Greenheck KSQ Series Rooftop Supply Mixed Flow Fans

Introduction

This manual provides instructions for the installation, operation, and maintenance of Greenheck KSQ Series Rooftop Supply Mixed Flow Fans. It is essential to read and save these instructions for future reference. Failure to comply with these instructions may void the product warranty and result in personal injury or property damage.

Product Description: Fans are direct-driven with mixed flow wheels, featuring rigid construction, high efficiency, and low sound levels. They are designed for filtered roof supply applications, such as providing non-tempered make-up air. Available in twelve sizes, these fans feature permanent, washable aluminum filters.

General Safety Information

Only qualified personnel familiar with these instructions and general safety precautions should install this fan. Improper installation can lead to electric shock, injury from moving parts, or other hazards. Consult a licensed professional engineer if more information is needed.

1. Follow all applicable local electrical and safety codes, including the National Electrical Code (NEC), National Fire Protection Agency (NFPA), and the Canadian Electric Code (CEC) in Canada.
2. Ensure the fan wheel rotates freely without striking stationary objects.
3. The motor must be securely and adequately grounded.
4. Do not operate the fan wheel faster than the maximum cataloged RPM to prevent catastrophic wheel failure. Adjustments to fan speed affect motor load; check motor current against the nameplate rating if RPM is changed.
5. Prevent power cables from kinking or contacting oil, grease, hot surfaces, or chemicals. Replace damaged cords immediately.
6. Verify the power source is compatible with the equipment.
7. Never open access doors to a duct or fan while it is running.
8. Never remove covers protecting electrical components while the fan is energized.

DANGER: Always disconnect, lock, and tag the power source before installing or servicing. Failure to do so can result in fire, shock, or serious injury.

CAUTION: The motor may be hot enough to cause pain or injury during servicing. Allow the motor to cool before proceeding.

French Safety Warning: Pour écarter les risques d'incendie, de choc électrique ou de blessure grave, veiller à toujours débrancher, verrouiller et étiqueter la source de courant avant l'installation ou l'entretien. Lors de toute intervention sur la soufflante, le moteur peut être suffisamment chaud pour provoquer une douleur voire une blessure. Laisser le moteur refroidir avant toute maintenance.

Receiving, Unpacking, and Handling

Receiving

Upon receipt, verify all items against the delivery receipt or packing list. Inspect crates/cartons for shipping damage before accepting delivery. Note any damage or shortages on the delivery receipt and contact your local representative immediately if damage is detected. Physical damage after acceptance is not the manufacturer's responsibility.

Unpacking

Confirm all required parts and quantities are received. Report any missing items to your local representative. Items may be shipped separately due to transportation logistics.

Handling

Lift fans carefully to avoid housing damage. Use isolator holes on top or the skid with a forklift. Use a minimum of four lifting straps. Avoid scratching or chipping the coating, as this can reduce corrosion resistance.

Position the fan, ensuring at least three duct diameters of straight duct before obstructions at the inlet and outlet. Attach the fan to a suitable framework using hanging or base vibration isolators as recommended. Check motor amperage and voltage ratings for power supply compatibility before electrical connection. All wiring must comply with local and national codes.

Storage

Fans are protected during shipment. If immediate installation is not possible, take precautions to prevent deterioration. The user is responsible for stored units and accessories.

Storage Environment

Store fans indoors, above grade, in a low-humidity, sealed atmosphere to prevent dust, rain, or snow. Maintain temperatures between 30° to 110°F (-1° to 43°C). Store accessories in a clean, dry atmosphere.

Remove any dirt, water, ice, or snow and wipe dry. Use a portable electric heater to dry parts if needed. Leave coverings loose for air circulation and inspection. Store units at least 3-1/2 inches (89 mm) off the floor on wooden blocks, covered with moisture-proof paper or polyethylene sheathing. Ensure aisles allow for air circulation and inspection.

