Greenheck Vektor Installation Manual

READ AND SAVE THESE INSTRUCTIONS

Part # 464652

BELT & DIRECT DRIVE

High Plume Dilution Blower Laboratory Exhaust System

Installation, Operating and Maintenance Manual

TABLE OF CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

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

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

PRE-INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Riser / Roof Curb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Plenum Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Plenum, Fan Housing, Windband Assembly. . . . . . . . . .6

Duct Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Coating Touch-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Drainage Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Fan-Disconnect / Isolation Damper Wiring Diagram . . .8

UNIT START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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

SERVICEABLE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 10

ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Fan Operation & V-Belt Drives. . . . . . . . . . . . . . . . . . . 11

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

Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

V-Belt Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . .13

Jib Cane Assem, Motor Change-Out & Coupling. . . . . 14

Radial Gap & Alignment. . . . . . . . . . . . . . . . . . . . . . . . 15

FAN RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Report any damaged equipment to the shipper immediately!

All Vektor systems are shipped on a skid or packaged to minimize damage during shipment. The transporting carrier has the responsibility for delivering all items in their original condition as received from Greenheck. The individual receiving the equipment is responsible for inspecting the unit for obvious or hidden damage, recording any damage on the bill of lading before acceptance and filing a claim (if required) with the final carrier.

UNIT IDENTIFICATION

The tag below is an example of an identification label 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.

MODEL

S/N

MARK

GREENHECK

P.O. BOX 410 SCHOFIELD, WISCONSIN 54476-0410

PH. 715-359-6171

www.greenheck.com

Tags are mounted in an area which is clearly visible, usually on the side of the fan housing.

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.

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 ability of fan to resist corrosion. See coating repair section of this manual for details involving touch-up of damaged surfaces.

FANS SHOULD NEVER BE LIFTED BY THE SHAFT, HOUSING, MOTOR, BELT GUARD, WEATHERHOOD, OR ACCESSORIES.

STORAGE

When a fan is not going to be in service for an extended amount of time, certain procedures should be followed to keep the fan in proper operating condition.

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

• Cover unit with tarp to protect from dirt and moisture (Note: do not use a black tarp as this will promote condensation)

• 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

• Motor weep holes should be checked to be clear of any obstructions or debris to permit drainage of condensation

• 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 motor and fan shaft bearings once a month. Improper storage which results in damage to the fan will void the warranty.

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: weatherhoods, motor covers and electrical disconnects.

Check local codes to ensure compliance for all protective devices.

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.

GUARDS (Motor Cover, Weatherhoods) Do not operate fans without proper protective devices in place. Failure to do so may result in serious bodily injury and property damage.

PLENUM ACCESS DOORS Before opening access doors ensure the fan wheel has stopped moving and that the wheel has been secured from being able to rotate. Do not operate fan without access door in its fully closed position.

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.

BELT DRIVE

MOTOR COVER

DIRECT DRIVE

MOTOR ACCESS AND AIR ENTRAINMENT

EXTENDED LUBE LINES

LIFTING LUGS

ROOF LINE

PRIMARY AIR

- OPTION A

DRAIN

WEATHERHOOD W/ BIRD SCREEN

DRAIN

BYPASS AIR

ROOF CURB OR STRUCTURAL SUPPORT

BYPASS DAMPER

ISOLATION DAMPER

PRIMARY AIR

- OPTION B

BOLTED AND GASKETED ACCESS PANEL

PRE-INSTALLATION FAN CHECKS

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

1) Check all fasteners, set screws and locking collars 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 (see page 15)

INSTALLATION

Installations with inlet or discharge configurations that deviate from this standard 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 and increased sound levels.

SYSTEM IDENTIFICATION TAGS

Vektor fan systems may arrive in component pieces due to shipping restrictions. Individual components of a system have matching identification tags which should be used to identify and assemble the complete system. Assembling systems with different identification tags can cause reductions in the fan(s) performance.

RIGGING / ASSEMBLY INSTRUCTIONS

Rigging Instructions

• Use standard lifting and rigging practices

• All lifting lugs on each component must be utilized at the same time

• Plenum, Blower, and Windband are to be kept level during installation

System Component Parts

Windband

Blower Housing

Bypass Air Plenum

Roof Curb or

Structural Support

VEKTOR INSTALLATION (CONTINUED)

The figures below illustrates four common methods used to install Vektor systems. Methods used to attach a Vektor unit are dependent on local codes, roof construction design and roof construction materials. Consult an architect or structural engineer for proper means of attachment.

