4Front Engineered Solutions 6022500 User manual

Direct Drive HVLS Fan
User's Manual
E506041
User’s Manual
Installation, Operations
Maintenance and Parts
Do not install, operate, or service this product
unless you have read and understand the
Safety Practices, Warnings, and Installation and
Operating Instructions contained in this manual.
Failure to do so could result in death or serious
injury.
This manual applies to fans manufactured
beginning September 2021.
Part No. 6022221B

A part of ASSA ABLOY
© ASSA ABLOY

November 2022 6022221B - Direct Drive HVLS Fan UM 3
Warranty
WARRANTY
THIS LIMITED WARRANTY IS 4FRONT’S SOLE AND EXCLUSIVE WARRANTY WITH RESPECT TO THE
HVLS FAN AND IS IN LIEU OF ANY OTHER GUARANTEES OR WARRANTIES, EXPRESS OR IMPLIED. THIS
LIMITED WARRANTY APPLIES ONLY TO THE ORIGINAL PURCHASER OF THE HVLS FAN AND CANNOT BE
TRANSFERRED.
4FRONT warrants that this HVLS FAN will be free from aws in material and workmanship under normal use for a period
of one (1) year from the earlier of 1) 60 days after the date of initial shipment by 4FRONT, or 2) the date of installation of
the HVLS FAN by the original purchaser, provided that the owner maintains and operates the HVLS FAN in accordance
with this User’s Manual.
In the event that this HVLS FAN proves decient in material or workmanship within the applicable Limited Warranty
period, owner shall so notify 4FRONT, and 4 Front will, at its option:
1. Replace the HVLS FAN, or the decient portion(s) thereof, without charge to the owner (to include all parts and
labor); or
2. Alter or repair the HVLS FAN, on site or elsewhere, without charge to the owner.
In addition, 4FRONT warrants the HVLS FAN for fourteen (14) years for Mechanical and six (6) years for Electrical.
Mechanical is dened as mechanical components of the fan, including the fan hub, mounting airfoils and winglets.
Electrical is dened as all electrical components of the fan including the motor, Variable Frequency Drive, and all
components or the VFD panel, not including the touchscreen. The warranty for the touchscreen is one (1) year.
Exclusions to the limited warranty: U.S. and Canada only. For international, contact the factory.
This Limited Warranty does not cover any failure caused by improper installation including mounting location and
exclusion zone violations, abuse, improper operation, negligence, or failure to maintain and adjust the HVLS FAN
properly. Parts requiring replacement due to damage resulting from vehicle impact, abuse, or improper operation are not
covered by this warranty. 4FRONT DISCLAIMS ANY RESPONSIBILITY OR LIABILITY FOR ANY LOSS OR DAMAGE
OF ANY KIND (INCLUDING WITHOUT LIMITATION, DIRECT, INDIRECT, CONSEQUENTIAL OR PUNITIVE DAMAGES,
OR LOST PROFITS OR LOST PRODUCTION) arising out of or related to the use, installation or maintenance of the
HVLS FAN (including premature product wear, product failure, property damage or bodily injury resulting from use of
unauthorized replacement parts or modication of the HVLS FAN). 4FRONT’s sole obligation with regard to a HVLS
FAN that is claimed to be decient in material or workmanship shall be as set forth in this Limited Warranty. This Limited
Warranty will be null and void if the original purchaser does not notify 4FRONT’s warranty department within ninety (90)
days after the product deciency is discovered.
THERE ARE NO WARRANTIES, EXPRESS OR IMPLIED, WHICH EXTEND BEYOND THE DESCRIPTION ON THE
FACE HEREOF, INCLUDING, BUT NOT LIMITED TO, A WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A
PARTICULAR PURPOSE, ALL OF WHICH 4FRONT HEREBY DISCLAIMS.
