Greenheck Fan Fan 474051 User Manual

Part #474051

Fiberglass Centrifugal Fan

Installation, Operation and Maintenance Manual

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the

product described. Protect yourself and others by observing all safety information. Failure to comply with instructions

could result in personal injury and/or property damage! Retain instructions for future reference.

Model BCSW-FRP

General Safety Information

Only qualiﬁed personnel should install this fan. Personnel

should have a clear understanding of these instructions

and should be aware of general safety precautions.

Improper installation can result in electric shock, possible

injury due to coming in contact with moving parts, as well

as other potential hazards. Other considerations may

be required if high winds or seismic activity are present.

If more information is needed, contact a licensed

professional engineer before moving forward.

1. Follow all local electrical and safety codes, as well

as the National Electrical Code (NEC), the National

Fire Protection Agency (NFPA), where applicable.

Follow the Canadian Electric Code (CEC) in

Canada.

2. The rotation of the wheel is critical. It must be free

to rotate without striking or rubbing any stationary

objects.

3. Motor must be securely and adequately grounded.

4. Do not spin fan wheel faster than max cataloged

fan rpm. Adjustments to fan speed signiﬁcantly

effects motor load. If the fan RPM is changed, the

motor current should be checked to make sure it is

not exceeding the motor nameplate amps.

DANGER

Always disconnect power before working on or near

a fan. Lock and tag the disconnect switch or breaker

to prevent accidental power up.

CAUTION

5. Do not allow the power cable to kink or come in

contact with oil, grease, hot surfaces or chemicals.

Replace cord immediately if damaged.

6. Verify that the power source is compatible with the

equipment.

When servicing the fan, motor may be hot enough

to cause pain or injury. Allow motor to cool before

servicing.

CAUTION

7. Never open access doors to a duct while the fan is

running.

Precaution should be taken in explosive

atmospheres.

Fiberglass Centrifugal Fan

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. Wipe clean thoroughly with Tectyl^®506

(Ashland Inc.) or the equivalent. For hard to reach internal

surfaces or for occasional use, consider using Tectyl^®

511M Rust Preventive or WD-40_®or the equivalent.

Table of Contents

General Information

Receiving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation Recommendations

BCSW-FRP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Bases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Belt Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Drain Connections . . . . . . . . . . . . . . . . . . . . . . . . . 5

Ductwork / Stacks. . . . . . . . . . . . . . . . . . . . . . . . . . 5

Rotatable Housing . . . . . . . . . . . . . . . . . . . . . . . . . 5

Radial gap, overlap & wheel alignment . . . . . . . . . 6

Flexible Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

V-Belt Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Unit Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . 9-10

Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Shaft Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

V-Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Unit Identiﬁcation . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Maintenance Log . . . . . . . . . . . . . . . . . . . . Backcover

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . Backcover

CAUTION

When installing a fan, ensure the proper protective

devices are used to protect personnel from

moving parts and other hazards. A complete

line of protective accessories are available from

Greenheck including belt guards, shaft guards, and

electrical disconnects.

Electrical Disconnects

All fan motors should have disconnects located in

close visual proximity to turn off electrical service.

Service disconnects shall be locked out when

maintenance is being performed.

Moving Parts

All moving parts must have guards to protect

personnel. Refer to local codes for requirements

as to the number, type and design. Fully secure fan

wheel before performing any maintenance. The fan

wheel may start “free wheeling” even if all electrical

power has been disconnected. Before the initial

start-up or any restart, check the belt and shaft

guards and the access doors to ensure that they

are installed and secure.

Model BCSW-FRP

Ducted Outlet Installations

Discharge Duct Turns - Duct turns located near the

fan discharge should always be in the direction of the

fan rotation.

Installation

Installations with inlet or discharge configurations

that deviate from this standard may result in reduced

fan performance. Restricted or unstable flow at the

fan inlet can cause pre-rotation of incoming air or

uneven loading of the fan wheel yielding large system

losses and increased sound levels. Free discharge

or turbulent flow in the discharge ductwork will also

result in system effect losses. Refer to the following

diagrams for the most efficient installation conditions.

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.

