Loren Cook CCP Installation Manual

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Page 1

CCP

Centrifugal Plug Fans

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

This publication contains the installation, operation

and maintenance instructions for standard units of the

CCP-Centrifugal Plug Fans

tion prior to any installation or maintenance procedure.

Loren Cook catalog, 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 on special equipment, contact Loren Cook Company Customer Service Department at 417/869-

6474.

Safety Practices for Users and Installers of

. Carefully read this publica-

CCP

, provides additional information

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 age.

Delivery Receipt

any visible sign of dam-

Handling

Lift the fan by the base or lifting eyes on the housing.

Never lift by the shaft, wheel, or motor

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.

Outdoor Storage

To maintain good working condition of the fan when it is

stored outdoors, follow the additional instructions below.

• Coat the shaft with grease or a rust preventative compound.

• Wrap bearings for weather protection.

• Cover the inlet and outlet to prevent the accumulation of dirt and moisture in the housing.

• Periodically rotate the wheel and operate dampers (if supplied).

• Periodically inspect the unit to prevent damaging condi-

tions.

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

When mounting the fan, be sure that the structure of the wall is rigid enough to support the weight of the fan and its motor.

Consult the speciﬁc fan type submittal for the exact fan dimensions needed to determine the size of your wall opening. The wall opening should be just large enough for the wheel to ﬁt through.

For non-ducted inlet, be sure the inlet is placed at least one fan wheel diameter away from walls and bulkheads.

Motor Installation

Most motors are shipped mounted on the fans with belts and drives installed. However, extremely heavy motors and drives are shipped separately. These motors and drives wll require ﬁeld installation. Please refer to page 2 and 3.

Storage

If the fan is stored for any length of time prior to installation, completely ﬁll the bearings with grease or moistureinhibiting oil (refer to wheel several revolutions every three to ﬁve days to keep a coating of grease on all internal bearing parts.

Store the fan in its original crate and protect it from dust, debris and the weather.

Lubricants

on page 5). Rotate the

CCP

Page 2

Wheel-to-Inlet Clearance

The correct wheel-to-inlet clearance is critical to proper fan performance. This clearance should be veriﬁed before initial start-up since rough handling during shipment could cause a shift in fan components. Refer to wheel/inlet drawing for correct overlap.

Adjust the overlap by loosening the wheel hub and moving the wheel along the shaft to obtain the correct value.

A uniform radial gap (space between the edge of the cone and the edge of the inlet) is obtained by loosening the inlet cone bolts and repositioning the inlet cone.

Size Overlap

100 120 135

5/8”

3/4”

1”

Radial Clearance

Wheel/Inlet Overlap

Overlap

150 165 180 195 210 225 245 270 300 330 365 402 445

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.

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.

Personal Safety

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).

Airfoil Backward

Proper Wheel Rotation

Inclined

Wheel Rotation

Test the fan to ensure the rotation of the wheel is the

same as indicated by the arrow marked Rotation.

115 and 230 Single Phase Motors

Fan wheel rotation is set correctly at the factory. Changing the rotation of this type of motor should only be attempted by a qualiﬁed electrician.

208, 230, and 460, 3 Phase Motors

These motors are electrically reversible by switching two of the supply leads. For this reason, the rotation of the fan cannot be restricted to one direction at the factory. See Wiring Diagrams on page 3 for speciﬁc information on reversing wheel direction.

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.

1/4 inch

1 foot

Figure 1

Belt and Pulley Installatio

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.

Do not change the pulley pitch diameter to change tension. This will result in a different fan speed than desired.

a. Loosen motor plate adjustment bolts 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.

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Wiring Diagrams

Single Speed, Single Phase Motor

Ground A

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.

Line L

Wiring Diagrams

3 Phase, 9 Lead Motor

Low Voltage

208/230 Volts

728

L2L

To reverse, interchange any 2 line leads.

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

Low Speed

Line

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

Motor

High Speed

Together

2 3

5 6

1 2

Line

Motor

Single Speed, Single Phase, Dual Voltage 2 Speed, 2 Winding, 3 Phase

Ground A

Line

T- 5

J-10

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

Line

Low Speed

Motor

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

High Speed High Speed High Speed

and T

. Both Speeds-interchange any 2

Typical Damper Motor Schematic

Fan

Motor

Transformer**

L3 L2 L1

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

. For single phase application, disregard L

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.

. *Damper motors may be

High Voltage

460 Volts

456

789

L2L

Low Speed

1 2 3

4 5

and T

and

Line

Open

Line

Damper

Motor*

Second

Damper

Motor

Belt and Pulley Installation continued

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 1

c. Lock the motor plate adjustment bolts in place.

d. Ensure pulleys are properly aligned. Refer to

Figure 2

Pulley Alignment

Pulley alignment is adjusted by loosening the motor pul-

ley 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 align-

ment. 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.

Page 4

Correct

Incorrect Incorrect

Figure 2

Incorrect

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

for Setscrews/Bolts

Recommended Torque

b. Inspect for correct voltage with volt-

meter.

c. Ensure all accessories are installed.

Field Balancing

Figure 3

Due to the innumerable methods for mounting the CCP fan, ﬁeld balancing must be performed after ﬁnal installation. The fan must be dynamically two-plane balanced to obtain a maximum vibration velocity of .0785 inches/second. Failure to perform this ﬁeld balance may result in excessive vibration levels which can lead to early failure of the fan and/or mounting structure and will void the warranty.

