4Front Engineered Solutions HVLS User Manual

* The preview only show first 10 pages of manuals. Please download to view the full documents.

Loading preview... Please wait.

Manuals information


Report / DMCA this file

Manuals Content

HVLS Fans

This manual applies to fans manufactured beginning September 2011 with the serial numbers 10111500 and higher.

Do not install, operate or service this product unless you have read and understand the Safety Practices, Warnings, and Installation and Operating Instructions contained in this User’s Manual. Failure to do so could result in death or serious injury.

User’s Manual Installation, Operations, Maintenance and Parts

Part No. 6011315C

table of contents Introduction..................................................................2 Safety Signal Words ...................................................2 Safety Practices..........................................................3 Owner’s Responsibilities.............................................4 Fan Kit.........................................................................5 Fan Information Tag.....................................................6 Installation Considerations..........................................7 Installation...................................................................8 Components and Specifications................................15 Electrical System Operation......................................16

Operating Instructions...............................................17 Planned Maintenance................................................18 Troubleshooting Guide..............................................19 VFD Fault Codes.......................................................21 Fire Control System Option.......................................22 Electrical Schematics................................................24 Parts List...................................................................28 Warranty Information.................................................35 Distributor Information...............................................36

introduction Welcome and thank you for choosing this industrial fan from 4Front® Engineered Solutions. This User’s Manual contains information that you need to safely install, operate and maintain the fan. It also contains a complete parts list and information about ordering replacement parts. Please keep and read this User’s Manual before using your new fan.

safety signal words You may find safety signal words such as DANGER, WARNING, CAUTION or NOTICE throughout this User’s Manual. Their use is explained below: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury. Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided may result in minor or moderate injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Notice is used to address practices not related to personal injury.

2

6011315C — HVLS Fans ©2012 4Front® Engineered Solutions, Inc.

January 2012

Safety Practices Read these safety practices before installing, operating or servicing the fan. Failure to follow these safety practices could result in death or serious injury. READ AND FOLLOW THE OPERATING INSTRUCTIONS IN THIS MANUAL BEFORE OPERATING THE FAN. If you do not understand the instructions, ask your supervisor to teach you how to use the fan. Be certain to follow the instructions in this manual. If you do not understand the instructions, ask your supervisor to explain them to you or call your authorized 4Front® distributor.

the VFD enclosure with the power on, USE EXTREME CAUTION. Do not place fingers or un-insulated tools inside the enclosure. Touching wires or other parts inside the enclosure could result in electrical shock, death or serious injury. Variable Frequency Drive (VFD) fan controllers contain high voltage capacitors. Before working on the fan controller, ensure isolation of the main voltage supply and verify voltage has bled off prior to beginning work. Failure to do so may result in death or serious injury. If you have problems or questions, contact your local 4Front® distributor for assistance.

installation and OPERATION:

Do not use this industrial fan until you have received proper training. Improper use could result in property damage, bodily injury and/or death. Read and follow the complete OPERATING INSTRUCTIONS on page 16 before use. If you do not understand the instructions, ask your supervisor to explain them to you or call your authorized 4Front® distributor. DO NOT USE THE FAN IF IT APPEARS DAMAGED OR DOES NOT OPERATE PROPERLY. Inform your supervisor immediately. Do not operate the fan until all personnel, building structure and moveable equipment are clear of all moving parts. Install guards as required. Do not install the fan unit onto structure of insufficient strength. Consult a professional engineer or registered architect. Improper installation of the fan could result in death or serious injury.

MAINTENANCE AND SERVICE:

If the fan does not operate properly using the procedures in this manual, BE CERTAIN TO REMOVE POWER FROM THE UNIT AND LOCK-OUT THE DISCONNECT ON THE POWER CIRCUIT. Call your local 4Front® distributor for service. Keep your body clear of moving parts at all times. All electrical troubleshooting and repair must be done by a qualified technician and meet all applicable codes. If it is necessary to make troubleshooting checks inside

January 2012

6011315C — HVLS Fans

3 ©2012 4Front® Engineered Solutions, Inc.

Owner’s Responsibilities The owner’s responsibilities include the following: The owner should recognize the inherent danger of the interface between the industrial fan and shop worker. The owner should, therefore, train and instruct operators in the safe use of the industrial fan. Nameplates, cautions, instructions and posted warnings shall not be obscured from the view of operating or maintenance personnel for whom such warnings are intended. Warnings which are worn or non-legible should be replaced. Manufacturer’s recommended periodic maintenance and inspection procedures in effect at date of shipment shall be followed, and written records of the performance of these procedures should be kept. Industrial fans that are structurally damaged or have experienced impacts from external sources, shall be removed from service, inspected by the manufacturer’s authorized representative, and repaired as needed before being placed back in service. The owner shall see that all nameplates and caution and instruction markings or labels are in place and that the appropriate operating and maintenance manuals are provided to users. Modifications or alterations of industrial fans shall be made only with written permission of the original manufacturer.

4

6011315C — HVLS Fans ©2012 4Front® Engineered Solutions, Inc.

January 2012

FAN KIT PACKING KIT (Standard) 1. Blade Box – 6 each 2. Fan Motor Box a. Motor/gearbox assembly with VFD assembly. b. Remote control panel. c. Category 5e cable set – 100 ft (one gray, one blue) d. Mounting hardware PACKING KIT (Networked) 1. Blade box – 6 each

REQUIRED TOOLS 5/8" Wrenches (2) 5/8" Socket 1/2" Wrenches (2) 1/2" Socket Torque Wrench (for use with sockets) 7/16" Wrenches (2) 1/4" Cable cutter #2 Standard screwdriver Small Standard screwdriver *For glulam installations, a drill and 1/2" dia. drill bit are required.