Ducted Inlet Installations

Inlet Duct Turns - Installation of a duct turn or elbow

too close to the fan inlet

POOR

reduces fan performance

because air is loaded

unevenly into the fan

Length of Straight Duct

wheel. To achieve full fan

performance, there should

be at least three fan wheel

diameter between the turn

GOOD

POOR

or elbow and the fan inlet.

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

one fan wheel diameter between parallel fan units

and a minimum of three-fourths of a wheel diameter

between the fan inlet and the wall.

Three fan wheel diameters

Turning

Vanes

GOOD

One fan

wheel

One fan

wheel

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.

diameter

Single Fan Installation

Turning

Vanes

3/4 to

one fan

wheel

3/4 to

one fan

wheel

One fan

diameter

POOR

GOOD

Parallel Fan Installation

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.

Model BCSW-FRP

Bases (Foundation and Isolation)

Drain Connection

In order to assure continued alignment, a high

strength, non-shrink epoxy grout is recommended

to provide the desired mechanical properties for

support of the fan. This type of support ensures the

appropriate transmission of static and dynamic loads

to the equipment foundation.

Make sure to either connect the drain or keep it

plugged. Never leave the drain open to drain freely.

The drain line must be installed using either a U-trap

arrangement or an equivalent method (drain leg is

submerged in liquid). To obtain a proper seal, the leg

length must be greater than the system pressure drop.

To eliminate vibration and noise from being transferred

to the building, vibration isolators should be used.

The fan is mounted directly on the base and must be

supported for the entire length of the fan base angle.

Isolators are installed between the base and the

foundation.

Ductwork / Stacks

All ductwork and/or stacks must be self-supporting

and independent of the fan. The fan inlet and outlet

are not designed to support the connecting duct or

stack. The use of ﬂexible connectors is recommended

to limit the transmission of stress to the fan. Excessive

pressure applied when bolting a ﬂange connection

may cause damage to the fan housing or ﬂange.

After the fan and isolators are installed, the entire

assembly must be leveled. Position the level on

the 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.

Rotatable Housings

It may be necessary to rotate the scroll of the fan

to achieve a different discharge position than what

was originally supplied. Fiberglass fan model BCSW-

FRP (sizes 6-25; arr. 4 and 10, Class I, II, III, and

IV) has the flexibility to be rotated in the field. This

is accomplished by removing the housing bolts,

rotating the housing to a new discharge position and

reinstalling the bolts.

Belt Guards

If the belt guard is not factory mounted, then it must

be ﬁeld mounted. Brackets and mounting hardware

are the responsibility of the installer. Mounting

bracket locations vary with motor mounting position,

arrangement, and fan type. The bearing supports and

fan structure are used in most instances and when

the motor is not mounted to the fan itself, a bracket

should also be located near it. This information is

intended as only a guide and actual ﬁeld conditions

may dictate another mounting location for the guard

brackets. Refer to local codes for securing guarding.

Model BCSW-FRP

Radial Gap, Overlap and Wheel 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 after the

unit has been serviced.

Impeller Wheel

Inlet Cone

Overlap

Impeller Wheel

Inlet Cone

Radial

Gap

Wheel

Radial

Gap

Overlap

Inlet Cone

BCSW-FRP

Sizes 6 thru 10

BCSW-FRP

Sizes 15 thru 73

A Dimension

Radial Gap

Overlap (maximum)

Unit

Size

Tolerance

(in.)

Tolerance

(mm)

Tolerance

(in.)

Tolerance

(mm)

Tolerance

(in.)

Tolerance

(mm)

1/8

⁄

1/32

⁄

1/16

1/8

102

127

138

181

202

232

283

337

394

435

487

533

654

1/32

1/16

⁷⁄16

5⁷⁄16

7¹⁄8

7¹⁵⁄16

9¹⁄8

11¹⁄8

13¹⁄4

15¹⁄2

17¹⁄8

19³⁄16

⁄4

1¹⁄8

1¹⁄4

³⁄16

⁄

1¹⁄4

1³⁄4

1¹⁄2

1⁷⁄16

⁷⁄32

⁄4

25³⁄4

⁄4

1¹⁄4

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.

Radial Gap is adjusted by loosening the housing bolts

and centering the inlet cone 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.

