Loren Cook SQI Installation Manual

Page 1

SQI

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.

Square Centrifugal Inline Fan

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

This publication contains the installation, operation and maintenance instructions for standard units of the SQI-Square Centrifugal Inline Fans. Carefully read this publication prior to any installation or maintenance procedure.

Loren Cook catalog, SQI, 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 417/869-647 4, exten sion 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.

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 for free operation of all moving parts.

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

plate. Refer to the Wiring Diagrams, on page 3.

Lock off all power sources befo re unit is wired to power source.

Direct drive - Wire the electrical box on the blower hous-

ing.

Belt drive - The motor can be wired directly since the

motor is external to the fan.

Handling

Lift the 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

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.

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 name-

SQI-B

Motor Plate

Motor Plate Adjustment Nut

Motor Plate Adjustment

Page 2

Wiring Installation contin ued

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.

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”

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.

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.

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

a. Loosen motor plate adjustment nuts on stud 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.

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 Figure1. c. Lock the motor plate adjustment nuts in place. d. Ensure pulleys are properly aligned. Refer to Figure

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 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.

OFFSET ANGULAR OFFSET/ANGULAR

CENTER

DISTANCE

(CD)

GAP

X Y

Final Installation Steps

a. Ensure that all accessories are

installed.

b. Ensure that the blower is secured

to ductwork.

c. Inspect wheel-to-inlet clearance.

Ensure wheel does not rub against the inlet.

d. Test the fan to ensure the rotation

of the wheel is the same as indicated by the rotation label.

Figure 3

e. Inspect for correct amperage with an ammeter and

correct voltage with a voltmeter.

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 loc ation 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 and tighten fasteners and setscrews, particu-

larly fan mounting and bearing fasteners. Refer to

Torque chart. c. Inspect belt tension and pulley alignment. d. Inspect motor wiring. e. Ensure fan and ductwork are clean and free of

debris. f. Close and secure all access doors. g. 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.

GAP

Page 3

Fan

Motor

Damper

Motor*

Second Damper

Motor

ransformer**

L3 L2 L1

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

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

Single Speed, Single Phase Motor

Wiring Diagrams

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

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

If a problem is discovered, immediately sh u t th e fa n 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 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 and tighten

as necessary.

24 Hour Interval

Inspect belt tension. Adjust and tighten as necessary.

For 3 phase, damper motor voltage should be the same between L For single phase application, disregard L *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.

and L2.

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

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

and T2. Both Speeds-interchange any 2

and T12.

SQI-D 70-90

White Line

Black (High)

Blue (Medium)

Red (Low)

NOTE: Insulate Unused Leads Separately

FSC

WHITE

SQI-D

FAN*

FSC

BLACK

*See SQI Wiring Diagram for correct lead.

* *

Line

Page 4

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

Maintenance

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” 29 348 7/8”-9 2040

1/2” 1/4” 42 504 5/8” 5/16” 92 1104 3/4” 3/8” 120 1440

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.

Yearly 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. Refer to Torque chart.

• 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.

• 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 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 accordan ce with th e 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 superse de 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 unit s 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 5

Motors are provided with a polyurea mineral oil NGLI #2

Above - Drilled hole placement. Right - Wheel puller.

grease. All additions to the motor bearings are to be with a compatable grease such as Exxon Mob il 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-ye ar period, contact your local Loren Cook Company representative or your nearest authorized electric motor service representative.

Changing Fan Speed

All belt driven fans with motors up to and including 5 HP are equipped with variable pitch pulleys.

Maximum RPM

SQI-B

Size

120 2966 150 2692 135 2460 165 2687 150 2209 180 1958 165 2158 195 1901 180 1814 210 1702 195 1590 225 1797 210 1417 245 1775 225 1490 270 1525 245 1485 300 1271 270 1244 330 1208 300 1041 365 1000 330 992 402 995 365 833 402 714

Maximum RPM

90 3341 135 2624

a. Loosen setscrew on motor pulley. b. Open or close the groove facing to change the pitch

diameter.

