4Front Engineered Solutions HVLS Series, User Manual

Page 1: ...product unless you have read and understand the Safety Practices Warnings and Installation and Operating Instructions contained in this User s Manual Failure to do so could result in death or serious injury This manual applies to fans manufactured beginning May 2014 with serial numbers F61111180 and higher HVLS Fans ...

Page 2: ...Obey all safety messages that follow this symbol to avoid possible death or injury safety signal words Introduction 2 Safety Signal Words 2 Safety Practices 3 Owner s Responsibilities 4 Hardware 5 Fan Kit 6 Installation Considerations 7 Installation 9 Components and Specifications 16 table of contents Operating Instructions 17 Planned Maintenance 21 Troubleshooting Guide 22 VFD Fault Codes 24 Fire...

Page 3: ...of all moving parts Install guards as required Do not install the fan unit onto structure of insufficient strength Consult a professional engineer or registered architect Improper installation of the fan could result in death or serious injury MAINTENANCE AND SERVICE Before service inspection or cleaning make certain that the power is disconnected and properly locked out If the fan does not operat...

Page 4: ...d be replaced Manufacturer s recommended periodic maintenance and inspection procedures in effect at date of shipment shall be followed and written records of the performance of these procedures should be kept Industrial fans that are structurally damaged or have experienced impacts from external sources shall be removed from service inspected by the manufacturer s authorized representative and re...

Page 5: ...ter Fan diameter Voltage Voltage Fastener torque requirements Description Torque Wrench size 1 2 dia mount hardware 44 48 ft lbs 3 4 hex 3 8 dia blade mount hardware 24 28 ft lbs 9 16 hex 3 8 dia safety bracket hardware 24 28 ft lbs 9 16 hex 1 3 4 dia hub retaining nut 125 ft lbs 1 3 4 hex 1 2 dia hub cover fastener 44 48 ft lbs 3 4 hex Cable clamp guy wire Secure tight 1 4 nut driver Cable clamp ...

Page 6: ...ength matches fan model size See Fig 1 Consult fan model designation located on the side of the fan powerhead frame 3 Ensureallmountinghardwareshownonpage5ispresent FOR OPTIONAL iFAN NETWORK FANS ONLY Ensure fan number matches network layout Consult the round network ID number label on shipping box FAN KIT National Fire ProtectionAssociation Standard In accordance with NFPA 13 Standard from the Na...

Page 7: ...r Consult your local distributor for assistance with fan placement and extension selection Roof slope rise run rise run Angled roof beam Exclusion zone Extension optional Pendant light Length ft 12 std with fan Blade length 24 r a d i u s Fig 1 300 300 300 300 300 300 300 300 300 Roof Slope 2 12 4 12 Roof Angle 9 5 18 4 Fan Diameter Ft Recommended Extension Length Ft Exclusion Zone Radius In 8 6 N...

Page 8: ...SPACING Consult your local distributor to help you plan the most efficient installation of your fans Ensure fan placement is such that the fans blades are a minimum of 10 from any manned working suface floor or mezzanine Ensure fan blade does not extend into exclusion zone Extensions are available if required See Fig 1 Avoid mounting fans directly under lights or skylights to avoid visual strobing...

Page 9: ...tboard Leave the 1 2 dia x 4 1 2 bolts and nylock nuts finger tight See Fig 2 INSTALL fan mount STANDARD I BEAM 1 Locate fan mount assembly on bottom of building support beam Align mount assembly so that it is centered and square to the beam Orient mount such that the pivoting axis is aligned with the building slope if required See Fig 3 2 Install clamps For thick flange I beams add shims as requi...

Page 10: ...f the frame assembly Do not support using the hub or hub cap NOTE Fan powerhead may be oriented as required for aesthetics or commonality 2 Raise the powerhead up until it contacts the bottom of the fan mount assembly See Fig 6 3 Immediately attach safety cable See Fig 8 a Slide two of the supplied 1 4 dia cable clamps over each end of the cable spaced 6 apart b Slide the ends through the cable cl...

Page 11: ...he quick link with attached turnbuckle to the fan as shown Repeat for all four quick links 3 Attach one end of the guy wire to the building structure Ensure the structure has sufficient strength to withstand the wire tension Repeat for all four guy wires a Slide two of the supplied 1 8 dia cable clamps over one end of the wire b Feedthatendofthewirethoughthebuildingstructure and back through the c...

