Greenheck Fan 459968 Ventilation Hood User Manual
Contents
1. Radial the inlet cone Gap TCF Size Dimension A in Dimension A mm 18 6 86 3 20 7 2146 178 5 22 TAs e 198 29 24 8 4 219 6 27 976 4 240 6 30 10 6 268 10 33 11 6 291 10 36 12 324 10 40 14 6 360 10 44 15 6 395 10 49 17 435 13 54 18 s 478 13 60 20 6 2 532 13 66 22 2 581 13 73 25 2 12 648 13 A QEI QEID Radial Gap Adjust inlet cone position such that the radial gap between the wheel cone and inlet cone is evenly distributed around the wheel QEI QEID Alignment If necessary adjust wheel position by loosening the wheel hub from the fan shaft so that a straight edge held tight to the wheel cone just touches the inlet cone Refer to drawing below Inlet Cone Installation Installations with poor inlet or discharge configurations may result in reduced fan performance Ducted Installations Inlet Duct Turns Installation of a duct turn or elbow too close to the fan inlet reduces fan performance Restricted or unstable flow at the fan inlet can cause pre rotation of incoming air or uneven loading of the fan wheel yielding large system losses and increased sound levels To achieve full fan performance there should be at least one fan wheel diameter between the turn or elbow and the fan inlet gt Good x Poor TA Wheel Dia S S r SE Turning Vanes2. Discharge Duct Turns Fan performance is reduced when duct turns are made immediately off the fan discharge To achieve cataloged fan performance there should be at least three equivalent duct diameters of straight ductwork between the fan discharge and any duct turns Poor 7 saat Good lt Models TCF and Model QEI QEID Centrifugal EJ Non Ducted Installation Unit Start Up Inlet Clearance Installation of a fan with an open inlet too close to a wall or bulkhead will cause DANGER reduced fan performance Itis eaea havea fe High voltage electrical input is needed for this ao a equipment This work should be performed by a minimum of one fan wheel Wheel serie electrician p y diameter between the fan Dia q inlet and the wall TA WARNING Free Discharge Free Disconnect and secure to the Off position all or abrupt discharge electrical power to the fan prior to inspection into a plenum results or servicing Failure to comply with this safety in a reduction in fan precaution could result in serious injury or death performance The effect as of discharge static regain 1 Disconnect and lock out all power switches to is not realized and g fan performance is reduced 2 Check all fasteners set screws and locking collars on the fan wheel bearings drive motor Duct Connections g ne base and accessories for tig
3. Faulty belts Drive component unbalance Poor inlet outlet conditions Foundation stiffness Many of these conditions can be discovered by careful observation Refer to the Troubleshooting section of this manual for corrective actions If observation cannot locate the source of vibration a qualified technician using vibration analysis equipment should be consulted If the problem is wheel unbalance in place balancing can be done providing there is access to the fan wheel Any correction weights added to the wheel should be welded to either the wheel back single plane balance or to the wheel back and wheel cone two plane balance Maintenance WARNING Disconnect and secure to the Off position all electrical power to the fan prior to inspection or servicing Failure to comply with this safety precaution could result in serious injury or death Once the unit has been put into operation a routine maintenance schedule should be set up to accomplish the following 1 Lubrication of bearings and motor 2 Variable inlet vanes should be checked for freedom of operation and wear 3 Wheel housing bolts and set screws on the entire fan should be checked for tightness 4 Any dirt accumulation on the wheel or in the housing should be removed to prevent unbalance and possible damage 5 Isolation bases should be checked for freedom of movement and the bolts for tightness Springs should be checked for breaks and fatigue
4. P GREENHECK Building Value in Air Part 459968 Tubular Centrifugal amp Mixed Flow Installation Operation and Maintenance Manual Please read and save these instructions Read carefully before attempting to assemble install operate or maintain the product described Protect yourself and others by observing all safety information Failure to comply with instructions could result in personal injury and or property damage Retain instructions for future reference Model TCF Tubular Centrifugal Inline Fan General Safety Information Only qualified personnel should install this fan Models QEI and QEID Mixed Flow Inline Fan Follow all local electrical and safety codes as Personnel should have a clear understanding of these instructions and should be aware of general safety precautions Improper installation can result in electric shock possible injury due to coming in contact with moving parts as well as other potential hazards Other considerations may be required if high winds or seismic activity are present If more information is needed contact a licensed professional engineer before moving forward DANGER Always disconnect power before working on or near a fan Lock and tag the disconnect switch or breaker to prevent accidental power up CAUTION When servicing the fan motor may be hot enough to cause pain or injury Allow motor to cool before servicing CAUTION Precaution should be taken
