Remcor Gemini Installation Manual

Gemini

Ceiling and Cabinet Fans

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

This publication contains the installation, operation
and maintenance procedures for standard units of the
Gemini - Ceiling and Cabinet Fans. Carefully read this
publication prior to installation.

Loren Cook catalog, Gemini, 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 [phone], exten­sion 166; by FAX at [phone]; or by e-mail at
[e-mail].

For information and instructions on special equipment,
contact Loren Cook Company at [phone].

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.

• Remove mounting brackets from packing insert (Gem-

ini 100 only).

• Gemini 100 - install mounting brackets as shown in

Figure 6.

• Remove shipping tape.

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

Handling

Lift fan by the outside housing (box) or by the blower

mounting brace. Never lift by the shaft or motor.

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.

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.

Direction of Discharge (200-900 Series)

The duct collar (damper frame), for fastening a standard
duct, is located so discharge will be from the top. Refer to
figure 1 on page 2. When discharge from the side is desired,
follow these steps:

a. Remove the side panel and install with the duct collar in

the side position. Refer to figure 2 on page 2.

b. Move the mounting bracket from the top discharge to

the side discharge position for securing the housing to
the joists. Refer to figures 1 and 2 on page 2.

Gemini 100 Ceiling to Inline Conversion

The Gemini 100 series can be field converted from ceiling
to inline by following these steps:

a. Remove and discard the inlet box end plate. See page

7, Parts List illustration.

b. Install the inline cover panel with sheet metal screws as

shown in figure 9 on page 7.

c. Ceiling to Inline Conversion Kit can be ordered from

Loren Cook Company (Part Number 797181), or fabri­cate the required part using the sketch provided on
page 7, figure 10.

Gemini 100 Inline to Ceiling Conversion

The Gemini 100 series can be converted from inline to
ceiling by ordering the Inline to Ceiling Conversion Kit from
Loren Cook Company (Part Number 797180). The kit
includes all parts required, plus detail instructions on how to
convert the Gemini 100.

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.

Installation

Motor Installation

All Gemini units are shipped with motors mounted at the

factory.

Gemini 100

Do not install above or inside shaded area

45

Cooking

Equipment

45

Floor

Fan Installation

a. Fasten duct work to the outside of the duct collar

(damper frame) using sheet metal screws. Make sure
sheet metal screws are placed where they do not inter­fere with damper operation.

b. Fasten the housing to the bottom of the joists through

the holes provided in the mounting bracket. Refer to
figures 1 and 2.

c. Adjust housing, using the adjust mounting bracket pro-

vided, to allow for the thickness finished ceiling and
grille. Refer to figure 3. If a unit is furnished with filters
allow 3/8” for filters. Refer to figure 4.

Outlet

Box

Mounting

Brackets

Side

Panel

Mounting

Brackets

Exhaust

Duct Collar

Side

Panel

Intake

Figure 1

Duct Collar

Exhaust

Side Discharge

Intake

Figure 2

Mounting

Bracket

Ceiling Radiation Damper Installation (See Gemini/CRD
Installation Supplement)

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 4.

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

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.

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).

Allow 3/8"

for filter

SEE NOTE

Grill

Knurled Screw

Note: Allow for ceiling thickness

Suggested Installation: Unit without filter.

Figure 3

Mounting

Bracket

SEE NOTE

Filter

Grill

Knurled Screw

Note: Allow for ceiling thickness

Suggested Installation: Unit with filter

Figure 4

2

Final Installation Steps

a. Inspect fasteners and setscrews, particularly fan

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

e. Inspect wheel-to-inlet clearance. Make sure wheel

does not rub against the inlet.

f. 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 switch. It is possi­ble 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 motor wiring.
d. Ensure fan and ductwork are clean and free of debris.
e. Test the fan to ensure the rotation of the wheel is the

same as indicated by the rotation label.

f. Restore power to unit.

the holes provided in the filter frame.

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.

Fans exhausting contaminated air (airborne abrasives)
should be inspected every three months.

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

It is recommended the following inspections be con­ducted twice per year.

• Inspect bolts and setscrews for tightness. Tighten as
necessary.

• Inspect for cleanliness. Clean exterior surfaces only.
Removing dust and grease on motor housing assures
proper motor cooling.

Grille

Mounting

Hole

Mounting

Brackets

Start Up

Before attaching the grille, turn the fan on and inspect for

the following:

• Direction of rotation.

• Excessive vibration.

• Unusual noise.