Warranty and Factory Service Request
Procedure
HVLS Warranty Request
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4 6022221B - Direct Drive HVLS Fan UM November 2022
TABLE OF CONTENTS
WARRANTY.................................................................................................................................... 3
INTRODUCTION ............................................................................................................................ 7
USER MANUAL ........................................................................................................................ 7
HOW TO USE HOW TO USE THIS MANUAL........................................................................ 7
SAFETY SIGNAL WORDS....................................................................................................... 8
OPERATIONAL SAFETY......................................................................................................... 9
OWNER’S RESPONSIBILITIES............................................................................................ 12
NATIONAL FIRE PROTECTION ASSOCIATION STANDARD .......................................... 13
HARDWARE ................................................................................................................................. 14
FAN KIT......................................................................................................................................... 15
PACKING KIT (STANDARD) ................................................................................................. 15
REQUIRED TOOLS ................................................................................................................ 15
PRIOR TO FAN INSTALLATION........................................................................................... 15
FOR OPTIONAL NETWORK (IFAN OR MULTI-FAN FANS ONLY)................................... 16
INSTALLATION CONSIDERATIONS ......................................................................................... 17
ROOF SLOPE ......................................................................................................................... 17
ROOF ANGLES....................................................................................................................... 18
CLEARANCE FROM HVAC EQUIPMENT ........................................................................... 19
CLEARANCE FROM SOLID OBSTRUCTIONS .................................................................. 21
BUILDING STRUCTURE ....................................................................................................... 22
INSTALLATION ............................................................................................................................ 24
INSTALL FAN MOUNT ........................................................................................................... 24
INSTALL THE POWERHEAD (MOTOR ASSEMBLY)......................................................... 26
INSTALL THE VFD BOX ........................................................................................................ 27
INSTALL GUY WIRES............................................................................................................ 28
INSTALL MOTOR COVER ..................................................................................................... 29
INSTALL BLADES.................................................................................................................. 30
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November 2022 6022221B - Direct Drive HVLS Fan UM 5
VERIFY CLEARANCE AND CABLE TENSION................................................................... 31
INSTALL THE REMOTE CONTROL..................................................................................... 32
ELECTRICAL SCHEMATICS...................................................................................................... 33
1PH WIRING DETAILS.......................................................................................................... 33
VARIABLE FREQUENCY DRIVE I/O.................................................................................... 36
MULTI-FAN WIRING DETAILS — OPTIONAL..................................................................... 37
IFAN WIRING DETAILS ......................................................................................................... 38
TEMPERATURE/HUMIDITY CONTROL WIRING DETAILS — OPTIONAL ..................... 39
FIRE CONTROL SYSTEM FAN SHUTDOWN — OPTIONAL ............................................ 40
FIRE CONTROL SYSTEM FAN SHUTDOWN — STANDARD INSTALLATION (6015291)42
FIRE CONTROL SYSTEM FAN SHUTDOWN — NETWORK INSTALLATION (6020547)43
550-600V SUPPLY WIRING DETAILS — OPTIONAL ......................................................... 44
HMI SETUP................................................................................................................................... 45
DEFINE THE NUMBER OF FANS........................................................................................ 45
SET THE DIAMETER OF THE FANS ................................................................................... 45
ENABLE THE TEMPERATURE CONTROL OPTION (OPTIONAL) ................................. 46
SET THE TEMPERATURE SETTINGS................................................................................. 46
ENABLE THE WIND CONTROL OPTION............................................................................ 46
SET THE UNIT OF WIND SPEED ......................................................................................... 47
CORRECT ERRORS DURING HMI CONFIGURATION...................................................... 47
POST CONFIGURATION TASKS ........................................................................................ 47
TEMPERATURE CONTROL INSTALLATION — OPTIONAL ............................................ 48
WIND CONTROL INSTALLATION — OPTIONAL .............................................................. 48
OPERATING INSTRUCTIONS.................................................................................................... 49
FAN CONTROL SCREEN ...................................................................................................... 49
VERIFY PRIOR TO OPERATION.......................................................................................... 50
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6 6022221B - Direct Drive HVLS Fan UM November 2022
LOGIN SCREEN ..................................................................................................................... 50
START THE FAN..................................................................................................................... 50
CHANGE THE FAN DIRECTION........................................................................................... 51
DIAGNOSTIC SCREEN.......................................................................................................... 51
BUTTON INFORMATION....................................................................................................... 52
FAULT CODE .......................................................................................................................... 52
FAULT CODE DEFINITIONS ................................................................................................. 53
PASSCODE PROTECTION ................................................................................................... 54
MULTI-FAN CONTROL — OPTIONAL ................................................................................. 55
TEMPERATURE CONTROL — OPTIONAL......................................................................... 55
PLANNED MAINTENANCE ........................................................................................................ 57
ANNUAL MAINTENANCE ..................................................................................................... 57
TROUBLESHOOTING GUIDE .................................................................................................... 59
VARIABLE FREQUENCY DRIVE FAULT CODES.................................................................... 61
COMPONENTS AND SPECIFICATIONS................................................................................... 62
VFD BOX ................................................................................................................................. 62
MOTOR ................................................................................................................................... 62
PARTS LIST.................................................................................................................................. 64
FAN........................................................................................................................................... 65
VFD BOX ................................................................................................................................. 68
REMOTE CONTROL PANEL................................................................................................. 71
TEMPERATURE CONTROL — OPTIONAL......................................................................... 72
NOTES .......................................................................................................................................... 73
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November 2022 6022221B - Direct Drive HVLS Fan UM 7
Introduction
INTRODUCTION
Welcome and thank you for choosing this Direct Drive fan from 4Front Engineered Solutions, Inc.
