BIG ASS FANS Powerfoil X 2.0 Plus Installation Manual Download

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Официальный дистрибьютор в России

Компания

ООО «Альфа Инвест Инжиниринг»

109052, г.Москва, ул. Нижегородская, д. 50

Сайт: www.ai-engineering.ru Эл. почта: [email protected] Тел.: +7-(499) 390-79-31

Summary of Contents for Powerfoil X 2.0 Plus

Page 1: ...Официальный дистрибьютор в России Компания ООО Альфа Инвест Инжиниринг 109052 г Москва ул Нижегородская д 50 Сайт www ai engineering ru Эл почта info ai engineering ru Тел 7 499 390 79 31 ...

Page 2: ...0PLUS FANS Installation Guide 8 24 Powerfoil X2 0 Официальный дистрибьютор в России Компания ООО Альфа Инвест Инжиниринг 109052 г Москва ул Нижегородская д 50 Сайт www ai engineering ru Эл почта info ai engineering ru Тел 7 499 390 79 31 ...

Page 3: ...an requires the removal or disconnection of a safety device the safety device is to be reinstalled or remounted as previously installed WARNING Risk of fire electric shock or injury to persons during cleaning and user maintenance Disconnect the fan from the power supply before servicing CAUTION Do not bend the airfoils when installing adjusting or cleaning the fan Do not insert foreign objects bet...

Page 4: ...o Extension Tube 19 4 Attach Main Fan Unit to Lower Yoke 19 5 Confirm Orientation 19 Installing Guy Wires 1 Attach Locking Carabiner to Main Fan Unit 20 2 Attach Beam Clamp 20 3 Route Guy Wire through Gripple 21 4 Install Remaining Guy Wires 21 Installing Airfoils 1 Attach Winglets to Airfoils 22 2 Position Airfoils 22 3 Attach Airfoils to Hub 22 Installing Hub Cover Secure Hub Cover 24 Electrical...

Page 5: ...r Changes 41 Operating the Fan Heating Season 45 Cooling Season 45 User Servicing Annual Preventive Maintenance 46 General Preventative Maintenance 46 Cutting the Extension Tube 47 Troubleshooting 47 E Series Fan Error Codes 48 M Series Fan Error Codes 50 Warranty Big Ass Fans Warranty Policy 52 Return Instructions 56 Warranty Claim Form Instructions 56 Warranty Claim Form 57 Responsibility Agreem...

Page 6: ...cturing We re ready to answer any questions or comments at 1 877 BIG FANS or visit our Web site at www bigassfans com Who we are and what we do Big Ass Fans has been the preeminent manufacturer of large diameter low speed fans since 1999 With a worldwide presence and located in beautiful Lexington KY we research design and manufacture the most effective air movement solutions on the market Our nev...

Page 7: ...it size 15A 200 250V 3Φ 10A 400 480V 3Φ 30A 200 250V 1Φ 15A 200 250V 3Φ 10A 400 480V 3Φ 30A 200 250V 1Φ 15A 200 250V 3Φ 10A 400 480V 3Φ 30A 200 250V 1Φ 15A 200 250V 3Φ 10A 400 480V 3Φ 30A 200 250V 1Φ Full load current 5 0A 200 250V 2 5A 400 480V 5 0A 200 250V 2 5A 400 480V 6 0A 200 250V 3 0A 400 480V 6 4A 200 250V 3 0A 400 480V Max RPM 95 RPM 77 RPM 70 RPM 55 RPM Airfoil length 85 5 in 2 17 m 97 5...

Page 8: ...6 1 m 24 ft 7 3 m Motor size 2 0 HP 1 5 kW 2 0 HP 1 5 kW Required supply circuit size 15A 200 250V 3Φ 10A 400 480V 3Φ 30A 200 250V 1Φ 15A 200 250V 3Φ 10A 400 480V 3Φ 30A 200 250V 1Φ Full load current 6 0A 200 250V 3 0A 400 480V 6 0A 200 250V 3 0A 400 480V Max RPM 58 RPM 48 RPM Airfoil length 109 5 in 2 78 m 133 5 in 3 39 m Suggested distance from the ceiling1 7 ft 2 1 m 7 ft 2 1 m 1 The distance o...