Operation

Pre-Start Checks

a. Lock out all the primary and secondary power

sources.

b. Ensure fasteners and setscrews, particularly those

used for mounting the fan, are tightened.

c. Inspect belt tension and pulley alignment.

d. Inspect motor wiring.

e. Ensure belt touches only the pulleys.

f. Ensure fan and ductwork are clean and free of debris.

g. Inspect wheel-to-inlet clearance. The correct wheel-

to-inlet clearance is critical to proper fan performance.

h. Close and secure all access doors.

i. 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 .

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., bolts, and setscrews and motor nting bolts. Adjust and tighten as necessary.

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

Key Hex

Across

Flats

Recommended

Torque

Min. Max. Size

Hold Down Bolts

Wrench

Torque

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 exhaust-

ing non-contaminated air.

It is recommended the following inspection be conducted

twice per year.

• Inspect bolts and setscrews for tightness. Tighten as necessary. Worn setscrews should be replaced immediately.

• Inspect belt wear and alignment. Replace worn belts with new belts and adjust alignment as needed. Refer to

Belt and Pulley Installation

• Bearings should be inspected as recommended in the

Conditions Chart

, page 2.

Page 5

Maintenance continued

• Inspect variable inlet vanes for freedom of operation and excessive wear. The vane position should agree with the position of the control arm. As the variable inlet vanes close, the entering air should spin in the same direction as the wheel.

• 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.

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

Lubricants

Loren Cook Company uses petroleum lubricant in a lithium base. Other types of grease should not be used unless the bearings and lines have been ﬂushed clean. If another type of grease is used, it should be a lithium-based grease conforming to NLGI grade 2 consistency.

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.

Fan Bearings

Greasable fan bearings are lubricated through a grease ﬁtting on the bearing and should be lubricated by the schedule,

Conditions Chart

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 burst seals thus reducing 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.

Changing Shaft Speed

All belt driven fans with motors up to and including 5 HP (184T max.) 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.

Maximum RPM

CCP-A

Size

120 3948 5151 120 3692 4817 135 3508 4577 135 2953 3853 150 2749 3587 150 2656 3465 165 2509 3273 165 2414 3150 180 2150 2805 180 2389 3117 195 1987 2592 195 2204 2876 210 1841 2402 210 1786 2330 225 1712 2234 225 1659 2164 245 1608 2098 245 1532 1999 270 1418 1850 270 1391 1815 300 1276 1665 300 1251 1632 330 1162 1516 330 1141 1489 365 1065 1389 365 1022 1333 402 964 1258 402 936 1221 445 873 1139 445 846 1104

Maximum RPM

Class I Class II Class I Class II

CCP-F

Size

RPM Derating Factor

Operating

Temperature (˚F)

For elevated airstream temperatures, the maximum fan speed limits must be derated by the factors above.

Steel Aluminum

Speed Limit

Factor

70 1.00 70 1.00 200 0.98 200 0.93 300 0.96 300 0.79 400 0.94 500 0.91 600 0.87 700 0.81 800 0.75

Operating

Temperature (˚F)

Maximum RPM

Speed Limit

Factor

Page 6

Pulley and Belt Replacement

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 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 are pillow block ball bearings. An emery cloth or ﬁle may be needed to remove imper-

fections in the shaft left by the setscrews.

a. Mark the location on the shaft of both bearing races,

setscrews, and the wheel and pulley. Mark the location

and orientation of the inlet cone. Note the clearance

between the wheel and inlet cone. b. Remove the pulley. c. Remove the inlet cone. d. Remove the wheel from the shaft. A 2-jaw puller may

be required. e. Remove bearing hold-down bolts. Remove shaft and

bearings as one unit.

f. Remove the anti-corrosion coating from the shaft with

a suitable degreaser. g. Remove the bearing from the shaft using a bearing

puller. If a bearing puller is not available, tap on the

bearing with a wood block and hammer to remove it. h. Smooth and clean the shaft and bearing bore thor-

oughly.

i. Place the bearings into position making sure they are

not on a worn section of the shaft. Tapping the inner

ring face with a soft driver may be required.

Do not hammer on the housing.

j. The outer ring of the bearing is spherical and swivels

in the housing to compensate for misalignment.

Secure hold-down bolts, but k. Align the setscrews on the bearings and tighten one

setscrew on each bearing.

l. Rotate the shaft to allow the bearing outer rings to ﬁnd

their center of free movement.

do not fully tighten

m. Install the wheel on the shaft. Install the inlet cone in

its original location. And adjust bearing position and inlet cone to center the wheel in the inlet cone.

n. Tighten hold-down bolts to proper torque. Refer to

torque chart.

o. Turn the shaft by hand. Resistance should be the

same as it was before hold-down bolts were fully tight-

ened. p. Tighten bearing setscrews to speciﬁed torque. q. Re-install the pulley and adjust the belt tension.

Refer to

Belts and Pulley Installation

r. Test run and retighten all setscrews and bolts and trim

balance as necessary (.0785 in/sec max.).

After 24 hours of operation, retighten the setscrews to

the appropriate torque. This assures full locking of the inner race to the shaft. Make sure the socket key or driver is in good condition with no rounded corners. The key should be fully engaged in the setscrew and held squarely to prevent rounding out of the setscrew socket when applying maximum torque.

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 or incorrect inlet or outlet condition.

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

CCP Parts List

Part

No.

1 Fan Sheave 2 Belt Set 3 Motor Sheave 4 Motor 5 Motor Plate 6 Mounting Plate 7 Shaft 8 Insulated Plug (Optional)

9 Inlet Cone 10 Wheel 11 Inboard Bearing 12 Outboard Bearing 13 Scroll (Optional)

Description

Sizes 120 - 445

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

CCP IOM - January 2001