FANWALL TECHNOLOGY Field Installed Retrofit Fan Cubes/Array

Transcription

1 FANWALL TECHNOLOGY Field Installed Retrofit Fan Cubes/Array Aston-built Products Installation, Operation and Maintenance Instructions Manual 2012 Venmar CES Inc.

2 Table of Contents Safety Considerations...3 General Information...3 Inspection on Arrival...4 Installation...4 Installation Precautions...4 Electrical Connections...4 FANWALL Retrofit Fan Array Assembly...5 Start-up...7 Pre Start-up Check...7 Start-up Procedure...7 Maintenance...8 FANWALL Array...8 Motor...12 Troubleshooting...13 Appendix A: Long-term Storage or Dormant Maintenance Procedures...15 Appendix B: FANWALL Inlet Cone Alignment...17 Appendix C: FANWALL TECHNOLOGY Fan Array Start-up Report and Checklist...18 Venmar CES Inc All rights reserved throughout the world. Illustrations cover the general appearance of Venmar CES products at the time of publication and Venmar CES reserves the right to make changes in design and construction at any time without notice. The following are registered trademarks of their respective companies: FANWALL from Huntair, Inc. CES Group, LLC d/b/a Venmar CES furnishes equipment pursuant to its then-current Terms and Conditions of Sale and Limited Warranty, copies of which can be found under the Terms & Conditions of Sale and Warranty link at Extended warranties, if any, shall be as offered and acknowledged in writing by Venmar CES. Manufacturer reserves the right to discontinue or change specifications or designs without notice or obligation. VCES-FWT-IOM-1A 2

3 Safety Considerations Warning, Caution and Important notes appear throughout this manual in specific and appropriate locations to alert Installing Contractors and maintenance or service personnel of potential safety hazards, possible equipment damage or to alert personnel of special procedures or instructions that must be followed as outlined below.! WARNING Identifies an instruction which, if not followed, might cause serious personal injuries including possibility of death. CAUTION Identifies an instruction which, if not followed, might severely damage the unit, its components, the assembly or final installation. IMPORTANT Indicates supplementary information needed to fully complete an instruction or installation. Hazards may exist within this equipment because it contains electrical and powerful moving components. Only qualified service personnel should install or service this equipment. Untrained personnel can perform basic maintenance such as maintaining filters. Observe precautions marked in literature and on labels attached to the unit. Follow all safety codes.! WARNING Disconnect the main power switch to the unit before performing service or maintenance. Electric shock can cause personal injury or death.! WARNING Improper installation, adjustment, alteration service or maintenance can cause property damage, injury or death. Read the installation, operating and maintenance instructions thoroughly before installing or servicing this equipment.! WARNING Installing and servicing air conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should install or service air conditioning equipment. Untrained personnel can perform basic maintenance, such as cleaning and replacing filters. All other operations should be performed by trained service personnel. When working on air conditioning equipment, observe precautions listed in literature, tags and labels attached to unit. Follow all safety codes: Wear safety glasses and work gloves. Use quenching cloth for brazing operations. Have fire extinguisher available. Read these instructions thoroughly. General Information The Venmar CES Model FWT Fan Cubes/Array is a FAN- WALL TECHNOLOGY field installed retrofit approach that uses several smaller fan cubes to replace one larger fan within an existing air handling unit, providing design flexibility, reducing maintenance costs and increasing energy savings. This manual is designed to provide general information on the common operation of all standard and optional components that may have been installed in the fan array. Note that some sections of this manual may not apply to your fan array. This manual has been designed for general purpose and describes all options offered by Venmar CES that could be included in your FANWALL TECHNOLOGY field installed retrofit fan array. All documentation that was specifically designed for your fan array has been included in the motor overload panel lid or documentation package including (and if applicable): Warranties Mechanical drawings Electrical Schematics Sequence of Control DDC controller documentation (when supplied) Variable Frequency Drive (VFD) instructions manual on CD or DVD (if supplied) Please refer to Appendix A for maintenance instructions to follow if the FWT fan cubes/array are to be stored for a period of time exceeding one month prior to installation or installed and not placed in service for a period of one month. Following the instructions in this appendix will assist in preventing potential unit damage that may result from an extended storage or dormant period. VCES-FWT-IOM-1A 3

