Loren Cook AQB24 Installation Manual

Page 1
AQ/SEP/ETE/ETS
Propeller Roof Fans
INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
This publication contains the installation, operation
and maintenance procedures for standard units of the
AQ/SEP/ETE/ETS - Propeller Roof Fans.
Carefully read this publication prior to any installa-
tion or maintenance procedure.
Loren Cook catalog, tional information describing the equipment, fan perfor­mance, available accessories and specification data.
For additional safety information, refer to AMCA publica­tion 410-96,
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 info@loren­cook.com.
For information and instructions on special equipment, contact Loren Cook Company at 417/869-6474.
Safety Practices for Users and Installers of
Propeller Roof Fans
.
, provides addi-
Receiving and Inspection
Carefully inspect the fan and accessories for any damage and shortage immediately upon receipt of the fan.
• Turn the propeller 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 damage.
Delivery Receipt
any visible sign of
Handling
Lift the fan by the base or by the shipping carton. Never
lift by the shaft, motor or housing.
If your fan is covered with a protective coating (e.g., phe-
nolic enamels, or other protective coatings), handle with
extreme care . Even a small chip will break the coating’s
continuity and destroy its ability to protect the metal.
Propellers are carefully balanced to give smooth, vibra­tion-free operation. If the propeller is damaged during han­dling, it will require rebalancing.
WARNING
This unit has rotating parts. Safety precautions should be exercised at all times during installation, operation, and maintenance. ALWAYS disconnect power prior to working on fan.
To maintain good working condition of the fan when it is stored outdoors or at a construction site, follow the addi­tional instructions below.
• Coat the shaft and bearings with grease or rust preven­tative compound to help seal out moisture.
• Periodically rotate the propeller and operate the damp­ers (if supplied) to keep a coating of grease on all inter­nal bearing parts.
• Periodically inspect the fan to prevent damaging condi­tions.
• Block propeller to prevent natural rotation.
• Cover the unit with some type of weather cover to pre­vent moisture, corrosion, dirt or dust accumulation.
Personal Safety
Disconnect switches are recommended. Place the disconnect switch 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.

Installation

Damper Installation
If your fan is supplied with dampers, follow the directions
below. If your fan does not include dampers, proceed to
Motor 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 by installing at least
two sheet metal screws (#10 x 1/2”) on each side of the damper, through the tray, with the screw head catching the flange on the damper. This will prevent the exhaust dampers from lifting and keep the supply dampers cen­tered.
Damper Installation continued
.
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.
Outdoor Storage
SEP/AQD
1
Page 2
.
c. Drill a hole in the curb shelf for conduit needed for
motor wiring.
d. Operate the dampers manually to ensure the blades
move freely. Dampers should be released from full open position to check for proper closing.
1/4 inch
1 foot
Figure 1
Motor Installation (Belt Drive fans)
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.
a. Remove the motor plate mounting bolts and the motor
plate.
b. Remove the motor mounting bolts from the motor
plate.
c. Mount the motor to the motor plate aligning to the
appropriate holes.
d. Place the motor plate on the power assembly and rein-
stall the mounting bolts.
Correct
Incorrect
c. Lock the motor plate adjustment nuts
in place.
d. Ensure pulleys are properly aligned.
Refer to
Figure 2
Pulley Alignment
Pulley alignment is adjusted by loosen­ing the motor pulley setscrew and by moving the motor pulley on the motor shaft or by moving the entire motor along the motor mounting bracket.
Figure 2
illustrates correct and incorrect pulley alignment.
Figure 3
A recommended method of inspecting the pulley alignment is shown in
Figure 3
. With the shorter leg of a carpenter’s square or other straight edge lying along the case of the motor, adjust the position of the motor pulley (or the motor) until the longer leg of the square is parallel to the belt.
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
on page 3.
Lock off all power sources before unit is wired to power source.
Leave enough slack in the wiring to allow for motor move-
ment when adjusting belt tension.
Personal Safety
Disconnect switches are recommended. Place the disconnect switch 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.
Incorrect Incorrect
Figure 2
Belt and Pulley Installation
If your fan is a direct drive, proceed to
Wiring Installation
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
.
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).
Fan Installation
The fan support (roof curb) should provide a level surface for installation. If the roof is pitched more than 1/2:12, a sloped curb must be used to correct for the incline.
.
Place fan over roof opening. Secure the fan with lag screws, anchor bolts, or other suitable fasteners.
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
2
Key Hex
Across
Flats
Recommended
Torque
Min. Max. Size
Hold Down Bolts
Wrench
Torque
Page 3

