Loren Cook ASP Installation Manual

Page 1

ASP/KSP

WARNING

This unit has rotating parts. Safety precautions should be exercised at all times during installat io n, operation, and maintenance. ALWAYS disconnect power prior to working on fan.

Centrifugal Filtered Supply Fans

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

This publication contains the installation, operation and maintenance instructions for standard units of the ASP/KSP-Centrifugal Filtered Supply Fans.

Carefully read this publication prior to any installation or maintenance procedure.

Loren Cook catalog, ASP/ASP-T and KSP, provides additional information describing the equipment, fan performance, available accessories, and specification data.

For additional safety information, refer to AMCA publication 410-96, Safety Practices for Users and Install- ers of 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 F AX at 41 7/832-9431 ; or by e- mail at info@lorencook.com.

For information on special equipment, contact Loren Cook Company Customer Service Department at 417/ 869-6474.

Receiving and Inspection

Carefully inspect the fan and accessories for any damage and shortage immediately upon receipt of the fan.

• Turn the wheel by hand to ensure it turns freely and does not bind.

• Inspect dampers (if supplied) for free operation of all moving parts.

• Record on the Delivery Receipt any visible sign of

damage.

Installation

Motor Installation

To prevent damage to the fan du ring shipping, motors 5 HP and larger, and extremely heavy motors (cast iron or severe duty) are shipped loose and must be field mounted by bolting the motor on the motor mounting plate in the e xisting mo unting slots.

KSP Assembly

NFPA 96 installation guidelines for KSP fans are shown in figure 1 and 2 on page 2.

a. Remove the top cap (item 3) from the fan.

b. Remove the intake hood (item 2) and the filter(s) (item 1)

from the inside of the fan. c. Replace the topcap. d. Slide the intake hood over the flange on the fan and

secure with the nine screws provided. e. Remove the two thumb screws and the filter retainer. f. Slide the filter(s) down between the angles inside the

intake hood and the flange on the front of the hood. g. Replace the filter retainer and secure with the two thumb

screws. h. Caulk the top of the intake hood where the hood meets

the fan. Use an appropriate caulk for exterior use.

Handling

Lift the fan by the base or lifting eye s. Never lift by the

shaft, motor, or housing.

Storage

If the fan is stored for any length of time prior to installation, store the fan in its original crate and protect it from dust, debris and the weather.

ASP

KSP

Page 2

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.

Figure 3

1 foot

1/4 inch

Figure 1 - NFPA 96 Standard Installation

Figure 2 - NFPA 96 Alternate Installation

10' MIN.

KSP with

Curb Cap

Curb

Vented Extension

VCR with Hinged Base

Intake

Extension

View 1 - KSP Shipping Arrangement

2 4

CaulkCaulk

View 2 - KSP Field AssemblyView 2 - KSP Field Assembly

Leave enough slack in the wiring to allow for motor movement when adjusting belt tension. Some fractional motors have to be removed in order to make the connection with the terminal box at the end of the motor. To remove motor, remove bolts securing motor base to power assembly. Do not remove motor mounting bolts.

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).

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.

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.

Lock off all power sources before unit is wired to power source.

Belt and Pulley Installation

Belt tension is determined by the sound the belts make when the fan is first started. Belts will produce a loud squeal which dissipates after the fan is operating at full capacity. If the belt tension is too tight or too loose, lost efficiency and possible damage can occur.

Page 3

Wiring Diagrams

Fan

Motor

Damper

Motor*

Second Damper

Motor

ransformer**

L3 L2 L1

728

3 9

L2L

456

789

L2L

Low Voltage

208/230 Volts

High Voltage

460 Volts

3 Phase, 9 Lead Motor Y-Connection

789

456

Low Voltage

208/230 Volts

High Voltage

460 Volts

8 2

9 3

L1L

3 Phase, 9 Lead Motor Delta-Connection

T-1

T-4

Ground B

Ground A

Line

Ground A

Ground B

T-1

T-4

Low Speed

High Speed

Line

Ground B

J-10

T-5

Ground A

Link A Link B

Low Voltage

Line

Ground A

Link A & B

Line

Ground B

T-5

J-10

Motor

1 2 3

4 5

Together

High Speed

Line

1 2 3

4 5

Open

Low Speed

Line

Motor

Low Speed Low Speed Low Speed

High Speed High Speed High Speed

Motor

Line

Single Speed, Single Phase Motor

When ground is required, attach to ground A or B with no. 6 thread forming screw. To reverse, interchange T-1 and T-4.

2 Speed, 2 Winding, Single Phase Motor

When ground required, attach to ground A or B with No. 6 thread forming screw. To reverse, interchange T-1 and T-4 leads.