Page 12: ...eader tool to facilitate installation onto the upper studs as shown Angle the blade upward as needed to slide blade onto studs See Fig 11 3 Still supporting the blade assembly rotate the blade assembly down as shown and allow the bottom blade strut to ride up and over the bottom attachment studs on the hub assembly See Fig 12 Do not lean on blade Damage to strut may occur 4 Install blade retention...

Page 13: ...ut on each and secure it with the turnbuckle strap See Fig 16 ELECTRICAL INSTALLATION Before doing any electrical work make certain the power isdisconnectedandproperlylockedortaggedoff Failure to do so may result in death or serious injury All electrical troubleshooting and repair must be done by a qualified technician and meet all applicable codes Do not route control wiring for any other device ...

Page 14: ...ting See Fig 17 4 Route supply power from the building source to the VFD box 5 Wire VFD box in accordance with electrical schematics located on pages 26 30 6 Attach remote signal blue and diagnostic gray CAT5e cables INSTALL REMOTE CONTROL 1 Mount touch screen remote to factory supplied junction box inside building 60 above the floor as close to the fan assembly as practical Direct line of sight i...

Page 15: ...of the fan and press the SET button Ensure selected size matches the size specified on the label on the front of the VFD box If it matches select the YES button on the following confirmation screen if it differs select the NO button and try again See Fig 18 Operate the industrial fan following the operating instructions beginning on page 17 Check for proper rotation direction stability and noise l...

Page 16: ...PH 208 240VAC1PH 208 480VAC 3PH line reactor where required Class CC fuses UL and UL C listed panel and components Power disconnect motor NEMA standard T E F C 1 2 HP continuous duty single or three phase Gearbox Double helical gear reduced sealed lubrication VFD box VFD unit Blade Winglet Motor cover Powerhead Safety cable Clamp Universal mount Guy wires Fig 19 ...

Page 17: ... Inc May 2014 6015653B HVLS Fans 17 operating instructions Fig 20 Start Stop RPM increase Reverse Communication status Green Comm Black No Comm Forward Diagnostic screen RPM decrease 24 Software version Fan diameter fan control screen ...

Page 18: ...you must log in before operating the fan NOTE Default password 1111 NORMAL OPERATION 1 Verifynormalcommunication thecommunicationstatus symbol in bottom lefthand corner will be green 2 Set desired speed by pressing either RPM increase or RPMdecreaseuntildesiredspeedisdisplayed Maximum speed is 10 minimum speed is 1 See Fig 21 3 SelectfandirectionbyselectingeitherForwardorReverse CHANGING DIRECTION...

Page 19: ...er andgivesadescriptionofeachfaultcode Ifthefaniscurrently under fault the error code being displayed in the box under the green arrow will be displaying a number that caused the fault Match the number with the error codes and remove the faultcondition Oncetheconditionhasbeenremoved pressing the reset button will reset the fan and allow operation again Note that the error code will still be displa...

Page 20: ... it now If not the default password 1111 On the password screen the options are to enable the password disable the password and change the password By default the password is not enabled Toenablepassword ensurethePasswordOnboxischecked To disable password ensure the Password On box is un checked Updating password 1 Enter the desired password using the numeric keypad 2 Press the Update Password but...

Page 21: ...control panel for loose connections Tighten as required 2 Using dry air shop air blow out debris from fan motor cooling fan as required 3 Inspect motor gearbox for oil leaks If present consult distributor 4 Inspectmountinghardwareandtightenasrequired Torque to 44 48 ft lbs 5 Inspect safety and guy wires for chaffing or wear Ensure turnbuckle nut is secure Replace as required 6 Inspect guy wires fo...

Page 22: ...1 Fan does not operate a No power to control panel b Primary fuse s blown a Ensure that the disconnect is in the on position Check for primary power at terminals b Replace fuse s 2 Fan does not operate Control panel has power 3 Fan operating but turning in wrong direction 4 Fan operating but generating high pitched whine 6 Fan generating a ticking noise tick increases with speed 5 Fan operating bu...

Page 23: ...e to PARAMETER mode 2 The display should be reading P 888 If it is not turn the rotary dial until the display reads P 888 3 Press the SET key The display is now the first 3 digits of the serial number 4 Press the SET key again and the display will show P 889 If it is not turn the rotary dial until the display reads P 889 5 Press the SET key The display is now the last 4 digits of the serial number...