Wiring Diagrams

Single Speed, Single Phase Motor
Ground A
L
T- 1
T- 4
Ground B When ground is required, attach to ground A or B with no. 6 thread forming screw. To reverse, interchange T-1 and T-4.
1
Line L
2
Wiring Diagrams
3 Phase, 9 Lead Motor
Low Voltage
208/230 Volts
4
6
5
3
1
9
728
L2L
L
3
To reverse, interchange any 2 line leads.
1
High Voltage
2 Speed, 2 Winding, Single Phase Motor 2 Speed, 1 Winding, 3 Phase Motor
Ground A
T- 1
T- 4
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.
High Speed
L
1
L
2
Low Speed
Line
To reverse, interchange any 2 line leads. Motors require magnetic control.
Motor
High Speed
1
Together
2 3
L
4
L
5 6
L
1 2
Line
3
Motor
Single Speed, Single Phase, Dual Voltage 2 Speed, 2 Winding, 3 Phase
Ground A
L
Line
L
1
T- 5
J-10
2
Ground B
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.
Link A Link B
Low Voltage
Ground A
Link A & B
L
1
Line
L
2
Low Speed
T
3
Low Speed
T
2
Low Speed
T
Motor
To reverse: High Speed-interchange leads T Low Speed-interchange leads T line leads.
1
T
11
T
12
T
13
High Speed High Speed High Speed
and T
1
. Both Speeds-interchange any 2
2
Typical Damper Motor Schematic
460 Volts
456
789
12
L2L
L
1
Low Speed
and T
11
3
3
L
1
1
L
2
2
3 4
5 6
12
Line
L
3
Open
L
1
Line
L
2
L
3
.
Fan
Motor
Transformer**
Damper
Motor*
Second Damper
Motor
Transformer**
L3 L2 L1
For 3 phase, damper motor voltage should be the same between L L
. For single phase application, disregard L
2
available in 115, 230 and 460 volt models. The damper motor nameplate voltage should be verified prior to connection. ** A transformer may be provided in some installations to correct the damper motor voltage to the specified voltage.
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 below,
Recommended Torque for Setscrews/Bolts
b. Inspect for correct voltage with voltmeter.
c. Ensure all accessories are installed.
d. Test the fan to be sure the rotation is the same as indi-
cated by the arrow marked Rotation .
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 in the wrong direction, check the control switch. It is possi­ble to interchange two leads at this location so that the fan is operating in the correct direction.
.
and
. *Damper motors may be
3
1
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 unit, 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. Rotate the propeller to ensure it does not rub against
the base. g. Ensure fan and ductwork are clean and free of debris. h. Test the fan to ensure the rotation of the propeller is the
same as indicated by the rotation label.
i. Restore power to unit.
3
Page 4
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.
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 5.
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.
WARNING Disconnect power before checking and cleaning
filters. Inadvertent operation of the fan could pull objects from the roof into the propeller.
Filter
If you fan is not supplied with filters proceed to
.
nance
Inspect filters within the first two weeks of operation. If there is no excessive build-up, monthly servicing should be adequate.
To clean reusable aluminum filters, back flush with soap and water. When clean, shake off excess water and allow the filter to air-dry before reinstalling it.
Mainte-

