4Front Engineered Solutions HVLS Series User manual


Installation, Operations,
Maintenance and Parts
Part No. 6015653B
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 User’s Manual. Failure to do so could result in death
or serious injury.
This manual applies to fans
manufactured beginning May
2014 with serial numbers
F61111180 and higher.


©2014 4Front® Engineered Solutions, Inc.
2 6015653B — HVLS Fans May 2014
You may nd safety signal words such as DANGER, WARNING, CAUTION or NOTICE throughout this User’s
Manual. Their use is explained below:
Indicates an imminently hazardous situation which,
if not avoided, will result in death or serious injury.
Indicates a potentially hazardous situation which, if
not avoided, could result in death or serious injury.
Indicates a potentially hazardous situation which, if
not avoided may result in minor or moderate injury.
Notice is used to address practices not related to
personal injury.
This 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.

Introduction .................................................................2
Safety Signal Words ..................................................2
Safety Practices..........................................................3
Owner’s Responsibilities ............................................4
Hardware ....................................................................5
Fan Kit ........................................................................6
Installation Considerations .........................................7
Installation ..................................................................9
Components and Specications ...............................16

Operating Instructions ..............................................17
Planned Maintenance ...............................................21
Troubleshooting Guide .............................................22
VFD Fault Codes ......................................................24
Fire Control System Option ......................................25
Electrical Schematics ...............................................26
Parts List...................................................................31
Warranty Information ................................................43
Distributor Information ..............................................44

Welcome and thank you for choosing this industrial fan from 4Front® Engineered Solutions, Inc.
This User’s Manual contains information that 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.

©2014 4Front® Engineered Solutions, Inc.
May 2014 6015653B — HVLS Fans 3

Read these safety practices before installing, operating
or servicing the fan. Failure to follow these safety
practices could result in death or serious injury.
READ AND FOLLOW THE OPERATING INSTRUCTIONS
IN THIS MANUAL BEFORE OPERATING THE FAN. If you
do not understand the instructions, ask your supervisor
to teach you how to use the fan.
Be certain to follow the instructions in this manual.
If you do not understand the instructions, ask your supervisor
to explain them to you or call your authorized local distributor.

Do not use this industrial fan until you have received proper
training. Improper use could result in property damage,
bodily injury and/or death. Read and follow the complete
OPERATING INSTRUCTIONS on pages 17-20 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 moveable equipment are clear of all moving parts. Install
guards as required.
Do not install the fan unit onto structure of insuf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
that 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 off 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.

©2014 4Front® Engineered Solutions, Inc.
4 6015653B — HVLS Fans May 2014
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The owner’s responsibilities include the following:
The owner should recognize the inherent danger of the
interface between the industrial 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 effect at date of shipment shall be
followed, and written records of the performance of these
procedures should be kept.
Industrial 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 industrial fans shall be made
only with written permission of the original manufacturer.

©2014 4Front® Engineered Solutions, Inc.
May 2014 6015653B — HVLS Fans 5
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(x4) 1/2-13UNC x 2-1/2
Mount ─ Building
(x4) 1/2-13UNC lock nut
(x2) 1/2-13UNC x 4-1/2 bolt
(x2) 1/2 dia. washer
(x2) 1/2-13UNC nyloc lock nut
(x12) 3/8-16UNC lock nut
(x8) #12 14 x 3/4 TEKS
Guy wire assembly
Safety cable
Mount ─ Assembly
Mount ─ Blade
Mount ─ Fan cover
Identification labels
Fan diameter
Fan diameter
Voltage
Voltage
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
3/8 dia safety bracket hardware 24-28 ft-lbs. 9/16 hex
1-3/4 dia hub retaining nut 125 ft-lbs. 1-3/4 hex
1/2 dia hub cover fastener 44-48 ft-lbs. 3/4 hex
Cable clamp, guy wire Secure tight 1/4 nut driver
Cable clamp, safety cable Secure tight 5/16 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

©2014 4Front® Engineered Solutions, Inc.
6 6015653B — HVLS Fans May 2014
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1. Blade Box – 5 each
2. Fan Motor Box
a. Motor/gearbox assembly with covers.
b. Remote control panel with junction box.
c. Category 5e cable set – 100 ft (one blue, one gray)
d. Mounting hardware. See page 5.
e. VFD box.

See iFAN user's manual 6015948.

• Wrenches: 7/16, 9/16, 3/4 (x2), 1/2
• Sockets: 7/16, 1/2, 9/16, 3/4, 1-3/4
• Nut drivers: 1/4, 5/16
• Torque wrench: 15-60 Ft-lbs (for use with sockets)
• Wire strippers
• 1/4" cable cutter
• Tape measure
• Spirit level, short
• Gloves
• For laminated wood beam installs, a drill and 1/2" dia.
drill bit are required.

1. Ensure that 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 blade length matches fan model size. See Fig.
1. Consult fan model designation located on the side of
the fan powerhead frame.
3. Ensure all mounting hardware shown on page 5 is present.

Ensure fan number matches network layout. Consult the
round, network ID number label on shipping box.


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:
• The maximum fan diameter shall be 24 feet (7.3 m).
• The fan shall be approximately centered between four
adjacent sprinklers.
• The vertical clearance from the fan to sprinkler deector
shall be a minimum of 3 feet (0.9 m).
• All 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.

