Loren Cook DBX Installation Manual

Page 1

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

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.

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.

This publication contains the installation, operation and maintenance procedures for standard units of the DB - Ceiling, Wall and Cabinet Fans.

•DB/TDB

•SDB/DBX

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

Loren Cook catalog, DB, 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 Installers of Industrial and Commercial Fans.

All of the publications listed above can be obtained from Loren Cook Company by phoning 417/869-6 47 4, 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.

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 included) for free operation of all moving parts.

• Record on the Delivery Receipt any visible sign of damage.

Duct Blower

Cabinet Fans

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 2.

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

Leave enough slack in the wiring to allow for motor m ovement 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.

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).

Handling

Lift fan by the base or lifting eyes. Never lift by the shaft,

motor, or housing.

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.

Installation

Motor Installation

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 by bolting the motor on the motor mounting plate in the existing mounting slots.

DB/DBX

Page 2

1 foot

1/4 inch

1 728

3 9

L2L

456

789

L2L

Low Voltage

208/230 Volts

High Voltage

460 Volts

3 Phase, 9 Lead Motor Y-Connection

7 1

789 456

Low Voltage

208/230 Volts

High Voltage

460 Volts

8 2

9 3

L1L

3 Phase, 9 Lead Motor Delta-Connection

Fan

Motor

Damper

Motor*

Second Damper

Motor

ransformer**

L3 L2 L1

Wiring Diagrams

Single Speed, Single Phase Motor

Ground A

T-1

T-4

Ground B

Line L

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

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

Together

Motor

Line

Motor

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

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

Ground A

T-5

J-10

Ground B

Link A Link B

Low Voltage

Line

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.

Ground A

Link A & B

High Voltage

Line

Low Speed

Motor

T T T

11 12 13

High Speed High Speed High Speed

To reverse: High Speed-interchange leads T11 and T12. Low Speed-interchange leads T line leads.

and T2. Both Speeds-interchange any 2

Typical Damper Motor Schematic

Low SpeedHigh Speed

2 3

4 5 6

Open

Line

L L L

1 2

Line

Belt and Pulley Installation

Belt tension is determined by the sound of the belts whe n the fan is first started. The belts will produce a loud squeal, which dissipates after the fa n is operatin g 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.

Models SDB

a. Loosen the motor plate bolts and move the motor

plate (with motor installed) so 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 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.

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 nuts in place. d. Ensure pulleys are properly aligned. Refer to Figure 2.

Figure 1

Page 3

All other fans

Figure 2

Tolerance

Center Distance

Maximum

Gap

Up thru 12” 1/16”

12” up through 48 1/8”

Over 48” 1/4”

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

a. Loosen the pivoting motor base bolts and turn the

adjustment screws to lower the motor base so 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. c. Lock the motor plate adjustment nuts in place. d. Ensure pulleys are properly aligned. Refer to Figure 2.

OFFSET ANGULAR OFFSET/ANGULAR

CENTER

DISTANCE

(CD)

X Y

Pulley Alignment

Pulley alignment is adjusted by loosening the motor pulley

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

Figure 2 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 3 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.

Figure 3

Final Installation Steps

a. Inspect fasteners and setscrews, par-

ticularly fan mounting and bearing fasteners, and tighten according to the recommended torque shown in the table, Recommended Torque for Setscrews/Bolts.

b. Inspect for correct amperage and

voltage with an ammeter and voltme-

ter. c. Ensure blower is secured to duct work. d. Ensure all accessories are installed.

e. Inspect wheel-to-inlet clearance. f. Test the fan to be sure the rotation is the same as indi-

Do not allow the fan to run in the wrong direction.

cated by the arrow marked Rotation.

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 possi-

GAP

ble to interchange two leads at this location so that the fan is operating in the correct direction.

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 fan, 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. Ensure fan and ductwork are clean and free of debris. g. Test the fan to ensure the rotation of the wheel is the

same as indicated by the rotation label. h. Close and secure all access doors. i. Restore power to unit.

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 directions 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.

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Inspection

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 months6 months 1 months

Inspection of the fan should be co nducted at the first 30 minute, 8 hour and 24 hour intervals of satisfactory operation. During the inspections, stop the fan and inspect as per directions 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.

Filters (if included)

Filters should be inspected 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.

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 conta minated air (airborne abrasives) should be inspected every three months.

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 need ed. 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.

Fan Bearings

The fan bearings are provided prelubricated. Any spe cialized 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.

Conditions Chart

RPM Temp °F Greasing Interval

Up to 1000

1000 to 3000

Over 3000

Any Speed < -30 Consult Factory Any Speed > 200 1 week

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.