4 Inspection on Arrival Inspect the FWT fan cubes and optional components for any damage that may have occurred during shipment. Ensure there is no damage to any internal components. File a claim with the shipping company if any of the components are damaged. Check the packing list against all items received. If any items are missing sign the carrier s bill of landing with the notation. Shipment received less item #. Contact the factory immediately if damage is found. No return shipment will be accepted without authorization. Installation Installation Precautions The services of qualified field service personnel are mandatory for safe and proper installation of this equipment. Authorities having jurisdiction should be consulted before installations are made to verify local codes, installation procedures and installation clearances. The following clearances from combustible materials are to be maintained: Top: 6 Control side: 48 Opposite controls: 6 Bottom: 0 If roofcurb is provided by others, it must be at least 4 high and constructed from non-combustible material. The fan array is designed for installation on a level surface. Do not locate the fan array inlet opening within 10 feet of any exhaust discharge point or within 24 or any obstruction. Provide access and clearance upstream and downstream of the fan array for maintenance. Electrical Connections! WARNING When installed, the fan array and optional controls must be wired and electrically grounded in accordance with local codes, with the National Fire Protection Association (National Electrical Code), ANSA/NFPA70 and/or the Canadian Electrical Code CSA C22.1. Installation must have an uninterrupted, unbroken electrical ground to minimize the possibility of personal injury if any electrical fault should occur. Failure to follow this warning could result in the Installer being liable for personal injury of others. The FWT nameplate and the drawings state the line voltage and minimum ampacity requirements for this fan array. Electrical characteristics are shown on each motor nameplate and inside left hand corner of motor starter protector (MSP) lid for complete system. All wiring must be within approved conduit and have a minimum temperature rating of 75 C. IMPORTANT If any of the original wire supplied with the unit must be replaced, it must be replaced with type THHN 75 C wire or its equivalent. VCES-FWT-IOM-1A 4

5 FANWALL Retrofit Fan Array Assembly! WARNING Many of the following steps need to be performed with the unit powered off and locked out. Disconnect the main power switch to the unit before performing service and maintenance procedures. 1. Verify factory furnished components are complete against enclosed packing list. Each FWT fan cube is numbered and must be located in the array per the submittal drawing. Refer to submittal for number of FWT fan cubes and location in assembled array if applicable. 2. Prior to demolition of existing fan: Verify FWT fan cube dimensions are correct and assembled array will fit inside existing air handling unit. Internal floor to ceiling and inside wall to wall dimensions were provided to Venmar CES by others. 3. Disconnect power to the existing fan at the main disconnect control panel. 4. Make note of all wire locations for reinstallation later. 5. Disconnect motor power cable from terminal located in motor J-box and conduit fitting from J-box (see Figure 1). 7. Make sure that floor on the air handler is level and rigid. 8. Locate and mark inlet for new fan array on floor of air handling unit (see Figure 3). Figure 3: Existing fan removed 9. Determine offset for the assembled array (from inside walls) on both sides of the unit and mark accordingly. 10. Align first FWT fan cube (bottom row furthest from access side of unit) and only secure first cube to floor using tek screws (see Figure 4a and Figure 4b). Figure 1: Disconnect motor power cable Figure 4a: Align first fan cube 6. Remove existing fan/motor assembly and clean the area thoroughly (see Figure 2). Figure 4b: Secure first cube to floor Figure 2: Remove existing fan/motor assembly VCES-FWT-IOM-1A 5

6 11. Continue setting FWT fan cubes along line (see above Item 8) until bottom row is completed (do not secure to floor) (see Figure 4a and Figure 4b). 12. Check alignment and verify clearance on both sides of air handling unit inside walls. Adjust accordingly. 13. After alignment is verified, secure entire first row of FWT fan cubes to floor with tek screws (see Figure 5). 15. To secure the fan array to the unit, attach tie-off walls to sides and ceiling of unit then secure to FWT fan cubes. Apply caulking to tie-off walls and FWT fan cubes as required to prevent air from bypassing the fan array (Figure 7). IMPORTANT Tie-off walls and caulking are furnished by others. Figure 7: Apply caulking to tie-off walls and fan cubes Figure 5: Secure first row of fan cubes to floor 14. Install remaining FWT fan cubes and bolt together at corners on both inlet and discharge side of FWT fan cubes (see Figure 6). 16. Re-assemble air handling unit walls, doors, safety devices, etc. removed during retrofit per unit Manufacturer s recommendations. 17. Wire each FWT fan cube motor to motor overload panel (if furnished by Venmar CES) per wiring diagram. Diagram is located inside the motor overload panel lid. 18. Prior to connection of main power, check fan wheel/ cone alignment per the FANWALL Array Maintenance section, item 10. Figure 6: Secure fan array to the unit VCES-FWT-IOM-1A 6