2. Fan motor box a. Motor/gearbox assembly with VFD assembly. b. Mounting hardware.

**For network installations, a RJ45 crimping tool is required.

3. Network Kit (one per order) a. Touchscreen computer b. Communication gateway with cable c. Patch cable d. Software key e. Wall mount bracket f. USB adapters (2)

Prior to fan installation: 1. Ensure that the supplied voltage matches the fan voltage. A label containing voltage information specific to the individual fan is located on top of the VFD enclosure. 2. Ensure blade length matches fan model size. Consult fan model designation located on the side of the fan powerhead frame.

4. Network Cable a. Bulk Category 5e Cable b. RJ45 connectors (male)

For Network Fans only 3. Ensure fan number matches network layout. Consult stenciled number on shipping box.

fan properties Fan Diameter (Ft)

Horse Power

Hanging

Maximum

Typical

Weight (Lb)

Torque (Ft. Lb)

Spacing (Ft)

8

1

160

55

10

1

181

60

12

1

190

65

14

1

194

70

16

1

208

18

1

222

20

1

232

95

20

1-1/2

232

95

24

1

240

100

24

2

240

100

300

90 90

NOTE: For fan installations in facilities over 3,300' above sea level, consult factory for fan performance factors. January 2012

6011315C — HVLS Fans

5 ©2012 4Front® Engineered Solutions, Inc.

fan information tag To aid in troubleshooting, an information tag is included with the fan. This tag contains voltage, horsepower and serial number information specific to the individual fan. The tag is attached to the bottom of the remote control panel.

Fig. 1

1. Verify the information on the tag matches the information located inside the VFD enclosure. 2. Affix the information tag to the bottom of the remote control panel. See Fig. 1. NOTE: Once the information tag is in place, the remote is now linked to this specific fan. Do not use with another fan.

Remote control panel Fan information tag

6

6011315C — HVLS Fans ©2012 4Front® Engineered Solutions, Inc.

January 2012

installation considerations run Roof slope =

rise run

rise Extension (optional)

Length (ft.)

Angled roof beam

Pendant light

36"

Exclusion zone roof slope Roof Slope

2/12

4/12

6/12

8/12

10/12

Roof Angle

9.5°

18.4°

26.6°

33.7°

39.8°

Fan Diameter (Ft)

Recommended Extension Length (Ft)

Exclusion Zone Radius (In.)

8

N/A

N/A

1

1

2

15

10

N/A

1

1

2

3

18

12

N/A

1

2

3

4

22

14

1

2

3

4

5

26

16

1

3

4

5

7

29

18

2

3

5

6

8

33

20

2

4

5

7

9

36

24

3

5

7

9

11

44

NOTE: The extension lengths shown are minimum recommendations only, based solely of roof pitch and fan diameter. Other considerations must be evaluated when determining extension requirements, such as placement of lights, sprinkler systems, HVAC systems, etc. In addition, OSHA requirements state that fan blades must be a minimum of 10' above the floor. Consult a 4Front® Engineered Solutions authorized distributor for assistance with fan placement and extension selection. January 2012

6011315C — HVLS Fans

7 ©2012 4Front® Engineered Solutions, Inc.

installation MOUNTING CONSIDERATIONS

Fig. 2

BUILDING STRUCTURE For open structure roof designs, the fan should only be hung from either I-beam or angle iron. Do not hang from purlins, joists or truss structure. For solid beam or glulam mounting, use the glulam mounting kit (40-40021) available from 4Front® Engineered Solutions. Consult a professional engineer or registered architect for specific mounting concerns. Ensure fan blade clearance meets the requirements. See Fig. 1. PLACEMENT AND SPACING Consult your authorized 4Front® Sales representative to help you plan the most efficient installation of your fans.

Universal mounting bracket

Ensure fan placement is such that the fans blades are a minimum of 10' from any manned working suface (floor or mezzanine) Ensure fan blade does not extend into exclusion zone. Extensions are available if required. See Fig. 1.

Fig. 3

Avoid mounting fans directly under lights or skylights to avoid visual strobing affect.

Clamp

Avoid mounting fans directly below fire sprinkler systems. Fan blades should be a minimum of 3' below sprinkler outlets. NOTE: If the fan is part of a networked system, ensure placement is in accordance with the building layout. Fan network identification number is located on the top surface of the VFD enclosure.

A

Clamp

INSTALL MOUNTING ATTACHMENT STANDARD I-BEAM 1. Locate universal mount assembly on bottom of building support beam. Align mount assembly so that it is centered and square to the beam. See Fig. 2. 2. Install clamps as shown. See Fig. 3 For thick flange I-beams add shims as required. Fasten using the 1/2" dia x 2-3/4" screws, nylock lock nuts and washers supplied by 4Front® oriented as shown. Torque to 40-57 ft-lbs.

8

6011315C — HVLS Fans ©2012 4Front® Engineered Solutions, Inc.

Shim Detail A

January 2012

installation, continued Fig. 4 If building support beam is not level, ensure proper fan clearance using the mounting information shown on page 6 or add mounting extensions as required to ensure clearance. See Fig. 3.

Glulam Glulam bracket

GLULAM MOUNTING (40-40021) 1. Attach glulam brackets to the wooden beam using a minimum of four 1/2" dia. grade 5 thru bolts (not supplied). Ensure brackets are square to the bottom of the beam. 2. Attach mount assembly to the glulam brackets using 1/2" dia x 2-3/4" screws, nylock lock nuts and washers supplied by 4Front® oriented as shown. Torque to 40-57 ft-lbs. See Fig. 4.

Fig. 5

INSTALL POWERHEAD (MOTOR/GEARBOX ASSY) 1. Drape 1/4" dia wire safety rope over building support beam in preparation for powerhead installation.