Single Speed, Single Phase, Dual Voltage

Wiring Diagrams

To reverse, interchange any 2 line leads.

2 Speed, 1 Winding, 3 Phase Motor

To reverse, interchange any 2 line leads. Motors require magnetic control.

2 Speed, 2 Winding, 3 Phase

When ground required, attach to ground A or B with No. 6 thread forming screw. To reverse, interchange T-5 and J-10 leads.

Typical Damper Motor Schematic

For 3 phase, damper motor voltage should be the same between L1 and

. For single phase application, disregard L3. *Damper motors may be

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.

KSPD 94 - 97 and 103-106 Series

White Line

Black (High)

Red (Low)

NOTE: Insulate Unused Lead

Line

To reverse: High Speed-interchange leads T Low Speed-interchange leads T line leads.

and T2. Both Speeds-interchange any 2

KSPD 98 and 99 Series

White Line

Black

FSC

and T12.

Line

WHITE

KSPD 122 - 127 Series

Black (High)

Blue (Medium)

Red (Low)

NOTE: Insulate Unused Leads Separately

White Line

* *

Line

KSPD

FAN*

FSC

BLACK

*See KSPD Wiring Diagram for correct lead.

Page 4

Belt and Pulley Installation (cont.)

Figure 4

Tolerance

Center Distance

Maximum

Gap

Up thru 12” 1/16”

12” up through 48 1/8”

Over 48” 1/4”

OFFSET ANGULAR OFFSET/ANGULAR

X Y

CENTER

DISTANCE

(CD)

GAP

Recommended Torque for Setscrews/Bolts (IN/Lb)

Setscrews

Hold Down Bolts

Size

Key Hex

Across

Flats

Recommended

Torque

Min. Max. Size

Wrench

Torque

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

Do not change the pulley pitch diameter to change ten-

sion. This will result in a different fan speed than desired.

a. Loosen motor plate adjustment screw 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. Slide the motor plate back 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 3. c. Lock the motor plate adjustment nuts in place. d. Ensure pulleys are properly aligned. Refer to Figure 4.

Pulley Alignment

Pulley alignment is adjusted by loosening the motor pulley

setscrew and by moving the motor pulley on the m otor shaft.

Figure 4 indicates where to measure the allowable gap

for the drive alignment tolerance. All contact points (indicated by WXYZ) are to have a gap less than the tolerance shown in the table. When the pulleys are not the same width, the allowable gap must be adjusted by half of the difference in width. Figure 5 illustrates using a carpenter’s square to adjust the position of the motor pulley until the belt is parallel to the longer leg of the square.

f. Ensure fan and ductwork are clean and free of debris. g. Close and secure all access doors. h. Restore power to the fan.

Start Up

Turn the fan on. In variable speed units, set the fan to its

lowest speed and inspect for the following:

• Direction of rotation.

• Excessive vibration.

• Unusual noise.

• Bearing noise.

• Improper belt alignment or tension (listen for squealing).

• Improper motor amperage or voltage.

If a problem is discovered, immediately shut the fan off. Lock out all electrical power and check for the cause of the trouble. See Troubleshooting.

Final Installation Steps

a. Inspect fasteners and setscrews, particularly fan

mounting and bearing fasteners, and tighten accord ing to the recommended torque shown in the table Recom- mended Torque for Setscrews/Bolts.

b. Inspect for correct voltage with volt-

meter. c. Ensure all accessories are installed. d. If applicable, ensure fan is secureld

to ductwork.

Operation

Pre-Start Checks

a. Lock out all the primary and secondb. Ensure fasteners and setscrews, par-

c. Inspect belt tension and pulley alignment. d. Inspect motor wiring. e. Ensure belt touches only the pulleys.

ary power sources.

ticularly those used for mounting the

fan, are tightened.

Figure 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 Conditions Chart.

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.

Page 5

Filters

For moist or otherwise contaminated installations; divide the interval by a factor of 3. For vertical shaft installations divide the interval by a factor of 2.