USER MANUAL
This User’s Manual contains information you need to safely install, operate, and maintain the fan. It
also contains a complete parts list and information about ordering replacement parts. Please keep
and read this User’s Manual before using your new fan.
HOW TO USE HOW TO USE THIS MANUAL
This section explains the visual clues and conventions that will help you quickly locate the information
you need. Other conventions and icons identify interactive elements that will provide additional
information when using the online version of this manual.
BASIC ELEMENTS
zNames of menus, buttons, icons, and elds are highlighted in bold text
zText highlighted in blue indicates a link you can click to navigate to another topic.
INTERACTIVE ONLINE ELEMENTS
These elements are available in the online version of the document. The URL for the online version is
provided on the back page of the manual. Scan the QR code above the URL for quick access to the
online document.
zNumbered blue circles on diagrams and gures indicates a link to more information about the
numbered part or element. Click on the circle for additional information.
zA pointing hand icon next to a gure indicates that the gure is interactive. Click on the gure for
a di󰀨erent view of the feature or part or for additional information.
zA play button (triangle) on a gure indicates a video that provides additional information about the
part or feature. Click on the triangle to play the video.
The blue TOC icon at the top of every page takes you back to the Table of Contents.
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8 6022221B - Direct Drive HVLS Fan UM November 2022
Introduction
SAFETY SIGNAL WORDS
You may nd safety signal words such as DANGER, WARNING, CAUTION, or NOTICE in the User’s
Manual. The use of Safety Signal Words is explained below.
WARNING AND CAUTION SYMBOL
This symbol is the Safety alert symbol. It is used to alert you to potential personal injury hazards,
Obey all safety messages that follow this symbol to avoid possible death or injury..
DANGER SYMBOL
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
ELECTRICAL WARNING SYMBOL
Indicates an electrical hazard with a medium level of risk that could result in death or serious
injury.
CAUTION SYMBOL
Indicates a potentially hazardous situation, which, if not avoided may result in minor or moderate
injuries.
WARNING SYMBOL
Indicates a potentially hazardous situation, which, if not avoided, could result in death or serious
injury.
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November 2022 6022221B - Direct Drive HVLS Fan UM 9
Introduction
NOTICE SYMBOL
Notice is used to address practices not related to personal injury.
OPERATIONAL SAFETY
READ THESE SAFETY PRACTICES BEFORE INSTALLING, OPERATING, OR SERVICING
THE FAN.
READ AND FOLLOW THE OPERATING INSTRUCTIONS IN THIS MANUAL BEFORE
OPERATING THE FAN. If you do not understand the instructions, ask your supervisor for
instruction.
To reduce the risk of personal injury, do not bend the blade brackets when installing the brackets
or cleaning the fan. Do not insert foreign objects in between rotating fan blades.
To reduce the risk of re, HVLS fan motor assemblies must be installed with the blade
assemblies that are marked on their cartons to indicate the suitability with this model,
Other blade assemblies cannot be substituted.
Be certain to follow the instructions in this manual.
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10 6022221B - Direct Drive HVLS Fan UM November 2022
Introduction
Installation of the equipment must comply with local and national electrical codes and must be in
accordance with ANSI/NFPA 7-1999.
Do not use this fan until you have received proper training. Improper use could result in property
damage, bodily injury and/or death. Read and follow Operating Instructions on page 49 before
use. If you do not understand the instructions, ask your supervisor to explain them to you or call
your local distributor.
DO NOT USE THE FAN IF IT APPEARS DAMAGED OR DOES NOT OPERATE PROPERLY.
Inform your supervisor immediately.
Do not operate the fan until all personnel, building structure, and equipment are clear of all
moving parts and exclusion zones. Install guards as required.
To reduce the risk of electrical shock, do not expose to water or rain.
Support directly from building structure. Do not install the fan unit onto structure of insucient
strength. Consult a professional engineer or registered architect. Improper installation of the fan
could result in death or serious injury.
Before service, inspection, or cleaning, make certain the power is disconnected and properly
locked out.
If the fan does not operate properly using the procedures in this manual, BE CERTAIN TO
REMOVE POWER FROM THE UNIT AND LOCK-OUT THE DISCONNECT ON THE POWER
CIRCUIT. Call your local distributor for service.
Keep your body clear of moving parts at all times.
All electrical troubleshooting and repair must be done by a qualied technician and meet all
applicable codes.
