FANWALL TECHNOLOGY® Field Installed Retrofit Fan
Cubes/Array
Aston-built Products
Installation, Operation and Maintenance Instructions Manual
©2012 Venmar CES Inc.
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. 2012. 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 www.ces-group.com.
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
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
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.
WARNING
Disconnect the main power switch to the unit before performing service or maintenance. Electric shock can cause
personal injury or death.
General Information
The Venmar CES Model FWT – Fan Cubes/Array is a FANWALL 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.
•
•
•
•
•
•
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.
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):
VCES-FWT-IOM-1A
3
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.
If roofcurb is provided by others, it must be at least 4”
high and constructed from non-combustible material.
Authorities having jurisdiction should be consulted before
installations are made to verify local codes, installation
procedures and installation clearances.
The fan array is designed for installation on a level surface.
The following clearances from combustible materials are
to be maintained:
•
•
•
•
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.
Top: 6”
Control side: 48”
Opposite controls: 6”
Bottom: 0”
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.
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.
The FWT nameplate and the drawings state the line voltage and minimum ampacity requirements for this fan
array.
VCES-FWT-IOM-1A
4
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).
Figure 1: Disconnect motor power cable
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 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
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
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6
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.
2.
3.
4.
Before proceeding, complete the pre start-up checklist.
Check that all access panels or doors are closed.
Energize incoming power circuit.
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
VCES-FWT-IOM-1A
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.
7
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.
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.
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 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.
VCES-FWT-IOM-1A
Figure 11: Remove motor pedestal retaining bolts
8
!
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.
VCES-FWT-IOM-1A
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.
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.
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.
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.
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
VCES-FWT-IOM-1A
Figure 17: Fan wheel/cone alignment – Step 3
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.
7. Gently rotate the fan wheel to verify cone adjustment for proper clearance from wheel.
4. Gently rotate the fan wheel to verify location of adjustment required.
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
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)
Figure 20: Fan wheel/cone alignment – Step 6
VCES-FWT-IOM-1A
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 as11
!
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.
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.
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 (www.baldor.com) 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.
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.
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
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12
Troubleshooting
Table 1: Troubleshooting Guide – FWT
Problem
Possible Cause
Solution
No main power.
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.
FANWALL® will not
start or run at all.
Faulty control circuit auxilliary contact on unit dis- Check contact with ohm meter.
connect switch.
Replace switch if faulty.
No control transformer output.
Tripped overloads on motor starters.
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.
Motor will not start.
Usually caused by line trouble, such as single
phasing at the starter.
Check source of power. Check overloads, fuses, controls, etc.
Check voltage at motor.
Improper supply voltage.
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.
Motor overheating.
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.
Motor failure.
Motor overloaded.
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.
Overload – compare actual amps (measured) with Locate and remove source of excessive friction on motor or load.
nameplate rating.
Reduce load or replace with motor of greater capacity.
Check current at all phases (should be approximately equal) to
Single phasing.
isolate and correct the problem.
Check external cooling fan to be sure air is moving properly
across cooling fins.
Improper ventilation.
Excessive dirt build-up on motor. Clean motor.
Check voltage at all phases (should be approximately equal) to
Unbalanced voltage.
isolate and correct the problem.
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13
Table 1: Troubleshooting Guide – FWT
Problem
Possible Cause
Rotor rubbing on stator.
Motor failure
continued
Check air gap clearance and bearings.
Tighten ‘through bolts’.
Over voltage or under voltage.
Check input voltage at each phase to motor.
Open stator winding.
Check stator resistance at all three phases for balance.
Grounded winding.
Perform dielectric test and repair as required.
Inspect all electrical connections for proper termination, clearance, mechanical strength and electronic continuity.
Refer to motor lead connection diagram.
Improper connections.
Excessive humming.
Solution
High voltage.
Check input line connections.
Eccentric air gap.
Have motor serviced at local Baldor Service Center.
High external static pressure.
Dampers improperly positioned.
Air leaks in system.
Fan capacity low.
Damaged fan wheel.
Incorrect fan rotation.
Obstructed inlet.
Misalignment.
Misalignment of wheel.
Dirty fan wheel.
Broken or loose bolts or set screws.
Fan delivering more than rated capacity.
Loose dampers.
Vibration and noise.
Shipping bolts and/or braces not removed.
Rubbing between rotating parts and stationary
parts.