5. Rubber isolators should be checked for deterioration 6 Inspect fan impeller and housing looking for fatigue corrosion or wear WARNING Changing the belts or drives can significantly increase the amp draw of the motor If changes are made to the drives or belts the amps must be checked to assure no overamping V Belt Drives V belt drives must be checked on a regular basis for wear tension alignment and dirt accumulation Premature or frequent belt failures can be caused by improper belt tension either too loose or too tight or misaligned sheaves Abnormally high belt tension or drive misalignment will cause excessive bearing loads and may result in failure of the fan and or motor bearings Conversely loose belts will cause squealing on start up excessive belt flutter slippage and overheated sheaves Either excessively loose or tight belts may cause fan vibration When replacing V belts on multiple groove drives all belts should be changed to provide uniform drive loading Do not pry belts on or off the sheave Loosen belt tension until belts can be removed by simply lifting the belts off the sheaves After replacing belts ensure that slack in each belt is on the same side of the drive Belt dressing should never be used Do not install new belts on worn sheaves If the sheaves have grooves worn in them they must be replaced before new belts are installed The proper tension for operating a V belt drive is t
6. in explosive atmospheres E Model TCF and Models QEI QEID Centrifugal well as the National Electrical Code NEC and the National Fire Protection Agency NFPA where applicable Follow the Canadian Electric Code CEC in Canada The rotation of the wheel is critical It must be free to rotate without striking or rubbing any stationary objects Motor must be securely and adequately grounded Do not spin fan wheel faster than max cataloged fan rpm Adjustments to fan speed significantly effects motor load If the fan RPM is changed the motor current should be checked to make sure it is not exceeding the motor nameplate amps Do not allow the power cable to kink or come in contact with oil grease hot surfaces or chemicals Replace cord immediately if damaged Verify that the power source is compatible with the equipment Never open access doors to a duct while the fan is running Receiving Upon receiving the product check to make sure all items are accounted for by referencing the bill of lading to ensure all items were received Inspect each crate for shipping damage before accepting delivery Notify the carrier if any damage is noticed The carrier will make notification on the delivery receipt acknowledging any damage to the product All damage should be noted on all the copies of the bill of lading which is countersigned by the delivering carrier A Carrier Inspection Report should be filled o
7. and allow the belts to set properly 6 With the fan off adjust the belt tension by moving the motor pivot plate Belts are adjusted by raising or lowering the motor pivot plate When in operation the tight side of the belts should be in a straight line from sheave to sheave with a slight bow on the slack side Aligning sheaves with a straight edge Motors Motor maintenance is generally limited to cleaning and lubrication Cleaning should be limited to exterior surfaces only Removing dust and grease build up on the motor housing assists proper motor cooling CAUTION Do not allow water or solvents to enter the motor or bearings Under no circumstances should motors or bearings be sprayed with steam water or solvents Greasing of motor bearings is only required when fittings are provided Many fractional motors are permanently lubricated and require no further lubrication Motors supplied with grease fittings should be greased in accordance with the manufacturer s recommendations When motor temperature does not exceed 104 F 40 C the grease should be replaced after 2000 hours of running time EG Model TCF and Models QEI QEID Centrifugal Fan Bearing Lubrication The bearings for Greenheck fans are carefully selected to match the maximum load and operating conditions of the specific class arrangement and fan size The instructions provided in this manual and those provided by the bearing manufacturer w
8. ductwork Access door filters grilles not installed Change obstructions in system Use correction factor to adjust for temperature altitude Resize ductwork Clean filters coils Change fan speed Excessive Power Consumption High Horsepower Duct System Resize ductwork Check proper operation of face and bypass dampers Check filters and access doors Electrical Suppl Check fuses circuit breakers Check for switches turned off or PPly disconnected Check for correct supply voltage Fan Doesn t Operate Check for broken belts Tighten loose pulleys Assure motor is correct horsepower and not tripping overload protector Check for excessive or insufficient grease in the bearing Bearings Overheated Replace damaged bearing Relieve excessive belt tension Align Mechanical bearings Check for bent shaft Bets 0 Adjust tightness of belts Replacement belts should be a matched set Excessive Vibration Check alignment of shaft motor and pulleys Adjustable pitch pulleys System Unbalance with motors over 15 hp motors are especially prone to unbalance Check wheel balance rebalance if necessary Duct system has more or less restriction than anticipated Static Pressure Wrong Warranty Greenheck warrants this equipment to be free from defects in material and workmanship for a period of one year from the purchase date Any units or parts which prove defective during the warranty period will be replaced at our option when returned to
