Cardiffair 900 Vantage User manual

COOLING AUSTRALIAN’S FOR OVER 30 YEARS
FAN, MOTOR & LOUVRE
INSTALLATION
MANUAL
Cardiffair is a proud member of the HIA and is an
active company in the HIA Greensmart Program
Cardi Air Control Systems Pty Ltd
Family owned and operated
Unit 3, 28 Cavendish Road, Coorparoo Qld 4151
PO Box 1541, Coorparoo DC, Qld 4151
Ph 1800 800 943
Fax [phone] | Email [email protected]
www.cardiffair.com.au

Cardiffair provides efcient natural
cooling of domestic, industrial and
commercial buildings.
With specialised technology that
quietly replaces hot air, with fresh,
free and more importantly non-
recycled air.
This manual is
designed to provide clear
instructions for Motor
Installation and
assembly of the Fan.
FAN ASSEMBLY
Tools Required
Box Contents
Cardiffair 900 Elite Fan
Motor Mounting Plate /
Bend Bar
Fan Position
Bearing Housing
Fan Tightening
Installation Materials
MOTOR INSTALLATION
Tools Required
Motor
Mount Plate
Mounting Pulley / V Belt
Speed Motor / Variable Speed
Control Box
Speed Sensor Coil Brackets
Motor Pulley
Fan Unit
Motor Capacitor
Switch Positions
Louvre Actuator
LOUVRE ACTUATOR
Parts
Assembley
Installation
1
2
2
4
5
6
9
12
16
18
20
20
21
22
25
27
29
30
31
32
33
34
35
35
36
CONTENTS
1
Motor Installation
FAN ASSEMBLY
Cardiffair Fan Assembly Instructions for 900/1070
Fan Units

Cardiffair provides efcient natural
cooling of domestic, industrial and
commercial buildings.
With specialised technology that
quietly replaces hot air, with fresh,
free and more importantly non-
recycled air.
This manual is
designed to provide clear
instructions for Motor
Installation and
assembly of the Fan.
FAN ASSEMBLY
Tools Required
Box Contents
Cardiffair 900 Elite Fan
Motor Mounting Plate /
Bend Bar
Fan Position
Bearing Housing
Fan Tightening
Installation Materials
MOTOR INSTALLATION
Tools Required
Motor
Mount Plate
Mounting Pulley / V Belt
Speed Motor / Variable Speed
Control Box
Speed Sensor Coil Brackets
Motor Pulley
Fan Unit
Motor Capacitor
Switch Positions
Louvre Actuator
LOUVRE ACTUATOR
Parts
Assembley
Installation
1
2
2
4
5
6
9
12
16
18
20
20
21
22
25
27
29
30
31
32
33
34
35
35
36
CONTENTS
1
Motor Installation
FAN ASSEMBLY
Cardiffair Fan Assembly Instructions for 900/1070
Fan Units

WD40 Spray
Sand Paper
Phillips Head Screwdriver
Large Flat Blade Screwdriver
8mm Ring Open Ender
10mm Ring Open Ender
13mm Ring Open Ender
Adjustable Wrench
3mm Allen Head Key
Stanley Knife
Cable Ties (any small size will do)
Level
Tools required to install motor and control box:
Contents inside box reveal; fan shroud, fan in the middle, pulley, parts box
and bend bars wrapped in plastic.
2Fan Assembly 3
Fan Assembly
Contents show the bearing housing, motor mounting bracket, fan belt,
assembly nuts and bolts, pulley and contents page.
Contents of the complete fan box unpacked and laid out. Contents show 4
bend bars, fan shroud, fan, pulley and parts box.
1
2
4
3

WD40 Spray
Sand Paper
Phillips Head Screwdriver
Large Flat Blade Screwdriver
8mm Ring Open Ender
10mm Ring Open Ender
13mm Ring Open Ender
Adjustable Wrench
3mm Allen Head Key
Stanley Knife
Cable Ties (any small size will do)
Level
Tools required to install motor and control box:
Contents inside box reveal; fan shroud, fan in the middle, pulley, parts box
and bend bars wrapped in plastic.
2Fan Assembly 3
Fan Assembly
Contents show the bearing housing, motor mounting bracket, fan belt,
assembly nuts and bolts, pulley and contents page.
Contents of the complete fan box unpacked and laid out. Contents show 4
bend bars, fan shroud, fan, pulley and parts box.
1
2
4
3