Speed Reduction - Open the pulley in order that the

belt rests deeper in the groove.

Speed Increase - Close the pulley in order that the

belt rests higher in the groove. Ensure RPM limits of the fan and the horsepower limits of the motor are maintained.

c. Retighten pulley setscrew on one of the flat areas of

the motor shaft.

d. After the adjustment is made, check for proper belt

tension. See the Belt and Pulley Installation section.

SQI-HP

Size

Maximum RPM

Do not hammer the pulleys onto the shafts because this may damage the bearings.

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

Belt and Pulley Installation section.

Bearing Replacement

The SQI-B fan bearings are pillow block ball bearings.

a. Remove outer access door. b. Remove bolts/screws to inner housing access doors.

Open and remove the inner access door to reveal

bearings. 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

support. Bearing bolts and set screws should be loose

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

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

to the shaft.

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

h. Inspect the wheel position again. If necessary, read-

just by loosening the bearing bolts and setscrews and

repeat from step e.

Wheel Replacement

a. Drill two 1/4” diameter holes, 180° apart centered

approximately between the shaft and the outside

diameter of the hub, 3/8” to 1/2” in depth. b. Tap 1/4” holes to 5/16” thread with a 5/16” hole tap.

Do not drill or tap greater than recommended. c. Screw the puller arms to the full depth of the threads

into the tapped holes. Align center of the puller with

the center of the shaft. Ensure all setscrews in the

hub, normally two, are fully removed. d. Slowly remove wheel from the shaft.

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 hea vy

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.

Page 6

Recommended 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

Lisle No. 45000 S ter ling Whee l 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 verified 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 moving the wheel along the shaft to obtain the corre ct value.

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

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.

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.

Overheated Bearings

•Improper bearing lubrication

•Excessive belt tension.

Page 7

SQI-D Parts List

Discharge ViewDischarge View

Inlet ViewInlet View

Air FlowAir Flow

Part

No.

1 Hex Bolts) Hex Bolt Hex Bolt Hex Bolt 2 Inlet Panel Inlet Panel Inlet Panel Inlet Panel 3 Inlet Inlet Inlet Inlet 4 Access Door Access Door Access Door Access Door 5 Electric Box Electric Box Electric Box Electric Box 6 Straightening Vanes Straightening Vanes Straightening Vanes Straightening Vanes

Not Shown:

7 Wheel Assembly Wheel Assembly Wheel Assembly Wheel Assembly 8— — — Slot Cover 9 Motor Motor Motor Motor

Sizes 70-90 Size 120 Size 135 Sizes 150-165

Description

Page 8

SQI-B Parts List

1010

Discharge ViewDischarge View

Inlet ViewInlet View

Air FlowAir Flow

Part

No.

90 - 165 180 - 210 225 - 402

Description

1 Motor Plate Motor Plate Motor Plate 2 Hex Bolt Hex Bolt Hex Bolt 3 Inlet Panel Inlet Panel Inlet Panel 4 Inlet Inlet Inlet 5 Access Door Access Door Access Door 6 Straightening Vane Straightening Vane Straightening Vane 7 Driven Sheave Driven Sheave Driven Sheave 8 Belt Set Belt Set Belt Set 9 Driver Sheave Driver Sheave Driver Sheave

10 Motor Motor Motor

Not Shown:

11 Wheel Assembly Wheel Assembly Wheel Assembly 12 Slot Cover Slot Cover Slot Cove r 13 Bearings Bearings Bearings 14 Shaft Shaft Shaft

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 alt ered or mod ified fr om its origina l design or has bee n abuse d, misused, damaged or is in worn condition or if the fan has been used other than for the uses described in the company manua l. 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 compla int, i n writing , as to t he manner in which your claim will be han dled. I f you are ent itled 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

SQI IOM - November 2007