Inspection and Maintenance During Storage

Inspect fans monthly and record all inspections and maintenance. If moisture or dirt is found, locate and eliminate the source. Rotate the wheel by hand ten to fifteen revolutions monthly to distribute motor lubricant. Address paint deterioration with touch-up or repainting as needed. Restore machined parts with rust preventive promptly if rust appears, using petroleum solvent and lint-free cloths, then polish with crocus cloth or fine emery paper and oil. Use Tectyl® 506 or equivalent for external surfaces and Tectyl® 511M Rust Preventive or WD-40® for internal surfaces.

Removing From Storage

Protect and maintain fans similarly when removing them from storage for installation.

Dimensional Data

Intake Configurations

The following tables provide dimensional data for Horizontal and Bottom Intake configurations.

^Weight shown is standard galvanized construction and largest cataloged totally enclosed motor.

^Weight shown is standard galvanized construction and largest cataloged totally enclosed motor.

Discharge Configurations

The following tables provide dimensional data for Horizontal and Bottom Discharge configurations.

All dimensions in inches.

Pre Start-Up Checks

Before Fan Installation

Check all fasteners for tightness, especially cap screws in the wheel bushing.

Wheel Alignment

Rotate the fan wheel by hand to ensure it rotates freely and without rubbing. The wheel position is preset at the factory. Realignment may be necessary due to shipment movement.

• Radial Gap: Adjust inlet cone position to ensure an even radial gap between the wheel cone and inlet cone.
• Alignment: Loosen wheel hub screws to adjust wheel position. Use a straight edge held against the wheel cone to touch the inlet cone. (Refer to Figure 1 description: A diagram showing a wheel cone, inlet cone, and a straight edge indicating the gap alignment).

Operation

IMPORTANT: Fans are factory-checked for mechanical noise. Refer to the Troubleshooting section for corrective actions if noise develops.

1. After installation, disconnect and lock out all power switches to the fan.
2. Before powering the fan, manually rotate the wheel to ensure it does not strike the inlet cone or any obstacles.
3. Start the fan briefly and shut it off immediately to check wheel rotation direction. (Refer to Figure 2 description: A diagram illustrating correct counterclockwise wheel rotation when viewed from the fan inlet). Reversed rotation leads to poor performance, motor overloading, and potential burnout. If rotation is incorrect, switch two wiring leads for 3-phase power or check motor wiring for single-phase. Verify fan RPM with a tachometer.
4. Observe the fan during startup for unusual noises.
5. With the system fully operational and ductwork attached, measure motor current input and compare it to the nameplate rating to ensure safe load conditions.
6. Keep fan inlets and approaches clear of obstructions.

Inspection

Conduct inspections at 30-minute and 24-hour intervals after satisfactory operation begins.

• 30 Minute Interval: Inspect and tighten bolts, setscrews, and motor mounting bolts as needed.
• 24 Hour Interval: Check all internal components.

Typical Installation

Roof Mounting

1. STEP 1 - Roof Opening (bottom discharge units only): Cut an appropriately sized hole in the roof surface.
2. STEP 2 - Install Roof Curb: Position and install the roof curb according to manufacturer's instructions. Caulk and flash for a watertight seal.
3. STEP 3 - Install Ductwork (bottom discharge units only): Follow good duct practices (SMACNA, AMCA, NFPA 96, local codes). Ensure approximately three duct diameters of straight duct for performance. Ductwork should extend above the roofline. A duct adapter is recommended for bottom discharge to align ductwork. (Diagram shows a fan unit on a curb with ductwork and a duct adapter).
4. STEP 4 - Apply Sealant: Apply sealant around the supply duct perimeter to isolate the fan and minimize vibration. (Diagram shows ductwork with adapter and sealant).
5. STEP 5 - Install Unit: Use a crane and spreader bars hooked to isolator holes to lift and center the unit on the curb. Fasten the unit to the curb with self-tapping sheet metal screws. Electrical connections can be made now. (Note: Use all four lifting holes when using a sling).
6. STEP 6 - Assemble Filter Tracks x2: Retrieve ship loose intake hood/cover package. Align holes on top and bottom filter tracks and install spring nuts over overlapping holes. (Note: Sizes 30 and 33 top tracks differ). (Diagram shows filter tracks and spring nuts).
7. STEP 7 - Fasten Filter Tracks to Side Panels: Position filter tracks on side panel flanges. Install 1/4 inch thumb screws and 1/4 inch bolts into spring nuts to secure. (Diagram shows filter track, side panel, thumb screw, and bolt).