Page 24: ...ration or stop E OV1 Regenerative overvoltage trip during acceleration E OV2 Regenerative overvoltage trip during constant speed E OV3 Regenerative overvoltage trip during deceleration or stop E THT Inverter overload trip electronic thermal O L relay function E THM Motor overload trip electronic thermal O L relay function E FIN Heatsink overheat to E ILF Input phase loss E OLT Stall prevention sto...

Page 25: ...snotenabled when shipped To enable the fire control system fan shutdownoption removethejumperbetweenenable EN and 24 and replace with a set of dry normally closed contacts See schematics for optional Fire Control Panels on pages 26 and 27 3 To test the fire control system fan shutdown operation remove the wire from the NC contact at the building fire control panel The fan should coast to a stop Se...

Page 26: ...gedoff Failure to do so may result in death or serious injury All electrical troubleshooting and repair must be done by a qualified technician and meet all applicable codes Do not route control wiring for any other device through this control box Ensure that the voltage and phase of the incoming power agrees with the label located on top of the VFD box and fan Be certain power is off when wiring t...

Page 27: ... 2014 4Front Engineered Solutions Inc May 2014 6015653B HVLS Fans 27 Fire control system fan shutdown optional continued Fig 30 Fire control system fan shutdown panel network installation 6011644 ...

Page 28: ... the voltage and phase of the incoming power agrees with the label located on top of the VFD box and fan Be certain power is off when wiring to the control box Failure to do so could result in electrical shock death or serious injury electrical schematics continued 6014870 6014871 6014872 VOLTAGE 120 1PH 50 60HZ 230 1PH 50 60HZ 230 1PH 50 60HZ FLA 10 2A 8A 14 3 FUSE KTKR15 KTKR12 KTKR20 MOTOR 1HP ...

Page 29: ...A 6A 2 5A 4 5A 2 1A 3 6A FUSE KTKR5 KTKR10 KTKR3 KTKR5 KTKR3 KTKR5 MOTOR 1HP 2 6FLA 2HP 5 1FLA 1HP 1 6FLA 2HP 3 0FLA 1HP 1 6FLA 2HP 3 0FLA 265V 60HZ 265V 60HZ 460V 60HZ 460V 60HZ 460V 60HZ 460V 60HZ LINE REACTOR 6010719 6010720 6010722 6010718 6010722 6010718 VFD 200 230 3PH 200 230 3PH 360 480 3PH 360 480 3PH 575 3PH 575 3PH 1HP 75KW 4 2A 2HP 1 5KW 7 0A 1HP 75KW 2 2A 2HP 1 5KW 3 6A 1HP 75KW 2 2A ...

Page 30: ... 2014 4Front Engineered Solutions Inc 30 6015653B HVLS Fans May 2014 electrical schematics continued Fig 33 variable frequency drive i o ...

Page 31: ...l operation of the product must be used Incorporation of replacement parts or modifications that weaken the structural integrity of the product or in any way alter the product from its normal working condition at the time of purchase from 4Front Engineered Solutions could result in product malfunction breakdown premature wear death or serious injury Fig 34 30 26 28 29 33 16 15 17 3 4 7 13 14 12 8 ...

Page 32: ... 2014 4Front Engineered Solutions Inc 32 6015653B HVLS Fans May 2014 Fig 35 parts list fan continued 32 31 18 2 25 23 24 19 20 1 22 21 ...

Page 33: ... MNT 84 6015871 HVLS EXT MNT 96 6015872 HVLS EXT MNT 108 6015873 HVLS EXT MNT 120 6015874 HVLS EXT MNT 132 6015875 HVLS EXT MNT 144 6015876 6 4 1 2 13UNC X 1 1 4 LG SER FLG 6015851 7 4 1 2 13UNC X 2 1 2 LG SER FLG 6015852 8 8 NUT HEX FLG SER 1 2 13UNC 6015853 9 2 LN 1 2 NYLON INSERT LOCKNUT 214505 10 4 PW 1 2 ID SAE 234260 11 2 HHB 1 2 13UNC X 4 1 2 LG GRD5 6013220 12 2 PIVOT HANGER BRACKET MOUNT ...

