Greenheck GJ Installation, Operation And Maintenance Manual

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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!

Jet Fan

Document 480189

Model GJ

Only qualied personnel should install this unit. 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 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.

2. The rotation of the propeller 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 propeller faster than the maximum cataloged fan rpm. Adjustments to fan speed with Variable Frequency Drives (VFD) may affect 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 cable immediately if damaged.

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

DANGER

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

CAUTION

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

General Safety Information

CAUTION

Precaution should be taken in explosive atmospheres.

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Receiving

Upon receiving the product, check the bill of lading to ensure all items were received. Inspect each crate for shipping damage before accepting delivery. Notify the carrier if any damage is noticed. The carrier will make notication on the delivery receipt acknowledging any damage to the product. All damage should be noted on all the copies of the bill of lading which is countersigned by the delivering carrier. A Carrier Inspection Report should be lled out by the carrier upon arrival. If damaged upon arrival, le claim with carrier. Any physical damage to the unit after acceptance is not the responsibility of Greenheck India Pvt. Ltd.

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. Conrmation of shipment(s) must be limited to only items on the bill of lading.

Handling and Lifting

Handle in such a manner as to keep from scratching or chipping the nish. Damaged nish may reduce ability of unit to resist corrosion. Fans should not be lifted by the motor shaft, motor housing, fan impeller or fan accessories, to ensure proper operation, reliability and performance.

Fan model GJ is to be lifted using a minimum of four (4) points on the fan housing or attach two suitable chains/ straps around the entire fan housing, one near each duct ange. For ange mounted fans, attach suitably sized chains or lifting straps to two locations on the inlet and outlet anges. The two chains/straps must be lifted at the same rate of speed.

NOTE

Do not attach straps or lift the fan by the silencer.

Storage

Units 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 unit 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 — The ideal environment for the storage of

units 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 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. Leave coverings loose to permit air circulation and to allow for periodic inspection.

The unit should be stored at least 3½ inches (89 mm) off the oor 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.

OUTDOOR — Units 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 unit. The unit should be elevated on an adequate number of wooden blocks so that 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 unit parts on blocking supports so that rain water will run off.

Do not wrap parts with plastic lm or tarps as these cause condensation of moisture from the air passing through heating and cooling cycles. A covered shelter is preferred.

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 fan propeller by hand ten to fteen revolutions to distribute lubricant in motor bearings. Every three months, the fan motor should be energized. 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. Consult factory for details.

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 ne emery paper and oil. Do not destroy the continuity of the surfaces. Wipe thoroughly 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 or WD-40® or the equivalent.

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Installation

The component parts of the fan assembly, including silencers, must be fully aligned before being bolted together so that no stress is placed on the equipment. After components are fully aligned, all bolts can be tightened in an alternating pattern.

The examples shown below is installed using standard mounting brackets. Before beginning installation, reference the airow direction as indicated by the direction decal attached to the fan.

REMOVING FROM STORAGE — As units are removed

from storage to be installed in their nal location, they should be protected and maintained in a similar fashion, until the equipment goes into operation.

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

1. Check all fasteners on the fan, propeller, motor base, and accessories for tightness.

2. Rotate the fan propeller by hand and assure no parts are rubbing.

Prop Cut Diameter for Std and High Temp

Outer

Tube

Inner

Tube

Minimum Tip

Clearance for

Standard Temp Fan

Minimum Tip

Clearance for

High Temp Fan

315 225 1.0 3.5 355 225 1.0 3.5 400 225 1.0 3.5

Propeller Clearance

Blade

Interior of tube

Hub

Airflow

Wheel

Rotation

Decals

This is the label for a model GJ-AU.

Mounting Pattern

Unit Size A B Ø

315-225 341 300 10

355-225 341 326 10

400-225 341 350 12

All dimensions are in millimeters.

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Mounting

The fan should be mounted either rigidly or through the use of vibration isolators. If vibration isolators are used, consideration should be given to ensure the safety of the installation. One method of ensuring safety is through the use of a drop rod that would ‘catch’ the fan if the isolator were to fail during normal operation or due to the excessive heat of a ﬁre.

Silencer Installation

The fan and silencers are shipped disassembled in order to prevent freight damage. Required quantity of bolts are provided for installation of silencer on fan. Ensure that the silencer is centered on the fan housing before tightening the bolts.

Unit Start-Up and Operation

Electrical Installation

Particular attention should be given when connecting power to the unit. The power cable should be installed to meet local requirements for high temperature operation. The power cable should be capable of meeting, as a minimum, the time and temperature applications which the fan is capable of.