If a mounting extension has been used, it may be necessary to obtain a longer cable from a local supplier. 2. Using a powered lift, orient the powerhead with the blade hub down. Block motor as required for installation. 3. Raise the powerhead up until it contacts the bottom of the universal mount assembly. See Fig. 5. 4. Fasten the powerhead to the mount assembly using the 1/2" dia x 1-1/2" screws, nylock lock nuts and washers supplied by 4Front, oriented as shown. Torque to 40-57 ft-lbs. See Fig. 6.

January 2012

6011315C — HVLS Fans

9 ©2012 4Front® Engineered Solutions, Inc.

installation, continued 5. Immediately attach safety cable. See Fig. 6. a. Slide two of the supplied 1/4" dia cable clamps over each end of the cable spaced 6" apart. b. Make a loop in one end of the cable, sliding the end back through the cable clamps. c. Feed the other end of the safety cable though the loop, making sure that the cable goes through the motor frame. d. Repeat step B for the other end of the cable. e. Torque the clamp fasteners to 4-6 ft-lbs. Make sure the u-bolts are over the free ends of the cable.

Fig. 6

Safety cable

INSTALL GUY WIRES Guy wires are designed to constrain lateral movement of the fan in operation. This movement may be due to impacts on the fan or winds impinging on the blades that would cause the fan to sway. Failure to attach guy wires may result in loss of warranty. ft lbs that the If a mounting extension has been used, ensure longer guy wires accompanying the extension are used.

Fig. 7 Safety links Stop nut

Ensure that the angle formed by the guy wire with the roof structure is less than 45º. See Fig. 8. Avoid any sharp edges or corners to reduce fatiguing and fraying of the guy wires.

Quick link

1. Adjust turnbuckles to their longest position. 2. Attach the quick link with attached turnbuckle to the fan as shown. Repeat for all four quick links. 3. Attach one end of the guy wire to the building structure. Ensure the structure has sufficient strength to withstand the wire tension. Repeat for all four guy wires. a. Slide two of the supplied 1/4" dia cable clamps over one end of the wire. b. Feed that end of the wire though the building structure and back through the cable clamps. c. Torque the clamp fasteners to 4-6 ft-lbs. Make sure the u-bolts are over the free end of the cable.

Fig. 8

4. Using a spirit level, individually tighten the turn buckle on each cable until each cable is tight and the powerhead unit is level.

45°

45°

5. Lock the individual turn buckles using the stop nut on each.

10

6011315C — HVLS Fans ©2012 4Front® Engineered Solutions, Inc.

January 2012

installation, continued INSTALL BLADES AND SAFETY LINKS 1. Orient as shown in Fig. 9. Slide the individual blade onto the blade strut opposite each other as shown in Fig. 10. Align the holes in the blade with the holes in the blade strut. Repeat for each blade. See Fig. 9 and 12. Failure to install the blade safety interlocks could result in death or serious injury. 2. Place a 1/2" dia x 1-1/2" screw and washer (supplied by 4Front) in the outer hole. 3. Moving counter-clockwise as viewed from above, line up another link on top of the previous link as shown and place a screw and washer in the inner hole. See Fig 12.

Fig. 9 Blade strut

Blade

6010843

Winglet fasteners 6010844

Winglet

Fig. 10

4. Repeat this process with the remaining blades. See Fig 12. 5. Place a screw and washer in each of the open holes remaining. Ensure that all links are properly adjusted. 6. Place a washer and nut on each screw. While supporting the end of the blade so that it is perfectly horizontal, torque the nuts on each blade. Torque to 16-18 ft-lbs. DO NOT OVERTIGHTEN. DO NOT USE IMPACT OR HAMMER DRIVE. DAMAGE MAY OCCUR. The safety link will bend slightly as the nuts are tightened to conform to the blade surface.

Fig. 11

2X washer,  5/16 (part of 6013288 fastener kit)

7. Check each blade for tightness. Lift the end of the blade. There should not be any slack or rattle. Re-tighten using the process in step 6 as required.

Link (part of 6013287 link kit)

Install winglets 1. Insert winglet into open end of fan blade until the mounting hole on the winglet lines up with the mounting hole on the blade. See Fig. 9. 2. Fasten the winglet ensuring that the female fastener (6010843) of the fastener is on top.

Bolt, 5/16 - 18 UNC x 2, GR 5 (part of 6013288 fastener kit)

Blade

Strut - 60-40001 (on replacement, ensure proper orientation) Nut,  5/16 - 18 UNC (part of 6013288 fastener kit)

3. Repeat for each blade. VERIFY CLEARANCE AND CABLE TENSION 1. Rotate fan by hand and observe clearance of each blade with closest obstruction. If necessary, reposition fan. Blade tips droop when not in operation and rise when in operation. Reference chart on page 7 for min. clearance.

Fig. 12

Safety links

2. Verify guy wire tension by attempting to move powerhead in any horizontal direction. If movement is detected, retension guy wires. January 2012

6011315C — HVLS Fans

11 ©2012 4Front® Engineered Solutions, Inc.

installation, continued ELECTRICAL INSTALLATION

Fig. 13

Before doing any electrical work, make certain the power is disconnected and properly locked or tagged off. Failure to do so may result in death or serious injury. All electrical troubleshooting and repair must be done by a qualified technician and meet all applicable codes. Do not route control wiring for any other device through this control box. Ensure that the voltage and phase of the incoming power agrees with the label located on top of the VFD enclosure and fan. Be certain power is off when wiring to the control box. Failure to do so could result in electrical shock, death or serious injury.

Standard installation

Remote control panel

standard UNITS NOTE: Reference wiring diagrams on pages 23 through 26 for all field connections. NOTE: The VFD assembly does not contain fusing. See tables on pages 23 and 24 for power requirements. It is the customer's responsibility to provide disconnecting means and circuit protections in accordance with national and local codes.