If it is necessary to make troubleshooting checks inside the VFD box with the power on, USE
EXTREME CAUTION. Do not place ngers or un-insulated tools inside the enclosure. Touching
wires or other parts inside the enclosure could result in electrical shock, death, or serious injury.
Variable Frequency Drive (VFD) fan controllers contain high voltage capacitors. Before working
on the fan controller, ensure isolation of the main voltage supply and verify voltage has bled o
prior to beginning work. Failure to do so may result in death or serious injury.
If you have problems or questions, contact your local distributor for assistance.
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November 2022 6022221B - Direct Drive HVLS Fan UM 11
Introduction
To reduce the risk of injury to persons, install fan so that the blades are at least 3.05m (10’)
above the oor.
Installation work and electrical wiring must be done by qualied person(s) in accordance
with all applicable codes and standards.
When cutting or drilling into wall or ceiling, do not damage electrical wiring and other hidden
utilities.
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.
When service or replacement of a component in the fan requires the removal of disconnection of
a safety device, the safety device is to be reinstalled or remounted as previously installed.
Risk of re, electric shock, or injury to persons during cleaning and user-maintenance.
Disconnect the fan from the power supply before servicing.
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12 6022221B - Direct Drive HVLS Fan UM November 2022
Introduction
Stay alert, watch what you are doing, and use common sense when installing fans. Do not install
fans when tired, or under the inuence of drugs, alcohol, or medications. A moment of inattention
while installing fans may result in serious personal injury.
The installation of this fan requires the use of some power tools. Follow the safety procedures
found in the owner’s manual for each of these tools and do not use them for purposes other than
intended by the manufacturer.
OWNER’S RESPONSIBILITIES
The owner’s responsibilities include the following:
The owner should recognize the inherent danger of the interface between the fan and shop worker.
The owner should, therefore, train and instruct operators in the safe use of the industrial fan.
Nameplates, cautions, instructions and posted warnings shall not be obscured from the view of
operating or maintenance personnel for whom such warnings are intended. Warnings which are worn
or non-legible should be replaced.
Manufacturer’s recommended periodic maintenance and inspection procedures in e󰀨ect at date of
shipment shall be followed, and written records of the performance of these procedures should be
kept.
Direct Drive fans that are structurally damaged or have experienced impacts from external sources,
shall be removed from service, inspected by the manufacturer’s authorized representative, and
repaired as needed before being placed back in service.
The owner shall see that all nameplates and caution and instruction markings or labels are in place
and that the appropriate operating and maintenance manuals are provided to users.
Modications or alterations of Direct Drive fans shall be made only with written permission of the
original manufacturer.
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November 2022 6022221B - Direct Drive HVLS Fan UM 13
Introduction
NATIONAL FIRE PROTECTION ASSOCIATION STANDARD
In accordance with NFPA 13 Standard from the National Fire Prevention Association as referenced in
sections 12.1.4 and 11.1.7: High Volume Low Speed (HVLS) Fans: The installation of HVLS fans in
buildings equipped with sprinklers, including ESFR sprinklers, shall comply with the following:
zThe maximum fan diameter shall be 24 feet (7.3m).
zThe fan shall be approximately centered between four adjacent sprinklers.
zThe vertical clearance from the fan to the sprinkler deector shall be a minimum of 3 feet (0.9m).
zAll fans shall be interlocked to shut down immediately upon receiving a water ow signal from the
alarm system in accordance with the requirements of NFPA 72-National Fire Alarm and Signaling
Code.
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14 6022221B - Direct Drive HVLS Fan UM November 2022
Hardware
HARDWARE
(x4) 1/2-13UNC x 2-1/2
Mount ─ Building
(x4) 1/2-13UNC lock nut
Guy wire assembly
Safety cable
(x20) 3/8-16UNC lock nut
Mount ─ Blade
SCREW, TEKS4, HWH, #12-24 X 7/8
Mount ─ Fan cover
Identification labels
Fan diameter
Fan diameter
Voltage
Fan ID label
(optional)
Fastener torque requirements
Description Torque Wrench size
1/2 dia mount hardware 44-48 ft-lbs. 3/4 hex
3/8 dia blade mount hardware 24-28 ft-lbs. 9/16 hex
Cable clamp, guy wire Secure tight 5/16 nut driver
Cable clamp, safety cable Secure tight 1/2 nut driver
5/16 nut driver
Motor cover fastener Secure tight
(x4) 1/2-13UNC x 1-1/4 bolt
(x4) 1/2-13UNC lock nut
Mount ─ Motor frame
(x2) 1/2-13UNC x 4-1/2 bolt
(x4) 1/2 dia. washer
(x2) 1/2-13UNC nyloc lock nut
Mount ─ Assembly
NOTE:
Additional spare hardware is provided as a courtesy.
