Loren Cook Lo-Pro Installation Manual

Page 1

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.

Lo-Pro

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.

Low Profile Centrifugal Exhaust Fans

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

This publication contains the installation, operation

and maintenance procedures for standard units of the

Lo-Pro - Low Profile Centrifugal Exhaust Fans.

• LPD/LPB

Carefully read this publication prior to installation.

Loren Cook catalog, Lo-Pro, 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 417/869-6474 , exte nsion 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.

• Check dampers (if included) for free operation of all moving parts.

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

existing mounting slots.

Damper Installation

If your fan is supplied with dampers, follow the directions below. If your fan does not include dampers, proceed to Belt and Pulley 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. c. Drill a hole in the curb shelf for conduit needed for

motor wiring. d. Operate the dampers manually to ensure the baldes

move freely. e. Install ventilator over curb.

Wall Installation

a. Position unit so that hinge on topcap is facing down.

Handling

Lift the fan by the base or by the shipping carton. 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

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

Lo-Pro

Page 2

Personal Safety

Conduit Nipple

Diverter

Terminator Lid

Sealing Nut

Terminator

Roof Top Installation Shown

Figure 4

Belt and Pulley Installation

1 foot

1/4 inch

Figure 1

Figure 2

Tolerance

Center Distance

Maximum

Gap

Up thru 12” 1/16”

12” up through 48 1/8”

Over 48” 1/4”

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 oper ating 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. c. Lock the motor plate adjustment nuts in place. d. Ensure pulleys are properly aligned. Refer to Figure 2.

OFFSET ANGULAR OFFSET/ANGULAR

X Y

CENTER

DISTANCE

(CD)

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, next page.

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

Leave enough slack in the wiring to allow for moto r 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).

Optional Diverter

a. Position diverter so that air flow is directed up. b. Seal between diverter flange and unit side panel with

RTV 400 silicone. (RTV Silicone is NOT supplied.)

c. Use screws provided to secure diverter to unit.

Optional Grease Terminator Installation

a. Attach hardware to drain hole in the diverter. See Figure 4. b. Screw new canister into lid.

Roof Top Installation Shown

Conduit Nipple

GAP

Pulley Alignment

Pulley alignment is adjusted by loosening the motor pulley

setscrew and by moving the motor pulley on the motor 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 cap less than the tolerance sh own 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

GAP

Diverter

Terminator Lid

Sealing Nut

Terminator

Figure 4

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 on page 4,

Terminator

Page 3

Fan

Motor

Damper

Motor*

Second Damper

Motor

ransformer**

L3 L2 L1

1 728

3 9

L2L

456

789

L2L

Low Voltage

208/230 Volts

High Voltage

460 Volts

3 Phase, 9 Lead Motor Y-Connection

Wiring Diagrams

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

789 456

Low Voltage

208/230 Volts

High Voltage

460 Volts

8 2

9 3

L1L

3L2

3 Phase, 9 Lead Motor Delta-Connection

Single Speed, Single Phase Motor

Wiring Diagrams

When ground is required, attach to ground A or B with no. 6 thread forming

To reverse, interchange any 2 line leads.

screw. To reverse, interchange T-1 and T-4.

2 Speed, 2 Winding, Single Phase Motor 2 Speed, 1 Winding, 3 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.

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

Single Speed, Single Phase, Dual Voltage 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.

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

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 transfomer may be provided in some installations to correct the damper motor voltage to the specified voltage.

Page 4

Final Installation Steps Continued

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

Recommended Torque for Setscrews/Bolts. b. Inspect for correct amperage and voltage with an

ammeter and voltmeter. c. Ensure all accessories are installed. d. Check wheel-to-inlet clearance on power roof fans. e. 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 swit ch. If is possible to interchange two leads at this location so that t he fan is operating in the correct direction.

Fan Installation

Place fan over roof opening. Secure the fan with lag

screws, anchor bolts, or other suitable fasteners.

Operation

Pre-Start Checks

a. Lock out all the primary and secondary p ower sour ces. 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.

minute, 8 hour and 24 hour intervals of satisfactory operation. 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 an d tighten as necessary.