7 Start-up Pre Start-up Check Before requesting start-up, check that the installation is complete and the FWT fan array and air handling unit are ready. Complete the pre start-up below (if items are applicable) and the checklist in Appendix C for the FWT fan array 1. Check the electrical disconnect is locked out in the Off position. 2. Check fan array fan cubes for damage and operation. a. On discharge side visually check for damage to fans, motors, cubes, etc. b. On inlet side visually check for damage to inlet straightening grids, frames and cubes. c. Rotate fan wheels by hand and check to ensure they are properly aligned with inlet cones. d. While fan wheels are rotating check motor bearings are operating freely and free of noise. e. Check that the shaft grounding kits are installed properly. f. Check backdraft dampers for smooth operation if supplied. Open dampers by hand to ensure full range of motion without constriction. 3. Check the AHU that all air openings and penetrations have been sealed and interior is clean and free of debris. 4. Check that all shipped loose or field supplied components have been correctly installed and wired. 5. Check that all power supplies and control wiring added have been inspected and approved by the Local Authorities having jurisdiction. 6. Check all factory and field wiring connections for tightness. Tighten if necessary. 7. Check that all fuses are properly installed in holders. 8. Check circuit breaker disconnect mechanism and/or mechanical interlock operate properly. 9. Check VFD sizes and ratings for voltage and horsepower. 10. Check and set motor start protectors (MSPs) for correct size and setting. 11. Check that all safety switches, overloads or other manual reset devices are reset. 12. Check all system components are adjusted to proper settings (temperature, amperage). 13. Check the voltage at the disconnect switch against the nameplate and against phase-to-phase readings on three-phase. If the voltage is not within 10% of rated or 2% of phase-to-phase, have the condition corrected before continuing start-up. Start-up Procedure To ensure proper operation of the FWT fan array, qualified personnel should perform the start-up as outlined below (based on options included) and complete the Start-up Report and Checklist in Appendix C for permanent record. A completed report and checklist will provide valuable information for personnel performing future maintenance. IMPORTANT A completed copy of the Start-up Report and Checklist must be sent back to the factory for warranty validation and for factory assistance.! WARNING Electric shock can cause personal injury or death. Only qualified service personnel should install and service this equipment. 1. Before proceeding, complete the pre start-up checklist. 2. Check that all access panels or doors are closed. 3. Energize incoming power circuit. 4. Check internal power supplies for proper voltage output(s) and adjust as required. 5. Test and verify proper operation of all GFCI devices. 6. Check operation of cabinet cooling fans, adjust thermostats as specified on drawing. 7. Energize each MSP one at a time to start each motor slowly to ensure each fan rotation is correct. If the fan wheel is not rotating correctly, check the motor leads for proper installation. a. Drive Side Clockwise rotation when looking at motor end. b. Inlet side Counter-clockwise rotation looking at fan inlet. 8. Perform start-up on VFD as specified by VFD Manufacturer. Adjust the fan motor VFDs to the correct air volume/hertz. 9. Check that the cfm monitoring system is functioning (if supplied). 10. Check amperage draw to each motor on each phase against motor nameplate FLA. 11. Re-check the voltage at the disconnect switch against the nameplate and against phase-to-phase readings on three-phase with all blowers operating. If the voltage is not within 10% of rated or 2% of phaseto-phase, have the condition corrected before continuing start-up. 12. When unit has achieved steady state, take measurements and complete the Start-up Readings portion of the Start-up Report and Checklist in Appendix C. Send a copy of the completed Start-up Report and Checklist to Venmar CES to validate warranty. Maintain a copy of the report at the unit for future reference. VCES-FWT-IOM-1A 7

8 Maintenance FANWALL Array! WARNING Many of the following steps need to be performed with the unit powered off and locked out. Disconnect the main power switch to the unit before performing service and maintenance procedures. Maintenance Schedule FANWALL array of multiple direct drive plenum fan and motor cubes are equipped with permanently sealed bearings and do not require lubrication. The following maintenance schedule is recommended. Monthly Check the fan wheel to inlet cone alignment for possible noise from the wheel rubbing against the inlet cone. See Fan Wheel/Cone Alignment below for instructions. Every six months Check motor bearings for possible binding noise or overheating. Check fan wheels for dirt and grease accumulation. Clean as necessary. Do not use any caustic cleaning solutions. Annually Lightly lubricate damper and linkage bushings on back draft dampers (if equipped). Every Two Years Examine fan housings and motor pedestal for corrosion. Clean and touch up with paint as necessary. Figure 9: Remove safety screen on motor end 3. Disconnect the four-wire electrical cable from the motor junction box. Make note of wire locations for re-installation later. See Figure 10. Figure 10: Remove electrical cable 4. Mark motor pedestal location on the motor pedestal mounting angles (both sides), then loosen and remove (4) ½ bolts that retain the motor pedestal to the mounting angles. See Figure 11. Figure 8: FANWALL array Fan Wheel and Motor Removal 1. Disconnect power to the fan array control panel before maintenance. Follow all lockout and tag out procedures. 2. Remove the optional safety screen (if provided) on the motor end only of the cube in question by removing all four hex screws from the holding flange that retains the safety screen. See Figure 9. Figure 11: Remove motor pedestal retaining bolts VCES-FWT-IOM-1A 8

