Caryaire LVLS Manual

INSTALLATION MAINTENANCE MANUALLVLS FAN
CARYAIRE EQUIPMENTS INDIA PVT. LTD.
Head office :- B-34 sector-85 Noida UP 201305 India.
Works:- I-61 Site v Surajpur Industrial Area Kasna Greater Noida UP 201306 India.

LVLS FAN
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FIG-1

LVLS FAN
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CONTENTS
1) Table of Contents-------------------------------------------------
2) Important Information------------------------------------------
3) Pre-Installation Item Check List------------------------------
4) Technical details-------------------------------------------------
5) VFD Controller Installation------------------------------------
6) Different Mounting Arrangements---------------------------
7) Retaining/Safety Cable Installation--------------------------
8) Guy /Guide Wire Installation----------------------------------
9) Motor Wiring & Rotation Check-------------------------------
10) Blade Fixing-------------------------------------------------------
11) Trial Check--------------------------------------------------------
12) Fan Maintenance schedule------------------------------------
13) Packing List -----------------------------------------------------
03
04
05
06
07
08
12
13
14
15
1
6
16
18

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Technical Information
Fan size in
Diameter
8 Ft. 10 Ft. 12 Ft. 16 Ft. 20 Ft. 24 Ft.
2.4M 3.0M 3.7M 4.9M 6.1M 7.3M
Motor Power 1.5 HP 1.5 HP 1.5 HP 2 HP 2 HP 2 HP
1.1 KW 1.1 KW 1.1 KW 1.5 KW 1.5 KW 1.5 KW
Ampere
At 400 volt
2.42 A 2.42 A 2.42 A 3.35 A 3.35 A 3.35 A
Speed (RPM) 154 140 123 73 63 56
Air flow
CMH(Approx.)
64 500 1 56 000 2 06 000 2 80 500 5 04 900 612000
Maximum
Coverage
Diameter
9.4M/30.8Ft 15.8M/51.8Ft 21.3M/69.9Ft 36M/118Ft 42M/138Ft 50M/164Ft
Weight (Kg) 98 104 108 124 132 140
Important information:-
-Fan for se wareho ses, A to Plants, Distrib tion Centers, Man fact ring nits, Gyms,
Banq et Halls, Retail Stores and Worship Centers and all areas where air ventilation and
air circ lation req ire.
-This appliance is not intended for se by persons (incl ding children) with red ced
physical, sensory or mental capabilities, or lack of experience and knowledge, nless
they have been given s pervision or instr ction concerning se of the appliance by a
person responsible for their safety.
-Use CE certify cable for better performance and better safety.
-If the s pply cord is damaged, it m st be replaced by the man fact rer, its service agent
or similarly q alified persons in order to avoid a hazard.
Tools Req ired For Installation
•Level indicator
•Cable C tters(for stainless steel aircraft cables)
•Ratchet or Impact g n
•Basic Metric socket set
•Basic metric wrench set
•Lifting Device or Scaffolding

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Pre-Installation Item Check List
Hardware
1) VFD controller received is as per rated Voltage and Phase
2) Motor & gear Box assembly received are as per rated voltage & Phase
3) VFD controller is placed within the desired distance from the Fan
4) Check for any damage or loss during transit.
5) Has the Installation site been decided?
Installation site Clearances
6) Ensure that fan blades are a minimum 10ft or more from floor level.
7) Ensure that any obstructions are at least 2ft away horizontally from
the fan blade tip.
8) Ensure that Fan is installed so that minimum clearance from ceiling
is as per Table -1
Parts List:
9) Packing list of Fan parts & Hardware
10) Mounting Extension Kit (If ordered)
11) Installation Tools Kit