Page 9: ... fan Note Dashed lines indicate internal boxes The drawings below are not to scale 2 Lower Yoke 2 Beam Clip 2 Spacer Upper Yoke Extension Tube3 Safety Cable Main Box 1 Powerfoil winglet shown Powerfoil or PowerfoilPlus winglets are available 2 Airfoil retainers are packed in a bag with the Installation Guide Do not attempt to remove or adjust the AirFence The position is set at the factory 3 The s...

Page 10: ...are Note The drawings below are not to scale No hardware substitutions are acceptable 1 Guy wires are designed to constrain fan s lateral movement and are only included in some fan packages Big Ass Fans recommends using guy wires if the fan s extension tube is 4 ft or longer if the fan is exposed to high winds or similar conditions or if the fan is close to any building fixtures Guy Wire hardware ...

Page 11: ...tion cont Understanding roof pitch To ensure the fan is properly mounted the fan must always hang plumb to the ground and the yoke must be installed using the bolt holes at the widest locations possible To accommodate building structures on which the standard upper yoke does not allow the fan to properly orient itself the 90 Degree Offset mount should be purchased The example below shows one situa...

Page 12: ...ower Yoke Connects the main fan assembly to the extension tube E VFD Enclosure Contains the variable frequency drive F Gearbox NitroSeal Drive custom gearbox for increased durability and cooler operation G Motor See pages 2 3 for more information H Hub Secures the airfoils to the gearbox output shaft I Airfoil Provides air movement The unique patented design provides efficient and effective air mo...

Page 13: ...irement Minimum distances Clearance 2 ft from all fan parts The fan installation area must be free of obstructions such as lights cables sprinklers or other building structure Blade height 10 ft above the floor HVAC equipment 1x fan diameter if above diffuser 2x fan diameter if below diffuser Refer to the illustration below Fan spacing 2 5x fan diameter center to center Radiant IR heaters Minimum ...

Page 14: ...an enclosed area The floor jet radiates outward until it reaches the walls which deflect the jet upward After it hits the ceiling the upward flow is directed inward to the low pressure area above the fan where it is then pulled down toward the floor This creates a convection like air current that gathers momentum Once this current is established the fan begins to move air outside of the current es...

Page 15: ...uch higher angle resolving many of the issues outlined below Make sure people are not hidden behind structures that would block airflow This may seem obvious but work areas are routinely blocked by shelving crates and machinery Position large obstructions so that their smallest profiles are perpendicular to the direction of air movement For example a sheet metal press brake might have five times t...

Page 16: ... Before beginning installation confirm that you have the appropriate mount for your roof pitch Attach upper yoke to I beam Measure the flange width of the I beam from which the fan will be hung Select the upper yoke mounting holes that match the flange width of the I beam Secure the upper yoke to the I beam with the Upper Yoke Hardware as shown Tighten the bolts to 40 ft lb 54 2 N m using a torque...

Page 17: ... mounted is of sound construction undamaged and capable of supporting the loads of the fan and its method of mounting A structural engineer should verify that the structure is adequate prior to fan installation Verifying the stability of the mounting structure is the sole responsibility of the customer and or end user and Big Ass Fans hereby expressly disclaims any liability arising therefrom or a...

Page 18: ... 4 socket Repeat this step for the remaining two angle irons Proceed to step 4b Grade 8 Hardware Customer Supplied a 2 1 2 13 Bolt b 4 1 2 Washer c 2 1 2 Nut Side View a b b c 2 Pre drill angle irons Drill two Ø9 16 1 4 cm holes exactly 5 3 8 13 7 cm apart in the centers of two angle irons Measure the distance between the mounting points of the roof structure that the angle irons will span Measure...

Page 19: ... 5 Big Ass Fans recommends orienting the angle irons so that the horizontal legs are facing each other or the vertical legs are on the outside Proceed to step 5 Grade 8 Hardware Customer Supplied a 4 1 2 13 Bolt b 8 1 2 Washer c 4 3 Square Washer BAF Supplied see diagram d 4 1 2 Nylock Nut Mounting Method Angle Irons cont 3 7 6 cm 3 7 6 cm Ø 9 16 1 4 cm Thickness 1 4 6 mm Square Washer If the angl...