Model BCSW-FRP

Flexible Couplings (Arr. 8 Only)

V-Belt Drives

The V-belt drive components, when supplied by

Greenheck Fan Corporation, have been carefully

selected for this unit’s specific operating condition.

Check for misalignment between the coupling halves.

Parallel and angular misalignment and separation gap

are illustrated below. Refer to coupling manufacturer’s

installation instructions for allowable misalignment

and separation gap tolerances. When correcting for

misalignment using shims, the shims should only be

located under the motor. Do not place shims under the

shaft bearings.

CAUTION

Changing V-belt drive components could result in

unsafe operating conditions which may cause

personal injury or failure of the following

After aligning procedure, check for tightness of all

coupling component pieces and ensure that they are

clean from dirt and debris.

components:

1. Fan shaft

2. Fan wheel

3. Bearings

4. V-belt

5. Motor

V-Belt Drive Installation

1. Remove the protective coating from the end of the

fan shaft and assure that it is free of nicks and burrs.

Parallel Misalignment

Angular Misalignment

Separation Gap

2. Check fan and motor shafts for parallel and angular

alignment.

3. Slide sheaves on shafts - do not drive sheaves on as

this may result in bearing damage.

4. Align fan and motor sheaves with a straight-edge or

string, and tighten.

5. Place belts over

sheaves. Do not pry or

force belts, as this could

result in damage to the

cords in the belts.

6. Adjust the tension until

the belts appear snug.

Run the unit for a few

minutes (see section

Aligning sheaves with

on unit start-up) and

allow the belts to seat

a straight-edge

properly.

7. With the fan off, adjust the belt tension by moving

the motor base. (See belt tensioning procedures in

the maintenance section of this manual). 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.

Improper sheave

alignment

Proper sheave

alignment

Model BCSW-FRP

Vibration

Unit Start-Up

Excessive vibration is the most frequent problem

experienced during initial start-up.

1. Disconnect and lock-out all power switches to fan.

See warning below.

2. Check all fasteners, set screws and locking collars on

the fan, bearings, drive, motor base and accessories

for tightness.

Common Sources of Vibration

1. Wheel Unbalance

2. Drive Pulley Misalignment

3. Incorrect Belt Tension

4. Bearing / Coupling Misalignment

5. Mechanical Looseness

6. Faulty Belts

7. Drive Component Unbalance

8. Poor Inlet/Outlet Conditions

9. Foundation Stiffness

3. Rotate the fan wheel by hand and assure no parts

are rubbing.

4. Check for bearing alignment and lubrication.

5. Check for coupling alignment (Arr. 8 only).

6. Check the V-belt drive for proper alignment and tension.

7. Check all the guarding (if supplied) for being securely

attached and not interfering with rotating parts.

Left unchecked, excessive vibration can cause a

multitude of problems, including structural and/or

component failure.

8. Check all electrical connections for proper

attachment.

Many of these conditions can be discovered by careful

observation. Refer to the troubleshooting section

of this manual for corrective actions. If observation

cannot locate the source of vibration, a qualified

technician using vibration analysis equipment should

be consulted. If the problem is wheel unbalance,

the wheel should be sent back to the factory to be

properly rebalanced.

9. Check housing and ductwork, if accessible, for

obstructions and foreign material that may damage

the fan wheel.

10. Check that the drain is connected, or plugged, and

the housing is being properly drained.

WARNING

Greenheck performs a vibration test on all centrifugal

fans before shipping. Three vibration readings are

taken on each bearing in the horizontal, vertical, and

axial directions. The allowable maximum vibration

for belt drive units is 0.078 in/sec. peak (0.05 in/

sec. direct drive) velocity filter-in at the fan RPM per

AMCA Standard 204. These vibration signatures are a

permanent record of how the fan left the factory and

are available upon request.

Disconnect and secure to the “Off” position all

electrical power to the fan prior to inspection

or servicing. Failure to comply with this safety

precaution could result in serious injury or death.

Additional Steps for Initial Start-Up

1. Check for proper wheel

rotation by momentarily

energizing the fan. Rotation

is always determined by

viewing the wheel from

the drive side and should

correspond to the rotation

decal affixed to the unit.