9 ! WARNING Many of the following steps need to be performed with the unit powered off and locked out. Disconnect the main power switch to the unit before performing service and maintenance procedures. 5. After removing the motor pedestal retaining bolts, slide the motor/fan/pedestal assembly out to the point where the motor lifting ring is clear of the cube frame enough to use. If a mechanical device is available for use, attach it to the motor lifting ring. Lift and remove the motor pedestal with motor and fan wheel from the cube. The motor pedestal with motor and fan wheel can be turned 180 and slid back into the cube on the pedestal mounting angles or removed from unit for further disassembly. 6. Mark the location of the trans-torque bushing on the shaft and the fan. To remove the fan wheel from the motor shaft, remove the trans-torque bushing retaining hex nut using a 1 socket with a 12 extension by turning counter-clockwise. Loosen progressively until the bushing is free from wheel hub and motor shaft. Remove fan wheel/hub assembly. See Figure 12. Figure 12: Mark location and remove trans-torque bushing and fan wheel from motor 7. If needed the motor may now be removed for service by removing all (4) 3/8 motor retaining nuts and bolts. Be sure to mark the motor base pattern and bolt holes used on the motor pedestal. Rubber isolator pads between the motor base and the pedestal are optional and, if supplied, be sure not to lose them. See Figure 13. If the motor is to be replaced, make sure to remove the shaft grounding ring off the front of the motor that is being replaced. Install the shaft grounding ring onto the new motor by drilling and taping mounting holes. Use a 7/64 or a #35 drill bit and #6-32 tap. Clean away any chips and shavings before installing the shaft grounding ring. Figure 13: Remove motor retaining bolts; do not lose rubber isolation pads (if provided) 8. To re-install the motor, fan wheel and fan wheel/ motor/pedestal assembly back into the cube, reverse the steps above noting the following: a. Insert the (4) 3/8 motor retaining bolts into the holes in the motor pedestal from the underside; make sure to use a standard washer on the bolt side, install the rubber isolator pads (if supplied) between the pedestal and motor base and only a locknut is required on the motor side. b. Square the motor on the pedestal according to markings and tighten the bolts. With rubber isolator pads tighten the bolts to 20 ft-lbs. Without rubber isolator pads tighten the bolts to 40 ft-lbs. c. Install the fan wheel on the motor shaft with the hub facing towards you. Line up the markings on the hub/trans-torque bushing/shaft. Make sure that the trans-torque bushing nut is flush to the hub. Tighten the bushing nut progressively to 80 ft-lbs turning clockwise. 9. Lift the motor pedestal with motor and fan wheel (turn 180 if placed on the pedestal mounting angles or disassembly) with the fan wheel inlet toward the inlet cone. Place motor pedestal into the cube on the pedestal mounting angles and slide the pedestal forward to the line that you previously marked. Line the four pedestal bolt holes up with the bolt holes on the mounting angles. Insert (4) ½ bolts into the holes, make sure to use a standard washer on the bolt side and a standard washer and lock washer on the nut side. Hand tighten the bolts for now. VCES-FWT-IOM-1A 9

10 ! WARNING Many of the following steps need to be performed with the unit powered off and locked out. Disconnect the main power switch to the unit before performing service and maintenance procedures. frame to the inlet side panel and remove it from the cube. The purpose of the damper is so that maintenance staff can block the intake of a single fan to prevent back flow until service on an inoperative assembly can be performed. Note the directions of the damper blades are running vertical. The damper is installed directly onto the FANWALL cube inlet side panel and over the optional airflow straightener (if supplied). Figure 14: Check fan wheel/cone alignment and overlap 10. Check the inlet cone alignment to the fan wheel. Fan wheel should not be rubbing against the fan inlet cone when rotated by hand. The fan wheel to inlet cone clearance should be approximately 1/16 gap and the overlap should be as indicated in Appendix B for the fan wheel size. Adjust the overlap of the wheel and cone by moving the motor pedestal forward or back. Fan wheel should not be rubbing on the inlet cone. If cone alignment is required see instructions for Fan Wheel/Cone Alignment below. Once alignment and overlap are correct, tighten the (4) ½ pedestal mounting bolts to 90 ft-lbs. 11. Reconnect the four-wire electrical cable from the motor junction box. Before operation, start the motor slowly to ensure the fan rotation is correct. If the fan wheel is not rotating correctly, check the motor leads for proper installation. a. Drive Side Clockwise rotation when looking at motor end. b. Inlet side Counter-clockwise rotation looking at fan inlet. IMPORTANT Before re-starting, re-balance the fan wheel once the motor rotation and alignment have been corrected before placing the unit in operation. Fan Wheel/Cone Alignment 1. To align fan wheel/cone, first disconnect power to the fan array control panel. Follow all lockout and tag out procedures. 2. If the optional backdraft damper is furnished on the inlet side of the fan it must be removed first. Remove all tek screws on all sides attaching the damper Figure 15: Fan wheel/cone alignment Step 2a Figure 16: Fan wheel/cone alignment Step 2b 3. If the optional airflow straighteners are furnished on the inlet side of the fan it must be removed next. Remove all tek screws on the airflow straightener panel frame and remove it from the cube. Figure 17: Fan wheel/cone alignment Step 3 VCES-FWT-IOM-1A 10