24 Hour Interval

Inspect belt tension. Adjust and tighten as necessary.

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 wheel and air inlets if material build-up is excessive. Excessive build-up can cause imbalance and failure of the wheel.

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

Regular inspections of the Grease Terminator 2 are recommended. Depending on the amount of grease discharged through the fan, the Terminator 2 should be changed every 30 to 45 days to ensure proper operation. Any buildup of grease is easily seen during a visual inspection of the clear canister. However, if the Terminator 2 becomes saturated, grease will no longer be absorbed.

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, page 5.

• Inspect for cleanliness. Clean exterior surfaces only.

Removing dust and grease on motor housing assures proper motor cooling.

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 6.

Inspection

Inspection of the fan should be conducted at the first 30

Fan Bearings

The fan bearings are provided prelubrica te d . 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.

Page 5

For best results, lubricate the bearing while the fan is in

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

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 advisable 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 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 inter-

Maximum RPM

LPB Size

100 3320 - 245 1011 1335 120 2755 - 270 871 1154 135 2481 - 300 835 1121 150 2051 - 330 713 963 165 1832 1971 365 623 884 180 1608 1754 402 538 746 195 1428 1758 445 462 739 210 1270 1507 490 357 682 225 1143 1319 540 345 581

Maximum RPM

Standard Reinforced Standard Reinforced

LPB Size

Maximum RPM

vals of the table below.

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 representative or your nearest authorized electric motor service representative.

Changing Shaft Speed

All belt driven H-Series 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.

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, 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.

Page 6

f. Place fan pulley on the fan shaft and the motor pulley

Caution

If the Grease Terminator becomes completely saturated, grease will no longer be absorbed and will run through to the roof.

Wheel Replacement Components

Above - Drilled Hole Location

Above - Wheel Puller

Size

Maximum

Overlap

Size

Maximum

Overlap

100

5/8”

300

1”

120 330 135 365 150 402 165 445 180 490

1-1/4”

195 540 210

3/4”

600 225 660 245 730 270

Radial Clearance

Overlap

Wheel/Inlet Overlap

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 Pulley Installation, page 2.

Replacing Grease Terminator

Set up a regular schedule for changing the Grease Terminator. Depending on the amount of grease going through the fan, the Grease Terminator should be changed every 30 to 45 days.

To replace the Grease Terminator, simply unscrew the used canister and screw on a new one.

Bearing Replacement

The fan bearings are pillow block ball bearings.

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.

Never tighten both pairs of setscrews before secur-

ing bearing mounting bolts. This may damage the shaft .

h. Inspect the wheel position again. If necessary , readjus t

by loosening the bearing bolts and setscrews and

repeat from step e.

Wheel Replacement

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 certain all set screws in

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

Work puller slowly to back wheel off the shaft.

Recommended Puller

Lisle No. 45000 Sterling Wheel Puller. This puller is avail-

able at most automotive parts retail outlets.

Wheel-to-Inlet Clearance

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

Adjust the overlap by loosening the wheel hub and mov-

ing the wheel along the shaft to obt ain the correct value.

A uniform radial gap (space between the edge of the

cone and the edge of the inlet) is obt ained by loo sening the inlet cone bolts and repositioning the inlet cone.

Page 7

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 8

LPD Parts List

Parts No.

1 Top Cap 2 Motor

Description

100-540

3 Wheel Hub

4 Wheel 5 Outside Housing Panel 6 Upblast Diverters (Optional) 7 Inlet Side Inner Panel 8 Inlet 9Base

10 Wrapper

LPB Parts List

Parts No.

Description

100-540

1 Top Cap 2 Belt Set 3 Bearing Support Channel 4 Driven Sheave 5 Bearings (2) 6 Shaft 7 Top Cap Hinge 8Hatch

9 Cooling Fan 10 Wheel Hub 11 Wheel 12 Upblast Diverters (Optional) 13 Outside Housing Panel 14 Inlet Side Inner Panel 15 Inlet 16 Base 17 Wrapper 18 Motor Access Panel 19 Motor Plate 20 Drive Side InnerPanel 21 Motor 22 Driven Sheave

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

lorencook.com

Lo-Pro IOM - November 2007