Operation and Maintenance Manual

MODEL FWT-Fanwall Technology® Retrofit
INSTALLATION / MAINTENANCE
GUIDE
FOR YOUR SAFETY
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.
TABLE OF CONTENTS
PAGE
GENERAL DESCRIPTION ...........................................................................................................
INSTALLATION CODES / PRECAUTIONS ................................................................................
INSTALLATION
ELECTRICAL CONNECTIONS ........................................................................................
FANWALL ASSEMBLY
FAN MOTOR CARTRIDGE ALIGNMENT .......................................................................
SECURING FAN MOTOR CARTRIDGE ..........................................................................
WIRING ............................................................................................................................
MAINTENANCE
FANWALL OPTION - FAN WHEEL/MOTOR REPLACEMENT ......................................
FANWALL OPTION - FAN CARTRIDGE REPLACEMENT ............................................
LONG TERM STORAGE (Over 1 Month) ..........................................................................
MONTHLY, YEARLY MAINTENANCE .............................................................................
TROUBLESHOOTING ..................................................................................................................
START-UP INSPECTION REPORT .............................................................................................
WARRANTY ..................................................................................................................................
© Copyright 2007, HUNTAIR, Inc.
ALL RIGHT RESERVED. NO PART OF THIS BOOK MAY BE REPRODUCED,
STORED IN A RETRIEVAL SYSTEM, OR TRANSMITTED IN ANY FORM BY AN
ELECTRONIC, MECHANICAL, PHOTOCOPYING, RECORDING MEANS OR
OTHERWISE WITHOUT THE WRITTEN PERMISSION OF HUNTAIR, INC.
COPYRIGHT 2007.
The manufacturer reserves the right to modify the materials and specifications resulting from a continuing program of
product improvement or the availability of new materials.
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GENERAL DESCRIPTION
GENERAL DESCRIPTION
Follow all safety codes. Wear safety glasses and work
gloves. Use quenching cloth for brazing operations. Have
fire extinguisher available. Read these instructions thoroughly.
Huntair Fanwall Technology® is a fan-array approach to air
handler design that that uses several smaller fans to replace
one larger fan, providing design flexibility, reducing maintenance costs, and increasing energy savings.
WARNING
Before installing or servicing system, always turn off
main power to system. There may be more than one
disconnect switch. Turn off accessory heater power if
applicable. Electrical shock can cause personal injury
or death.
Safety Considerations
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 in literature and on tags and labels attached to unit.
CAUTION: Before proceeding, make sure all electrical
service to unit is locked in “Off” position.
INSTALLATION CODES / PRECAUTIONS
INSTALLATION CODES
3. The following clearances from combustible materials are
to be maintained: Top - 6", control side - 48", opposite
controls - 6", bottom - 0". If roof curb is provided by
others, it must be at least 4" high and constructed from
non-combustible material.
Electrical characteristics are shown on the unit rating plate.
The unit shall be carefully installed in accordance with the
standards of the National Fire Protection Association (National Electrical Code). Authorities having jurisdiction should
be consulted before installations are made to verify local
codes and installation procedures.
4. This unit is designed for installation on a level surface.
This is especially true if provided with an evaporative
cooler.
5. Do not locate the supply inlet opening within 10' of any
exhaust discharge point or within 24" of any obstruction.
INSTALLATION PRECAUTIONS
1. The services of qualified field service personnel are
mandatory for safe and proper installation of this equipment.
2. Air volumes and external static pressures that do not
coincide with those listed on the rating plate will adversely affect the performance of the unit. Please
consult the factory if either of these values change.
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INSTALLATION
Electrical Connections
All electrical wiring and connections including electrical
grounding must be made in accordance with the latest
edition of the National Electric Code (or the edition your
authority having jurisdiction has adopted). There may also
be local ordinances that apply.
b. IMPORTANT: If any of the original wire supplied with the
unit must be replaced, it must be replaced with type
THHN 90°C wire or its equivalent, except for miscellaneous 120 volt control wiring that must be type SJO
90°C.
a. The FWT nameplate and the drawings in Appendix A
state the line voltage and minimum ampacity requirements for this unit. A separate line voltage power supply
should be run directly from the building distribution panel
to the electrical panel provided on the side of the FWT
unit. The quantity of wires and the connection terminals
are identified on the wiring diagram in Appendix A. All
external wiring must be within approved conduit and have
a minimum temperature rating of 90°C.
c. Refer to Appendix A for other control interface connections.