60"

1. Mount remote control panel inside building 5' above the floor as close to the hanging fan assembly as is practicable. 2. Route fan voltage supply wiring as shown in the appropriate schematic. Ensure proper cable sizing and fusing is in accordance with national and local codes. For installations consisting of more than one fan, wire motor leads in a consistent manner to avoid issues during commissioning and maintenance.

REMOTE IN

SERVICE

REMOTE I/O

3. Route the two 100' Category 5e cables (blue and gray) supplied by 4Front® from the VFD enclosure ports to the remote control panel. Plug the blue cable (part number 10-40783) in the blue port (REMOTE I/O) on the VFD enclosure and remote control panel and the gray cable (part number 10-40781) into the gray port (REMOTE IN) on the VFD enclosure and the remote control panel. NOTE: If longer Category 5e cables runs are required, do not exceed 1,000 feet in length. If more than 1,000 feet is required, consult factory.

12

6011315C — HVLS Fans ©2012 4Front® Engineered Solutions, Inc.

January 2012

installation, continued NETWORKED UNITS NOTE: Reference wiring diagrams on pages 23 through 26 for all field connections. 1. Route and terminate Category 5e cable (supplied by 4Front®) from fan to fan. Plug one end of cable into gray port (MODBUS IN) on first VFD enclosure and second end into gray port (MODBUS OUT) on next VFD enclosure. See Fig 12.

NOTE: For cable runs exceeding 1000', consult authorized 4Front® distributor. NOTE: The VFD enclosure does not contain fusing. See tables on pages 23 and 24 for power requirements. It is the customer's responsibility to provide disconnecting means and circuit protections in accordance with national and local codes.

2. Pin-out cables. See Fig. 14. 3. See installation instructions in publication 6011665.

Fig. 14 Network Installation

Fan position number

1

2

3

10

Category 5e ethernet cable (supplied by 4Front)

Network Kit (6011464) USB port

Gateway

Coupler

1. White and orange 2. Orange 3. White and green 4. Blue 5. White and blue 6. Green 7. White and brown 8. Brown 1234

5678

Computer

January 2012

RJ-45 connector pin-out

6011315C — HVLS Fans

13 ©2012 4Front® Engineered Solutions, Inc.

installation, continued VERIFY OPERATION — standard installation Operate the industrial fan following the operating instructions on page 16. Check for proper rotation direction, stability and noise level. Instruct shop personnel how to use the industrial fan using the operating procedures on page 16. VERIFY OPERATION — NETWORK installation See instructions in publication 6011665.

14

6011315C — HVLS Fans ©2012 4Front® Engineered Solutions, Inc.

January 2012

components and specifications VFD Assembly – NEMA 1, Solid State VFD (Variable Frequency Drive), 120VAC 1PH, 208-240VAC 1PH, 208 – 600 VAC, 3PH, line reactor (where required), UL and UL-C listed panel and components. motor NEMA standard T.E.F.C., 1-2 HP, continuous duty single or three phase Gearbox Double helical gear reduced, sealed lubrication.

Fig. 15

Clamp Shim

Safety cable

Universal mount VFD assembly Guy wires Motor

Gearbox

Blade

Safety links

Winglet

January 2012

6011315C — HVLS Fans

15 ©2012 4Front® Engineered Solutions, Inc.

electrical system operation The following describes the operation of the remote control panel: FAN SPEED CONTROL: Controls the rotational speed (rpm) of the fan. The higher the number, the faster the speed. ACTIVATION SWITCH: Three position switch that activates the fan in either the forward or reverse direction or turns the unit off.

Fig. 16 Fan speed control

Activation switch

16

Standard installation only

6011315C — HVLS Fans ©2012 4Front® Engineered Solutions, Inc.

January 2012

operating instructions Fig. 17 Before operating the industrial fan, read and follow the Safety Practices, Warnings and Operating Instructions in this manual. Use by untrained personnel could result in death or serious injury. STARTING THE FAN (FORWARD DIRECTION) 1. Visually inspect the fan to ensure that there are no obstructions or personnel in the movement area.

Ensure three position switch is in the off position before supplying power to the fan. Allow 5 seconds for VFD to stabilize before operating three position switch. 2. Rotate the three position switch to the FORWARD position. See Fig. 17. 3. Rotate the speed control knob to select the desired fan speed (1-10). The fan may take up to one minute to reach full speed.

Fig. 18

4. Verify fan is turning in a counter-clockwise direction as viewed from the floor. NOTE: The fan may be started using the selector switch with the speed control set at any speed. STARTING THE FAN (REVERSE DIRECTION) 1. Visually inspect the fan to ensure that there are no obstructions or personnel in the movement area. 2. Rotate the three position switch to the REVERSE position. See Fig. 18. 3. Rotate the speed control knob to select the desired fan speed (1-10). The fan may take up to one minute to reach full speed.

Fig. 19

4. Verify fan is turning in a clockwise direction as viewed from the floor. NOTE: The fan may be started using the selector switch with the speed control set at any speed or re-started if the blades are still in motion. STOPPING THE FAN 1. Rotate the three position switch to the OFF position. See Fig. 19. January 2012

6011315C — HVLS Fans

17 ©2012 4Front® Engineered Solutions, Inc.

Planned maintenance Before servicing the industrial fan, read and follow the Safety Practices on page 3 and the Operation section in this manual. Failure to do so could result in death or serious injury. To ensure the continued proper operation of your industrial fan, perform the following planned maintenance procedures. annually 1. Inspect control panel for loose connections. Tighten as required. 2. Inspect all safety labels, replace as required.

3. Using dry air (shop air), blow out debris from fan motor cooling fan as required. 4. Inspect motor/gearbox for oil leaks. If present, consult distributor. 5. Inspect mounting hardware and tighten as required. Torque to 40–57 ft-lbs. 6. Inspect safety and guy wires for chaffing or wear. Replace as required. 7. Inspect guy wires for tension. Re-tighten as required. 8. Clean fan blades as required. Use a soft dry cloth. If necessary, use a mild detergent to clean surfaces. Do not use harsh cleansers.