11 ! WARNING Many of the following steps need to be performed with the unit powered off and locked out. Disconnect the main power switch to the unit before performing service and maintenance procedures. 4. Gently rotate the fan wheel to verify location of adjustment required. 7. Gently rotate the fan wheel to verify cone adjustment for proper clearance from wheel. Figure 21: Fan wheel/cone alignment Step 7a and Step 9a Figure 18: Fan wheel/cone alignment Step 4 5. To make adjustment, loosen (do not remove) all the cone retaining fasteners. Figure 22: Fan wheel/cone alignment Step 7b and Step 9b 8. Tighten all the cone retaining fasteners. Figure 19: Fan wheel/cone alignment Step 5 6. Using a rubber mallet, gently tap around the cone until desired clearance is acquired between fan wheel and inlet cone. Figure 23: Fan wheel/cone alignment Step 8 Figure 20: Fan wheel/cone alignment Step 6 9. Once again gently rotate the fan wheel to verify cone alignment. 10. To install the optional airflow straightener or backdraft damper reverse the steps above. Blank-off Plate (if applicable) 1. Optional blank-off plate(s) are available so that maintenance staff can block the intake of a single fan to prevent back flow until service on an inoperative as- VCES-FWT-IOM-1A 11

12 ! WARNING Many of the following steps need to be performed with the unit powered off and locked out. Disconnect the main power switch to the unit before performing service and maintenance procedures. sembly can be performed or it can be mounted on spare FANWALL cube(s) until they are required to be put into service. 2. First disconnect power to the fan array control panel. Follow all lockout and tag out procedures. 3. The blank-off plate is fitted to the inlet side of the FANWALL cube on the optional airflow straightener panel frame (if supplied) or onto a matching Z frame. There are 12 pre-drilled holes which are located in the corners and middle of the airflow straightener panel frame or Z frame matching pre-drilled holes in the blank-off plate for fastening together with tek screws. 4. Place the blank-off plate over the optional airflow straightener panel frame (if supplied) or onto the matching Z frame and pre-drilled holes and fasten together with or remove tek screws. Figure 25: Blank-off plate Step 4 Figure 24: Blank-off plate Step 3 Motor! WARNING UL Listed motors must only be serviced by UL Approved Authorized Baldor Service Centers if these motors are to be returned to a hazardous and/or explosive atmosphere. Check Baldor website ( for closest office. Inspect the fan motors at regular intervals, approximately every 500 hours of operation or every three months, whichever occurs first. Keep the motors clean and the ventilation fins clear. The following steps should be performed at each inspection. 1. Check that the motors are clean. Check that the exterior of the motors are free of dirt, oil, grease, water, etc. Oily vapor, paper pulp, textile lint, etc. can accumulate and block motor ventilation. If the motor is not properly ventilated, overheating can occur and cause early motor failure. 2. Use a Megger periodically to ensure that the integrity of the winding insulation has been maintained. Record the Megger readings. Immediately investigate any significant drop in insulation resistance. 3. Check all electrical connectors to be sure that they are tight. VCES-FWT-IOM-1A 12