Weatherhood w/ birdscreen (optional)

3/8 in. bolt (typical) (by Greenheck)

Bolt or weld in field (by others)

Bypass Air

Plenum

3/16 in. silicone gasket (by Greenheck)

Structural Support (by others)

5/16 in. bolt (typical) (by Greenheck)

Fiberglass Insulation

Roof Curb

5/16 in. bolt (typical) (by Greenheck)

Weatherhood w/ birdscreen (optional)

Field drilled and bolted (by others)

Bypass Air

Plenum

3/16 in. silicone gasket (by Greenheck)

Structural Support (by others)

Fan, Plenum, and Curb to Structural Steel Fan and Plenum (no Curb) to Channel Base

5/16 in. self-tapping screws (by Greenheck)

Weatherhood w/ birdscreen (optional)

Bypass Air

Plenum

Fan

3/16 in. silicone gasket (by Greenheck)

Exhaust Duct (by others)

(Roofing felt & material

Fiberglass Insulation

Roof Curb

Roof Line

by others)

3/8 in. bolt (typical) (by Greenheck)

Bolt or weld in field (by others)

3/16 in. silicone gasket (by Greenheck)

Exhaust Duct (by others)

Fiberglass Insulation

Roof Curb

Roof Line

(Roofing felt & material

by others)

3/8 in. bolt (typical) (by Greenheck)

Bolt or weld in field (by others)

Fan, Plenum, and Curb to Roof Deck Fan and Curb (no Plenum) to Roof Deck

VEKTOR RISER INSTALLATION

Check curb or structural supports for levelness. Both must be level to ensure proper drainage from plenum and fan(s).

Riser duct(s) run up through the curb and are flanged over the curb. (By Contractor)

Roof Curb

Anchor curb to roof deck structure in accordance with project construction documents.

PLENUM ASSEMBLY

The Vektor plenum is modular in design. Each fan on a system has its own plenum section. This modular approach allows for flexibility in the field to allow for on-site lifting capacity. The plenum sections can either be assembled all together into one single piece and then fitted on the roof curb / support structure or each section can be placed on individually. The method used would be dependent on the lifting capacity for the equipment on-site. If moving each piece separately onto the roof curb or support structure, each section should be joined to its mating part before moving another section into place.

For a 1 X 1 system there is only a single plenum section and no multiple plenum assembly would be required.

Determine the placement of the plenum sections relative to each other

When looking at the individual section one will notice that each plenum section is missing at least one side panel. These areas are the locations where the sections are to be joined together. If you have two plenum sections, then each one would be missing a side panel. If you have a three-fan system, there are three plenum sections. The two end plenum sections would each be missing one side panel and the middle section would not have panels on two sides. Please refer to the submittal drawing for the orientation of any Bypass Air Plenum (BAP) dampers or air inlet locations.

Putting the Plenum together

After identifying the plenum sections arrangement order, one of the two mating sections has weld nuts on the inside of the plenum. The assembly hardware (stainless steel bolts) required to join the sections is located here for shipping purposes. These bolts should be removed and set-aside prior to placing the mating sections together. The bolts are located every 6 – 10 inches to provide the best seal between the mating sections.

Before moving the sections into position, gasketing must be installed to seal the plenum sections against leakage. This silicone gasketing is supplied with the fans and only needs to be applied to one of the two mating plenum sections. The bands or strips of gasketing should be attached around the perimeter of the joining face and with an additional strip making a triangular area in each corner. If there are two openings in the side access panel (as shown in the figure below) then an additional strip of gasketing and triangular area are made for each.

Note: Gasketing material (shipped with fan) should be placed on the top edge of already installed roof curb prior to placing the plenum or individual plenum sections on the curb.

After the gasketing has been attached and the hardware has been removed, place the two mating sections together. The

Plenum Section

Bolt Holes

stainless steel bolts, which were set aside earlier, are now run first through the holes of the plenum section without the weld nuts and tighten into the weld nuts on the other plenum section. An additional side (or access) panel may need to be removed in order to gain access to the inside of the plenum assembly. The bolts should be tightened in a manner as to pull the two sections together and compress the gasketing.

After the plenum is assembled

Use all provided hardware to tighten and join the mating sections together. Any side panels removed to gain access to the interior of the plenum should be reattached. The assembled plenum has holes in the curb cap to fasten the plenum to the already installed roof curb.

Gasket Material

The plenum is now ready to have gasketing placed in the mounting location between the plenum and the fan. After the gasketing has been attached the fans can be lifted into place.

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