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November 2022 6022221B - Direct Drive HVLS Fan UM 15
Fan Kit
FAN KIT
PACKING KIT (STANDARD)
1. Blade Box - Five (5) blades
2. Fan Motor Box
a. Motor assembly with covers.
b. Remote control panel with junction box (optional)
c. Category 5e cable - 100 ft (blue) (optional)
d. Mounting hardware - See Hardware on page 14
e. Variable Frequency Drive (VFD) box
REQUIRED TOOLS
zWrenches: 7/16, 9/16, 3/4 (x2), 1/2
zSockets: 7/16, 1/2, 9/16, 3/4
zNut drivers: 1/4, 5/16
zTorque wrench: 15-60 Ft-lbs (for use with sockets)
zWire strippers
z1/4” cable cutter
zTape measure
zSpirit level, short
zGloves
zFor laminated wood beam installations, a drill and 1/2” dia. drill bit are required.
PRIOR TO FAN INSTALLATION
1. Ensure the supplied voltage matches the fan voltage. A label containing voltage information
specic to the individual fan is located on top of the VFD box.
2. Ensure the blade length matches the fan model size by consulting the fan model designation
located on the side of the fan powerhead frame.
3. Ensure all mounting hardware shown in Hardware on page 14 is present.
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16 6022221B - Direct Drive HVLS Fan UM November 2022
Fan Kit
FOR OPTIONAL NETWORK (IFAN OR MULTI-FAN FANS ONLY)
Ensure the Fan Network Address number matches the network layout drawing where applicable.
Consult the square Network Address label on the front of the VFD enclosure.
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November 2022 6022221B - Direct Drive HVLS Fan UM 17
Installation Considerations
INSTALLATION CONSIDERATIONS
Figure 1
ROOF SLOPE
The chart below does not account for any possible obstructions below the mounting positions. All
fans must still maintain 3’ between blades and typical obstructions.
DIRECT DRIVE FAN
Roof Slope* 0 2/12 3/12 4/12 Hanging
Weight
(LB)
Maximum
Torque
(Ft. Lb.)
Roof Angle* 0 9.5° 14.0° 18.4° Blade
Length (in)
Fan Diameter Extension requirement from mounting point (FT)
8 0 1 1 2 179.1 300 21.16
10 0 1 2 2 187.4 300 33.16
12 0 1 2 2 195.8 300 45.16
14 0 2 2 3 230.0 300 57.16
16 0 2 2 3 238.7 300 69.16
18 0 2 3 3 247.0 300 81.16
20 0 2 3 4 255.4 300 93.16
24 0 2 3 4 272.1 300 117.16
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18 6022221B - Direct Drive HVLS Fan UM November 2022
Installation Considerations
* Non-standard obstructions may require additional length to the extensions. Please consult the
factory for additional clarication on non-standard obstructions and assistance with fan placement
and extension selection.
Failure to maintain exclusion zones outlined in this section could result in fan failures, including
blade separation, which could result in death or serious injury.
DO NOT operate fans when physical obstructions or HVAC air ows extend into exclusion zones.
Regularly inspect fans to ensure exclusion zones remain clear of interference before operating
the fan.
All fan blade parts must be greater than 3’ from all obstructions including lights, cables, sprinklers,
and other building components and greater than one half (1/2) fan diameter from any wall to the end
of the blade.
ROOF ANGLES
For roof angles in excess of 20°, consult the factory. The extension lengths shown are minimum
recommendations only, based solely o󰀨 roof pitch and fan diameter. Other considerations, such as
placement of lights, sprinkler systems, HVAC systems, etc., must be evaluated when determining
extension requirements. OSHA requirements state that fan blades must be at minimum 10’ above the
oor.
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November 2022 6022221B - Direct Drive HVLS Fan UM 19
Installation Considerations
CLEARANCE FROM HVAC EQUIPMENT
For applications near HVAC equipment, such as di󰀨users, radiant heaters, exhaust fans, louvers, etc.,
the HVLS fan must be installed at minimum distances. Refer to the gures below. Fans located above
HVAC equipment must have a minimum clearance of greater than or equal to 1 fan diameter. See
Figure 2.
Figure 2
Greater than
1 fan dia.
Placement of the Fan
Click here to view the video
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20 6022221B - Direct Drive HVLS Fan UM November 2022
Installation Considerations
Fans located at or below HVAC equipment musts have a minimum clearance of greater than or equal
to 2 fan diameters. See Figure 3.
Figure 3
Greater than
2 fan dia.
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