-30 to 120 6 months

120 to 200 2 months

-30 to 120 3 months

120 to 200 1 month

-30 to 120 1 month

120 to 200 2 weeks

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 units 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 advisa ble to add lubricant after 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 cond itions, 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 bear in gs after 3 years of operation to prevent interruption of service.

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

Page 5

Motors are provided with a polyurea mineral oil NG LI #2 grease. All additions to the motor bearings are to be with a compatable grease such as Exxon Mo bil 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 representative or your nearest authorized electric motor service representative.

Changing Shaft Speed

All belt driven Propeller Wall 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 fa cing.

If the pulley has multiple grooves, all must be adjusted to the same width.

c. After adjustment, inspect for proper belt tension.

Maximum RPM

Size

8 1494 8 1494

9 1594 9 1594 10 1382 10 1382 13 1094 13 1094 15 973 15 973 18 906 18 906

Maximum

RPM

DBX Size

Maximum

RPM

Maximum RPM

SDB Size

100 2795 9 1469 120 2486 10 1382 135 2281 13 1094 150 2088 15 1030 180 1727 18 907 210 1399 245 1284

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

TDB Size

Maximum

RPM

Replacing Pulleys and Belts

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, how-

ever, 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 Belt and Pul-

ley Installation, page 2.

Bearing Replacement

If you have a model DB or TDB, the fan bearings are per-

manently sealed and will not require replacement.

If you have a model SDB or DBX, the fan bearings are pillow block ball bearings. Follow the instructions below for replacement.

a. Loosen screws on bearing cover. b. Push bearing cover toward the wheel. As the bearing

cover moves toward the wheel it will slide down to

reveal the bearings and shaft. c. Remove the old bearing. d. Remove any burrs from the shaft by sanding. e. Slide new bearings onto the shaft to the desired loca-

tion and loosely mount bearings onto the bearing sup-

port. Bearing bolts and setscrews should be loose

enough to allow shaft positioning. f. Correctly position the wheel and tighten the bearing

bolts securely to the bearing support. g. Align setscrews bearing to bearing and secure tightly

to the shaft. Do not tighten both pairs of setscrews

before securing bearing mounting bol t s. This may dam-

age the shaft. h. Inspect the wheel position again. If necessary , readjust

by loosening the bearing bolts and setscrews and

repeat from step e.

Wheel Replacement—SDB

a. Drill two holes approximately centered between the

shaft and the edge of the hub OD with the following

dimensions.

• 1/4” diameter

• 3/8” to 1/2” deep

• 180° apart in face of hub b. Tap 1/4” holes to 5/16” thread with the 5/16” hole tap.

Do not drill or tap any larger than recommended. c. Screw the puller arms into the tapped holes full depth

of threads (3/8” to 1/2” approximately). Align center of

puller with center of shaft. Make cert ain all setscrews in

hub (normally a quantity of two) are fully removed.

Work puller slowly to back wheel off the shaft.

Page 6

Recommended Puller

Above - Drilled hole placement. Right - Wheel puller.

Lisle No. 45000 Steering Wheel Puller. This puller is available at most automotive parts retail outlets.

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

DB and TDB Parts List

Airflow

Part No.

1 Motor Motor 2 Rubber Isolators (4) Rubber Isolators (8) 3 Pivoting Motor Base Pivoting Motor Base 4 Hanger Channel (2) Hanger Channel (2) 5 Blower Bracket (2) Blower Bracket (4) 6 Bearings (2) Bearings (4) 7Blower Blower (2) 8 Driven Sheave Driven Sheave

9 Shaft Shaft 10 Belt Set Belt Set 11 Driver Sheave Driver Sheave 12 Outlet Flange Outlet Flange (2) 13 Wheel Wheel (2)

DB TDB

TDB

Description

Page 8

SDB and DBX Parts List

AIRFLOW

Part No.

SDB Sizes 100 - 180 SDB Sizes 210 - 245 DBX Sizes 10 -18

Description

1 Rubber Isolators (4) Rubber Isolators (4) Rubber Isolators (4) 2 Hanger Channel (2) Hanger Channel (2) Hanger Channel (2) 3 Driver Sheave Driver Sheave Driver Sheave 4 Motor Motor Motor

Pivoting Motor Base (shown) — Pivoting Motor Base (shown)

— Slide Motor Base (not shown) — 6 Belt Set Belt Set Belt Set 7 Driven Sheave Driven Sheave Driven Sheave 8 Blower Blower Blower 9 Blower Brackets (2) Blower Brackets (2) Blower Brackets (2)

10 Outlet Flange Outlet Flange Outlet Flange

11 Wheel Wheel Wheel 12 Shaft Shaft Shaft 13 Bearings (3) Bearings (3) Bearings (3)

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

DB IOM - November 2007