Generally, fan vibration and noise is transmitted

to other parts of the building by the ductwork. To

eliminate this undesirable effect, the use of heavy

canvas connectors is recommended. If fireproof

material is required, Flexweave^TM1000 - Type FN-30

can be used.

One of the most frequently

encountered problems with

Centrifugal Fans is motors

which are wired to run in the

Clockwise Rotation

Always viewed from

the drive side.

wrong direction. This is especially true with 3-phase

installations where the motor will run in either

direction, depending on how it has been wired. To

reverse rotation of a 3-phase motor, interchange any

two of the three electrical leads.

2. Check for unusual noise, vibration or overheating of

bearings. Refer to the “Troubleshooting” section of

this manual if a problem develops.

3. Grease may be forced out of the bearing seals

during initial start-up. This is a normal self-purging

feature of this type of bearing.

Model BCSW-FRP

Shaft Bearings

Routine Maintenance

The bearings for Greenheck fans are carefully

selected to match the maximum load and operating

conditions of the specific class, arrangement, and

fan size. The instructions provided in this manual

and those provided by the bearing manufacturer, will

minimize any bearing problems. Bearings are the

most critical moving part of the fan, therefore special

care is required when mounting them on the unit and

maintaining them.

Once the unit has been put into operation, a routine

maintenance schedule should be set up to accomplish

the following:

1. Lubrication of bearings and motor (see below).

2. Wheel, housing, bolts and set screws on the entire

fan should be checked for tightness.

3. Any dirt accumulation on the wheel or in the

housing should be removed to prevent unbalance

and possible damage.

Refer to the following chart and the manufacturers

instructions for grease types and intervals for various

operating conditions. Never mix greases made with

different bases. This will cause a breakdown of the

grease and possible failure of the bearing.

4. Springs should be checked for breaks and

fatigue. Rubber isolators should be checked for

deterioration.

5. Inspect fan impeller and housing looking for fatigue,

corrosion, or wear.

Recommended Fan Bearing Lubrication Schedule - Standard Grease

Lubrication Schedule in Months*

When performing any service to the fan, disconnect

the electrical supply and secure fan impeller.

Bearing Bore (inches)

⁄

1¹⁄8

1¹⁄2

1⁵⁄8

1¹⁵⁄16

2⁷⁄16

3³⁄16

3¹⁵⁄16 - 4¹⁵⁄16

Fan RPM

1⁷⁄8

2³⁄16

- 3

3¹⁄2

4¹⁄2

5⁷⁄8

Motors

To 250

500

Motor maintenance is generally limited to cleaning

and lubrication. Cleaning should be limited to exterior

surfaces only. Removing dust and grease build up on

the motor housing assists proper motor cooling. Never

wash-down motor with high pressure spray. Greasing

of motors is only intended when fittings are provided.

Many fractional motors are permanently lubricated for

life and require no further lubrication. Motors supplied

with grease fittings should be greased in accordance

with the manufacturer’s recommendations. When

motor ambient temperature does not exceed 104°F

(40°C), the grease should be replaced after 2000 hours

of running time.

750

1000

1250

0.5

1500

0.5

0.25

2000

0.5

2500

0.5

0.25

3000

0.5

0.25

3500

0.5

4000

0.5

0.25

5000

0.25

# of shots**

*Suggested initial greasing interval is based on 12 hour per

day operation and 160ºF maximum housing temperature.

For continuous (24 hour) operation, decrease greasing

interval by 50%.

CAUTION

When operating conditions of the fan are to be

changed (speed, pressure, temperature, etc.),

consult Greenheck to determine if the unit can

operate safely at the new conditions.

•

If possible, relubricate with grease while in operation

without endangering personnel.

•

For ball bearings (operating) relubricate until clean

grease is seen purging at the seals. Be careful not to

unseat the seal by over lubricating.

•

For ball bearings (idle) add 1-2 shots of grease up to

2 in. bore sizes, and 4-5 shots of grease above 2 in. bore

sizes with hand grease gun.

For roller bearings, relubricate with 4 shots of grease up

to 2 in. bore size, 8 shots for 2-5 in. bore size, and 16

shots above 5 in. bore size with hand grease gun.