Page 20: ...er supplied Grade 8 hardware as shown The angle irons with fan mounting holes should be positioned on the inside facing each other Do not tighten the hardware until the upper yoke has been mounted to the angle irons Grade 8 Hardware Customer Supplied a 8 1 2 13 Bolt b 16 1 2 Washer c 8 3 Square Washer BAF Supplied see diagram d 8 1 2 Nylock Nut A b a c b d Mounting Method Angle Irons cont 3 7 6 cm...

Page 21: ...e to the angle irons tighten all the bolts securing the angle irons to the roof structure to 40 ft lb 54 2 N m Proceed to Hanging the fan p 18 Upper Yoke Hardware BAF Supplied a 4 1 2 13 x 2 Bolt b 8 1 2 Flat Washer c 4 1 2 13 Nylock Nut Mounting Method Angle Irons cont The angle irons should be aligned with the outermost holes on the upper yoke Do not use beam clips on angle irons If the fan will...

Page 22: ...iagram below for distances between the angle irons Note The fan can only be directly mounted to angle irons Do not directly mount the fan to an I beam Tighten the bolts to 40 ft lb 54 2 N m using a torque wrench and 3 4 socket After attaching the main fan unit to the angle irons tighten all the bolts securing the angle irons to the roof structure to 40 ft lb 54 2 N m using a torque wrench and 3 4 ...

Page 23: ...iron if possible Securely tighten the shackle Angle Iron Mount I Beam Mount Shackle Direct Mount The safety cable is a crucial part of the fan and must be installed correctly If you have questions or require assistance call Customer Service at 1 877 BIG FANS for assistance 1 Attach extension tube to upper yoke Fasten the extension tube to the upper yoke with the Extension Tube Hardware as shown En...

Page 24: ...t and hub CAUTION The main fan unit is heavy Use caution when raising it Attach the main fan unit to the lower yoke with the Main Fan Unit Hardware as shown Do not rest the main fan unit on the ground Make sure the lower cable is positioned between the lower yoke brackets as shown on the right Tighten the bolts to 40 ft lb 54 2 N m using a torque wrench and 3 4 socket Do not discard the main fan u...

Page 25: ...r fans with shorter tubes to prevent any lateral movement If guy wires are needed and were not included with your fan order contact Big Ass Fans Customer Service at 1 877 BIG FANS WARNING Ensure power is disconnected from the fan before installing the guy wires 2 Attach beam clamp Attach the beam clamp to the mounting structure The guy wire should be approximately 45 from the horizontal plane Plac...

Page 26: ...ls Maintain a distance of 6 8 between the Gripple and the carabiner Once all of the guy wires are taut secure their loose ends with the wire rope clips and torque to 4 5 ft lb 8 1 N m Ensure all electrical cords cables are unobstructed by the guy wire system Wire Rope Clip 3 Route guy wire through Gripple Route the guy wire through the Gripple the carabiner on the main fan unit and then back throu...

Page 27: ...rely attached Attach the winglet to the airfoil using the Winglet Hardware as shown Both a Phillips head and flat head screwdriver are required to properly secure the fasteners Attach winglets to all 10 airfoils before attaching the airfoils to the fan Winglet Hardware BAF Supplied a 10 10 24 x 1 2 Bolt b 10 10 24 x 3 4 Barrel 2 Position airfoils Slide the airfoils onto the tabs of the fan hub The...

Page 28: ...A of the retainer should be positioned over top of Hole B Do not tighten the bolts until all the airfoil retainers have been attached Tighten the bolts along the outer perimeter to 29 ft lb 39 N m using a torque wrench and 1 2 socket After the outer perimeter bolts are torqued tighten the bolts along the inner perimeter to 29 ft lb 39 N m Airfoil Hardware BAF Supplied a 20 5 16 18 x 2 Bolt b 40 5 ...

Page 29: ... RESERVED 24 Attach the hub cover to the hub with the Hub Cover Hardware Hub Cover Hardware 4 8 32 x 3 8 Screw Installing Hub Cover WARNING Disconnect power to the fan before installing the hub cover If your fan order included accessories light camera etc consult the instructions packaged with those accessories ...

