Greenheck USF Universal Single Width Fans Installation, Operation, and Maintenance Manual

Unit and System Identification Tags

Each fan has a permanently affixed manufacturer's engraved aluminum nameplate containing the model number and individual serial number. The tag shown is an example of an identification nameplate on the fan. The information provides general details about the fan, as well as containing specific information unique to the unit. When contacting your local manufacturer's representative with future needs or questions, have the information on this label available. Tags are mounted in an area which is clearly visible, usually on the side of the fan cabinet.

The tag above depicts the factory provided tag on the outside of your unit. There are three lines labeled Model, S/N and Mark. In the Model line, the 4th figure in the nomenclature represents the Performance ID.

Receiving

Upon receiving the product, check to ensure all items are accounted for by referencing the delivery receipt or packing list. Inspect each crate or carton for shipping damage before accepting delivery. Alert the carrier of any damage detected. The customer will make a notation of damage (or shortage of items) on the delivery receipt and all copies of the bill of lading which is countersigned by the delivering carrier. If damaged, immediately contact your local representative. Any physical damage to the unit after acceptance is not the responsibility of manufacturer.

Unpacking

Verify that all required parts and the correct quantity of each item have been received. If any items are missing, report shortages to your local representative to arrange for obtaining missing parts. Sometimes it is not possible that all items for the unit be shipped together due to availability of transportation and truck space. Confirmation of shipment(s) must be limited to only items on the bill of lading.

Handling

Fans are to be rigged and moved by the lifting brackets provided or by the skid when a forklift is used. Location of brackets varies by model and size. Handle in such a manner as to keep from scratching or chipping the coating. Damaged finish may reduce the ability of the fan to resist corrosion. Fans should never be lifted by the shaft, fan housing, motor, belt guard, windband or accessories.

Inspection and Maintenance During Storage

While in storage, inspect fans once per month. Keep a record of inspection and maintenance performed. If moisture or dirt accumulations are found on parts, the source should be located and eliminated. At each inspection, rotate the wheel by hand ten to fifteen revolutions to distribute lubricant in motor and bearings. If paint deterioration begins, consideration should be given to touch-up or repainting. Fans with special coatings may require special techniques for touch-up or repair.

Machined parts coated with rust preventive should be restored to good condition promptly if signs of rust occur. Immediately remove the original rust preventive coating with petroleum solvent and clean with lint-free cloths. Polish any remaining rust from surface with crocus cloth or fine emery paper and oil. Do not destroy the continuity of the surfaces. Thoroughly wipe clean with Tectyl® 506 (Ashland Inc.) or the equivalent. For hard to reach internal surfaces or for occasional use, consider using Tectyl® 511M Rust Preventive, WD-40® or the equivalent.

Storage

• Rotate fan wheel monthly and purge bearings once every three months.
• Energize fan motor once every three months.
• Store belts flat to keep them from warping and stretching.
• Store unit in a location which does not have vibration.
• After storage period, purge grease before putting fan into service.

If storage of fan is in a humid, dusty or corrosive atmosphere, rotate the fan and purge the bearings once a month. Improper storage which results in damage to the fan will void the warranty.

Fans are protected against damage during shipment. If the unit cannot be installed and operated immediately, precautions need to be taken to prevent deterioration of the unit during storage. The user assumes responsibility of the fan and accessories while in storage. The manufacturer will not be responsible for damage during storage. These suggestions are provided solely as a convenience to the user.

INDOOR - The ideal environment for the storage of fans and accessories is indoors, above grade, in a low humidity atmosphere which is sealed to prevent the entry of blowing dust, rain or snow. Temperatures should be evenly maintained between 30° to 110°F (-1° to 43°C), wide temperature swings may cause condensation and “sweating” of metal parts. All accessories must be stored indoors in a clean, dry atmosphere. Remove any accumulations of dirt, water, ice, or snow and wipe dry before moving to indoor storage. To avoid “sweating” of metal parts allow cold parts to reach room temperature. To dry parts and packages use a portable electric heater to remove any moisture build up. Leave coverings loose to permit air circulation and to allow for periodic inspection.