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FANWALL ASSEMBLY
Fanwall Assembly
DANGER! Risk of Electric Shock
FAN
CARTRIDGE
Always disconnect power to the fan control panel
before maintenance. Follow all lockout and tag
out procedures.
1. To assemble fanwall, first disconnect power to
BOLTING
FLANGES
the existing fan at the main control panel.
2. Make note of all wire locations for reinstallation later.
3. Disconnect existing fan motor power cable from terminal located in motor J-Box and conduit fitting f r o m
J-Box as shown in the demolition drawings.
4. Remove existing fan/motor assembly and clean the
area thoroughly.
MOUNTING BOLTS
5. Make sure that floor on airhandler is level and rigid.
6. Find the center line of the fan cabinet air inlet opening
and mark it on the air handler floor to help align the
first fan cartridge.
7. Align the first fan cartridge frame needed at the center
bottom for the fanwall (inlet side). See drawings for fan
array. Align the next fan cartridge needed on either side
of the first cartridge and bolt together using the bolting
flanges and supplied bolts, washers, and lock washers.
8. When the base fan cartridges are aligned properly and
bolted together, use tek screws and washers to secure
the bases to the floor. To further secure the bases to the
floor, mount the blank-offs for the floor with tek screws.
BOLTING FLANGES
9. Lift the next row of fan cartridges in to place and bolt
together at the bolting flanges, both side-to-side and topto-bottom. Follow the same procedure until the entire
fanwall is complete.
10. To secure the fanwall to the cabinet, secure blank off
panels to the fan cartridge frame and the air handler
cabinet using tek screws. Apply caulking to blank-off
panels and fan cartridges where needed.
INLET SIDE VIEW
BLANK-OFFS
BOLTING
FLANGES
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FANWALL ASSEMBLY
Fanwall Electrical Installation
DANGER! Risk of Electric Shock
Always disconnect power to the fan control panel
before maintenance. Follow all lockout and tag
out procedures.
Flexible Metal
Conduit from J-Box
to Motor J-Box
1. Verify fanwall is in place.
2. Layout conduit run from fan(s) to enclosure
or j-box. See installation design drawings.
Conduit run from
J-Box to Enclosure
J-Box
3. Attach FMC ( flexible metal conduit ) to motor j-box
( Pecker head ), one J-box per motor.
4. Size wire ( per NEC code ) and pull from motor(s) to
enclosure/j-box.
5. Wire internal motor connection.
A. Crimp on ring terminals.
B. Bolt terminals together for what ever voltage you are
using (see motor nameplate).
C. First layer wrap with Friction tape ( 3M Varnished
Cambric ).
D. Second layer with rubber splicing tape ( 3M 130C ).
E. Third layer use vinyl tape ( 3M Super33 ).
Note: 3 wraps on all taped layers.
6. Hi-pot wires.
7. Connect wires to Enclosure / j-box.
Flexible Metal Conduit
to motor J-Box
Ring Terminals
Flexible Metal
Conduit
ELECTRICAL NOTE
All grounds are pulled continuously thru
fanwall j-boxes without splicing to accomodate
for box fill calculations.
Standoffs
Enclosure J~Box
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MAINTENANCE
Fanwall Option Fan Wheel/Motor Replacement
This procedure assumes that the fan cell is installed.
1. To replace a fan wheel/motor assembly, first
disconnect power to the FWT at the main control panel.
DANGER! Risk of Electric Shock
Always disconnect power to the fan control panel
before maintenance. Follow all lockout and tag
out procedures.
DANGER! Risk of Injury
FAN CONTROL
PANEL
Rotating equipment. Always disconnect power to the
fan motor before maintenance.
2. Set the motor pedestal rail onto the structural angle
brackets that run front to back along the cell (see figure 1).
3. Line the four pedestal bolt holes up with the bolt holes
on the angle bracket.
a. Insert 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 (see figure 1).