9. far enough apart to permit air circulation sunlight and space for periodic inspection To minimize water accumulation place all fan parts on blocking supports so that rain water will run off The use of a tarp to cover the unit will aid in keeping it clean and dry Avoid using a black plastic tarp as it will promote condensation Fan wheels should be blocked to prevent spinning caused by strong winds Inspection and Maintenance during Storage While in storage inspect fans once per month Keep a record of inspection and maintenance performed If moisture or dirt accumulations are found on parts the source should be located and eliminated At each inspection rotate the wheel by hand ten to fifteen revolutions to distribute lubricant on motor If paint deterioration begins consideration should be given to touch up or repainting Fans with special coatings may require special techniques for touch up or repair Machined parts coated with rust preventive should be restored to good condition promptly if signs of rust occur Immediately remove the original rust preventive coating with petroleum solvent and clean with lint free cloths Polish any remaining rust from surface with crocus cloth or fine emery paper and oil Do not destroy the continuity of the surfaces Wipe clean thoroughly with Tectyl 506 Ashland Inc or the equivalent For hard to reach internal surfaces or for occasional use consider using Tectyl 511M Rust Preven
10. frequently encountered problems with centrifugal fans is motors which are wired to run in the wrong direction This is especially true with 3 phase installations where the motor will run in either direction depending on how it has been wired To reverse rotation of a 3 phase motor interchange any two of the three electrical leads Single phase motors can be reversed by changing internal connections as described on the motor label or wiring diagram EJ Model TCF and Models QEI QEID Centrifugal A 11 If the fan has inlet vanes they should be partially closed to reduce power requirements 12 Fans with multi speed motors should be checked on low speed during initial start up 13 Ensure proper wheel location for radial gap overlap and alignment see Radial Gap Overlap amp Alignment section on page 3 14 Grease may be forced out of the bearing seals during initial start up This is a normal self purging feature of the bearing 15 Check for unusual noise vibration or overheating of bearings Refer to the Troubleshooting section of this manual if a problem develops Vibration Excessive vibration is the most frequent problem experienced during initial start up Left unchecked excessive vibration can cause a multitude of problems including structural and or component failure The most common sources of vibration are Wheel unbalance Drive pulley misalignment Incorrect belt tension Bearing misalignment Mechanical looseness
11. grease up to 2 in bore size 8 shots for 2 5 in bore size and 16 shots above 5 in bore size with hand grease gun e Adjust lubrication frequency based on condition of purged grease e A high quality lithium base grease conforming to NLGI Grade 2 consistency such as those listed below should be used Mobilith SHC 220 Mobilith AW2 Shell Alvania 2 Texaco Multifak AFB2 Texaco Premium RB Exxon Unirex N2 WARNING Lubricate bearings prior to periods of extended shutdowns or storage and rotate shaft monthly to aid in preventing corrosion If the fan is stored more than three months the bearings should be purged with new grease prior to start up Fan Bearing Replacement Replacement of bearings requires disassembly of internal components For this procedure access must be available to both the inlet and outlet ends The following procedure assumes belts have already been loosened and removed Belts are removed by adjusting the motor pivot plate Reinstall components in reverse order of removal Reference the Radial Gap Overlap amp Alignment section to ensure proper wheel installation Model TCF Remove cover plate from drive chamber outlet 1 2 3 side Unbolt and remove inlet cone inlet side Loosen set screws at the wheel hub and remove wheel inlet side outlet side Housing Shaft Bearing Assembly Unbolt both sets of bearings from support bars Remove shaft bearing assembly out