Conditions Chart

RPM Temp °F Greasing Interval

Up to 1000

-30 to 120 6 months

120 to 200 2 months

1000 to 3000

-30 to 120 3 months

120 to 200 1 month

Over 3000

-30 to 120 1 month

120 to 200 2 weeks Any Speed < -30 Consult Factory Any Speed > 200 1 week

Relubrication Intervals

Service

Conditions

NEMA Frame Size

Up to and

including 184T

213T-365T 404T and larger

1800 RPM

and less

Over 1800

RPM

1800 RPM

and less

Over 1800

RPM

1800 RPM

and less

Over 1800

RPM

Standard 3 yrs. 6 months 2 yrs. 6 months 1 yr. 3 months

Severe 1 yr. 3 months 1 yr. 3 months 6 months 1 months

Filter inspection and cleaning intervals can vary from once a week to twice per year depending on contaminant present and acceptable pressure drops across the filter. Under most conditions filters may be cleaned with hot water and a mild soap solution (such as dish washing liquid) or steam. Some caustic cleaners will damage the filter. If in doubt, please consult the factory for a compatibility list.

High pressure spray washers should be limited to 2,000psi operating pressure. Every attempt should be made to remove the contaminants from the filte r in a “backwash” flow (note airflow arrow on the filter frame). Once the filter is dry, it may be returned to the appropriate filter racks in the same orientation (airflow direction) as they were removed.

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.

Regular inspections are recommended for fans exhausting non-contaminated air.

It is recommended the following inspection 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. Refer to Belt and Pulley Installation, page 2.

• Bearings should be inspected as recommended in the

Conditions Chart.

• Inspect filters. Filters should be cleaned at regular inter-

vals (frequency will depend on the environment in which the fan is located). To remove, loosen the thumbscrews and remove the filter retainer.

• Inspect springs and rubber isolators for deterioration and replace as needed.

• Inspect for cleanliness. Clean exterior surfaces only. Removing dust and grease on motor housing assures proper motor cooling. Removing dirt from the wheel and housing prevent imbalance and damage.

Fan Bearings

The fan bearings are provided prelubricated. Any specialized lubrication instructions on fan labels supercedes information provided herein. Bearing grease is a petroleum lubricant in a lithium base conforming to a NLGI #2 consistency. If user desires to utilize another type of lubricant, they take responsibility for flushing bearings and lines, and maintaining a lubricant that is compatible with the installation.

A NLGI #2 grease is a light viscosity, low-torque, rustinhibiting lubricant that is water resistant. Its temperature range is from -30°F to 200°F and capable of intermittent highs of 250°F.

Bearings should be relubricated in accordance with the condition chart below.

For best results, lubricate the bearing while the fan is in operation. Pump grease in slowly until a slight bead forms around the bearing seals. Excessive grease can damage seal and reduce life through excess contamination and/or loss of lubricant.

In the event that the bearing cannot be seen, use no more than three injections with a hand operated grease gun.

Motor Bearings

Motors are provided with prelubricated bearings. Any lubrication instructions shown on the motor nameplate supersede instructions below.

Direct Drive 1050/1075,1200,1300 &1500 rpm unit s use a prelubricated sleeve bearing that has a oil saturated wicking material surrounding it. The initial factory lubrication is adequate for up to 10 years of operation under normal conditions. However, it is advisable to ad d lubricant af ter 3 years. Use only LIGHT grade mineral oil or SAE 10W oil up to 30 drops. If the unit has been stored for a year or more it is advisable to lubricate as directed above. For VCR direct drive units and other units in severe conditions, lubrication intervals should be reduced to half.

Motors without sleeve bearings (as described above) will have grease lubricated ball or roller bearings. Motor bearings without provisions for relubrication will operate up to 10 years under normal conditions with no maintenance. In severe applications, high temperatures or excessive contaminates, it is advisable to have the maintenance department disassemble and lubricate the bearings after 3 years of operation to prevent interruption of service.

For motors with provisions for relubrication, follow intervals of the table below.

Page 6

Motors are provided with a polyurea mineral oil NGLI #2 grease. All additions to the motor bearings are to be with a compatable grease such as Exxon Mobil Polyrex EM and Chevron SRI.

The above intervals should be reduced to half for vertical shaft installations.

Motor Services

Should the motor prove defective within a one-year period, contact your local Loren Cook repre sentative or

Maximum RPM

ASP/ASP-T

Size

90 1665 90 1672 100 1519 100 1534 120 1223 120 1297 150 1075 150 1052 180 978 180 979 200 844 200 835

your nearest authorized electric motor servic e re pr es en tative.

Maximum

RPM

KSP Size

Maximum

RPM

Changing Shaft Speed

All belt driven fans with motors up to and including 5 HP 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 r im to op en or clo se the g ro ove fa cin g.

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 mot or are maintained.

Replacing Pulleys and Belts

a. Remove pulleys from their respective shafts.

b. Clean the motor and fan shafts.

c. Clean bores of pulleys and coat the bores with heavy

oil.

d. Remove grease, rust, or burrs from the pulleys and

shafts. e. Remove burrs from shaft by sanding. f. Place fan pulley on fan shaft and motor pulley on its

shaft. Damage to the pulleys can occur when exces-

sive force is used in placing the pulleys on their

respective shafts. g. Tighten in place. h. Install belts on pulleys and align as described in the

Belt and Pulley Installation section.