13 Troubleshooting Table 1: Troubleshooting Guide FWT Problem Possible Cause Solution FANWALL will not start or run at all. Motor will not start. Motor failure. No main power. Faulty control circuit auxilliary contact on unit disconnect switch. No control transformer output. Tripped overloads on motor starters. Usually caused by line trouble, such as single phasing at the starter. Improper supply voltage. Motor overheating. Motor overloaded. Overload compare actual amps (measured) with nameplate rating. Single phasing. Improper ventilation. Unbalanced voltage. Check main power fuses with ohm meter. Correct problem and replace fuses with size indicated on electrical diagram. Check disconnect switch. Turn to On position. Use volt meter to check for proper main voltage to unit. Restore power to unit. Check contact with ohm meter. Replace switch if faulty. Check primary and secondary fuses on transformer. Correct problem and replace fuse(s) with size indicated on electrical diagram. Check control transformer primary and secondary voltages. Replace transformer if faulty. Verify overload trip setting is at or slightly above the motor nameplate FLA. Reset overloads and measure operating current of motors. If current values are above nameplate FLA, go to Motor failure. Consult Baldor Service Center. Check source of power. Check overloads, fuses, controls, etc. Check voltage at motor. If incorrect, correct to proper value. Check for proper wiring at motor. Wire motor per diagram on motor or inside motor junction box. Verify correct supply cfm. Adjust cfm to unit data plate value. Check for temperatures above 110 F. Consult Baldor Service Center. Check amperage at motor. Motor junction box if amperage outside of motor nameplate limits, conduct additional field tests that follow. Check rotation of fan. Correct rotation, if necessary. Check motor shaft for freedom of movement. Replace motor or motor bearings if necessary. Check for excessive cfm and/or static pressure. Correct cause of high static pressure and adjust airflow per start-up section instructions. Locate and remove source of excessive friction on motor or load. Reduce load or replace with motor of greater capacity. Check current at all phases (should be approximately equal) to isolate and correct the problem. Check external cooling fan to be sure air is moving properly across cooling fins. Excessive dirt build-up on motor. Clean motor. Check voltage at all phases (should be approximately equal) to isolate and correct the problem. VCES-FWT-IOM-1A 13

14 Table 1: Troubleshooting Guide FWT Problem Possible Cause Solution Rotor rubbing on stator. Check air gap clearance and bearings. Tighten through bolts. Over voltage or under voltage. Check input voltage at each phase to motor. Motor failure Open stator winding. Check stator resistance at all three phases for balance. continued Grounded winding. Perform dielectric test and repair as required. Improper connections. Inspect all electrical connections for proper termination, clearance, mechanical strength and electronic continuity. Refer to motor lead connection diagram. Excessive humming. High voltage. Check input line connections. Eccentric air gap. Have motor serviced at local Baldor Service Center. High external static pressure. Check actual pressure against unit data plate pressure. Correct static pressure. If not possible, consult factory. Verify proper position of unit air control dampers (if any) and all Dampers improperly positioned. external dampers/diffusers. Correct damper position. Check ductwork and duct connections for leaks. Air leaks in system. Fan capacity low. Repair any leaks. Damaged fan wheel. Visually inspect wheel. Replace fan wheel if necessary. Incorrect fan rotation. Check wheel rotation with arrow on fan. Correct rotation if backwards. Obstructed inlet. Inspect inlet. Clear inlet. Misalignment. Check and align motor and drive equipment. Misalignment of wheel. Check alignment. Align if necessary. Dirty fan wheel. Inspect fan wheel. Clean fan wheel. Broken or loose bolts or set screws. Check bolts and set screws for tightness. Replace or tighten as necessary. Fan delivering more than rated capacity. Refer to airflow verification in Start-up Procedure section. Adjust drives per instructions in Start-up Procedure section. Inspect dampers. Loose dampers. Vibration and noise. Tighten dampers if loose. Shipping bolts and/or braces not removed. Verify all shipping blocks and braces are removed. Remove shipping attachments. Rubbing between rotating parts and stationary parts. Isolate and eliminate cause of rubbing. See Fan Wheel/Cone Alignment for adjustment. Rotor out of balance. Have rotor balance checked or repaired at your Baldor Service Center. Resonance. Tune system or contact your Baldor Service Center for assistance. Remove rotor and foreign material. Foreign material in air gap or ventilation openings. Reinstall rotor. Check insulation integrity. Clean ventilation openings. VCES-FWT-IOM-1A 14