Before electrical connections are made, the supply voltage, phase and ampere capacity must be checked for compatibility with the fan motor. In addition, the supply wiring must be properly fused and conform to local and national electrical codes.

The supply wires are then connected to an optional safety disconnect switch, to the optional wiring pigtail, or directly to the motor junction box.

Pre-Start-Up Checks

1. Check all fasteners for tightness. Fasteners may come loose during transit or handling at the jobsite. This includes motor bolts, mounting brackets, and bushing bolts attaching the propeller to the motor shaft.

2. Ensure no debris, tools, or rubish is near the fan inlet which might get pulled into the fan.

3. Propeller rotation should be in the same direction as the rotation decal afxed to the unit. For 3-phase installations, fan rotation can be reversed by simply interchanging any two of the three electrical leads.

4. Lead the power supply wires into the terminal box on the outside of the fan.

5. Ensure the wiring conguration is connected as per the wiring diagram on the motor.

6. Securely connect the motor ground wire and building ground wire to the ground connection post in the fan terminal box.

Adjusting Performance with a Variable Frequency Drive

Before wiring a Variable Frequency Drive (VFD), determine that the motor is compatible with this type of equipment. Connecting a VFD to a non-compatible motor may reduce the life of the motor. Additionally, it is important to properly ground fans being wired with a VFD. For more information on these subjects, refer to Greenheck document “Are Bearing Currents Causing Your Motor Failures?” located at www. greenheck.com. Click on Application Info, then on Product Application Articles, and use the keyword “VFD”. Greenheck is not responsible for improper wiring of a VFD or for potential motor damage as a result of operating a fan over its maximum operating frequency.

Field Performance Adjustments

The performance of a GJ fan can be adjusted through the use of a Variable Frquency Drive (VFD) or adjusting the fan pitch.

Check motor load amperage and compare to nameplate rating when changing the fan speed or blade pitch.

Airflow

Wheel

Rotation

NOTE

Any change—increase or decrease—in fan speed (RPM) or blade pitch can represent a substantial increase in power required from the motor.

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WARNING

Disconnect and secure to the “Off” position all electrical power to the fan prior to inspection or servicing. Failure to comply with this safety precaution could result in serious injury or death.

Maintenance

Once the unit has been put into operation, a routine maintenance schedule should be set up to accomplish the following:

1. Lubrication of the motor if required.

2. Propeller, housing and bolts on the entire fan should be checked for tightness.

3. Any dirt accumulation on the propeller or in the housing should be removed to prevent unbalance and possible damage.

4. Inspection of fan propeller and housing looking for fatigue, corrosion or wear.

Motors

Motor maintenance is generally limited to cleaning and lubrication. Cleaning should be limited to exterior surfaces only. Removing dust and grease buildup on the motor housing assists proper motor cooling. Never wash down the motor with high pressure spray.

Many motors are permanently lubricated for life and require no further lubrication.

Consult fan manufacturer for instructions on the removal or replacement motors.

CAUTION

Do not allow water or solvents to enter the motor or bearings. Under no circumstances should motors or bearings be sprayed with steam, water or solvents.

Infrequent Use

Infrequent use is deﬁned as a fan that is used less than once per month or is used in emergency situations only.

The fan should be run at least four hours every month to ensure adequate lubrication in the motor bearings. Ideally this would be two hours every other week.

Fasteners and Set Screws

A periodic inspection should include checking all fasteners and bolts for tightness. Particular attention should be paid to the bushing attaching the propeller to the motor shaft and the motor to its mounting ﬁxture.

Removal of Dust and Dirt

Dirt clogs the cooling openings on the motor housing, contaminates bearing lubricant and collects on the propeller causing severe imbalance if left unchecked. The exterior surface of the motor and propeller should be thoroughly cleaned periodically. Use caution and do allow water or solvents to enter the motor. Under no circumstances should motors be sprayed with steam or water.

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Troubleshooting

Problem Cause Corrective Action

Excessive Noise

Propeller Rubbing Housing

Adjust motor plate. Tighten motor plate after centering propeller in housing.

Bearings

Replace defective bearing(s). Lubricate bearings. Tighten collars and fasteners.

Propeller Unbalance

Clean all dirt off propeller. Check propeller balance, rebalance in-place if necessary.

Volume Too Low Fan

Check propeller for correct rotation. Check blade pitch.

Excessive Power Consumption High Horsepower

Fan Check blade pitch.

Fan Doesn’t Operate

Electrical Supply

Check fuses/circuit breakers. Check for switches turned off or disconnected. Check for correct supply voltage.

Motor

Assure motor is correct horsepower and not tripping overload protector.

Bearings Overheated Lubrication Check for excessive or insufﬁcient grease in the bearing.

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