Cardiffair black powder coated 900 Elite fan. These fans also come in
stainless steel and galvanised applications. Fan should be placed on a table for
ease of assembly, at a comfortable working height.
Contents of plastic bag contained in parts box.
The contents of this packet are to suit a Elite 900 fan.
Photos below show the motor mounting plate holes on the bend bar.
When assembling this fan you should always start with the motor mounting
plate bend bar and work around from there. Of the 4 bend bars, you should
have one that has 3 holes in the side closest to the foot of the bend bars.
This identies the motor mounting plate bend bar. You should have 2 bend
bars that have a set of holes along the straight shaft of the bar, to indicate the
bearing housing mount position
The 4th bend bar will have no holes along the shaft, only one hole on the
foot and one hole on the hand.
Place the fan shroud over the top of the fan on the table.
4Fan Assembly 5
Fan Assembly
5
6 8
7

Cardiffair black powder coated 900 Elite fan. These fans also come in
stainless steel and galvanised applications. Fan should be placed on a table for
ease of assembly, at a comfortable working height.
Contents of plastic bag contained in parts box.
The contents of this packet are to suit a Elite 900 fan.
Photos below show the motor mounting plate holes on the bend bar.
When assembling this fan you should always start with the motor mounting
plate bend bar and work around from there. Of the 4 bend bars, you should
have one that has 3 holes in the side closest to the foot of the bend bars.
This identies the motor mounting plate bend bar. You should have 2 bend
bars that have a set of holes along the straight shaft of the bar, to indicate the
bearing housing mount position
The 4th bend bar will have no holes along the shaft, only one hole on the
foot and one hole on the hand.
Place the fan shroud over the top of the fan on the table.
4Fan Assembly 5
Fan Assembly
5
6 8
7

23
This picture shows the bend bars and fan in position around the fan shroud.
There is no particular start point to lay the bend bars out but what you have
to take care in, is that the bars have a running sequence. Start with the motor
mounting plate bend bar and place it at one of the 4 smaller holes punched
around the fan shroud and lay it over the fan in the middle. Then collect a
bearing housing bend bar (1 of 2 supplied) and lay it underneath the hand of
the motor mounting plate bend bar. What you effectively have, is left and over
right. Then take the bend bar with no additional holes along the shaft and lay
it underneath the 2nd bend bar (left hand over right). The last remaining bend
bar (should have 2 holes along the shaft for the bearing housing) is placed
underneath the 3rd bend bar and over the 1st. Again left hand over right.
Place the square piece of nylon (spacer) over the hole on the fan shroud
and underneath the foot of the bend bar.
Push the bolt from the underside of the fan shroud, up through the hole, the
nylon spacer and up through the foot of the bend bar. Place the washer over
the bolt and do the nylock nut up nger tight. Let go of the bend bar.
The smallest bolt, a washer and a nylock nut are used to locate the bend
bars into place. A 13mm spanner on both the nut and washer is generally all
that is needed.
6Fan Assembly 7
Fan Assembly
9
11
10

23
This picture shows the bend bars and fan in position around the fan shroud.
There is no particular start point to lay the bend bars out but what you have
to take care in, is that the bars have a running sequence. Start with the motor
mounting plate bend bar and place it at one of the 4 smaller holes punched
around the fan shroud and lay it over the fan in the middle. Then collect a
bearing housing bend bar (1 of 2 supplied) and lay it underneath the hand of
the motor mounting plate bend bar. What you effectively have, is left and over
right. Then take the bend bar with no additional holes along the shaft and lay
it underneath the 2nd bend bar (left hand over right). The last remaining bend
bar (should have 2 holes along the shaft for the bearing housing) is placed
underneath the 3rd bend bar and over the 1st. Again left hand over right.
Place the square piece of nylon (spacer) over the hole on the fan shroud
and underneath the foot of the bend bar.
Push the bolt from the underside of the fan shroud, up through the hole, the
nylon spacer and up through the foot of the bend bar. Place the washer over
the bolt and do the nylock nut up nger tight. Let go of the bend bar.
The smallest bolt, a washer and a nylock nut are used to locate the bend
bars into place. A 13mm spanner on both the nut and washer is generally all
that is needed.
6Fan Assembly 7
Fan Assembly
9
11
10

Repeat the same process for all 4 bend bars taking care to over-lap the left
hands of each bend bar over the shaft of the bend bar on the right.
A good way to ensure assembly goes right every time, is to start with the
mounting plate bend bar rst, be sure that the bearing housing bend bars are
opposite one another parallel to the motor mounting plate bend bar.
The next step is to locate the bearing housing into place.
Remove all of the rust inhibitor on the shaft of the bearing housing. The
easiest way to do this is to wipe the shaft down with some WD40 and some
sand paper. Do this to both ends of the bearing housing. Make sure the fan
boss has no internal burrs and lubricate the contact surface with WD40. The
shaft and the pulley and fan bosses are designed to be a slide t. Do not
under any circumstances use a hammer.
Once the shaft of the bearing housing has been located ush on the
underside of the fan boss (use index nger to feel the bearing housing shaft
just pass through the fan boss), locate the fan into position using the two grub
screws on the fan boss. Once the fan is located and the grub screws tightened,
do up the lock nuts to ensure the grub screws don’t work their way out.
238Fan Assembly 9
Fan Assembly
12 13
14