Rotor out of balance.
Resonance.
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
external dampers/diffusers.
Correct damper position.
Check ductwork and duct connections for leaks.
Repair any leaks.
Visually inspect wheel.
Replace fan wheel if necessary.
Check wheel rotation with arrow on fan.
Correct rotation if backwards.
Inspect inlet.
Clear inlet.
Check and align motor and drive equipment.
Check alignment.
Align if necessary.
Inspect fan wheel.
Clean fan wheel.
Check bolts and set screws for tightness.
Replace or tighten as necessary.
Refer to airflow verification in Start-up Procedure section.
Adjust drives per instructions in Start-up Procedure section.
Inspect dampers.
Tighten dampers if loose.
Verify all shipping blocks and braces are removed.
Remove shipping attachments.
Isolate and eliminate cause of rubbing.
See Fan Wheel/Cone Alignment for adjustment.
Have rotor balance checked or repaired at your Baldor Service
Center.
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
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
VCES-FWT-IOM-1A
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.
15
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.
VCES-FWT-IOM-1A
7. Coat all external machined surfaces with a rust preventing material. An acceptable product for this purpose is Exxon Rust Ban # 392.
8. 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.
16
Appendix B: FANWALL® Inlet Cone Alignment
Table A1: FANWALL Wheel/Cone Alignment Dimensions
Wheel Size
Backplate OD
Blade Width
Backplate Extension
Wheel/Cone Overlap
10
10.375
3.495
0.700
0.250
12
12.500
4.280
0.700
0.250
14
13.750
4.720
0.700
0.250
16
16.750
5.760
0.700
0.250
20
20.451
6.990
0.700
0.400
22
22.701
7.780
0.700
0.400
Blade width
(100% wide)
Backplate
extension
Wheel/cone
overlap
Backplate OD
Figure A3: FANWALL inlet cone alignment
VCES-FWT-IOM-1A
17
Appendix C: FANWALL TECHNOLOGY® Fan Array Start-up Report
and Checklist
IMPORTANT
•
Complete all forms under this appendix for each
unit and email, 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.
•
•
•
Unit Identification Information
Project_____________________________________________
Job Name__________________________________________
Job Address_ _______________________________________
__________________________________________________
__________________________________________________
__________________________________________________
Model Number______________________________________
Serial Number ______________________________________
Tag_ ______________________________________________
Jobsite Contact_ ____________________________________
Email______________________________________________
Telephone__________________________________________
Venmar CES Inc.
200 Rue Carter
St. Léonard d’Aston, QC
Canada J0C 1M0
Email to tech support: [email protected]
Fax: 899-319-2612
Phone: 1-866-4-VENMAR
Table C1: Pre Start-up Checklist
Checklist Item
1
Check √
N/A
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.
6
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.
Check the AHU that all air openings and penetrations have been sealed and interior is clean and
free of debris.
Check that all shipped loose or field supplied components have been correctly installed and wired.
Check that all power supplies and control wiring added have been inspected and approved by the
Local Authorities having jurisdiction.
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.
3
4
5
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
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.
13
VCES-FWT-IOM-1A
18
Serial Number:______________________________________
Table C2: Start-up Checklist
Check √
Checklist Item
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.
a. Drive Side – Clockwise rotation when looking at motor end.
7
N/A
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.
Check that the cfm monitoring system is functioning (if supplied).
8
9
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
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
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.
11
12
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
Rotation
Correct
Nameplate
Amps
Amp
Draw
L1/L2/L3
Full Load
Amps
O/L Amp
Setting
RPM
Min. Hertz
O/L Set at
Min. Hertz
Max.
Hertz
O/L Set at
Min. Hertz
Fan 1
Fan 2
Fan 3
Fan 4
Fan 5
Fan 6
Fan 7
Fan 8
Fan 9
Fan 10
Fan 11
Fan 12
VCES-FWT-IOM-1A
19
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:_ ______________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
VCES-FWT-IOM-1A
Start-up
By_________________________________________________
Company Name_____________________________________
Date_______________________________________________
Email______________________________________________
Telephone__________________________________________
Email to tech support: [email protected]
or Fax to: 819-399-2612.
20
[email protected]
www.venmarces.com
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 www.ces-group.com/patents.
©2012 Venmar CES Inc.
VCES-FWT-IOM-1A
February 2014