Page 30: ...y result in a malfunction of the fan system Verify correct voltage phase and horsepower before beginning installation WARNING Exercise caution and common sense when powering the fan Do not connect the fan to a damaged or hazardous power source Do not attempt to resolve electrical malfunctions or failures on your own Contact Big Ass Fans at 1 877 BIG FANS if you have any questions regarding the ele...

Page 31: ...rews Pull the RJ 11 connector through the junction box and mounting plate 2 Rest the fan controller in the fan controller cover and then connect the cable Secure the controller cover to the mounting plate with the 4 provided screws as shown below Only the Up Arrow Down Arrow RUN and STOP RESET buttons should be visible Electrical Installation cont Wall Controller RUN STOP FWD REV REM LOC U H F MOD...

Page 32: ...voltage references There are many different arrangements available for industrial and commercial power distribution in North America The most common are the following 575V 330V Three Phase Wye Secondary Provides 575V between phases and 330V from each phase to Neutral Ground 480V 277V Three Phase Wye Secondary Provides 480V between phases and 277V from each phase to Neutral Ground 208V 120V Three P...

Page 33: ...he fan controllers include fuses for branch short circuit protection If desired these fan controller models can be installed with a dedicated fusible disconnect and or input circuit breaker National and local industrial safety standards and or electrical codes may determine additional requirements for these installations Electrical Installation cont ...

Page 34: ...d electrician should perform the installation The diagram below shows a standard fan controller 200V 250V 1Φ 1HP using single phase input from AC power supply See Power Requirements on page 25 for detailed voltage current and circuit breaker fuse requirements Electrical Installation cont 200 250V 1Φ 1HP Frames Included NEMA L5 20P Twistlock Plug 15 ft Cord READY RUN FAULT 1 2 3 1 2 3 ON ON RA RB R...

Page 35: ...tor and controller A qualified electrician should perform the installation The diagram below shows a standard fan controller 200V 250V 1Φ 2HP using single phase input from AC power supply See Power Requirements on page 25 for detailed voltage current and circuit breaker fuse requirements 200 250V 1Φ 2HP Frames Included NEMA L5 30P Twistlock Plug 15 ft Cord AC INPUT WIRING MOTOR OUTPUT WIRING AC IN...

Page 36: ...trician should perform the installation The diagram below shows a standard fan controller 200V 250V 3Φ 1HP and 2HP using three phase input from AC power supply See Power Requirements on page 25 for detailed voltage current and circuit breaker fuse requirements Electrical Installation cont READY RUN FAULT 1 2 3 1 2 3 ON ON RA RB RC AVI NPN PNP PNP ACI ACI AC INPUT WIRING MOTOR OUTPUT WIRING AC INPU...

Page 37: ...nd controller A qualified electrician should perform the installation The diagram below shows a standard fan controller 400V 480V 3Φ 1HP and 2HP using three phase input from AC power supply See Power Requirements on page 25 for detailed voltage current and circuit breaker fuse requirements 400 480V 3Φ 1 HP 2HP Frames Included NEMA L16 20P Twistlock Plug 15 ft Cord READY RUN FAULT 1 2 3 1 2 3 ON ON...

Page 38: ...lectrician should perform the installation The diagram below shows a standard fan controller 575V 600V 3Φ 1HP and 2HP using three phase input from AC power supply See Power Requirements on page 25 for detailed voltage current and circuit breaker fuse requirements Electrical Installation cont 200 250V 3Φ 1HP 2HP Frames Included 15 ft Cord AC INPUT WIRING MOTOR OUTPUT WIRING AC INPUT FUSING FIRE REL...

Page 39: ...g WARNING Improper installation can cause electric shock or damage to the motor and controller A qualified electrician should perform the installation The diagram below shows a typical EMI RFI installation Electrical Installation cont READY RUN FAULT 1 2 3 1 2 3 ON ON RA RB RC AVI NPN PNP PNP ACI ACI AC INPUT WIRING MOTOR OUTPUT WIRING AC INPUT FUSING DATA CABLE SPARE ENTRY NPT plugged 6A 10A 6A 1...

Page 40: ...o the motor and controller A qualified electrician should perform the installation The diagram below shows a typical line reactor installation on a standard fan controller See Power Requirements on page 25 for detailed voltage current and circuit breaker fuse requirements Electrical Installation cont READY RUN FAULT 1 2 3 1 2 3 ON ON RA RB RC AVI NPN PNP PNP ACI ACI AC INPUT WIRING MOTOR OUTPUT WI...