The unit should be stored at least 3-1/2 inches (89 mm) off the floor on wooden blocks covered with moisture proof paper or polyethylene sheathing. Aisles between parts and along all walls should be provided to permit air circulation and space for inspection.

OUTDOOR - Fans designed for outdoor applications may be stored outdoors, if absolutely necessary. Roads or aisles for portable cranes and hauling equipment are needed.

The fan should be placed on a level surface to prevent water from leaking into the fan. The fan should be elevated on an adequate number of wooden blocks so it is above water and snow levels and has enough blocking to prevent it from settling into soft ground. Locate parts far enough apart to permit air circulation, sunlight and space for periodic inspection. To minimize water accumulation, place all fan parts on blocking supports so rain water will run off.

Do not cover parts with plastic film or tarps as these cause condensation of moisture from the air passing through heating and cooling cycles.

Fan wheels should be blocked to prevent spinning caused by strong winds.

Removing from Storage

As fans are removed from storage to be installed in their final location, they should be protected and maintained in a similar fashion until the fan equipment goes into operation.

Prior to assembly and installation of the unit and system components, inspect the fan assembly to make sure it is in working order.

1. Check all fasteners, set screws on the fan, wheel, bearings, drive, motor base and accessories for tightness.
2. Rotate the fan wheel by hand and assure no parts are rubbing. Access to the wheel is obtained through a bolted panel located on the side of the fan housing.
3. Ensure proper wheel settings for radial gap and alignment. Refer to Radial Gap, Overlap and Wheel Alignment sections.

Service Clearance Requirements

We do not recommend any specific clearance requirements for the USF line-up. Every application, location and customer is different. It is left up to the discretion of the customer to decide what is required for them to be able to access and service the unit.

Discharge Positions

Diagrams show various discharge orientations, including Clockwise (CW) and Counter-Clockwise (CCW) rotation for configurations such as BH, BAU, UB, TAU, TH, and DB (downblast). Not all discharges are possible on every USF configuration. Rotatable housings are standard on Class 0, I and II, on many configurations. Removal of the housing bolts, inlet cone and wheel allows the discharge to be rotated to the positions shown. For downblast (DB) discharge position, a portion of the frame angle must be removed. Fan rotation is always specified from the drive side of the housing.

NOTE
Existing holes will need to be plugged with self-threading fasteners. Some field housing rotations will require drilling into the fan housing. All grease fan applications will require the relocation of access door and drain connection. Trim balance is recommended on the USF to maximize fan and bearing life.

Ducted Inlet Installations

Inlet Duct Turns

Installation of a duct turn or elbow too close to the fan inlet reduces fan performance because air is loaded unevenly into the fan wheel. To achieve full fan performance, there should be at least three fan wheel diameters between the turn or elbow and the fan inlet. Diagrams illustrate this, showing a 'GOOD' configuration with adequate spacing and a 'POOR' configuration with a close turn.

Inlet Spin

Inlet spin is a frequent cause of reduced fan performance. The change in fan performance is a function of the intensity of spin and not easily defined. The best solution is proper duct design and airflow patterns. Turning vanes reduce the effects of inlet spin. Diagrams show 'GOOD' airflow patterns with turning vanes and 'POOR' patterns without.

Ducted Outlet Installations

Discharge Duct Turns

Duct turns located near the fan discharge should always be in the direction of the fan rotation. Fan performance is reduced when duct turns are made immediately off the fan discharge. To achieve cataloged fan performance there should be at least three equivalent duct diameters of straight ductwork between the fan discharge and any duct turns.

Non-Ducted Installations

Inlet Clearance

Installation of a fan with an open inlet too close to a wall or bulkhead will cause reduced fan performance. It is desirable to have a minimum of three-fourths of a wheel diameter between the fan inlet and the wall. Diagrams illustrate this with 'GOOD' and 'POOR' clearances.