12. he lowest tension at which the belts will not slip at peak load conditions Belts are adjusted by raising or lowering the motor pivot plate For initial tensioning the proper belt deflection half way between sheave centers is 1 64 of the belt span For example if the belt span is 64 inches the belt deflection should be 1 inch using moderate thumb pressure at mid point of the drive Check belt tension two times during the first 24 hours of operation and periodically thereafter Belt Span 64 Deflection Belt Span Models TCF and Model QEI QEID Centrifugal EJ V Belt Replacement The V belt drive components when supplied by Greenheck Fan Corporation have been carefully selected for this unit s specific operating condition Changing V belt drive components could result in unsafe operating conditions which may cause personal injury or failure of fan components 1 Remove the protective coating from the end of the fan shaft using mineral spirits or another similar solvent Check to ensure that the shaft is free of nicks and burrs 2 Slide sheaves on shafts Do not drive sheaves on as this may result in bearing damage 3 Align fan and motor sheaves with a straight edge or string and tighten 4 Place belts over sheaves Do not pry or force belts as this could result in damage to the cords in the belts 5 Adjust the tension until the belts appear snug Run the unit for a few minutes refer to unit start up section
13. htness It is highly recommended to use a flexible sleeve 3 Rotate the fan wheel by hand and assure no parts connection instead of a rigid duct connection This will bbing reduce vibration transmission through the ductwork PAES f ee a 4 Check for bearing alignment and lubrication Slip Fit End Connection QEI QEID Directly attach the flexible sleeve to the duct and fan 9 Gheck Ihe Nebelb alive Tor proper alignment and ae i tension No additional parts are required _ 6 Check all guarding if supplied to ensure that it is securely attached and not interfering with rotating parts 7 Check operation of variable inlet vanes or discharge dampers if supplied for freedom of Flexible Sleeve Fan Duct movement z z 8 Check all electrical connections for proper attachment Flanged End Connection TCF QEI QEID 9 Check housing and ductwork if accessible Optional companion flanges are bolted to the fan to as for obstructions and foreign material that may provide a slip fit connection for a flexible sleeve damage the fan wheel Flexible Sleeve 10 Check for proper wheel rotation by momentarily energizing the fan Rotation should correspond to the rotation decal affixed to the unit CCW rotation is correct as viewed from the fan inlet Fan Duct oe Companion Flange Note Flexible sleeve amp attachment hardware not provided Mixed Flow Centrifugal Airfoil NOTE One of the most
14. ill minimize any bearing problems Bearings are the most critical moving part of the fan Therefore special care is required when mounting them on the unit and maintaining them Refer to the following chart and the manufacturer s instructions for grease types and intervals for various operating conditions Never mix greases made with different bases This will cause a breakdown of the grease and possible failure of the bearing Recommended Fan Bearing Lubrication Schedule in Months Fan Bearing Bore RPM 1 1 1 1 1 ye 2 Sie Sie To 250 6 6 6 6 6 5 4 500 6 6 6 5 4 3 3 750 6 5 4 3 3 2 2 1000 6 4 3 2 2 1 1 1250 5 3 2 1 1 0 5 0 5 1500 5 2 1 1 0 5 0 5 0 25 2000 5 1 1 0 5 0 25 0 25 0 25 2500 4 0 5 0 5 0 25 0 25 0 25 3000 4 0 5 0 25 0 25 0 25 Suggested initial greasing interval is based on 12 hour per day operation and 150 F maximum housing temperature For continuous 24 hour operation decrease greasing interval by 50 e If possible relubricate with grease while in operation without endangering personnel e For ball bearings operating relubricate until clean grease is seen purging at the seals Be careful not to unseat the seal by over lubricating e For ball bearings idle add 1 2 shots of grease up to 2 in bore sizes and 4 5 shots of grease above 2 in bore sizes with hand grease gun e For roller bearings relubricate with 4 shots of
15. let side Replace bearings on drive shaft Cover Plate Model QEI If the bearings cannot be removed from the shaft due to corrosion or damage the bearing plates can be removed from the inner chamber The shaft bearing bearing plates can be removed as a complete assembly from the fan inlet 1 2 3 Remove bolts from wheel bearing plate inlet side Pull shaft bearing bearing plate assembly out of Unbolt and remove inlet cone inlet side Loosen set screws at the wheel hub and remove wheel inlet side Remove bolts from drive bearing plate outlet side the fan housing inlet side Replace bearings on shaft bearing bearing plate assembly Shaft Bearing Inlet Bearing Plate Assembly Cone Wheel Housing Models TCF and Model QEI QEID Centrifugal Troubleshooting Problem Cause Corrective Action Wheel Rubbing Inlet Adjust wheel and or inlet cone Tighten wheel hub or bearing collars on shaft Tighten sheaves on motor fan shaft Adjust belt tension Align sheaves V Belt Drive R i properly see page 6 Replace worn belts or sheaves Excessive Noise Replace defective bearing s Lubricate bearings Tighten collars and Bearings fasteners Wiel Unbalance Clean all dirt off wheel Check wheel balance rebalance in place if necessary Check wheel for correct rotation Increase fan speed Volume Too Low Fan Decreasefanspeed S Decrease fan speed Volume Too High Duct System Resize