Fig. 20 Legend Symbol

Description Cleaning (Location - Frequency) Visually Inspect (Replace Damaged Or Worn) Blow with Compressed Air (Location - Frequency)

6011240

6009762

18

6011315C — HVLS Fans ©2012 4Front® Engineered Solutions, Inc.

January 2012

troubleshooting guide Before servicing the industrial fan, read and follow the Safety Practices on page 3 and the Operation section in this manual. Failure to do so could result in death or serious injury. The functions of the industrial fan are controlled by a VFD (Variable Frequency Drive). Error codes can be displayed on a diagnostic screen available from your authorized distributor. See table on page 20 for VFD diagnostics. Use the Troubleshooting Guide if the industrial fan fails to perform properly. Find the condition that most closely matches your situation and make the recommended adjustments.

Problem 1. Fan does not operate.

2. Fan does not operate. Control panel has power.

Before doing any electrical work, make certain the power is disconnected and properly locked or tagged off. Failure to do so may result in death or serious injury. All electrical troubleshooting and repair must be done by a qualified technician and meet all applicable codes. Do not route control wiring for any other device through this control box. Ensure that the voltage and phase of the incoming power agrees with the label located on top of the VFD enclosure and fan. Be certain power is off when wiring to the control box. Failure to do so could result in electrical shock, death or serious injury.

Possible Cause

Solution

a) No power to control panel.

a) Ensure that the disconnect is in the on position. Check for primary power at terminals?

b) Primary fuse(s) blown.

b) Replace fuse(s)

a) Obstructions preventing movement.

a) Check fan unit, ensure there are no obstructions preventing movment.

b) Remote not properly connected b) Check for VFD fault. Check fault code action - reset drive. (power off/power on) c) VFD faulted.

c) Check connections between remote/ VFD.

d) Faulty fire jumper block.

d) Verify property P00-04 reads 1001. If not, inspect jumper block on VFD panel.

3. Fan operating, but not generating proper speed.

a) Faulty speed control potentiometer.

a) Replace remote unit.

4. Fan operating, but turning in wrong direction.

a) Wire sequence.

a) Reverse remote switch wiring.

b) Intermittent connectivity inside remote control panel.

b) Make sure the RJ-45 connector inside the remote control panel is plugged in securely.

5. Fan operating, but generating high pitched whine.

a) Incorrect PWM frequency set.

a) Consult authorized 4Front® distributor.

6. Fan operating, but shows excessive wobble.

a) Guy wires not tensioned properly.

a) Re-tension guy wires in accordance with the installation instructions on page 9.

b) Winglet missing.

b) Replace winglet.

a) Blades bolts not properly tightened.

a) Loosen the the blade bolts. Make sure there is a washer on both ends. Support the blade level (horizontally) before torquing the bolts to 16-18 ft-lbs.

7. Fan generating a ticking noise, tick increases with speed.

January 2012

6011315C — HVLS Fans

19 ©2012 4Front® Engineered Solutions, Inc.

troubleshooting guide FAN DIAGNOSTIC TROUBLESHOOTING Configuring the Remote Keypad Module A remote keypad module kit 6011423 is required from 4Front® for troubleshooting fan issues. 1. Attach the patch cable included in the kit to the remote keypad module via the port on the bottom. See Fig. 21. 2. Attach the other end of the patch cable to the REMOTE port on the top of the remote control panel. 3. The remote keypad module will immediately light. If the screen does not light, check your cable connections. If the screen still doesn’t light, consult the troubleshooting section on page 19.

3. Press the ENT/PROG key. The display will now be reading P00-01. Press and hold the UP arrow key until the display reads P00-10. 4. Press the ENT/PROG key. The display will now be reading the hour run time since power was last cycled. 5. Press and hold the ENT/PROG key to switch to display mode. Error History (If Required) 1. Press and hold the ENT/PROG key to switch from display mode to parameter mode. 2. Press and hold the UP arrow key until the display reads P-20.

Fan Troubleshooting If the fan is not running, the current error code will be displayed on the screen. Consult the VFD Fault Code section of this manual to work the issue.

3. Press the ENT/PROG key. The memory holds the last 4 trips as a coded fault. The codes are displayed most recent to oldest. Use the UP or DOWN arrow keys to scroll the fault list.

If the fan is running the screen will be in display mode. Display mode has current (VFD to motor) and drive frequency values. Press the ENT/PROG key to switch from one to the other.

4. Press and hold the ENT/PROG key to switch to display mode.

Serial Number 1. Press down the ENT/PROG key to switch from display mode to parameter mode. 2. The display should be reading P-00. If it is not, use the UP or DOWN arrow keys until the display reads P-00.

After troubleshooting, remove the patch cable from the remote control panel.

Fig. 21

3. Press and hold the ENT/PROG key. The display will now be reading P00-01. Press and hold the UP arrow key until the display reads P00-19.

Remote keypad module Patch cable

4. Press the ENT/PROG key. The display will now be reading the first 6 digits of the serial number. Press the UP key to read the remaining digits. 5. Press and hold the ENT/PROG key to switch to display mode. Total Run Time 1. Press and hold down the ENT/PROG key to switch from display mode to parameter mode.

REMOTE port

2. The display should be reading P-00. If it is not, use the UP or DOWN arrow keys until the display reads P-00.

20

6011315C — HVLS Fans ©2012 4Front® Engineered Solutions, Inc.

January 2012

VARIABLE FREQUENCY DRIVE (VFD) – FAULT CODES These codes will be shown on the VFD diagnostic device screen (non networked) or on the computer monitor (networked). FAULT CODES P-dEF

DESCRIPTION

O-1

Output over current condition. Excess load on the motor. Over temperature on the heatsink.