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FAN PLACEMENT & TECHNICAL DETAILS:
Placement of Fan is important in order to achieve optimal performance of the Fan.
Both Minimum horizontal and vertical clearances from the Fan are to be observed
strictly.
FIG-2
FIG-3
FIG-4
TABLE-1
FAN
DIAMETER
(Mt)
MOTOR
(KW. )
MOTOR
VOLTAGE
(V)
MOTOR
CURRENT
(AMPS.)
MOTOR
OUTPUT
RPM
MINIMUM
CLEARANCE
FROM CEILING
(mm.)
MINIMUM
HORIZONTAL
CLEARANCE FROM
BLADE TIP (mm. )
2.4 1.1 415 2.42 154 1500 mm. 600 mm
3.0
1.1
415
2.42
140
1500 mm.
600 mm
3.7 1.1 415 2.42 123 1500 mm. 600 mm
4.9 1.5 415 3.35 73 1500 mm. 600 mm

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VFD INSTALLATION
VFD CONTROLLER :
Generally Electrical installation is done before
installing the Fan. Number of wires to be used will
depend on whether the VFD is single or three phase.
Wire Size should adhere to the Local electrical codes.
However connection between VFD & Fan will need 4
wires. Whether the Input to VFD is Single phase or
three phase power to the fan will always be three
phase.
FIG-5
Rated motor power: 1.5 Kw & 1.1 Kw
Input voltage 3AC 380…480V -20%/+10% 47...63Hz
Rated current: 5.6 A
Output voltage 3 Phase DC link Volts
Rated output current: 4 A & 2.49A
Output frequency 0 Hz ...400 Hz
Enclosure: IP20
Ambient temperature 0°C ... +40°C (S1)
Approximate weight 2 kg
Specifications:
•four parameter sets selectable on-line
•Sensor less vector control
•Automatic motor identification
•5 Digital inputs 2 Analog inputs
•2 Relay outputs 1 Analog output
•Integrated brake chopper and dynamic
brake control
•RS232 and RS485 compatibility via
RJ12 connector
6.1 1.5 415 3.35 63 1500 mm. 600 mm
7.3 1.5 415 3.35 56 1500 mm. 600 mm

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Different mo ntig Applications :
Mounting applications shown below are representative only
CONCRETE BEAM MOUNT (FIG-6)
I BEAM MOUNTING (FIG-7)

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OWSJ MOUNTING (FIG-8)
PURLIN MOUNTING (FIG-9)

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PIPE MOUNTING (FIG-10)
STEP -2 STANDARD MOUNT
Following items are included in the
standard mount Kit.
•I-Beam Clamps
•Spacers (requirement depends on
Support structure thickness)
•Mounting Plate
•Standard Mount
(300mm & 600mm)
•Safety Cables
• Nuts & Bolts
FIG-11
Installing the Standard Mount
•Insert the I-Beam or the OWSJ Beam
between the I-Beam Clamps. Insert spacers if
needed.
•Insert Nuts& Bolts and tighten properly
•Place the safety cable as shown in the figure
•Cable clamps are to be tightened as
shown.(fig-13)
• Main safety cable should be inserted on the
saddle and the safety cable loop side has to
be on the U-bolt side.(fig-13)
FIG-12
FIG-13
FIG-14 FIG-15

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STEP -3 EXTENSIONS
Following items are part of the Extension Kit(fig-14,
fig-15)
•Extensions (Standard 600mm & 1200mm)
•Nuts Bolts & washers
•Safety Cables
Requirement of extension depends on place we have
to mount the fan . The length of extension along with
the standard mount will determine the drop length of
the Fan. Custom length extension can be provided if a
non standard drop length is desired. We can use a
maximum of two extensions per assembly.
Installing an Extension(fig-16 )
•Fasten top plate of extension to bottom plate
of standard mount using nuts bolts & washers
provided.
•Position the safety cables as per figure and fasten
the safety cable loops with the U-Clamps.
•For greater safety fasten two U-clamps at each
loop of the safety cable.
•Safety cables must always be used between fan
components. (Extensions Mounts Fan Frame etc.)
FIG-16
SAFETY
CABLE