Repeat the same process for all 4 bend bars taking care to over-lap the left
hands of each bend bar over the shaft of the bend bar on the right.
A good way to ensure assembly goes right every time, is to start with the
mounting plate bend bar rst, be sure that the bearing housing bend bars are
opposite one another parallel to the motor mounting plate bend bar.
The next step is to locate the bearing housing into place.
Remove all of the rust inhibitor on the shaft of the bearing housing. The
easiest way to do this is to wipe the shaft down with some WD40 and some
sand paper. Do this to both ends of the bearing housing. Make sure the fan
boss has no internal burrs and lubricate the contact surface with WD40. The
shaft and the pulley and fan bosses are designed to be a slide t. Do not
under any circumstances use a hammer.
Once the shaft of the bearing housing has been located ush on the
underside of the fan boss (use index nger to feel the bearing housing shaft
just pass through the fan boss), locate the fan into position using the two grub
screws on the fan boss. Once the fan is located and the grub screws tightened,
do up the lock nuts to ensure the grub screws don’t work their way out.
238Fan Assembly 9
Fan Assembly
12 13
14

Once the fan is located on the shaft then insert the bearing housing bolts
into the bend bars. Push the bolts through from the inside of the square
formed by the bend bars to the outside. Place a washer and a nylock nut on
each bolt. By using the nylock nuts and washers on the outside makes it easier
to service the fan unit down the track.
This photo shows the fan, bend bars and bearing housing in place.
Note: all the nylock nuts have not been tightened at this stage.
The next step in the assembly process is to insert a cardboard square (there
are 3 or 4 provided in the carton to prevent scratching) between the fan
and the fan shroud.
While all the nylock nuts have not been tightened, the use of the cardboard
insert assists in the central alignment of the fan in the fan shroud. This is an
important step because if the tightening sequence of nylock nuts is incorrect,
then the fan will almost certainly hit the shroud.
Once the cardboard is in place then pass the remaining 4 bolts down
through the fan bend bars and use a nylock nut and washer underneath.
Once all four bend bar bolts are in place the fan is starting to take shape. From
here you should do a quick check of how the fan has come together.
1. Check bend bar alignment (left over right)
2. Bend bars in correct positional sequence
3. Fan in place underneath the bearing housing and located correctly
4. Cardboard inserts between the fan and the shroud for fan spacing
5. All the bolts, nylock nuts and washers inserted the right way
6. None of the nylock nuts should be tight
2310 Fan Assembly 11
Fan Assembly
15
16
17
18

Once the fan is located on the shaft then insert the bearing housing bolts
into the bend bars. Push the bolts through from the inside of the square
formed by the bend bars to the outside. Place a washer and a nylock nut on
each bolt. By using the nylock nuts and washers on the outside makes it easier
to service the fan unit down the track.
This photo shows the fan, bend bars and bearing housing in place.
Note: all the nylock nuts have not been tightened at this stage.
The next step in the assembly process is to insert a cardboard square (there
are 3 or 4 provided in the carton to prevent scratching) between the fan
and the fan shroud.
While all the nylock nuts have not been tightened, the use of the cardboard
insert assists in the central alignment of the fan in the fan shroud. This is an
important step because if the tightening sequence of nylock nuts is incorrect,
then the fan will almost certainly hit the shroud.
Once the cardboard is in place then pass the remaining 4 bolts down
through the fan bend bars and use a nylock nut and washer underneath.
Once all four bend bar bolts are in place the fan is starting to take shape. From
here you should do a quick check of how the fan has come together.
1. Check bend bar alignment (left over right)
2. Bend bars in correct positional sequence
3. Fan in place underneath the bearing housing and located correctly
4. Cardboard inserts between the fan and the shroud for fan spacing
5. All the bolts, nylock nuts and washers inserted the right way
6. None of the nylock nuts should be tight
2310 Fan Assembly 11
Fan Assembly
15
16
17
18