1 _ t-trp

Driver has tripped on overload after delivering > 100% of value in P02 for a period of time.

O1 - b OL-br PS-trp

Brake channel over current Brake resistor overload Internal power stage fault

0_Volt U_Volt

Over voltage on DC bus Under voltage on DC bus

O-t U-t

Heatsink over temperature Under temperature

Th-Flt SC-trp

Faulty thermistor on heatsink Comms loss trip

P-LOSS

Input phase loss trip

Spin-F dAtA-F

Spin start failed Internal memory fault

4-20 F SC-Flt FAULtY

Analog input current out of range Internal drive fault Internal drive fault

January 2012

CORRECTIVE ACTION No error – unit ready to configure new properties Recycle power. If this does not clear the fault: 1. Check for wiring errors 2. Check for wire cable length/damage If this does not clear fault: 1. Consult T5 Recycle power. If this does not clear the fault: 1. Check fan unit, ensure there are no obstructions preventing movement. 2. Check cable length to ensure it is not too long. If this does not clear fault: Consult technical service. Consult technical service Consult technical service Check wiring to motor, look for ph -ph or ph-Earth short circuit. Check drive is not forced into overload. Supply problem. If this occurs during operation, check power supply voltage. Drive is too hot. Drive temperature below operating range. Raise temperature over -10 degrees C. Consult technical service Check communication between drive and remote sources. Drive intended for three phase has lost one leg. Consult technical service Parameters lost, reload. If repeated, consult technical service. Consult technical service Consult technical service Consult technical service

6011315C — HVLS Fans

21 ©2012 4Front® Engineered Solutions, Inc.

Fire control system option This fan includes a fire alarm jumper for a building fire control systems option that allows the fan to be shut-down by the fire control system in case of a fire emergency.

Fig. 22 FA

COM

EN

NOTE: Ensure fire control system plug is installed and either the fire alarm jumper is in place or the building fire control system is connected and jumper removed. 1. The fire option jumper block is shipped with the fire alarm jumper in place. To enable the fire option jumper block, remove jumper wires and wire in accordance with the schematic located on page 22. 2. The normally closed (NC) contacts must be dry contacts. They open in the even of an active fire alarm. 3. The fire control system option is disabled when shipped. To enable the fire control system option, remove the jumper between fire alarm com (com) and fire alarm (FA) and replace with a set of dry, normally closed contacts. See schematic on page 23.

Fire option jumper block

If the jumper is left installed, there is no emergency shutdown.

22

6011315C — HVLS Fans ©2012 4Front® Engineered Solutions, Inc.

January 2012

Fire control system option

January 2012

6011315C — HVLS Fans

23 ©2012 4Front® Engineered Solutions, Inc.

electrical schematics 1 PHASE

Fuse and Wire Size HP Input Current Fuse or MCB Supply Cable Size AMPS AMPS AWG 110-115VAC +/- 10% 1 PHASE INPUT/3 PHASE OUTPUT 1.0 12.5 12 15 200-240VAC +/- 10% 1 PHASE INPUT/3 PHASE OUTPUT 1.0 12.5 12 15 1.5 19.3 15 12 2.0 19.3 20 12

Before doing any electrical work, make certain the power is disconnected and properly locked or tagged off. Failure to do so may result in death or serious injury. All electrical troubleshooting and repair must be done by a qualified technician and meet all applicable codes. Do not route control wiring for any other device through this control box. Ensure that the voltage and phase of the incoming power agrees with the label located on top of the VFD enclosure and fan. Be certain power is off when wiring to the control box. Failure to do so could result in electrical shock, death or serious injury. 24

6011315C — HVLS Fans ©2012 4Front® Engineered Solutions, Inc.

January 2012

electrical schematics, continued 3 PHASE

Fuse and Wire Size HP Input Current Fuse or MCB Supply Cable Size AMPS AMPS AWG 200-240VAC +/- 10% 3 PHASE INPUT 1.0 5.8 5 14 1.5 9.2 6 14 2.0 9.2 8 14 380-480VAC +/- 10% 3 PHASE INPUT 1.0 2.9 3 14 1.5 5.4 4 14 2.0 5.4 5 14

Before doing any electrical work, make certain the power is disconnected and properly locked or tagged off. Failure to do so may result in death or serious injury. All electrical troubleshooting and repair must be done by a qualified technician and meet all applicable codes. Do not route control wiring for any other device through this control box. Ensure that the voltage and phase of the incoming power agrees with the label located on top of the VFD enclosure and fan. Be certain power is off when wiring to the control box. Failure to do so could result in electrical shock, death or serious injury. January 2012

6011315C — HVLS Fans

25 ©2012 4Front® Engineered Solutions, Inc.

electrical schematics, continued variable frequency drive i/o

26

6011315C — HVLS Fans ©2012 4Front® Engineered Solutions, Inc.

January 2012

electrical schematics, continued remote analog

January 2012

6011315C — HVLS Fans

27 ©2012 4Front® Engineered Solutions, Inc.

parts list — fan Fig. 23 To ensure proper function, durability and safety of the product, only replacement parts that do not interfere with the safe, normal operation of the product must be used. Incorporation of replacement parts or modifications that weaken the structural integrity of the product, or in any way alter the product from its normal working condition at the time of purchase from 4Front® Engineered Solutions could result in product malfunction, breakdown, premature wear, death or serious injury.

6

4

19

5

11

13

3 9 1

20

Optional

14 2

17

11

21

12 Hybrid hub assembly

22

7 9

23

18

24

10 25

28 27

26

28

6011315C — HVLS Fans ©2012 4Front® Engineered Solutions, Inc.