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STEP-4 Main Hub & Drive Assembly(fig-17)
Following items form part of the
main Hub & Drive Assembly
•Hub
•Fan Frame
•Motor & Gear Box
•Trantorque nut
(All above parts are shipped assembled)
•Safety Cables
•Nuts Bolts & washers
FIG-17
Installing Main Hub & Drive Assembly
•Raise the Fan & align its mountig plate with
the bottom plate of standard mount or the
bottom plate of extension if used.
•Fasten the two plates using Nuts bolts &
•washers provided.
•Position the safety cables as per the figure
•and fasten safety cable loops using two
•U-Clamps on each safety cable loop.
•Verify fan level by checking both directions
•on the fan frame vertical post.
FIG-18
STEP -5 Guy Wires (Guide Rope)
•Guy Cables must be fastened to the
Building structure at angles as
shown(FIG-20).
•Guy Wires should be tight enough to
allow free self levelling and should not
be over tightened.
•Main safety cable should be inserted on
the saddle side and the safety cable loop
side has to be on the U-bolt side(FIG-13).
Following items are included in the Kit
•Cable
•Cable Clamps
FIG-19
MOTOR HUB
ASSEMBLY
HUB
Fan f ame
Moto &
gea box

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•Thimbles
•Eye Bolts
• Nuts washers Bolts
FIG-20

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LVLS FAN MOUNTING WITH EXTENSION FRAME
FIG-20A

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Installing G y Wires (G ide Ropes)
•First determine the location on ceiling to mount the Guy Wire so that it makes an
angle of 45-60(FIG-20)
•Install the Eye Bolt and tighten with Nuts & Bolts using washers(FIG- 21).
•Measure the cable required and cut keeping about 0.5 mt. extra. If the cable
requirement is more than 4mt. extra hardware is required .
•Secure one end with thimble and 2 cable clamps(FIG-22).
•Repeat the process for the other 3 Guy Ropes.
•Guy ropes should be about 90 degree apart(FIG- 19).
•Check the fan level by placing the level vertically on the fan frame. Adjust Guy
Ropes if required.
•Once levelled tighten hardware and again verify Fan level.
FIG-21 FIG-22
STEP -6: Connect Motor Terminal
Once the Fan Motor & Hub assembly are installed we may connect the motor terminal
leads to the electric supply
FIG-23

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STEP-7 : Check Motor Rotation
•Do not turn on the Power before double checking the Installation and electric
connections.
•Turn on Power and slowly increase frequency .
•Check the fan rotation . Observing from below fan rotation should be counter-
clockwise.
•If the fan rotates clockwise disconnect power supply and interchange output
leads.Fan should now rotate counter clockwise
•Disconnect Power supply and proceed to install fan blades.
STEP-8 : Blade Assembly
Blade kit includes the following Items
•Blades
•Blade Toppers
•Nuts Bolts & washers
FIG-24
STEP-9 : Safety Ring
•Safety Ring kit includes the
following items.
•Safety ring (5 Pieces)
•Bolts & washers
FIG-26
Installing Safety Ring
•Take two pieces of safety ring match the hole of one with the slot of the other.
tighten slightly the piece on appropriate place using bolts and washers.
•Continue as above till all pieces are installed. Now tighten all bolts
properly.Check level once again as per procedure mentioned Earlier
STEP-10 : F ll Start p
•Activate Power to the Fan at power Distribution Board.
•Determine preferred speed for fan and set that speed.

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General Notes :-
•Avoid blocking areas where people will benefit from it. Move obstructios or
change orientation to get maximum advantage.
•Minimize interaction between path of fan blades and direction of local area
lighting.
•In summer it is advantageous to run the fan at the highest speed as it balances
comfort and work environments air speed tolerance. In winter maximum benefit
is achived by running the fan at a speed just below that which produces a
noticeable breeze.
FAN MAINTENANCE:
•Before carying out any maintenance cut power supply to fan and ensure no one
energizes the system while maintenance is going on.
•No maintenance is to be carried out on the Controller while the power supply is
on unless required for the job to be performed.
•A safety zone of 6mt. radius should be created while doing maintenance on the
fan safety wire and guy wires.
•Personal safety items are to be used by persons carrying maintenance work on
the fan.
•Risk assessment should be done before any maintenance work is carried out on
Fan Safety cables Guy wires etc.
•Before starting maintenance work a check list shall be prepared.
To ens re longevity of Caryaire LVLS fan, following checks need to be done
ann ally.
•Check torque of all mounting fasteners. Do not loosen or Re-Torque but check
torque in tightening direction with a calibrated torque wrench.
•Check gear motor for leaks.
•Check tightness of electrical leads of motor and controller
•Check if all safety cables are in place and also are not slack
•Remove dust accumulation to prevent fan from becoming unbalanced.