Free Discharge

Free or abrupt discharge into a plenum results in a reduction in fan performance. The effect of discharge static regain is not realized.

Fan Drainage Piping and Trap Detail (by others)

Fans may have been supplied with an optional drain. Drains are located at the underside of the scroll housing. The drain may need to be connected to a drainage system to ensure proper disposal of any water or condensate that may occur.

• Threaded drain connections are 1 inch (25.4 mm) NPT (National Pipe Thread). A simple, non-threaded hole is available as an economy option.
• Installed piping to have a downward angle to allow for drainage.
• Fill traps to recommended level before start-up.

Note: A conservative method of trap design is to set N = total static pressure.

V-Belt Drive Installation

1. Remove the protective coating from the end of the fan shaft using mineral spirits or another similar solvent. Check to ensure that the shaft is free of nicks and burrs.
2. Slide sheaves on shafts. Do not drive sheaves on as this may result in bearing damage.
3. Align fan and motor sheaves with a straight edge or string and tighten.
4. Place belts over sheaves. Do not pry or force belts, as this could result in damage to the cords in the belts.
5. Adjust the tension until the belts appear snug. Run the unit for a few minutes and allow the belts to “set” properly.
6. With the fan off and disconnect locked out, adjust the belt tension by moving the motor pivot plate. When in operation, the tight side of the belts should be in a straight line from sheave to sheave with a slight bow on the slack side.

Alignment of Pulleys and Belts

Check pulleys and belts for proper alignment to avoid unnecessary belt wear, noise, vibration and power loss. Motor and drive shafts must be parallel and pulleys in line as shown in Figure 1. Figure 1 illustrates correct and incorrect pulley alignment.

The adjustable motor pulley is set at the factory for the fan RPM specified by the customer. Fan RPM can be increased by closing or decreased by opening the adjustable motor pulley. Multigroove variable pitch pulleys must be adjusted an equal number of turns open or closed. Any increase in fan speed represents a substantial increase in load on the motor.

To avoid motor overheating and possible burnout, motor load amperes should always be checked and compared to nameplate rating when fan speed is increased.

For more information about measuring belt tension, refer to Product Application Guide, FA/127-11, Measuring Belt Tension, found online at greenheck.com/resources/library/application-articles.

Bases (Foundation and Isolation)

Critical to every fan installation is a strong, level foundation. A reinforced poured concrete pad with a steel base or inertia base provides an excellent foundation. Bases must be sturdy enough, with welded construction, to prevent flexing and vibration.

To eliminate vibration and noise from being transferred to the building, vibration isolators should be used. The fan is mounted directly on the isolation base and must be supported for the entire length of the fan base angle. Isolators are installed between the isolation base and the foundation.

After the fan, isolation base, and isolators are installed, the entire assembly must be leveled. Position the level on the isolation base, not the fan shaft, for proper leveling. Additionally, the motor and fan shafts must be level and parallel relative to each other for proper alignment.

Radial Gap and Alignment

Efficient fan performance can be maintained by having the correct radial gap, overlap and wheel alignment. These items should be checked after the fan has been in operation for 24 hours and before start-up when the unit has been disassembled.

Radial Gap

Adjust inlet cone position such that the radial gap between the wheel cone and inlet cone is evenly distributed around the wheel. Radial gap is adjusted by loosening the inlet cone/ring bolts and centering the cone/ring on the wheel. If additional adjustment is required to maintain a constant radial gap, loosening the bearing bolts and centering the wheel is acceptable as a secondary option.

Overlap

Overlap is adjusted by loosening the wheel hub from the shaft and moving the wheel to the desired position along the shaft. The transition between the inlet cone and wheel should be as shown; there is a smooth feel to the profile when moving from one component to the other.