©2014 4Front® Engineered Solutions, Inc.
May 2014 6015653B — HVLS Fans 7
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


For roof angles in excess of 20°, consult factory. The extension lengths shown are minimum recommendations only, based
solely of roof pitch and fan diameter. Other considerations must be evaluated when determining extension requirements,
such as placement of lights, sprinkler systems, HVAC systems, etc. In addition, OSHA requirements state that fan blades
must be a minimum of 10' above the oor.
*Consult your local distributor for assistance with fan placement and extension selection.
Roof slope = rise
run rise
run
Angled roof beam
Exclusion zone
Extension (optional)
Pendant
light
Length
(ft.)
12" (std. with fan)
Blade length
24"
radius
Fig. 1
300
300
300
300
300
300
300
300
300
Roof Slope*
2/12 4/12
Roof Angle* 9.5° 18.4°
Fan Diameter (Ft)
Recommended Extension Length (Ft)
Exclusion Zone
Radius (In.)
8
6
N/A N/A
8 N/A N/A 1 1 2
10 N/A 2
12 N/A 2
1
1
14 2 3
16 2 4
18 3 4
20 3 5
24 4 6
Hanging
Weight
(Lb)
Maximum
Torque
(Ft. Lb)
160
140
181
190
194
208
203
220
258
N/A
3/12
14.0°
N/A
3
4
4
5
N/A N/A
Extension Length (Ft.)
15
15
15
15
15
30
30
30
30
Blade length (In.)
27.5
25.0
39.5
51.5
63.5
75.5
87.5
99.5
123.5
2

©2014 4Front® Engineered Solutions, Inc.
8 6015653B — HVLS Fans May 2014
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
For open structure roof designs, the fan should only be hung
from either I-beam or angle iron. Do not hang from purlins,
joists or truss structure.
For solid beam or laminated wood beam mounting, use the
laminated wood beam mounting kit available from 4Front.
Consult a professional engineer or registered architect for
specic mounting concerns.
Ensure fan blade clearance meets the requirements. See
Fig. 1.

Consult your local distributor to help you plan the most
efcient installation of your fans.
Ensure fan placement is such that the fans blades are a
minimum of 10' from any manned working suface (oor or
mezzanine)
Ensure fan blade does not extend into exclusion zone.
Extensions are available if required. See Fig. 1.
Avoid mounting fans directly under lights or skylights to
avoid visual strobing affect.

If the fan is part of a networked system, ensure placement is in
accordance with the building layout. Fan network identication
number is located on the front panel of the VFD box.

Be certain to comply with all local and national codes during
installation.
Fig. 2
1/2-13UNC x 4-1/2 (x2)
1/2 dia washer (x2)
Pivot bracket
Mount tube

©2014 4Front® Engineered Solutions, Inc.
May 2014 6015653B — HVLS Fans 9

Fig. 4
Building structure
Clamp plate
Shim
Fig. 3
Pivot bolt
Shim (x2)
(as req’d)
1/2-13UNC x 2-1/2 bolts (x4)
1/2-13UNC
lock nut (x4) Angle
adjustment
bolt

1. Fasten pivot brackets to the extension tube with ears
outboard. Leave the 1/2" dia. x 4-1/2" bolts and nylock
nuts nger tight. See Fig. 2.


1. Locate fan mount assembly on bottom of building support
beam. Align mount assembly so that it is centered and
square to the beam. Orient mount such that the pivoting
axis is aligned with the building slope if required. See Fig.
3.
2. Install clamps. For thick ange I-beams add shims as
required. Fasten using the supplied 1/2" dia x 2-1/2"
screws, lock nuts and washers. Torque to 44-48 ft-lbs.
See Fig. 4.

©2014 4Front® Engineered Solutions, Inc.
10 6015653B — HVLS Fans May 2014
If building support beam is not level, ensure proper
fan clearance using the mounting information shown
on page 7 or add mounting extensions as required to
ensure clearance. See Fig. 1.


1. Attach laminated wood beam brackets to the wooden
beam using a minimum of four 1/2" dia. grade 5 thru bolts
(not supplied). Ensure brackets are square to the bottom
of the beam.
2. Attach mount assembly to the laminated wood beam
brackets using the supplied 1/2" dia x 2-1/2" screws,
nylock lock nuts and washers. Torque to 44-48 ft-lbs. See
Fig. 5.

1. Using a powered lift, orient the powerhead with the blade
hub down. Block motor as required for installation using
the bottom of the frame assembly. Do not support using
the hub or hub cap.

Fan powerhead may be oriented as required for aesthetics
or commonality.
2. Raise the powerhead up until it contacts the bottom of
the fan mount assembly. See Fig. 6.
3. Immediately attach safety cable. See Fig. 8.
a. Slide two of the supplied 1/4" dia cable clamps over
each end of the cable spaced 6" apart.
b. Slide the ends through the cable clamps.
c. Make sure that the cable goes through the motor
frame.
e. Securely tighten the clamp fasteners. Make sure the
u-bolts are over the free ends of the cable.
f. Ensure assembly does not interfere with fan motor
housing.
4. Fasten the powerhead to the mount assembly using the
supplied 1/2" dia x 1-1/4" bolts, nylock lock nuts and
washers. Torque to 44-48 ft-lbs. See Fig. 7.
If a mounting extension has been used, it may be necessary
to obtain a longer cable from a local supplier.
Fig. 5
Fig. 6
Fig. 7
 continued
Laminated wood
beam bracket
Laminated wood beam
Mount tube
Powerhead
1/2-13UNC x 1-1/4
bolt (x4)
1/2-13UNC
lock nut (x4)