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Maintenance Sched le: ( Motor & Gear Red cer)
•Caryaire LVLS fan is driven by Helical Gear reducer motors. These motors are
best suited for this application. These motors are known for precision
durability efficiency reliability and quiet operation.
Motor (First six-months)
•Check Hot Spots
•Tighten loose electric connections if any.
•Repeat every year.
Gear Red cer: (Yearly)
Check for any oil leakage. Plug leakage if any and top up oil.
Change oil after 20 000 hours of normal working.
Fan size Oil quantity
•2.4Mt 3.0Mt & 3.7Mt. 1.1 liters
•4.9Mt 6.1Mt & 7.3Mt. 3.1 liters
•Recommended Lubricant: Synthatic oil
Blades:
The blades are designed for maximum efficiency and quiet operation allowing
minimum air disruption directly below the fan.The airfoil blades are extruded
from 6063 aluminium alloy and heat treated to T-6 Temper condition. In
addition blades are also powder coated for corrosion resistence and ease of
cleaning.
Maintenance Sched le: ( First Six Months)
•Check tightness of Blades
•Ensure Blades are Level and Clean
•Repeat yearly.
Drop/ Mo nting:
The drop /mounting system helps prevent vibration or horizontal movement
from being transmitted to the building structure. Mounting system can be easily
installed in any building structure and allows Fan to hang level from the structure
beams.

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Maintenance Sched le: ( First Six Months)
•Physical check of safety cables tightening of clamps if required.
•Physical check of Guy wires tightening of clamps if required.
•Check all nuts bolts & clamps.
•Repeat yearly
Safety Check List:
•Disconnect all power at source before attempting Installation servicing or
cleaning.
•Installation to be done by certified electricians and contractors conversant with
local & National electric codes. If not complied by owners all warranty bligations
of Caryaire will stand Null & void.
•Wrong connection of Input and output terminals of controller will result in
damage to Controller (VFD). Faulty wiring is not covered by warranty.
•VFD parameters have been pre-set by manufacturer. These should not be altered
without consulting the Caryaire team.
•All safety devices removed during maintenance should be re installed before
•applying power to the fan.
Do’s and Don’ts:
•Check visually abnormal noise and vibration.
•Disconnect all power at source before attempting Installation servicing or
cleaning.
•Check oil leakage during internal checkup.
•Check all electrical points once in the month.
•Oil change to be done in motor after 20000 running Hours/3years.
•Use Synthetic oil – CLP 220 (3.3 ltrs/fan)
•Minimum distance to be maintained 2 meter from fan in running condition.
•Don’t change any parameter of VFD without consulting with Caryaire engineer.
•Don’t do any service related activity in running condition.
•VFD parameters have been pre-set by manufacturer. These should not be altered
•without consulting the Caryaire team.
•All safety devices removed during maintenance should be re installed before
applying power to the fan.
•Wrong connection of Input and output terminals of controller (VFD) will result in
damage to Controller (VFD). Faulty wiring is not covered by warranty.

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Critical & Recommended Spare parts:
•Gear Motor - Qty-1/Fan
•VFD Drive– Qty-1/Fan
Service Escalation Matrix:
Name Designation Cont. No. Mail ID
Mr. Dinesh Gupta Business Head 9818682723 [email protected]
Mr. Dipankar Joshi Asst. Manager Sales 9818660518 dj[email protected]
Mr. Surendra Pal Singh India Head Services 9818379932 [email protected]
Mr. Arvind Kumar Service Engineer (North East) 9818689352 s[email protected]
Mr. Suresh Chand Service Engineer (West) 9004301386 [email protected]
Mr. Joseph Service Engineer (South) 9739944344 [email protected]