15 Appendix A: Long-term Storage or Dormant Maintenance Procedures General Should storage of FWT fan cubes be required, caution should be taken to set FWT fan cubes indoors in a clean location to protect motor, fans, coplanar and optional components from excessive dust. Also avoid storage in a location where children play and/or public access. If units are to be stored for an extended period of time, the following maintenance procedures must be performed: Manually rotate motor/wheel monthly. Figure A1: FWT cube For complete fan wheel/motor spare assembly that will not be placed in service for at least six months from date of shipment, improper motor storage will result in seriously reduced reliability and failure. A wooden crate shell should be constructed to secure the motor during storage. This is similar to an export box but the sides and top must be secured to the wooden base with lag bolts (not nailed as export boxes are) to allow opening and reclosing many times without damage to the shell. Figure A2: Complete fan wheel/motor spare assembly Minimum resistance of motor winding insulation is 5 Meg ohms or the calculated minimum, whichever is greater. Minimum resistance is calculated as follows: Rm = kv + 1 where: (Rm is minimum resistance to ground in Meg Ohms and kv is rated nameplate voltage defined as Kilo Volts.) Example: For a 480 VAC rated motor Rm = 1.48 meg ohms (use 5 MÙ). For a 4,160 VAC rated motor Rm = 5.16 meg ohms. Dormant Maintenance Procedure 1. Some motors have a shipping brace attached to the shaft to prevent damage during transportation. The shipping brace, if provided, must be removed and stored for future use. The brace must be re-installed to hold the shaft firmly in place against the bearing before the motor is moved. a. Manually rotate motor/wheel monthly. 2. Store in a clean, dry, protected warehouse where control is maintained as follows: a. Shock or vibration must not exceed 2 mils maximum at 60 hertz, to prevent the bearings from brinelling. If shock or vibration exceeds this limit vibration isolation pads must be used. b. Storage temperatures of 50 F [10 C] to 120 F [49 C] must be maintained. c. Relative humidity must not exceed 60%. d. Motor space heaters (when present) are to be connected and energized whenever there is a possibility that the storage ambient conditions will reach the dew point. Space heaters are optional. IMPORTANT Remove motor from containers when heaters are energized, re-protect if necessary. 3. Measure and record the resistance of the winding insulation (dielectric withstand) every 30 days of storage. a. If motor insulation resistance decreases below the minimum resistance, contact your Baldor District Office. b. Place new desiccant inside the vapor bag and reseal by taping it closed. c. If a zipper closing type bag is used instead of the heat sealed type bag, zip the bag closed instead of taping it. Be sure to place new desiccant inside bag after each monthly inspection. d. Place the shell over the motor and secure with lag bolts. 4. Where motors are mounted to machinery, the mounting must be such that the drains and breathers are fully operable and are at the lowest point of the motor. Vertical motors must be stored in the vertical position. Storage environment must be maintained as stated in Step 2. VCES-FWT-IOM-1A 15

16 5. Motors with antifriction bearings are to be greased at the time of going into extended storage with periodic service as follows: a. Motors marked Do not Lubricate on the nameplate do not need to be greased before or during storage. b. Ball and roller bearing (antifriction) motor shafts are to be rotated manually every three months and greased every six months in accordance with the Maintenance section of this manual. c. Sleeve bearing (oil lube) motors are drained of oil prior to shipment. The oil reservoirs must be refilled to the indicated level with the specified lubricant (see Maintenance). The shaft should be rotated monthly by hand at least 10 to 15 revolutions to distribute oil to bearing surfaces. d. Provisions for oil mist lubrication: These motors are packed with grease. Storage procedures are the same as paragraph 5b. e. Oil mist lubricated: These bearings are protected for temporary storage by a corrosion inhibitor. If stored for greater than three months or outdoor storage is anticipated, connect to the oil mist system while in storage. If this is not possible, add the amount of grease indicated under Standard Condition in Section 3, then rotate the shaft 15 times by hand. 6. All breather drains are to be fully operable while in storage (drain plugs removed). The motors must be stored so that the drain is at the lowest point. All breathers and automatic T drains must be operable to allow breathing and draining at points other than through the bearings around the shaft. Vertical motors should be stored in a safe stable vertical position. 7. Coat all external machined surfaces with a rust preventing material. An acceptable product for this purpose is Exxon Rust Ban # Non-regreasable motors with Do not Lubricate on the nameplate should have the motor shaft rotated 15 times to redistribute the grease within the bearing every three months or more often. Removal from Storage 1. Remove all packing material. 2. Measure and record the electrical resistance of the winding insulation resistance meter at the time of removal from storage. The insulation resistance must not be less than 50% from the initial reading recorded when the motor was placed into storage. A decrease in resistance indicates moisture in the windings and necessitates electrical or mechanical drying before the motor can be placed into service. If resistance is low, contact your Baldor District Office. 3. Re-grease the bearings as instructed in this manual. 4. Re-install the original shipping brace if motor is to be moved. This will hold the shaft firmly against the bearing and prevent damage during movement. VCES-FWT-IOM-1A 16

17 Appendix B: FANWALL Inlet Cone Alignment Table A1: FANWALL Wheel/Cone Alignment Dimensions Wheel Size Backplate OD Blade Width Backplate Extension Wheel/Cone Overlap Backplate extension Blade width (100% wide) Wheel/cone overlap Backplate OD Figure A3: FANWALL inlet cone alignment VCES-FWT-IOM-1A 17