Bearing Replacement

The fan bearings for the 200 ASP, ASP-T and KSP are

pillow block ball bearings. Bearings should be replaced

individually for each side of fan.

An emery cloth or file may be needed to remove imper-

fections in the shaft left by the setscrews.

a. Remove topcap. b. Loosen motor plate adjustment bolts, then move the

motor plate so the belt will easily slip off. Remove

driven pulley by loosening the setscrews. c. Remove the bearings from shaft. d. Slide new bearings onto shaft to desired location and

mount bearings loosely onto support base. Bearing

bolts and setscrews should be loose to allow shaft

positioning. e. Position the wheel properly and tighten the bearing

bolts securely to the support base. f. Align setscrews bearing to bearing and tighten against

the shaft securely.

Never tighten both pairs of setscrews before securing bearing mounting bolts. This may damage the shaft.

g. Check wheel position again. If necessary, readjust by

loosening the bearing bolts and setscrew and repeat

step e.

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 wheel alignment.

Excessive Vibration and Noise

•Damaged or unbalanced wheel.

•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.

Page 7

ASP Parts List

ASP-T Parts List

Side Discharge fan shown.*

Part

No.

1 Hood 2 Housing 3Blower 4Base 5 Isolators (4) 6 Driven Sheave 7 Bearings (2)

Parts Not Shown

Ludwig Clip Filter Retainer (8) Driver Sheave Filter (4) Lower Retainer (4) Corner Post (4) Insulation

Motor Plate

Belts

Motor Topcap

Part

No.

1 Tiered Hood 2 Housing 3Blower 4Base 5 Isolators (4) 6 Driven Sheave 7 Bearings (2)

Parts Not Shown

Ludwig Clip Filter Retainer (8) Driver Sheave Filter (4) Lower Retainer (4) Corner Post (4) Insulation

Motor Plate

Belts

Motor Topcap

Description

Sizes 90 - 200

Description

Sizes 90 - 200

*Parts will be the same for bottom discharge units.

Page 8

1010

1111

1212

1313

1414

1515

1616

KSP-D Parts List

Part No.

1 Ludwig Clip (4) Ludwig Clip (4) 2 Topcap Topcap 3 Side Panel (2) Side Panel (2) 4 Intake Side Top Panel Intake Side Top Panel 5 Intake Top Panel Intake Top Panel 6 Intake Side Panel (2) Intake Side Panel (2) 7 Thumb Screw (2) Thumb Screw (2) 8 Nut Retainer (2) Nut Retainer (2)

9 Filter Retainer Filter Retainer 10 Filter Angle (2) Filter Angle (2) 11 Filter Filter 12 Intake Side Bottom Panel Intake Side Bottom Panel 13 Base Base 14 Motor Motor 15 Housing Housing 16 Side Panel Opposite Intake Side Panel Opposite Intake

Size 90 Sizes 91 - 121

Description

KSP-B Parts List

Part

No.

1 Ludwig Clip (4) Ludwig Clip (4) 2 Topcap Topcap 3Blower Blower 4 Side Panel (2) Side Panel (2) 5 Intake Side Top Panel Intake Side Top Panel 6 Intake Top Panel Intake Top Panel 7 Intake Side Panel (2) Intake Side Panel (2) 8 Thumb Screw (2) Thumb Screw (2)

9 Nut Retainer (2) Nut Retainer (2) 10 Filter Retainer Filter Retainer 11 Filter Filter (2) 12 Filter Angle (2) Filter Angle (2) 13 Intake Side Bottom Panel Intake Side Bottom Panel 14 Bearings (2) Bearings (2) 15 Base Base 16 Isolator (4) Isolator (4) 17 Driven Sheave Driven Sheave 18 Side Panel Opposite Intake Side Panel Opposite Intake

Size 90 - 120 Sizes 150 - 200

Description

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 th e fan or any pa rt thereof has been alt ered or modif ied from its original d esign or has been abused, misused, damaged or is in worn condition or if the fan has been used othe r t han for the uses described in th e compan y manual . This warran ty does not cover d efects result ing fr om 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. I f you are ent itled to warra nty relief, a war ranty adjustment will be completed within sixty (60) business days of the receipt of your written compla int by Loren Co ok Company. This warrant y gives only the or iginal pur chaser p lacing the fa n 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

lorencook.com

ASP/KSP IOM - November 2007