• Motor 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
minute interval of satisfactory operation. During the

inspection, stop the fan and inspect as per directions
below.

30 Minute Interval

Inspect bolts, setscrews, and motor mounting bolts.

Adjust and tighten as necessary.

Grille Installation

Attach the grille by hand-tightening the knurled screws.
When the unit is furnished with a filter, place the knurled
screws through the hole in the grille. Install the filter through

Plug-in Receptacle

Figure 6 - Gemini 100 Series Components

Access

Gemini 100

To inspect, clean or repair refer to figure 6 and follow

these steps:

a. Remove grille.

b. Remove blower assembly from housing:

1. Disconnect the motor from electrical supply.

2. Remove the mounting bolts on the inlet plate
assembly and remove the motor/wheel assembly.

c. Remove the blower wheel with an allen wrench.

Gemini 200 - 700 series

To inspect, clean, or repair, refer to figure 7 and follow

these steps:

a. Remove grille.
b. Remove blower assembly from housing:

1. Disconnect the motor from electrical supply.

2. Remove mounting bolts.

3. Slide discharge flange out of spring clip and remove
motor/blower assembly from box.

c. Remove inlet ring from blower housing.
d. Remove blower wheel with an allen wrench.

3

Gemini 800 - 2000 series

To inspect, clean, or repair, refer to figure 8 and follow

these steps:

a. Remove grille.
b. Remove blower assembly from housing:

1. Disconnect the motor from the electrical supply.

2. Remove motor plate bolts.

3. Slide motor plate and remove motor/blower assem­bly from box.

c. Remove inlet rings from blower housing (both sides).
d. Mark the wheel and housing to ensure correct replace-

ment of blower wheels (one is clockwise and the other
is counter-clockwise), then remove the blower wheels
with an allen wrench.

Blower Housing

Wheel

Inlet Ring(Ensure proper clearance

between wheel and inlet ring)

Motor Plate

Figure 8 - Gemini 800 through 2000 Series Components

Motor Plate Bolts

Motor

Reassembly

Simply reverse the disassembly instructions. Make sure
the wheels do not rub on the inlet rings. When replacing the
motor, make sure the motor and wheels are properly
aligned with the blower housing.

CAUTION
Ensure that the blower discharge flange is secured in
clip at box on Gemini 200 - 700 series.

Blower
Mounting

Mounting Bolts

Wiring Box

Motor

Brace

Spring Clip

(holds blower discharge flange)

Wheel

Unit Mounting
Bracket
Adjustment
Bolts

Duct Collar

Damper Blade

Figure 7 - 200 through 700 series Components

Motor Bearings

Motor bearings are pre-lubricated and sealed. Under nor­mal conditions they will not require further maintenance for
a period of ten years.

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.

Recommended Torque for Setscrews/Bolts (IN/LBS)

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

4

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.

•Damper held shut by tape.

•Screw attaching duct work to collar interfering with damper operation.

Excessive Vibration and Noise

•Damaged or unbalanced wheel.

•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.

•Motor needs 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.

Wiring Diagrams

Gemini 100 Series

White
(Common)
Wire

White
(Common)
Wire

Red
(Low Speed)
Wire

Black
(High Speed)
Wire

Snap either the red wire, low-speed
plug or the black wire, high-speed
plug into the field wiring compartment
as shown.

Low Speed

Connect red and white wires to line. Red wire, low-speed plug is for Model 122, 142, 162 and 182.

High Speed

Connect black and white wires to line. Black wire, high-speed plug is for Model 124, 144, 164 and 184.

Gemini 200 - 300 and 600 - 700 Series

White Line

Black (High)

Red (Low)

*

*

NOTE: Insulate Unused Lead

Gemini 400 - 500 Series

White Line

Black

Gemini 800 - 900 Series

White Line

Black (High)

Blue (Medium)

Red (Low)

NOTE: Insulate Unused Leads Separately

*

*

*

Line

Line

Line

FSC

WHITE

GEMINI

FAN*

FSC

BLACK

*See Gemini Wiring Diagram for correct lead.

TIME DELAY SWITCH

GEMINI

FAN*

LIGHT

RED

BLUE

WHITE

OFF

BLACK

*See Gemini Wiring Diagram for correct lead.

5

Wiring Diagrams Continued

Note: Insulate Unused Leads

Fan plug box is designed for single speed operation, using an FSC to vary speed if required. Do not wire to more than two leads.