Page 41: ...ller is the master controller local mode The remaining fans REM mode when connected with a two conductor shielded cable will follow command references provided by the master controller See the following page for detailed wiring diagrams Limit two conductor shielded cable runs to 200 ft 61 m or less Consult Big Ass Fans Customer Service Department at 1 877 BIG FANS for conversion to 4 20 mA current...

Page 42: ...Reserved 7 Reserved 8 Reserved Digital Input MI1 Digital Input MI2 Digital Input MI3 Digital Input MI4 Digital Input MI5 Digital Input MI6 DCM DCM 24VDC 20mA 24V ANL Common ACM ANL In 0 10VDC 47kΩ AVI ANL In 4 20mA 250Ω ACI 10VDC 3mA 10V Opto Out Common MCM ANL Out 0 10VDC 2mA 20kΩ AFM Opto Out Max 48VDC 50mA M01 Digital Common RA RB RC RS 485 1 Reserved 2 EV 3 GND 4 SG 5 SG 6 Reserved 7 Reserved ...

Page 43: ...es a Normally Open N O contact as shown The relay coil must be energized by the FACP for fan shutdown Two additional relay coil leads are provided to facilitate supervision pass through where required From main FACP or NAC box if applicable Optionally the relay can be used with a Normally Closed N C contact as shown The relay coil must remain energized by the FACP for fan operation This would be c...

Page 44: ...sidered a fail safe or fail open wiring arrangement Two additional relay coil leads are provided to facilitate supervision pass through where required An alarm condition will stop the fan and issue an EF External Fault at the fan controller s wall controller An alarm condition will stop the fan and issue an EF External Fault at the fan controller s wall controller RUN STOP FWD REV MODE RUN ENTER S...

Page 45: ...on of the fan Note The RUN STOP RESET and FWD REV buttons are disabled while External Automation Control is enabled REM LED illuminated To start the fan press the RUN button on the controller s display When the RUN button is pressed the STOP LED extinguishes and the RUN LED illuminates while the fan accelerates to the commanded speed To decelerate the fan press the STOP RESET button The RUN LED wi...

Page 46: ...ons are functional only when the LOC indicator is illuminated Note To access the LOCAL REM button on the controller the controller cover must be removed Toggling the fan s command source STOP RUN FWD REV REMLOC U F H EXTERNAL AUTOMATION CONTROL ENABLED STOP RUN FWD REV REMLOC U F H WALL CONTROL COMMANDS ENABLED RE M is Illuminated L OC is Illuminated LOCAL REM LOCAL REM LOCAL REM Cycling through t...

Page 47: ...e To access the required buttons the controller cover must be removed Wall Controller Operation cont RUN STOP FWD REV REM LOC U H F MODE RUN STOP FWD REV REM LOC U H F MODE Frequency Command F Frequency Output H MODE MODE RUN STOP FWD REV REM LOC U H F 4 Digit Code Entry Digit Selection OR PROG DATA RUN STOP FWD REV REM LOC U H F RUN STOP FWD REV REM LOC U H F Invalid Code PROG DATA Press hold to ...

Page 48: ...Value U Output Current Display RUN STOP FWD REV REM LOC U H F Lockout Entry Unlocked RUN STOP FWD REV REM LOC U H F OR 4 Digit Code Entry Digit Selection PROG DATA RUN STOP FWD REV REM LOC U H F Keypad Locked RUN STOP FWD REV REM LOC U H F Press to save code to memory PROG DATA FWD REV STOP RESET RUN LOCAL REM These buttons are disabled in LOC 1 IF NO CODE SAVED IN MEMORY IF CODE IS ALREADY SAVED ...

Page 49: ...ller or motor For example the error code for input power phase loss is shown on the left For a full list of error codes and their meanings see Fan Error Codes on page 47 Programming and parameter changes CAUTION Under no circumstances should an operator attempt to alter the programming of the fan s controller without the assistance of an authorized Big Ass Fans installer the Big Ass Fans Customer ...