•

Adjust lubrication frequency based on condition of

purged grease.

A high quality lithium base grease conforming to NLGI

Grade 2 consistency is recommended.

The use of synthetic lubricants will increase lubrication

intervals by approximately three (3) times.

WARNING

Lubricate bearings prior to periods of extended

shutdowns or storage and rotate shaft monthly to

aid in preventing corrosion. If the fan is stored more

than three months, the bearings should be purged

with new grease prior to start-up.

Model BCSW-FRP

V-Belt Drives

Unit Identiﬁcation

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.

This tag is an example of an identiﬁcation label on the

fan. The information provides general details about the

fan, as well as containing speciﬁc information unique to

the unit. When contacting your Greenheck representative

with future needs or questions, please have the

information on this label available.

MODEL

S/N

When replacing V-belts on multiple groove drives all

belts should be changed to provide uniform drive

loading. Do not pry belts on or off the sheave. Loosen

belt tension until belts can be removed by simply

MARK

MAX FRPM @ 70˚ F

lifting the belts off the

Belt Span

Deﬂection

Model = General description of fan

sheaves. After replacing

belts, insure that slack in

each belt is on the same

side of the drive. Belt

dressing should never

be used.

S/N

= Serial Number assigned by Greenheck,

which is a unique identifier for every unit

Mark = Customer supplied identification

Belt Span

Tags are mounted on the drive frame in an area which

is clearly visible, usually near the fan outlet on the drive

side of the fan. The exact tag location may differ due fan

model and size.

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. Check belt tension before start up

and after the first 24 hours of operation. The belt

tension should also be checked periodically thereafter.

Parts List

Outlet Flange

Housing

Inlet Cone

Wheel

Gasket

Backplate

Shaft Seal

Shaft Guard

Bearings

Shaft

Pulley

Belt

Guard

Motor

Pulley

Access Door

with Gasket

Base/Housing

Foot Angle (4)

Belt

Belt Guard

Cover

Adjustable Motor

Slide Base

Model BCSW-FRP

Troubleshooting

Problem

Cause

Corrective Action

Adjust wheel.

Tighten wheel hub or bearing collars on shaft.

Wheel rubbing (inlet)

Tighten Sheaves on motor/fan shaft. Adjust belt tension. Align

sheaves properly (see V-Belt Drives section). Replace worn belts

or sheaves.

V-belt drive

Excessive Noise

Replace defective bearing(s). Lubricate bearings.

Tighten collars and fasteners.

Bearings

Clean all dirt off wheel. Check wheel balance, rebalance if

necessary.

Wheel unbalance

Fan

Check wheel for correct rotation. Increase fan speed.*

See page 3.

Low CFM

High CFM

Duct system

Fan

Decrease fan speed.

Duct system

Resize ductwork. Access door, filters, grilles not installed.

Duct system

Static Pressure

Wrong

has more or less

restriction than

anticipated

Change obstructions in system. Use correction factor to adjust

for temperature/altitude. Resize ductwork. Change fan speed.*

Fan

Check rotation of wheel. Reduce fan speed.

High Horsepower

Resize ductwork. Check proper operation of face and bypass

dampers. Check filters and access doors.

Duct system

Check fuses/circuit breakers. Check for switches turned off or

disconnected. Check for correct supply voltage.

Electrical supply

Fan Doesn’t Operate Drive

Motor

Check for broken belts. Tighten loose pulleys.

Assure motor is correct horsepower and not tripping overload

protector.

Lubrication

Check for excessive or insufficient grease in the bearings.

Overheated Shaft

Bearing

Replace damaged bearing. Relieve excessive belt tension. Align

bearings. Check for bent shaft.

Mechanical

Belts

Adjust tightness of belts. Replacement belts should be a matched

set.

Check alignment of shaft, motor and pulleys. Check wheel

balance, rebalance if necessary.

Excessive

Vibration

System unbalance

Check alignment between coupling, motor and fan shafts.

Any adjustments should be made per coupling manufacturer’s

instructions. Shim only under motor.

Coupling

misalignment

* 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.

NOTE: Always provide the unit model and serial numbers when requesting parts or service information.

Model BCSW-FRP

Maintenance Log