Page 34: ...SILVER 6015024 BLADE ASSY 14FT Q 5X M3 SILVER 6015025 BLADE ASSY 16FT Q 5X M3 SILVER 6015026 BLADE ASSY 18FT Q 5X M3 SILVER 6015027 BLADE ASSY 20FT Q 5X M3 SILVER 6015028 BLADE ASSY 22FT Q 5X M3 SILVER 6015847 BLADE ASSY 24FT Q 5X M3 SILVER 6015029 BLADE ASSY 6FT Q 5X M3 BLACK 6015821 BLADE ASSY 8FT Q 5X M3 BLACK 6015822 BLADE ASSY 10FT Q 5X M3 BLACK 6015823 BLADE ASSY 12FT Q 5X M3 BLACK 6015824 B...

Page 35: ... 2014 4Front Engineered Solutions Inc May 2014 6015653B HVLS Fans 35 parts list VFD box 4 1 3 2 7 8 5 6 Fig 36 ...

Page 36: ...antity Part Description Part Number 1 1 INTERFACE HLVS DIN RAIL MOUNT PCB 6015547 2 3 1 MISTUBISHI VFD 230V 1PH 1HP 6014903 4 2 FUSE 12A 600V KTK R 12 6011799 5 1 ROTARY DISCONNECT 6015597 6 1 DISCONNECT SHAFT 150MM 6015599 7 1 DISCONNECT HANDLE 6015598 8 1 VFD CONTROL BOX ASSY 6014871 6014871 230V 1PH 1HP Item Quantity Part Description Part Number 1 1 INTERFACE HLVS DIN RAIL MOUNT PCB 6015547 2 3...

Page 37: ...ACE HLVS DIN RAIL MOUNT PCB 6015547 2 1 LINE REACTOR 600V 7 6A 6010720 3 1 MISTUBISHI VFD 230V 3PH 2HP 6014907 4 3 FUSE 10A 600V KTK R 10 6014015 5 1 ROTARY DISCONNECT 6015597 6 1 DISCONNECT SHAFT 150MM 6015599 7 1 DISCONNECT HANDLE 6015598 8 1 VFD CONTROL BOX ASSY 6014872 6014874 230V 3PH 2HP parts list VFD box continued Item Quantity Part Description Part Number 1 1 INTERFACE HLVS DIN RAIL MOUNT...

Page 38: ...FACE HLVS DIN RAIL MOUNT PCB 6015547 2 1 LINE REACTOR 600V 2 1A 6010722 3 1 MISTUBISHI VFD 575V 3PH 1HP 6014910 4 3 FUSE 3A 600V KTK R 3 6011795 5 1 ROTARY DISCONNECT 6015597 6 1 DISCONNECT SHAFT 150MM 6015599 7 1 DISCONNECT HANDLE 6015598 8 1 VFD CONTROL BOX ASSY 6014872 6014877 575V 3PH 1HP Item Quantity Part Description Part Number 1 1 INTERFACE HLVS DIN RAIL MOUNT PCB 6015547 2 1 LINE REACTOR ...

Page 39: ...ntrol panel continued Item Quantity Part Description Part Number 1 1 HVLS TOUCH SCREEN CONTROLLER KIT KELLEY 6015758 HVLS TOUCH SCREEN CONTROLLER KIT SERCO 6015759 2 1 J BOX PLASTIC IVORY 6015648 3 1 CABLE CAT5 100 W FERRULE blue 6015651 4 1 cable cat5 gray 6011643 WHT BRN GRN BRN WHT GRN 2 1 3 4 ...

Page 40: ... 2014 4Front Engineered Solutions Inc 40 6015653B HVLS Fans May 2014 NOTES ...

Page 41: ... 2014 4Front Engineered Solutions Inc May 2014 6015653B HVLS Fans 41 NOTES ...

Page 42: ... 2014 4Front Engineered Solutions Inc 42 6015653B HVLS Fans May 2014 NOTES ...

Page 43: ... of 12 years from either 1 60 days after the date of initial shipment by 4FRONT or 2 the date of installation of the HVLS FAN by the original purchaser provided that the owner maintains and operates the HVLS FAN in accordance with this User s Manual This Limited Warranty does not cover any failure caused by improper installation abuse improper operation negligence or failure to maintain and adjust...

Page 44: ...uestions about your fan to your local distributor Corporate Head Office 1612 Hutton Dr Suite 140 Carrollton TX 75006 Tel 972 466 0707 Fax 972 323 2661 Part No 6015653B 2014 4Front Engineered Solutions Inc WAVE ATEC 4Front Engineered Solutions ...