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 propeller and air inlets if material build-up is excessive. Excessive build-up can cause imbal­ance and failure of the propeller.
Regular inspections are recommended for fans exhaust­ing non-contaminated air.
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
.
• Inspect for cleanliness. Clean exterior surfaces only.
Removing dust and grease on motor housing assures proper motor cooling.
Lubricants
Loren Cook Company uses petroleum lubricant in a lith­ium base conforming to NLGI grade 2 consistency. Other grades of grease should not be used unless the bearings and lines have been flushed clean. If another grade of grease is used, it should be lithium-based.
A NLGI grade 2 grease is a light viscosity, low-torque, rust-inhibiting lubricant that is water resistant. Its tempera­ture range is from -30 ° F to +200 ° F and capable of intermit­tent highs of +250 ° F.
Motor Bearings
Motor bearings are pre-lubricated and sealed. Under normal conditions they will not require further maintenance for a period of ten years. However, it is advisable to have your maintenance department remove and disassemble the motor, and lubricate the bearings after three years of operation in excessive heat and or in a contaminated air­stream consisting of airborne abrasives.
Conditions Chart
RPM Temperature
100 Up to 120˚F Clean 6 to 12 months
500 Up to 150˚F Clean 2 to 6 months 1000 Up to 210˚F Clean 2 weeks to 2 months 1500 Over 210˚F Clean Weekly
Any
Speed
Any
Speed
Any
Speed
Any
Speed
Up to 150˚F Dirty 1 week to 1 month
Over 150˚F Dirty Daily to 2 weeks
Any Temperature Very Dirty Daily to 2 weeks
Any Temperature
Fan
Status
Extreme
Conditions
Greasing
Interval
Daily to 2 weeks
Fan Bearings
Fan bearings are lubricated through a grease connector
and should be lubricated by the schedule,
Chart
, shown above.
Conditions
For best results, lubricate the bearing while the fan is rotating. Slowly pump grease into the bearing until a slight bead forms around the bearing seals. Excessive grease can burst seals thus reduce bearing life.
In the event the bearing cannot be seen, use no more than three injections with a hand-operated grease gun.
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.
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Page 5
Changing Shaft Speed
All belt driven propeller roof 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.
Pulley and Belt Replacement
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
ley Installation
, page 2.
Belt and Pul-
Bearing Replacement
The fan bearings are pillow block ball bearings. a. Remove the top cap to gain access to the fan. b. Loosen the motor plate mounting bolts and remove the
drive belts.
c. Remove the propeller from the shaft. d. Remove the four (4) bearing hold-down bolts and then
remove the shaft and bearings from the fan as an assembly.
e. Measure and record the location of the bearings on the
shaft. This will aid the reassembly.
f. Loosen the bearing setscrews and remove the bear-
ings from the shaft.
g. Remove any imperfections in the shaft using a smooth
file or emery cloth.
h. Place new bearings on the shaft.
i. Locate one of the bearings using the previous mea-
surements and tighten one setscrew.
j. Install the propeller on the shaft. Center the propeller in
the opening and tighten the bearing bolts.
k. Rotate the propeller to allow the bearings to find their
center of free movement.
l. Align the bearing setscrews and tighten to proper
torque. Refer to the
Torque chart
on page 2.
m. Reassemble drive assembly and replace top cap.
Propeller and Shaft Replacement Precautions
• If the shaft is dropped and bent, it may cause unbal­anced operation of the fan.
• When handling the propeller separately from the shaft, place a support through the hub for lifting, making sure not to injure the finished bore of the propeller.
• Never allow the propeller to rest its entire weight on the blades. The propeller and shaft can be lifted by slings around the shaft on each side of the propeller so the propeller is supported by its hub.
• If using a chain to lift the propeller, make sure there is sufficient padding on the shaft and propeller. This pre­vents the scoring of the shaft or injury to the propeller. The chain or cable should be spread with timbers, or braced by some other method to prevent damage to the propeller side plates.

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 propeller alignment.
Excessive Vibration and Noise
•Damaged or unbalanced propeller.
•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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Page 6
AQB/SEP Parts List
1
2
19
18
1617
15
AQB
19
18
17
SEP
14
16
15
14
13
1
2
13
4
3
12
4
3
5
6
7
8
9
11
10
5
6
7 8
Parts
No.
10 3/8” Bolt (4) 3/8” Bolt (8) 11 Bearings (2) Bearings (2) 12 Cast Propeller Assembly Cast Propeller Assembly 13 Motor Plate Motor Plate 14 Base Base 15 Venturi Venturi 16 17 Baffle Brake Baffle Brake 18 Isolators (4) Isolators (4) 19 Motor Motor
Size 24 Size 30 Size 36 Size 42 Size 48
1 Baffle Baffle 2 Driver Sheave Driver Sheave 3 Belt Set Belt Set 4 Driven Sheave Driven Sheave 5 6 Shaft Shaft 7 Birdscreen Birdscreen 8 Power Assembly Power Assembly 9 3/8” Nut (4) 3/8” Nut (8)
Upper Post (4)
Lower Posts(4)
Description
Upper Post (8) Upper Post (8)
Lower Post (4)
9
12
11
10
AQD Parts List
13
12
11
10
Size 12
1
13
12
11
10
Size 16-24
9
1
8
8
7
2
3
4
6
7
2
3
4
5
6
Parts
No.
1 Baffle Baffle 2 5/16” Bolt (12) 5/16” Bolt (12) 3 Upper Post (4) Upper Post (4) 4 Birdscreen Birdscreen 5 Lower Post (4) 6 5/16” Nut (4) 5/16” Nut (4) 7 Motor Motor 8 Propeller Propeller
9 Motor Plate Motor Plate 10 Base Base 11 Venturi Venturi 12 Isolator (4) Isolator (4) 13 Power Assembly Power Assembly
Size 12 Size 16 Size 20 Size 24
Description
6
Page 7

ETE/ETS Parts List

2
4
3
10
4
3
12
ETE
13
12
11
1
2
1
5
6
7
8
9
5
6
Parts No.
1 Top Cap Top Cap 2 Motor Motor 3 Driver Sheave Driver Sheave 4 Belt Set Belt Set 5 Driven Sheave Driven Sheave 6 Bearings (2) Bearings (2) 7 Power Assembly Power Assembly 8 Propeller Propeller
9 Base Base 10 Shaft Shaft 11 Motor Plate Motor Plate 12 Tiered Hood Tiered Hood 13 Filters
ETE Sizes 24-60 ETS Sizes 24-60
Description
7
ETS
11
10
8
9
7
Page 8
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.
Corporate Offices: 2015 E. Dale Street Springfield, MO 65803 417.869.6474
www.lorencook.com
AQ/SEP/ETE/ETS IOM - January1999
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