Assembly Steps (Continued)

8. STEP 8 - Install Side Panels: Apply sealant to the inlet panel mating surface. Install side panels to the inlet using 5/16 inch fasteners, with filter tracks facing each other. Do not fully tighten. (Sizes 18-33 have two panels per side, fastened to mullions and plates). (Diagram shows side panels being attached).
9. STEP 9 - Install Top Panel: Apply sealant to the inlet panel mating surface. Place the top panel over side panels, ensuring side panels are inside the top panel. Attach the top panel to the inlet using 5/16 inch fasteners, and to side panels with sheet metal screws. Fully tighten the 5/16 inch fasteners. (Diagram shows top panel installation).
10. STEP 10 (Horizontal Discharge Only) - Install Ductwork: Apply sealant to the fan outlet mating surface. Use provided holes to mount ductwork/adapters to the horizontal discharge. C-clamp locking pliers can assist. (Diagram shows horizontal discharge ductwork connection).
11. STEP 11 - Install End Caps: Take care not to damage foam tape. Orient flanges away from the fan. Align half-moon cutouts on end caps with screws on inlet/outlet. Use self-tapping sheet metal screws to fasten end caps; do not over-tighten. (Diagram shows end cap installation).
12. STEP 12 (Sizes 18-33 only) - Install Side Mullions: Install left and right side mullions using two self-tapping sheet metal screws per side. (Diagram shows mullion installation).
13. STEP 13 - Install Side Panels: Install with drip edge down, aligning half-moon cutouts with inlet/outlet fasteners. Fasten side panels with self-tapping sheet metal screws. (Sizes 18-33 have two panels per side, fastened to mullions and plates). (Diagram shows side panel installation for different size ranges).
14. STEP 14 - Mount Disconnect Switch (if applicable): Determine ideal location and install the switch per manufacturer's suggestions.
15. STEP 15 - Install Conduit: Connect flexible metal conduit (FMC) to the power junction box. Route the opposite end with the female connector to the end cap hole. Insert liquid-tight connector into the end cap hole and screw into the female connector. Cut liquid-tight conduit to length and install from elbow to disconnect switch or power supply. (Diagram shows conduit connection).
16. STEP 16 - Route Wiring to Junction Box: Route wiring from the junction box to the disconnect through conduit. Junction boxes on top of the fan are inaccessible once the outdoor cover is installed.
17. STEP 17 - Install Top Panel(s) of Cover: Take care not to damage foam tape.
    • Size 7-16: Install the top panel of the outdoor cover using self-tapping sheet metal screws.
    • Sizes 18-33: Install the first top panel with a single return flange using self-tapping screws. Install the second top panel with a double return flange, hinging it around the first panel. Secure both with self-tapping sheet metal screws. (Diagrams illustrate these steps).
18. STEP 18 - Install Filter(s): Loosen thumb screws on the intake hood and drop filter tracks. Aluminum washable filters are standard; optional MERV 13 pleated filters are available for some bottom intake configurations. Return filter tracks to operating position and tighten thumb screws. Follow filter supplier guidelines for replacement/cleaning intervals. (Table lists filter sizes and quantities).

Parts List

Each fan has a manufacturer's nameplate with model and serial number for service and parts identification. Ensure the unit is not capable of operation during repairs.

Diagram Description: A simplified illustration of the fan components is shown, labeling the Intake Hood, Inlet Cone, Housing, Motor, Motor Plate, Mounting Rails, and Mixed Flow Wheel. Note: Fan sizes 18 and larger include additional internal structural supports.

Maintenance

DANGER: Always disconnect, lock, and tag the power source before servicing. Failure to do so can result in fire, shock, or serious injury.