Gemini 1000

1 PH / 60 HZ / 115V

MARATHON 6.0 AMPS

Purple

White

Yellow

Orange

Brown

1 PH / 60 HZ / 115V

MAGNETEK 8.0 AMPS

Black

White

Red

Blue

Orange

T4 T1

P4 T7

T5 T2

P6 T8

T6 T3

P6 T9

T4 T1

T7 T2

T6 T3

T9 P4

T5 P5

T8 P6

Line 1

Line 2

Insulate

Line 1

Line 2

Insulate

3 PH / 60 HZ / 208-230 V
MARATHON 2.2-2.0 AMPS
MAGNETEK 2.2-2.0 AMPS

Insulate

Insulate

Insulate

3 PH / 60 HZ / 460 V
MARATHON 1.0 AMP
MAGNETEK 1.0 AMP

Insulate

Insulate

Insulate

1 PH / 60 HZ / 208-230 V

MARATHON 2.8-3.0 AMPS

Purple

Yel lo w

Brown

Orange

White

1 PH / 60 HZ / 208-230 V

MAGNETEK 4.1 AMPS

Purple

Yellow

Blue

Orange

White

Line 1

Line 2

Insulate

Insulate

Insulate

Line 2

Line 1

Line 1

Line 1

Line 2

Line 2

Line 3

Line 3

Line 1

Line 2

Line 3

Insulate

Insulate

Insulate

Gemini 2000

1 PH / 60 HZ / 115V

MARATHON 10.8 AMPS

Orange

Brown

Blue

White

Black

1 PH / 60 HZ / 115 V

LEESON 10.2 AMPS

P1

P2

T3

T2
T4
T5

T4 T1

P4 T7

T5 T2

P5 T8

T6 T3

P6 T9

T4 T1

T7 T2

T6 T3

T9 P4

T5 P5

T8 P6

Line 1

Insulate

Line 2

LINE 1

INSULATE

LINE 2

3 PH / 60 HZ / 208-230 V

MARATHON 4.1-4.2 AMPS

LEESON 3.4 AMPS

Insulate

Insulate

Insulate

3 PH / 60 HZ / 460 V

MARATHON 2.1 AMPS

LEESON 1.7 AMPS

Insulate

Insulate

Insulate

MARATHON 6.0-5.4 AMPS

Orange

Brown

Blue

White

Black

P1

P2

T3

T2

T4

T5

1 PH / 60 HZ / 208-230 V

Line 1

Insulate

Insulate

Line 2

1 PH / 60 HZ / 208-230 V

LEESON 5.2 AMPS

INSULATE

INSULATE

LINE 2

Line 1

Line 2

Line 3

Insulate

Insulate

Insulate

LINE 1

Line 1

Line 2

Line 3

6

Gemini 100 Parts List

11

Parts

No.

1

2

10

3

Air Flow

Grill not shown in this view.

4

7

5

6

9

Gemini 100

11

1 Inlet Box End Plate (Ceiling only) 7 Backdraft Damper

2 Housing/Scroll 8 Wheel

3 Field Wiring Compartment 9 Motor Mount/Inlet

4 Motor 10 Inlet Box

5 Tinnerman Clip (Grill) 11 Grille

6 Mounting Bracket

8

Inline cover

panel

Figure 9 - Inline Cover Panel Installation

14-1/16

11-15/16

1-7/16

Formed Views

Figure 10 - Fabricated Inline Cover Panel Pattern

16-3/4

13-15/16

Break up at 90

Flat Pattern View

18 Ga. Galvanized Steel

1-3/8

11-15/16

13-5/16

7

Gemini 200 - 900 Series Parts List

2

1

3

Air Flow

4

67

8

5

Part No.

Gemini 200 - 700 Gemini 800 -900

Description

1 Backdraft Damper Backdraft Dampers (2)
2 Damper Frame Damper Frame (2)
3 Mounting Bracket (2) Mounting Bracket (2)
4 Wheel Wheel (2)
5 Grille (Ceiling and Wall) Grille (Ceiling and Wall)
6 Blower Housing Blower Housing (2)
7 Motor Motor
8 Insulation Insulation

Gemini 1000 - 2000 Parts List

2

1

Part No.

Description

Gemini 1000 & 2000

1 Grille (ceiling and wall)
2 Backdraft Damper (2)
3 Wheel (2)
4 Blower Housing (2)
5Motor
6 Insulation
7 Mount Brackets (2)

3

4

7

5

6

Grill not shown in this view.

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

8

Gemini IOM - July 2004