Method for Centering Wheel

On belt drive units, centering can be accomplished by (a) loosening the inlet cone bolts to move the inlet cone or by (b) loosening the bearings in order to move the shaft. Wheel and inlet cone overlap can be adjusted by loosening the wheel hub set screws and moving the wheel to the desired position. Tighten all fasteners and set screws securely and realign drive pulleys after adjustment.

Wheel Rotation

Rotation direction of the wheel is critical. Incorrect rotation will result in reduced air performance, increased motor loading and possible motor burnout.

Check wheel rotation by momentarily energizing the unit and noting if rotation is in the same direction as the airflow at the outlet and conforms to the rotation decal affixed to the unit. Diagrams show wheel rotation for Backward Inclined, Airfoil, and Forward Curved fan types.

Visual Inspection of Equipment

The equipment type and arrangement should be verified as ordered at once when it arrives at the jobsite. If a discrepancy is found, the local representative must be notified immediately so that corrective action may be investigated. Verify electrical conformance to specifications. Unauthorized alterations and unauthorized backcharges will not be recognized by manufacturer.

After the unit has been assembled, installed and all utilities have been hooked up, the unit is ready for operation.

Check

Before starting the unit, check the following:

1. Confirm that building supply voltage matches the voltage for which the unit is wired.
2. Check all piping and wiring penetrations made by contractors for water tightness. All penetrations must be made watertight to prevent water damage to the unit and building.
3. Rotate the fan wheel manually to be sure that it is free to operate. Remove any dirt or debris that may have accumulated during installation.
4. Check the fan bearing setscrews for tightness.
5. Check alignment of sheaves and V-belts. See Belt Drive Maintenance section.
6. Inspect all fasteners to ensure that none have loosened during shipment.
7. Check flex coupling for proper alignment and connect between motor shaft and fan shaft (arrangement 8).
8. Check all guarding to ensure that it is securely attached and not interfering with rotating parts.
9. Check all electrical connections for proper attachment.
10. Check housing and ductwork, if accessible, for obstructions and foreign material that may damage the fan wheel.
11. Fill drainage piping trap if installed.

Fan Operation

All fans should be run every thirty (30) days, or at least “bumped” every thirty days. It is preferred that each fan is run as this causes all electrical and mechanical components to get up to temperature, displacing any formed condensation, redistributes load on bearings, and redistributes grease in the bearings (motor and shaft bearings).

IMPORTANT
When operating conditions of the fan are to be changed (speed, pressure, temperature, etc.), consult manufacturer to determine if the unit can operate safely at the new condition.

Belt Drive Maintenance

V-belt drives must be checked on a regular basis for wear, tension, alignment and dirt accumulation. Premature or frequent belt failures can be caused by improper belt tension (either too loose or too tight) or misaligned sheaves. Abnormally high belt tension or drive misalignment will cause excessive bearing loads and may result in failure of the fan and/or motor bearings. Conversely, loose belts will cause squealing on start-up, excessive belt flutter, slippage and overheated sheaves. Either excessively loose or tight belts may cause fan vibration.

When replacing V-belts on multiple groove drives, all belts should be changed to provide uniform drive loading. Use a set of matched belts whenever possible. Do not pry belts on or off the sheave. Loosen belt tension until belts can be removed by simply lifting the belts off the sheaves. After replacing belts, ensure that slack in each belt is on the same side of the drive. Belt dressing should never be used.

Do not install new belts on worn sheaves. If the sheaves have grooves worn in them, they must be replaced before new belts are installed.

The proper tension for operating a V-belt drive is the lowest tension at which the belts will not slip at peak load conditions. Belts are adjusted by raising or lowering the motor pivot plate. For initial tensioning, the proper belt deflection halfway between sheave centers is 1/64-inch for each inch of belt span.

Check belt tension two times during the first 24 hours of operation and periodically thereafter.

Wheel and Fastener Maintenance

Wheels require very little attention when exhausting clean air, however, air heavily laden with grease or dirt will tend to accumulate on the wheel causing unbalance. Wheels exhausting dirty or grease-laden air require frequent cleaning to assure smooth and safe operation.