3/8" MOTOR BOLTS
1/2" PEDESTAL
BOLTS
4. Set the motor on the pedestal (see figure 1). Use
proper lifting techniques, crane or motor/rail system if
possible for lifting the motor into position. Once the
motor is placed on the pedestal align the bolt holes on
the motor to the bolt holes on the pedestal making
sure that the motor shaft is pointing towards the fan
inlet wall.
a. Next, insert 3/8" bolts into the holes from the
underside, make sure to use a standard washer on
the bolt side, only a locknut is required on the motor
side (see figure 1).
b. Square the motor and tighten the bolts to 40 ft-lbs.
MOTOR PEDESTAL
MOTOR STRUCTURE
ANGLE BRACKETS
FIGURE 1
AIRFLOW STRAIGHTNER GRID
5. Locate the fan wheel and cone and associated hardware
and move to the inlet side of the fan wall (see figure 2).
a. Install trantorque bushing into hub on fan wheel.
Make sure that the nut pattern on the bushing is
facing towards the fan wheel blades.
b. Place the fan wheel onto the motor shaft through
the trantorque bushing. Slide the wheel onto the
shaft until the trantorque is fully engaged on the
motor shaft. Be careful not to push the fan wheel too
far onto the shaft as interference with the pedestal
may occur. Hand tighten the bushing for now (see
figure 2).
TRANTORQUE
BUSHING
CONE
FASTENER
INLET CONE
FORMED ANGLE
BRACKET
FIGURE 2
5
MAINTENANCE
Fanwall Option Fan Wheel/Motor Replacement
(CONTINUED)
8. Attach the inlet airflow straightener using the formed
angle brackets (see figure 2).
a.Start by loosely installing (don’t tighten screws all
the way) the bottom angle bracket. Set the
airflow grid on the angle bracket. Align the side of
the grid with the end of the bracket.
b.Install either vertical angle bracket loosely and
check fit up.
c.Install the two remaining brackets and tighten (see
figure 2).
6. Temporarily attach the cone to the cell inlet using the
screws and washers provided (see figure 2). Use a
minimum of four screws for this step.
a. Refer to the fan wheel overlap drawings provided to
determine where to set the wheel with respect to the
cone (see figures 4-7).
b. Adjust the amount of overlap by moving the motor
pedestal forward or backward to line up the cone with
the wheel (wheel/cone overlap is designed to insert
the cone 50% of the distance of the rolled shroud lip
on the wheel). Once you have the wheel approximately located tighten the ½” pedestal bolts to 90ftlbs.
c. Next make sure that the wheel is located properly
and tighten the trantorque bushing. Once the wheel
depth alignment is verified tighten the trantorque
bushing to 70ft-lbs. Please note that a bar or some
other device may need to be inserted into the blade
of the fan wheel to hold the wheel while applying the
torque. Please refer to Table 1 for shaft size and
associated socket size to be used to tighten the
trantorque.
9. Wire the motor per the electrical schematic provided.
Make sure to wire the motors to NEC standards.
10. Bump test the motors and check for proper rotation.
TYPICAL FAN~CONE
CLEARANCE
7. Center the cone in the wheel shroud. The attached
figures 4-7 show the proper wheel/cone alignment.
a. The cone alignment can be a tedious process as
there are no tools that effectively work to align the
cone. It is a hands on process to align the cone.
Huntair cones have a running clearance of about
1/16" (see figure 3).
b. Start by loosening the four screws that were used to
hold the cone for the depth alignment. Hold the cone
with one hand and with the other use a drill to attach
a screw to hold the cone in place. Feel between the
wheel inlet shroud and the cone and set the gap to
approximately 1/16" and tighten the screw in that
location (top of the cone is usually the best place to
start). At this point you should be able to move the
cone about that screw location, adjust the cone on
the left or right until there is approximately a 1/16"
gap.
c. Spin the wheel by hand at this point to check for any
clearance issues. If the wheel spins clear tighten
the remaining screws on the cone. Check that the
wheel spins clear after tightening each screw.