WARNING: This unit must be made non-functional during cleaning (fuses removed, disconnect locked off).

French Warning: Pour écarter les risques d'incendie, de choc électrique ou de blessure grave, veiller à toujours débrancher, verrouiller et étiqueter la source de courant avant l'installation ou l'entretien. L'appareil doit être rendu non opérationnel lors du nettoyage de la turbine ou du caisson (fusibles retirés, sectionneur verrouillé).

Installation and maintenance should only be performed by qualified personnel familiar with local codes, regulations, and this type of equipment.

Motor

Motor maintenance is primarily cleaning and lubrication (if applicable). Clean exterior surfaces to ensure proper motor cooling. Greasing is only for motors with fittings; many fractional HP motors are permanently lubricated. If grease fittings are present, follow manufacturer recommendations. Replace grease every 2,000 hours of running time if motor temperatures do not exceed 104°F (40°C).

Wheel

Wheels require minimal attention in clean air. Oil and dust accumulation can cause imbalance. Clean the wheel and housing if imbalance occurs. IMPORTANT: Uneven cleaning can cause imbalance and vibration.

Tapered Bushing Hub

Follow these procedures for installation and removal of tapered bushing hubs.

Bushing Removal

1. Loosen setscrew holding the bushing and shaft key.
2. Remove socket head cap screws fastening the bushing to the hub. (Refer to Figure 3 description: A diagram showing a wheel hub with cap screws).
3. Install removed socket head cap screws into the threaded holes on the wheel hub.
4. Tighten these screws incrementally (one-eighth turn at a time, alternating) until the bushing loosens.

Bushing Installation

1. Clean all hub and bushing surfaces of oil/residue. Do not use lubricant for installation.
2. Slide the bushing and shaft key onto the fan shaft, followed by the wheel and hub assembly. Use the keyway setscrew to secure the shaft key and bushing, but do not overtighten. Align unthreaded hub holes with threaded bushing holes.
3. Install bushing socket head cap screws into aligned holes by hand or with minimal torque.
4. Adjust the wheel's axial location relative to the inlet cone (refer to Figure 1 description). Tighten socket head cap screws incrementally (one-eighth turn at a time, alternating) to 10 ft-lbs for QT bushings or 9 ft-lbs for SD bushings. (Note: QT/SD is labeled on the bushing edge; QT has two cap screws, SD has three).

Filters

One-inch washable aluminum mesh filters are standard. Optional two-inch MERV 13 filters are available for some bottom intake configurations. Clean or replace filters regularly for optimal efficiency. To remove filters, loosen thumb screws on the Weatherhood, drop the filter tray, and slide filters out. Aluminum filters can be washed in mild detergent. Adhesive spray can enhance filter efficiency. Follow filter manufacturer guidelines for pleated filters.

All fasteners should be checked for tightness before restarting the unit after maintenance. A proper maintenance program ensures years of dependable service.

Troubleshooting

WARNING: Ensure the unit is not capable of operation during repairs before taking corrective action.

French Warning: Avertissement: Avant d'entreprendre toute action corrective, s'assurer que l'appareil ne pourra pas fonctionner durant les réparations.

For Vari-Green® motor troubleshooting, refer to the Vari-Green Motor Installation, Operation, and Maintenance Manual.

Maintenance Log

This section provides space to record maintenance activities. Entries should include Date, Time, and Notes.

(Placeholder for a table or structured input for maintenance log entries)

Our Commitment

Greenheck reserves the right to change specifications without notice as part of its commitment to continuous improvement. Product warranties are available online at Greenheck.com, on specific product pages or in the literature section.

AMCA Publication 410-96, Safety Practices for Users and Installers of Industrial and Commercial Fans, provides additional safety information and can be obtained from AMCA International, Inc. at www.amca.org.

Contact Information:

Phone: 715.359.6171 • Fax: 715.355.2399 • Parts: 800.355.5354 • E-mail: gfcinfo@greenheck.com • Website: www.greenheck.com

Document: 486132 KSQ, Rev. 1, June 2023

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