January 2012

parts list — fan, continued Item Quantity Description

Part Number

1 1

Motor, 1 HP consult factory Motor, 1-1/2 HP consult factory Motor, 2 HP consult factory

2 1

Gearbox, Nord consult factory Gearbox, Lenze (8, 10, 12, 14 Ft) consult factory Gearbox, Lenze (16, 18, 20 Ft) consult factory Motor/Gearbox, Dodge (24 Ft) consult factory



3

1

Universal Mounting Bracket

60-50101



4

2

Mounting Clamp

40-40026



5

4

Mounting Shim

40-40052



6

1

Extension (Length in Ft) — OPTIONAL

50-50052-Length

7 1

Dust Cap – Serco Dust Cap - Kelley



Glulam Mounting Bracket — not shown

40-40021-02

Blade, XL – 8 Ft Blade, XL – 10 Ft Blade, XL – 12 Ft Blade, XL – 14 Ft Blade, XL – 16 Ft Blade, XL – 18 Ft Blade, XL – 20 Ft Blade, XL – 24 Ft

20-10000-08 20-10000-10 20-10000-12 20-10000-14 20-10000-16 20-10000-18 20-10000-20 20-10000-24

8

2

9 6

60-40023 60-40022

10

6 winglet

60-10840

11

1

Safety Link (Set of 6)

6013287

12 1

Fenner Bushing, Hub – 1-1/8 Dia Fenner Bushing, Hub – 1-1/4 Dia

10-20205 10-20210

13

1

Safety Cable Assembly

60-11667

14

1

Guy Wire Set — std

60-10899

15

1

Cable, Category 5, 100 Ft, Blue — not shown

10-40783

16

1

Cable, Category 5, 100 Ft, Gray — not shown

10-40781

17

6 winglet fastener, 1/4 dia, female

6010843

18

6 winglet fastener, 1/4 dia, male

6010844

19

1 blade mount hardware kit

6013288

20

6 blade strut

60-40001

21

1 hybrid hub assembly (optional)

60-60118-00

22

1

SAFETY RETAINING PLATE

40-40066-03

23

6

BOLT, 1/4-20UNC X 3/4", GR 8

10-10280

24

4

BOLT, 7/16-20UNC X 2, GR 5

10-10266

25

6

STRUT

60-40001

26

1

SAFETY DISC

27

1

BLADE MOUNT HARDWARE KIT

28

4

SAFETY PLATE SPACER

January 2012

40-40067-03 6013298 40-40050-01 6011315C — HVLS Fans

29 ©2012 4Front® Engineered Solutions, Inc.

parts list — VFD assembly Fig. 24 1 2

3

4

6010860 - 230V/3 Ph/1 HP (Standard) 6011189 - 230V/3 Ph/1 HP (Network)

Item Quantity Description

Part Number



1

1

VFD, 230V/3 Ph/1 HP

6010703



2

1

LINE REACTOR, 600V, 4.8A, 3%

6010719



3

1

Cat 5e Coupler Assy

6010711



4

1

Connector Assy, Fire Control

6011391

6010861 - 230V/3 Ph/1.5 HP (Standard) 6011190 - 230V/3 Ph/1.5 HP (Network) 1 1 VFD, 230V/3 Ph/2 HP

6010704



2

1

LINE REACTOR, 600V, 7.6A, 3%

6010720



3

1

Cat 5e Coupler Assy

6010711



4

1

Connector Assy, Fire Control

6011391

6010862 - 230V/3 Ph/2 HP (Standard) 6011191 - 230V/3 Ph/2 HP (Network) 1 1 VFD, 230V/3 Ph/2 HP

6010704



2

1

LINE REACTOR, 600V, 7.6A, 3%

6010720



3

1

Cat 5e Coupler Assy

6010711



4

1

Connector Assy, Fire Control

6011391

30

6011315C — HVLS Fans ©2012 4Front® Engineered Solutions, Inc.

January 2012

parts list — VFD assembly, continued 6010863 - 230V/1 Ph/1 HP (Standard) 6011192 - 230V/1 Ph/1 HP (Network)

Item Quantity Description

Part Number



1

1

VFD, 230V/1 Ph/1 HP

6010723



2

1

Cat 5e Coupler Assy

6010711



3

1

Connector Assy, Fire Control

6011391

6011199 - 230V/1 Ph/1.5 HP (Standard) 6011193 - 230V/1 Ph/1.5 HP (Network) 1 1 VFD, 230V/1 Ph/2 HP

6010724



2

1

Cat 5e Coupler Assy

6010711



3

1

Connector Assy, Fire Control

6011391

6010864 - 230V/1 Ph/2 HP (Standard) 6011194 - 230V/1 Ph/2 HP (Network) 1 1 VFD, 230V/1 Ph/2 HP

6010724



2

1

Cat 5e Coupler Assy

6010711



3

1

Connector Assy, Fire Control

6011391

6010865 - 460V/3 Ph/1 HP (Standard) 6011195 - 460V/3 Ph/1 HP (Network) 1 1 VFD, 460V/3 Ph/1 HP

6010705



2

1

LINE REACTOR, 600V, 2.2A, 3%

6010722



3

1

Cat 5e Coupler Assy

6010711



4

1

Connector Assy, Fire Control

6011391

6010866 - 460V/3 Ph/1.5 HP (Standard) 6011196 - 460V/3 Ph/1.5 HP (Network) 1 1 VFD, 460V/3 Ph/2 HP

6010706



2

1

LINE REACTOR, 600V, 3.4A, 3%

6010718



3

1

Cat 5e Coupler Assy

6010711



4

1

Connector Assy, Fire Control

6011391

6010867 - 460V/3 Ph/2 HP (Standard) 6011197 - 460V/3 Ph/2 HP (Network) 1 1 VFD, 460V/3 Ph/2 HP

6010706



2

1

LINE REACTOR, 600V, 4.8A, 3%

6010719



3

1

Cat 5e Coupler Assy

6010711



4

1

Connector Assy, Fire Control

6011391

6011166 - 120V/1 Ph/1 HP (Standard) 6011198 - 120V/1 Ph/1 HP (Network) 1 1 VFD, 120V/1 Ph/1 HP

6011167



2

1

Cat 5e Coupler Assy

6010711



3

1

Connector Assy, Fire Control

6011391

January 2012

6011315C — HVLS Fans

31 ©2012 4Front® Engineered Solutions, Inc.

parts list — remote control panel Fig. 25

32

6011315C — HVLS Fans ©2012 4Front® Engineered Solutions, Inc.