FIGURE 3
Frame
48
56
143T
145T
182T
184T
213T
215T
Shaft
0.625
0.625
0.875
0.875
1.125
1.125
1.375
1.375
TranTorque Socket
0.875
0.875
1.25
1.25
1.5
1.5
1.75
1.75
Table 1
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Figure 4
Figure 5
Figure 6
Figure 7
MAINTENANCE
Fanwall Option Fan Cartridge Replacement
DANGER! Risk of Electric Shock
Always disconnect power to the fan control panel
before maintenance. Follow all lockout and tag
out procedures.
TEK SCREWS
BLANK-OFFS
1. To replace fan cartridge, first disconnect
power to the FWT at the main control
panel.
DRIVE SIDE
2. Remove the safety screens and backdraft dampers
on discharge side (if equipped) and safety screens or
air straightener from inlet side (if equipped).
J -BOX
3. Make note of all wire locations for reinstallation
later.
4. Disconnect motor power cable from terminal
located in motor J-Box and conduit fitting from
J-Box as shown.
INLET SIDE VIEW
5. Remove all tek screws on both inlet and drive side
blank-off panels around the cartridge you are
removing.
6. Slide and lift the fan cartridge backwards to the
drive side by using the optional overhead motor
removal rail system, if equipped or with a
mechanical lift to remove cartridge.
BLANK-OFFS
7. To reinstall fan cartridge, follow the steps above in
reverse. Reapply caulking to blank-off panels and
fan cartridges were required.
BOLTING
FLANGES
REMOVE BOLTS
FAN
CARTRIDGE
BOLTING
FLANGES
BOLTING FLANGES
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MAINTENANCE
Long Term Storage (Over 1 Month)
3.
All fan and motor bearings equipped with greasee fittings
must be relubricated as soon as they arrive from the
factory. To prevent corrosion, all bearings should receive
grease and be rotated the first of every month. Turn the
wheel by hand while greasing the bearings. A clean 1/16"
bead of grease must appear on each side of each bearing.
Refer to specific bearing lubricating instructions on the fan.
CAUTION: Excessive amount of grease will overheat
the bearings.
Monthly
1.
Factory Service
Fan and motor bearings equipped with grease fittings
are to be lubricated. Bearings without fittings are
permanently sealed and do not require lubrication.
Huntair offers several levels of service to its customers.
- Service scheduling
- Recertification or preventative maintenance
scheduling
- Additional manual requests or updates
- Spare/replacement part ordering
For normal operation, use Shell Alvania No. 2, Moblith
SHC 100 (Mobile), Rykon Prem #2 (Rykon), Premium
RB2 (Texaco), or an equivalent grease. Caution should
be used in greasing bearings with a high pressure gun
which can blow bearing seals and overfill the bearing
with grease. This condition can result in excessive
churning and overheating. For normal operating conditions it is a standard practice to fill only 30% of the
bearing void with grease. Do not over-lubricate.
HUNTAIR Customer Service Manager:
Phone: 503-639-0113
Fax:
503-639-1269
Email: [email protected]
Address: 11555 SW Myslony Street
Tualatin, OR 97062
For temperatures below 0°F, it is suggested that a low
temperature lithium grease similar to Beacon #325
(humble oil) be used.
Every Six Months
1.
Check motor bearings for possible binding, noise or
overheating.
2.
Check supply fan and exhaust fan wheels for dirt and
grease accumulation. Clean as necessary. Do not use
caustic cleaning solutions.
Yearly
1.
Lightly lubricate damper bushings and associated
linkage.
2.
Lightly lubricate control valve linkage.
Every Two Years
1.
Examine unit housing for signs of corrosion. Clean,
replace or touch up with paint, as necessary.
Every Four Years
1.
Lubricate motor bearings, using CHEVRON BRB #2,
ALVANIA #2 (Shell Oil Co.), RYDEKN #2 (Standard Oil
Co.), or an equivalent grease.
2.
For ambient temperatures below 0°F use BEACON
#325 low temperature grease or equal
Lubricate while motor is warm and at standstill. Remove and clean plugs, insert grease fitting into upper
hole adding a small amount of clean grease with a low
pressure grease gun. Run motor for five (5) minutes
before replacing plugs.
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TROUBLESHOOTING
SYMPTOM
FAN WILL NOT
START OR RUN AT
ALL
POSSIBLE CAUSE
1.
