

Always disconnect, lock and tag power source before installing or servicing. Failure to disconnect power source can result in fire, shock or serious injury.

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.

FumeJet™ Fume Exhaust Fans 1

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 local representative. Any physical damage to the unit after acceptance is not the responsibility of manufacturer.

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 stack, shaft, motor, motor cover, weatherhood 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 and 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.

INDOOR -

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° to 110°F (-1° to 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 remove 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 inches 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.

The ideal environment for the storage of

(89 mm)

off

OUTDOOR - Fans designed for outdoor applications

may be stored outdoors, if absolutely necessary. Roads or aisles for portable cranes and hauling equipment are needed.

The fan should be placed on a level surface to prevent water from leaking into the fan. The fan should be elevated on an adequate number of wooden blocks so it is above water and snow levels and has enough blocking to prevent it from settling into soft ground. Locate parts far enough apart to permit air circulation, sunlight and space for periodic inspection. To minimize water accumulation, place all fan parts on blocking supports so rain water will run off.

Do not cover parts with plastic ﬁlm or tarps as these cause condensation of moisture from the air passing through heating and cooling cycles.

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

Inspection and 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 in motor and bearings. 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.

FumeJet® Fume Exhaust Fans2

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. Thoroughly wipe clean with Tectyl® 506 (Ashland Inc.) or the equivalent. For hard to reach internal surfaces or for occasional use, consider using Tectyl® 511M Rust Preventive, 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 assembly and installation of the unit and system components, inspect the fan assembly to make sure it is in working order.

1. Check all fasteners, set screws on the fan, 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 a bolted panel located on the side of the fan housing.

3. Ensure proper wheel settings for radial gap and alignment. Refer to Radial Gap, Overlap and Wheel Alignment section on page 8.

Table of Contents

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

General Information . . . . . . . . . . . . . . . . . . 4

System Set-Up. . . . . . . . . . . . . . . . . . . . . 4

Installation . . . . . . . . . . . . . . . . . . . . . . . 5

System Assembly . . . . . . . . . . . . . . . . . . . 6

Equipment Supports . . . . . . . . . . . . . . . . . . 6

Stack Installation. . . . . . . . . . . . . . . . . . . . 6

Fan Drainage Piping and Trap Detail

(by others) . . . . . . . . . . . . . . . . . . . . . . . 7

V-Belt Drives . . . . . . . . . . . . . . . . . . . . . . 7

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

Unit Start-Up . . . . . . . . . . . . . . . . . . . . . . 9

Vibration . . . . . . . . . . . . . . . . . . . . . . . . 9

Routine Maintenance and Operation . . . . . . . . .10

Bearing Replacement . . . . . . . . . . . . . . . . .12

Troubleshooting . . . . . . . . . . . . . . . . . . . .13

Maintenance Log . . . . . . . . . . . . . . . . . . .14

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

FumeJet® Fume Exhaust Fans 3

General Information

Turning

Vanes

POOR

GOOD

POOR

Length of Straight Duct

GOOD

One fan

wheel

diameter

3/4 to

one fan

wheel

diameter

One fan

diameter

3/4 to one fan

wheel

diameter

SYSTEM EFFECT FACTORS CURVES

STATIC PRESSURE LOSS

1.2

1.0

0.8

0.6

0.4

0.2

0.0

CURVE 1

CURVE 2

CURVE 3

CURVE 4

Turning

Vanes

POOR

GOOD

Length of Straight Duct

GOOD

3/4 to

one fan

wheel

diameter

SYSTEM EFFECT FACTORS CURVES

STATIC PRESSURE LOSS

1.2

1.0

0.8

0.6

0.4

0.2

0.0

CURVE 1

CURVE 2

CURVE 3

CURVE 4

Turning

Vanes

POOR

GOOD

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

MODEL

MARK

TAG

S/N

www.greenheck.com

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.

Guards – Motor Cover, Weatherhood

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.

FumeJet® Fume Exhaust Fans4

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.

System Set-Up

Installations with inlet or discharge conﬁgurations that deviate from this manual may result in reduced fan performance. Restricted or unstable ﬂow at the fan inlet can cause pre-rotation of incoming air or uneven loading of the fan wheel, yielding large system losses, increased sound levels and structural failure of the fan wheel. Free turbulent ﬂow in the discharge ductwork will also result in system effect losses. Refer to the following diagrams for the most efﬁcient installation conditions.

Three fan wheel diameters

Turning

Vanes

GOOD

Ducted Inlet Installations

Inlet Duct Turns - Installation of a duct turn or elbow too close to the fan inlet reduces fan performance because air is loaded unevenly into the fan wheel. To achieve full fan performance, there should be at least three fan wheel diameters between the turn or elbow and the fan inlet.

Inlet Spin - Inlet spin is a frequent cause of reduced fan performance. The change in fan performance is a function of the intensity of spin and not easily deﬁned. The best solution is proper duct design and airﬂow patterns. Turning vanes reduce the effects of inlet spin.

POOR

Ducted Outlet Installations

Turning

Vanes

POOR

GOOD

Length of Straight Duct

GOOD

One fan

wheel

diameter

One fan

diameter

3/4 to

one fan

wheel

diameter

Turning

Vanes

POOR

GOOD

Length of Straight Duct

GOOD

Discharge Duct Turns - Duct turns located near the fan discharge should always be in the direction of the fan rotation.

Fan performance is reduced when duct turns are made immediately off the fan discharge. To achieve cataloged fan performance there should be at least three equivalent duct diameters of straight ductwork between the fan discharge and any duct turns.

Free Discharge - Free or abrupt discharge into a plenum results in a reduction in fan performance. The effect of discharge static regain is not realized.

Installation

Move the fan to the desired location. Check and tighten fasteners throughout the unit and then fasten securely through mounting holes provided in the base angles. The unit must be set level (shimming may be necessary). Flexible duct connections and vibration isolators should be used where noise is a factor.

The motor voltage and ampere rating must be checked for compatibility with the electrical supply prior to ﬁnal electrical connection. Supply wiring to the fan must be properly fused, and conform to local and national electrical codes.

CAUTION

When installing a fan, ensure the proper protective devices are used to protect personnel from moving parts and other hazards.

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 guards (motor cover and weatherhood) and check the access doors to ensure that they are installed and secure.

FumeJet® Fume Exhaust Fans 5

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