Page 50: ...w speeds so turning the fan very slowly in the forward direction counterclockwise will provide enough air movement to circulate the hot air at the ceiling down to the floor without causing a draft Adjust the fan speed to the appropriate starting fan speed listed in the table below Floor to ceiling height ft Starting fan speed Display 40 15 Hz 20 30 40 20 Hz 30 40 Stand directly below the tips of t...

Page 51: ...pect the airfoils and main motor unit for signs of damage or cracks 10 Inspect the fan for signs of corrosion discoloration pitting and flaking of metal General preventative maintenance Periodically perform the following maintenance procedures on your fan Verify proper fan rotation The fan should be turning counterclockwise when viewed from the floor Dust the airfoils motor and motor housing If de...

Page 52: ... using the proper wiring practices outlined in Electrical Installation p 25 Verify the following Do not run your controller and sensitive equipment on the same power line Ensure the properly sized EM RFI filter p 34 is installed Ensure proper grounding at the motor controller and from the controller to the utility If the noise is still present contact Customer Service at 1 877 BIG FANS The motor m...

Page 53: ...at 1 877 BIG FANS Excessive Drive Output Current An abnormal condition exists on the motor side of the fan system Check the motor OL point parameters Reduce torque comp Pr 54 Over Current During Acceleration Motor circuit insulation failure or over boosting Check the torque boost If the deceleration time is too short check parameters Over Current During Steady Operation Motor circuit insulation fa...

Page 54: ...ng state Feedback Signal Error Check the AVI ACI wiring Various Unrecoverable Errors If the power cycle will not clear these faults contact Customer Service at 1 877 BIG FANS Pr 00 04 Diagnostics running display options Setting Run screen display 00 BAF Default Display user defined unit 01 Counter value pulses on TRG terminal 02 Not valid 03 DC buss voltage 1 414 approx AC line 04 RMS equivalent f...

Page 55: ...r Current During Acceleration Motor circuit insulation failure or over boosting Check the torque boost If the condition persists with a disconnected motor contact Customer Service at 1 877 BIG FANS Over Current During Acceleration Motor circuit insulation failure or over boosting Check the torque boost If the deceleration time is too short check parameters Over Current During Steady Operation Moto...

Page 56: ...e at 1 877 BIG FANS Communications Error Slave Verify proper data wiring between the drive s RS485 port and the command source Pr 64 Diagnostics running display options Setting Run screen display 00 Display drive output frequency Hz 01 Default User defined number Hz x PR 65 02 RMS equivalent output voltage to motor 03 DC buss voltage 1 414 approx AC line 04 PV i 05 Display internal counter value 0...

Page 57: ...ears parts Gearbox 7 years parts 15 years parts Controller components 7 years parts 15 years parts All other fan components 7 years parts 15 years parts Labor 1 year 1 year Refurbished units 6 months parts only 6 months parts only The 15 year Warranty Period and 1 year Labor apply to non residential installations only and require purchased installation by a Big Ass Fans factory certified installer...

Page 58: ...remove the fan and return it to us The cost of labor incurred for factory installed fans to remove repair or reinstall the fans will be covered only during the first 12 months after the warranty becomes effective and only pursuant to the terms of the definition of Labor below 6 If we ask you to ship the fan back to Big Ass Fans for repairs or replacement we will prepay the shipping and insurance f...

Page 59: ...o follow all relevant codes and ordinances including but not limited to the National Electric Code and state and local building codes c Failure to follow electrical engineering industry standards regarding the approved method of installing solid state electrical equipment having the characteristics of the fan the fan control and their related components even if such standards are not specifically ...

Page 60: ...mbursement apply to a Residential installations b Non residential applications where the initial installation was performed by an installer other than a Big Ass Fans factory approved and certified installer c Installations where the product has been moved subsequent to its initial installation or where any of the other warranty exclusions apply and d Installations involving a product that has been...

Page 61: ...ge for replacement component delivery and original component pickup At that time we will fax you a written acknowledgment of your call that includes a reminder of the return instructions Note Even if you are not able to replace the component immediately following your initial notice to us returning the Warranty Claim Form and Responsibility Agreement will effectively stop the warranty clock from r...

Page 62: ...Официальный дистрибьютор в России Компания ООО Альфа Инвест Инжиниринг 109052 г Москва ул Нижегородская д 50 Сайт www ai engineering ru Эл почта info ai engineering ru Тел 7 499 390 79 31 ...

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