Fan tightening sequence.
A tightening sequence is in place to assist the cardboard spacers in preventing
the fan from fouling the shroud. It is important that this sequence is done
properly as the fan will foul the shroud if not done correctly.
To tighten the bolts in the correct order, start at the bearing housing bolts
(marked as indicated) and tighten the diagonals one at a time. Be sure to
tighten the nylock nuts until the bend bar just starts to crimp the washer. This
step applies to all of the fan bolts and washers.
Then start with the diagonals on the bend bars, repeating the same process
as before.
What you are actually doing is working from the inside out, tightening the
bearing housing rst, then the bend bars and nally the fan shroud.
The last bolts to be tightened are the fan shroud bolts.These were the rst
bolts to go into the assembly process but are the last to be tightened.
2312 Fan Assembly 13
Fan Assembly
19 20
21

Fan tightening sequence.
A tightening sequence is in place to assist the cardboard spacers in preventing
the fan from fouling the shroud. It is important that this sequence is done
properly as the fan will foul the shroud if not done correctly.
To tighten the bolts in the correct order, start at the bearing housing bolts
(marked as indicated) and tighten the diagonals one at a time. Be sure to
tighten the nylock nuts until the bend bar just starts to crimp the washer. This
step applies to all of the fan bolts and washers.
Then start with the diagonals on the bend bars, repeating the same process
as before.
What you are actually doing is working from the inside out, tightening the
bearing housing rst, then the bend bars and nally the fan shroud.
The last bolts to be tightened are the fan shroud bolts.These were the rst
bolts to go into the assembly process but are the last to be tightened.
2312 Fan Assembly 13
Fan Assembly
19 20
21

Once the fan has been fully tightened up you can test the fan for fouling by
spinning the fan on the table. As you can see from the picture the fan spins
quite freely with no interference at all. You are now three quarters away from
completing a fan assembly.
Locating the motor mounting plate is easy (this picture shown is for the 900
fan unit). Insert the counter sunk screws into the appropriate mounting holes
(note there is two sets of holes for the 900 or 1070) for the unit size as shown
and do up the nylock nuts.
The only difference is the 1070 unit has the larger nuts behind the mounting
plate and the mounting holes used are closest to the edge of the bracket
2314 Fan Assembly 15
Fan Assembly
NB: 550 fan unit already has the motor mounting plate attached.
900 FAN UNIT:- NO SPACERS
1070 FAN UNIT : HAS SPACERS
22
23
24

Once the fan has been fully tightened up you can test the fan for fouling by
spinning the fan on the table. As you can see from the picture the fan spins
quite freely with no interference at all. You are now three quarters away from
completing a fan assembly.
Locating the motor mounting plate is easy (this picture shown is for the 900
fan unit). Insert the counter sunk screws into the appropriate mounting holes
(note there is two sets of holes for the 900 or 1070) for the unit size as shown
and do up the nylock nuts.
The only difference is the 1070 unit has the larger nuts behind the mounting
plate and the mounting holes used are closest to the edge of the bracket
2314 Fan Assembly 15
Fan Assembly
NB: 550 fan unit already has the motor mounting plate attached.
900 FAN UNIT:- NO SPACERS
1070 FAN UNIT : HAS SPACERS
22
23
24

All materials required to install a Cardiffair System correctly in a Domestic,
Commercial or Industrial application are to be supplied by the installer.
The remaining 12 rubbers grommets (rubber dampers) are pressed into place
around the fan shroud. There are 12 holes in the shroud and every hole will
have a vibration damper. The easiest way to insert these dampers is to lightly
spray the underside of the venturi ring with WD40 and press the damper up
through the hole. It’s extremely hard to insert these without WD40 and they
will split and tear if they are not inserted correctly.
16 Fan Assembly
Congratulations!
You have now completed the Fan Assembly section........ go and have a
cup of tea. While you are having your cup of tea read through the next
section ‘Motor Installation’ and get ready to go.
17
Fan Assembly
25

All materials required to install a Cardiffair System correctly in a Domestic,
Commercial or Industrial application are to be supplied by the installer.
The remaining 12 rubbers grommets (rubber dampers) are pressed into place
around the fan shroud. There are 12 holes in the shroud and every hole will
have a vibration damper. The easiest way to insert these dampers is to lightly
spray the underside of the venturi ring with WD40 and press the damper up
through the hole. It’s extremely hard to insert these without WD40 and they
will split and tear if they are not inserted correctly.
16 Fan Assembly
Congratulations!
You have now completed the Fan Assembly section........ go and have a
cup of tea. While you are having your cup of tea read through the next
section ‘Motor Installation’ and get ready to go.
17
Fan Assembly
25

MOTOR INSTALLATION
Cardiffair motor installation and MKIII variable speed
control box to suit ALL Cardiffair model units 550,
900 and 1070 fans
18 19
Motor Installation Motor Installation