No main power.
FIELD TEST
1.
1A.
1B.
Check contact with ohm meter.
2.
Replace switch if faulty.
3.
No control transformer
output.
3.
Check primary and secondary fuses on
transformer.
3.
Correct problem and replace fuse(s) with
size indicated on electrical diagram.
Tripped overloads on
motor starters.
1.
Improper supply
voltage.
2.
Motor overloaded.
Motor overheating.
4.
1.
1A.
Check voltage at motor.
Check for proper wiring at motor.
1.
1A.
2.
2A.
2B.
2C.
Check for excessive cfm and/or static
pressure.
2C.
3.
3A.
Verify correct supply cfm.
Check for temperatures above 110°F.
3.
3A.
FIELD TEST
3.
Repair any leaks.
4.
5.
6.
Replace fan wheel if necessary.
Correct rotation if backwards.
Clear inlet.
Check alignment.
1.
Align if necessary.
Check roof curb or mounting platform for
stability.
Inspect fan wheel.
Check bolts and setscrews for tightness.
2.
Correct roof curb or platform installation
deficiency.
Clean fan wheel.
Replace or tighten as necessary.
Refer to airflow verification in start-up
procedure section.
Inspect dampers.
Verify all shipping blocks and braces are
removed.
5.
Misalignment of
wheel.
Unstable foundation.
1.
2.
Dirty fan wheel.
Broken or loose bolts
or setscrews.
Fan delivering more
than rated capacity.
Loose dampers.
Shipping bolts and/or
braces not removed.
3.
4.
Damaged fan wheel.
Incorrect fan rotation.
Obstructed inlet.
1.
5.
6.
7.
If incorrect, correct to proper value.
Wire motor per diagram on motor or inside
motor junction box.
If amperage outside of motor nameplate
limits, conduct additional field tests that
follow.
Correct rotation, if necessary.
Replace motor or motor bearings if
necessary.
Correct cause of high static pressure and
adjust airflow per start-up section
instructions
Adjust cfm to unit data plate value.
Consult factory for motor heat shield.
Correct static pressure. If not possible,
consult factory.
Correct damper position.
4.
5.
6.
4.
5.
6.
Adjust overload trip setting (not to exceed
motor fla x 1.15 for ODP motors and not to
exceed motor fla for TEFC motors).
If current values are above nameplate fla, go
to Motor Failure.
2.
1.
2.
Replace transformer if faulty.
REMEDY
Check actual pressure against unit data plate
pressure.
Verify proper position of unit air control
dampers (if any) and all external
dampers/diffusers.
Check ductwork and duct connections for
leaks.
Visually inspect wheel.
Check wheel rotation with arrow on fan.
Inspect inlet.
3.
6.
7.
2.
Check rotation of fan.
Check motor shaft for freedom of movement.
Air leaks in system.
5.
Check amperage at motor.
2A.
2B.
3.
3.
4.
4.
4A.
1.
2.
Verify overload trip setting is at or slightly
above the motor nameplate fla.
3A.
Reset overloads and measure operating
current of motors.
High external static
pressure.
Dampers improperly
positioned.
1.
Check control transformer primary and
secondary voltages.
4A.
POSSIBLE CAUSE
2.
VIBRATION AND
NOISE
Correct problem and replace fuses with size
indicated on electrical diagram.
Turn to "On" position.
Restore power to unit.
2.
3.
FAN CAPACITY
LOW
1.
1A.
1B.
Faulty control circuit
auxiliary contact on
unit disconnect switch.
4.
SYMPTOM
Check disconnect switch.
Use volt meter to check for proper main
voltage to unit.
2.
3A.
MOTOR FAILURE
Check main power fuses with ohm meter.
REMEDY
9
3.
4.
6.
7.
Adjust drives per instructions in start-up
procedure section.
Tighten dampers if loose.
Remove shipping attachments.
FWT START-UP REPORT
VFD UNIT MODELS
Huntair recommends that the following FWT START~UP REPORT be performed on each unit and the results filed with the
appropriate facility engineering office.
Unit Nameplate Data:
Model No.
Serial No.