January 2012

parts list — remote control panel, continued Standard assemblies

Description

Fan Sizes

Part Number

FAN 230V50/60/3PH 1HP 5.8A

8, 10, 12, 14, 16, 18, 20, 24

6010860

FAN 230V50/60/3PH 1.5HP 9.2A

20

6010861

FAN 230V50/60/3PH 2HP 9.2A

24

6010862

FAN 230V50/60/1PH 1HP 12.5A

8, 10, 12, 14, 16, 18, 20, 24

6010863

FAN 230V50/60/1PH 1.5HP19.3A

20

6011199

FAN 230V50/60/1PH 2HP 19.3A

24

6010864

FAN 460V50/60/3PH 1HP 2.9A

8, 10, 12, 14, 16, 18, 20, 24

6010865

FAN 460V50/60/3PH 1.5HP 5.4A

20

6010866

FAN 460V50/60/3PH 2HP 5.4A

24

6010867

FAN 120V50/60/1PH 1HP 12.5A

8, 10, 12, 14, 16, 18, 20, 24

6011166

networked assemblies

Description

Fan Sizes

Part Number

FAN 230V/3PH50/60/1HP 5.8A N

8, 10, 12, 14, 16, 18, 20, 24

6011189

FAN 230V50/60/3PH 1.5HP 9.2A N

20

6011190

FAN 230V50/60/3PH 2HP 9.2A N

24

6011191

FAN 230V50/60/1PH 1HP 12.5A N

8, 10, 12, 14, 16, 18, 20, 24

6011192

FAN 230V50/60/1PH 1.5HP19.3A N

20

6011193

FAN 230V50/60/1PH 2HP 19.3 N

24

6011194

FAN 460V50/60/3PH 1HP 2.9A N

8, 10, 12, 14, 16, 18, 20, 24

6011195

FAN 460V50/60/3PH 1.5HP 5.4A N

20

6011196

FAN 460V50/60/3PH 2HP 5.4A N

24

6011197

FAN 120V50/60/1PH 1HP 12.5A N

8, 10, 12, 14, 16, 18, 20, 24

6011198

REMOTE ASSEMBLIES

Description

Fan Sizes

Part Number

REMOTE, FAN ANALOG KELLEY

ALL

6011060

REMOTE, FAN ANALOG SERCO

ALL

6011061

January 2012

6011315C — HVLS Fans

33 ©2012 4Front® Engineered Solutions, Inc.

Notes:

34

6011315C — HVLS Fans ©2012 4Front® Engineered Solutions, Inc.

January 2012

WARRANTY THIS LIMITED WARRANTY IS 4FRONT’S SOLE AND EXCLUSIVE WARRANTY WITH RESPECT TO THE HVLS FAN AND IS IN LIEU OF ANY OTHER GUARANTEES OR WARRANTIES, EXPRESS OR IMPLIED 4FRONT warrants that this HVLS FAN will be free from flaws in material and workmanship under normal use for a period of one (1) year from the earlier of 1) 60 days after the date of initial shipment by 4FRONT, or 2) the date of installation of the HVLS FAN by the original purchaser, provided that the owner maintains and operates the HVLS FAN in accordance with this Owner’s Manual. In the event that this HVLS FAN proves deficient in material or workmanship within the applicable Limited Warranty period, owner shall so notify 4FRONT, and 4 Front will, at its option: 1. Replace the HVLS FAN, or the deficient portion(s) thereof, without charge to the owner; or 2. Alter or repair the HVLS FAN, on site or elsewhere, without charge to the owner. This Limited Warranty does not cover any failure caused by improper installation, abuse, improper operation, negligence, or failure to maintain and adjust the HVLS FAN properly. Parts requiring replacement due to damage resulting from vehicle impact, abuse, or improper operation are not covered by this warranty. 4FRONT DISCLAIMS ANY RESPONSIBILITY OR LIABILITY FOR ANY LOSS OR DAMAGE OF ANY KIND (INCLUDING WITHOUT LIMITATION, DIRECT, INDIRECT, CONSEQUENTIAL OR PUNITIVE DAMAGES, OR LOST PROFITS OR LOST PRODUCTION) arising out of or related to the use, installation or maintenance of the HVLS FAN (including premature product wear, product failure, property damage or bodily injury resulting from use of unauthorized replacement parts or modification of the HVLS FAN). 4FRONT’s sole obligation with regard to a HVLS FAN that is claimed to be deficient in material or workmanship shall be as set forth in this Limited Warranty. This Limited Warranty will be null and void if the original purchaser does not notify 4FRONT’s warranty department within ninety (90) days after the product deficiency is discovered. . THERE ARE NO WARRANTIES, EXPRESS OR IMPLIED, WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF, INCLUDING, BUT NOT LIMITED TO, A WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE, ALL OF WHICH 4FRONT HEREBY DISCLAIMS.

January 2012

6011315C — HVLS Fans

35 ©2012 4Front® Engineered Solutions, Inc.

Please direct questions about your fan to your local distributor. Your local distributor is:

Corporate Head Office: 1612 Hutton Dr. Suite 140 Carrollton, TX. 75006 Tel. (972) 466-0707 Fax (972) 323-2661

©2012 4Front® Engineered Solutions, Inc.

Part No. 6011315C

Similar documents