18 Appendix C: FANWALL TECHNOLOGY Fan Array Start-up Report and Checklist IMPORTANT Complete all forms under this appendix for each unit and , fax or mail to Venmar CES immediately after start-up to validate warranty and to provide valuable information for personnel performing future maintenance or for factory assistance to address below. Read the Installation, Operation and Maintenance Instruction Manual before proceeding. Leave a copy of this report with the owner and at the unit for future reference and permanent record. To ensure proper operation of each unit, qualified personnel should perform the start-up, complete the checklist and report. Venmar CES Inc. 200 Rue Carter St. Léonard d Aston, QC Canada J0C 1M0 to tech support: venmarservice@venmarces.com Fax: Phone: VENMAR Unit Identification Information Project Job Name Job Address Model Number Serial Number Tag Jobsite Contact Telephone Table C1: Pre Start-up Checklist Checklist Item Check N/A 1 Check the electrical disconnect is locked out in the Off position. Check fan array fan cubes for damage and operation. a. On discharge side, visually check for damage to fans, motors, cubes, etc. b. On inlet side, visually check for damage to inlet straightening grids, frames and cubes. 2 c. Rotate fan wheels by hand and check to ensure they are properly aligned with inlet cones. d. While fan wheels are rotating, check motor bearings are operating freely and free of noise. e. Check that the shaft grounding kits are installed properly. f. Check backdraft dampers for smooth operation if supplied. Open dampers by hand to ensure full range of motion without constriction. 3 Check the AHU that all air openings and penetrations have been sealed and interior is clean and free of debris. 4 Check that all shipped loose or field supplied components have been correctly installed and wired. 5 Check that all power supplies and control wiring added have been inspected and approved by the Local Authorities having jurisdiction. 6 Check all factory and field wiring connections for tightness. Tighten if necessary. 7 Check that all fuses are properly installed in holders. 8 Check circuit breaker disconnect mechanism and/or mechanical interlock operate properly. 9 Check VFD sizes and ratings for voltage and horsepower. 10 Check and set motor start protectors (MSPs) for correct size and setting. 11 Check that all safety switches, overloads or other manual reset devices are reset. 12 Check all system components are adjusted to proper settings (temperature, amperage). Check the voltage at the disconnect switch against the nameplate and against phase-to-phase 13 readings on three-phase. If the voltage is not within 10% of rated or 2% of phase-to-phase, have the condition corrected before continuing start-up. VCES-FWT-IOM-1A 18

19 Serial Number: Table C2: Start-up Checklist Checklist Item Check N/A 1 Before proceeding, complete the pre start-up checklist. 2 Check that all access panels or doors are closed. 3 Energize incoming power circuit. 4 Check internal power supplies for proper voltage output(s) and adjust as required. 5 Test and verify proper operation of all GFCI devices. 6 Check operation of cabinet cooling fans, adjust thermostats as specified on drawing. Energize each MSP one at a time to start each motor slowly to ensure each fan rotation is correct. If the fan wheel is not rotating correctly, check the motor leads for proper installation. 7 a. Drive Side Clockwise rotation when looking at motor end. b. Inlet Side Counter-clockwise rotation looking at fan inlet. Perform start-up on VFD as specified by VFD Manufacturer. Adjust the fan motor VFDs to the correct air volume/hertz. 8 9 Check that the cfm monitoring system is functioning (if supplied). 10 Check amperage draw to each motor on each phase against motor nameplate FLA. Re-check the voltage at the disconnect switch against the nameplate and against phase-to-phase 11 readings on three-phase with all blowers operating. If the voltage is not within 10% of rated or 2% of phase-to-phase, have the condition corrected before continuing start-up. When unit has achieved steady state, take measurements and complete Start-up Readings portion 12 of the Start-up Report and Checklist. Send a copy of the completed Start-up Report and Checklist to Venmar CES to validate warranty. Maintain a copy of the report at the unit for future reference. Start-up Readings Allow unit to reach steady state before taking readings. Complete based on options included with unit Nameplate voltage Input voltage L1 L2 L2 L3 L1 L3 Table C3: Start-up Readings FWT Fan Array Amp Rotation Nameplate Draw Correct Amps L1/L2/L3 Fan 1 Fan 2 Fan 3 Fan 4 Fan 5 Fan 6 Fan 7 Fan 8 Fan 9 Fan 10 Fan 11 Fan 12 Full Load Amps O/L Amp Setting RPM Min. Hertz O/L Set at Min. Hertz Max. Hertz O/L Set at Min. Hertz VCES-FWT-IOM-1A 19

20 Serial Number: This unit has been checked out and started according with the above procedures and completed forms and is operating satisfactorily. After 24 hours of satisfactory operation shut down the unit and check all foundation bolts, shaft bearings, drive set screws, valve train and terminals. Tighten where required. Additional Comments: Start-up By Company Name Date Telephone to tech support: or Fax to: VCES-FWT-IOM-1A 20

21 Venmar CES Inc. has a policy of continuous improvement and reserves the right to change design and specifications without notice. FANWALL TECHNOLOGY and FANWALL are trademarks of Huntair, Inc. Products in this literature are covered by one or more of the patents listed on Venmar CES Inc. VCES-FWT-IOM-1A February 2014