Supply CFM:
Exhaust/Return CFM:
Supply HP:
Exhaust/Return HP:
Mechanical System Checks
1 Visually inspect fanwall for damage.
a. On Discharge side look for damage to Fans, Motors, Cells, etc.
b. On Inlet side look for damage to inlet straigtening grid and frame as well as cells.
2 Fan Wheel / Motor
a. Rotate fan wheel by hand to ensure it is properly aligned with inlet cone.
b. Check motor bearings as fan wheel is rotating. Bearings should operate freely and be free of noise.
c. Check that shaft ground kit is installed correctly.
d. Check backdraft damper for smooth operation if supplied. Open damper by hand to ensure a full
range of motion without obstruction.
3 HVAC System
a. Check that all ducts, dampers and registers are set.
b. Check that all openings and pentrations are sealed.
Electrical System Checks
1 De-Energized
a. Check for any loose connections
b. Check circuit breaker disconnect mechanisms / Mechanical interlocks operate properly
c. Check VFD size and rating (voltage and horsepower)
d. Check and set motor start protectors (MSP) for correct size and setting.
e. Ensure all system components are adjusted to proper settings (temperature, amperage)
2 Energized
a. Connect proper input voltage power to line side of panel
b. Energize incoming power circuit.
c. Check for proper line voltage.
d. Check voltage between all neutral terminations and panel ground (should be zero volts)
e. Check internal power supplies for proper voltage output(s) and adjust as required
f. Test and verify proper operations of all GFCI devices
g. Check operation of cabinet cooling fans, adjust thermostat as specified on drawing
h. Check and record all voltage readings
i. Energize MSP one at a time to ensure correct motor rotation.
j. Ensure that CFM monitoring system is functioning (if applicable).
Comments
10
WARRANTY
The materials and methods of construction
for the equipment provided by HUNTAIR are
of the highest quality and will comply
to the project specifications, with the
exception of items identified in HUNTAIR'S
quote for the project.
Component parts such as electrical
motors, and controls or accessories not
manufactured by HUNTAIR shall be
warranted under the terms and conditions
of the warranty by the manufacturer of said
component parts.
HUNTAIR warrants its products to be free of
defects in materials and workmanship
under normal use, when installed and
operated in accordance with factory
recommendations, for a period of 18 months
from shipment or 12 months after
initial equipment start-up, whichever occurs
first. Equipment found to be defective will
be replaced, or repaired as determined by
HUNTAIR.
All repairs and replacement parts furnished
under this warranty shall be provided F.O.B.
Huntair, Inc. The party making the warranty
claim shall be responsible for all necessary
freight charges, labor costs for removal and
installation of parts or components, and
all federal, state, or local taxes, unless
specifically stated otherwise and agreed to
in writing by Huntair Inc.
Items Not Covered By This Warranty
Work or repairs made without HUNTAIR'S
authorization or those items that require
periodic replacement due to wear, such as
fan belts, prefilters, electrical fuses, lamps,
and fan bearings.
Equipment that is not routinely serviced in
accordance with HUNTAIR'S recommended
maintenance guide as outlined in the O&M
Guide.
Factory Customer Service
HUNTAIR offers several levels of service to its customers.
- Service scheduling
- Recertification or preventative maintenance scheduling
- Additional manual requests or updates
- Spare/replacement part ordering
Please Direct Service Needs To:
HUNTAIR Customer Service Manager:
Phone: (503) 639-0113
Fax:
(503) 639-1269
Email:
[email protected]
Address: 11555 SW Myslony St.
Tualatin, OR. 97062
11
Fanwall Technology® Retrofit Guide
HUNTAIR, INC.
11555 SW Myslony Street • Tualatin, Oregon 97062 U.S.A.
Phone: 503-639-0113 • Fax: 503-639-1269 • www.huntair.com
HUNTAIR® is a registered trademark of HUNTAIR, Inc.®
FANWALL TECHNOLOGY ®and FANWALL® are registered trademarks of Huntair, Inc.
Huntair is a CES GroupTM Company
US Patents 7,137,775 B2 and 7,179,062 B2 Issued and others pending
FORM NO. FWT Retrofit Guide 0907
© COPYRIGHT 2007, HUNTAIR, INC.