All fasteners, including set screws in the bearing collars, should be checked for tightness each time maintenance checks are performed.

A proper maintenance program will help preserve the performance and reliability designed into the fan.

Bearing Lubrication Schedule

Shaft bearings are the most critical moving part of a fan. Therefore, special attention should be given to keeping the bearings clean and well lubricated. Proper lubrication provides for reduction in friction and wear, transmission and dissipation of heat, extended bearing life, and prevention of rust.

In order for a lubricant to fulfill these tasks, the proper grease applied at regular intervals is required. See the recommended bearing lubrication schedule below.

If unusual conditions exist (temperatures below 32°F or above 200°F), moisture or contaminants - more frequent lubrication is required.

Recommended Bearing Lubrication Schedule

• Lubrication interval is based on 12 hour per day operation and maximum 160°F housing temperature. For 24 hour per day operation, the interval should be cut in half.
• Lubricant should be added with the shaft rotating and until clean grease is seen purging from the bearing. The lubrication interval may be modified based on the condition of the purged grease. If bearing is not visible to observe purged grease, lubricate with number of shots indicated in chart for bore size.
• For conditions including high temperatures, moisture, dirt or excessive vibration, consult the factory for a specific lubrication interval for your application.
• Lubricant should be a high quality lithium complex grease conforming to NLGI Grade 2. Factory recommends Mobilux EP-2.
• The use of synthetic lubricants will increase lubrication intervals by approximately 3 times.

In addition to lubricating the bearings at specified intervals, set screws in the bearing collars should be checked for tightness. A bearing collar which has loosened will cause premature failure of the fan shaft. Fasteners attaching the bearings to the drive frame should also be checked.

Bearing Replacement

For Arrangements 1, 8 or 10

The intent of this procedure is to allow a field service technician to replace bearings with the fan remaining in place in its intended application. All work can be conducted accessing the bearings by either removing a shaft guard, a weatherhood or working under a weatherhood. This is dependent on the size of the unit. This procedure assumes the power source has been locked out prior to removing guards and covers, belts and pulleys have been loosened and removed properly, and extended lubrication lines have been disconnected at the bearing. In some cases, it may be necessary to remove the fan inlet cone and wheel if the bearings cannot be removed due to corrosion or damage. See Radial Gap, Overlap and Wheel Alignment sections to realign wheel upon installation.

Parts List

Each fan bears a manufacturer's nameplate with model number and serial number embossed. This information will assist the local manufacturer's representative and the factory in providing service and replacement parts. Before taking any corrective action, make certain unit is not capable of operation during repairs.

CAUTION
A fan manufactured with an explosion resistant motor does not certify the entire unit to be explosion proof. Refer to UL Listing Mark for the fans approved usage.

CAUTION
La présence d'un moteur antidéflagrant sur un ventilateur ne garantit pas que tout l'appareil est antidéflagrant. Pour connaître les emplois autorisés de l'appareil, voir son marquage de conformité UL.

Troubleshooting

WARNING
Before taking any corrective action, make certain unit is not capable of operation during repairs.

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

* Always check motor amps and compare to nameplate rating. Excessive fan speed may overload the motor and result in motor failure. Do not exceed the maximum cataloged rpm of the fan.

Warranty Statement

Failure to properly review this checklist and fill out the required information may result in loss of warranty. This document will be used to review field issues. Retain this document for your records.

Greenheck Warranty Statement: https://content.greenheck.com/public/DAMProd/Original/10002/CVI_warranty.pdf

Installation / Start-up Checklist

Our Commitment

As a result of our commitment to continuous improvement, Greenheck reserves the right to change specifications without notice. Specific Greenheck product warranties are located on greenheck.com within the product area tabs and in the Library under Warranties.

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

GREENHECK
Building Value in Air.

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

20 479870 USF, Rev. 11, May 2023 Copyright 2023 Greenheck Fan Corporation