16. our factory transportation prepaid Motors are warranted by the motor manufacturer for a period of one year Should motors furnished by Greenheck prove defective during this period they should be returned to the nearest authorized motor service station Greenheck will not be responsible for any removal or installation costs As a result of our commitment to continuous improvement Greenheck reserves the right to change specifications without notice Greenheck Catalogs Model TCF and Models QEI QEID AMCA Publication 410 96 Safety Practices for Users and provide additional information describing the equipment fan Installers of Industrial and Commercial Fans provides performance available accessories and specification data additional safety information This publication can be obtained from AMCA International Inc at www amca org PA GREENHECK Building Value in Air Phone 715 359 6171 Fax 715 355 2399 e E mail gfcinfo greenheck com Website www greenheck com Em 459968 TCF and QEI QEID Rev 3 July 2008 Copyright 2008 Greenheck Fan Corporation
17. ser INDOOR The ideal environment for the storage of fans and accessories is indoors above grade in a low humidity atmosphere which is sealed to prevent the entry of blowing dust rain or snow Temperatures should be evenly maintained between 30 F 1 C and 110 F 43 C wide temperature swings may cause condensation and sweating of metal parts All accessories must be stored indoors in a clean dry atmosphere H Model TCF and Models QEI QEID Centrifugal Remove any accumulations of dirt water ice or snow and wipe dry before moving to indoor storage To avoid sweating of metal parts allow cold parts to reach room temperature To dry parts and packages use a portable electric heater to get rid of any moisture build up Leave coverings loose to permit air circulation and to allow for periodic inspection The unit should be stored at least 3 inches 89 mm off the floor on wooden blocks covered with moisture proof paper or polyethylene sheathing Aisles between parts and along all walls should be provided to permit air circulation and space for inspection OUTDOOR Roads or aisles for portable cranes and hauling equipment are needed The fan should be placed on a level surface to prevent water from leaking into the fan The fan should be elevated on an adequate number of wooden blocks so that it is above water and snow levels and has enough blocking to prevent it from settling into soft ground Locate parts
18. tive or WD 40o or the equivalent REMOVING FROM STORAGE As fans are removed from storage to be installed in their final location they should be protected and maintained in a similar fashion until the fan equipment goes into operation Prior to fully assembling and installing the fan and system components inspect the fan assembly to make sure it is in working order 1 Check all fasteners set screws wheel bearings drive motor base and accessories for tightness 2 Rotate the fan wheel by hand and assure no parts are rubbing Access to the wheel is obtained through an access panel located on the side of the fan housing 3 Ensure proper wheel settings for radial gap and alignment See below Radial Gap Overlap amp Alignment Efficient fan performance can be maintained by having the correct radial gap overlap and alignment These items should be checked before start up and after the fan has been in operation for 24 hours TCF Radial Gap Radial gap is adjusted by loosening the inlet cone bolts and centering the cone on the wheel If additional adjustment is required to maintain a constant radial gap loosening the bearing bolts and centering wheel is acceptable as a secondary option TCF Overlap Overlap is adjusted by loosening the wheel hub from the shaft and moving the wheel to the desired position along the shaft The chart shows the proper distance between the wheel and Overlap
19. ut by the carrier upon arrival and the Traffic Department If damaged upon arrival file claim with carrier Any physical damage to the unit after acceptance is not the responsibility of Greenheck Fan Corporation Unpacking Verify that all required parts and the correct quantity of each item have been received If any items are missing report shortages to your local representative to arrange for obtaining missing parts Sometimes it is not possible that all items for the unit be shipped together due to availability of transportation and truck space Confirmation of shipment s must be limited to only items on the bill of lading Handling Fans are to be rigged and moved by the lifting brackets provided or by the skid when a forklift is used Location of brackets varies by model and size Handle in such a manner as to keep from scratching or chipping the coating Damaged finish may reduce the ability of the fan to resist corrosion Fans should never be lifted by the shaft fan housing motor belt guard windband or accessories Storage Fans are protected against damage during shipment If the unit cannot be installed and operated immediately precautions need to be taken to prevent deterioration of the unit during storage The user assumes responsibility of the fan and accessories while in storage The manufacturer will not be responsible for damage during storage The following suggestions are provided solely as a convenience to the u
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