Cook Hmd User manual

1B51242-002HMD IO&M

Receiving and Inspection

Carefully inspect the unit and accessories for any dam-

age and shortage immediately upon receipt of the unit.

• Turn the blower by hand to ensure it turns freely and

does not bind.

• Record on the Delivery Receipt any visible sign of

damage.

Handling

Lift unit fans by the lifting eyes.

NOTICE! Never lift by the housing.

Storage

If the fan is stored for any length of time prior to installa-

tion, store it in its original shipping crate and protect it from

dust, debris and the weather.

Rotate the wheel several revolutions every three to ve

days to keep a coating of grease on all internal bearing

parts.

HMD

Heated Makeup Direct: A Direct Fire Make-Up Air Unit

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Lifting

eyes

Rotating Parts & Electrical Shock Hazard:

Fans should be installed and serviced by qualied person-

nel only.

Disconnect electric power before working on unit (prior to

removal of guards or entry into access doors).

Follow proper lockout/tagout procedures to ensure the unit

cannot be energized while being installed or serviced.

A disconnect switch should be placed near the fan in order

that the power can be swiftly cut o󰀨, in case of an emergen-

cy and in order that maintenance personnel are provided

complete control of the power source.

Grounding is required. All eld-installed wiring must be

completed by qualied personnel. All eld installed wiring

must comply with National Electric Code (NFPA 70) and all

applicable local codes.

Fans and blowers create pressure at the discharge and

vacuum at the inlet. This may cause objects to get pulled

into the unit and objects to be propelled rapidly from the

discharge. The discharge should always be directed in a

safe direction and inlets should not be left unguarded. Any

object pulled into the inlet will become a projectile capable

of causing serious injury or death.

When air is allowed to move through a non-powered fan,

the impeller can rotate, which is referred to as windmill-

ing. Windmilling will cause hazardous conditions due to

unexpected rotation of components. Impellers should be

blocked in position or air passages blocked to prevent draft

when working on fans.

Friction and power loss inside rotating components will

cause them to be a potential burn hazard. All components

should be approached with caution and/or allowed to cool

before contacting them for maintenance.

Under certain lighting conditions, rotating components may

appear stationary. Components should be veried to be

stationary in a safe manner, before they come into contact

with personnel, tools or clothing.

Failure to follow these instructions could result in death or

serious injury.

The attachment of roof mounted fans to the roof curb as

well as the attachment of roof curbs to the building struc-

ture must exceed the structural requirements based on the

environmental loading derived from the applicable building

code for the site. The local code o󰀩cial may require varia-

tions from the recognized code based on local data. The

licensed engineer of record will be responsible for prescrib-

ing the correct attachment based on construction materi-

als, code requirements and environmental e󰀨ects specic

to the installation.

This publication contains the installation, operation and

maintenance procedures for standard units of the HMD:

Heated Makeup Direct.

Carefully read this publication and any

supplemental documents prior to any

installation or maintenance procedure.

Loren Cook catalog, Heated Makeup Air Unit, provides

additional information describing the equipment, fan

performance, available accessories and specication data.

For additional safety information, refer to AMCA

publication 410-96, Safety Practices for Users and

Installers of Industrial and Commercial Fans.

All of the publications listed above can be obtained

from Loren Cook Company by phoning (417) 869-6474,

extension 166; by fax at (417) 832-9431; or by e-mail at

[email protected].

For information and instructions on special equipment,

contact Loren Cook Company at (417) 869-6474.

2HMD IO&M B51242-002

FOR YOUR SAFETY

Improper installation, adjustment, alteration, service

or maintenance can cause property damage, injury

or death. Read the installation, operating and mainte-

nance instructions thoroughly before installing or ser-

vicing this equipment.

If you smell gas:

1. Open windows.

2. Don’t touch electrical switches.

3. Extinguish any open ame.

4. Immediately call your gas supplier.

The use and storage of gasoline or other ammable

vapors and liquids in open containers in the vicinity of

this appliance is hazardous.

Fire Or Explosion Hazard

Installation and service must be performed by a quali-

ed installer, service agency or gas supplier.

Intake Air

If HMD unit is used for make-up air for any type of

fuel burning equipment, HMD unit must NOT be prima-

ry source of intake air. Consult fuel burning equipment

manufacture for requirements and recommendations.

Environmental Hazards

Other considerations may be required if high winds

or seismic activity are present. If more information is

needed, contact a licensed professional engineer be-

fore moving forward.

Improper installation, adjustment, alteration, service

or maintenance can cause serious injury, death or prop-

erty damage. Carefully read this publication and any

supplemental documents prior to any installation or

maintenance procedure.

Installation

Clearance to Combustible / Service Clearances

The minimum distance required between the heater and

adjacent combustible surfaces is 42 inches (1066.8 mm),

on the controls side of the unit, to ensure the adjacent sur-

face’s temperature does not exceed 90 degrees above the

ambient temperature.

For specic dimensions, refer to the submittal drawing

for the specic fan type.

Installation of the heater (1) in airplane hangars

must be done in accordance with the Standard for

Aircraft Hangars, ANSI/NFPA 409, and (2) public

garages must be done in accordance with the

Standard for Parking Structures, ANSI/NFPA

88A, or the Standard for Repair Garages, ANSI/

NFPA 88B, and with CAN/CSA B149.1 Natural

Cas and Propane Installation Codes.

NOTICE! Adequate building relief shall be provid-

ed so as to not over pressurize the building when

the heating system is operating at its rated capacity.

It should be noted that this can be accomplished by

taking into account, through standard engineering

methods, the structure’s designed inltration rate; by

providing properly sized relief openings; or by inter-

locking a powered exhaust system; or by a combina-

tion of these methods.

NOTICE! All indoor and outdoor units require that

the air to the heater is ducted directly from the out-

doors. Recirculation of room air is not permitted.

NOTICE! The heater inlet shall be located in accor-

dance with the applicable building code provisions for

ventilation air.

NOTICE! Field constructed intake accessories

should be properly designed to minimize the entry of

snow and rain.

NOTICE! If in doubt regarding the application, con-

sult the heater manufacturer.

Indoor Hanging Arrangement

1. Install threaded hangers from ceiling supports. When

locating hangers, allow enough room to open access

panel(s). Two nuts must be used on the end of each

threaded hanger. Ceiling supports are not supplied.

2. Using sheet metal screws, attach the weatherhood/

thru-wall / lter section to the damper / burner sec-

tion. The ange on the weatherhood / thru-wall / lter

section should overlap the ange on the damper /

burner section.

3. Raise the unit into place

4. Using two nuts per hanger, fasten the unit supports

to the hangers under the unit. Appropriate unit sup-

ports, such as the optional hanging bracket kit or

c-channel and angle iron (not included) should be

used.

5. Attach ductwork to unit using self-tapping screws

NOTICE! In order to prevent the unit from swinging

and to provide a safe environment for service and

maintenance, additional measures may be needed to

secure the unit.

Hanging Mount Example

Hangers

Sealant

Unit

Supports

Duct

Wiring Entry

Good duct practices should be followed for all duc-

twork. Ductwork should be installed in accordance

with SMACNA and AMCA guidelines, NFPA 96 and

any local codes.

3B51242-002HMD IO&M

Custom Work:

Any wiring deviations may result in personal injury or

property damage. Manufacturer is not responsible for

any damage to, or failure of the unit caused by incor-

rect nal wiring.

Manufacturer’s standard control voltage is 120 VAC.

Control wire resistance should not exceed 0.75 ohms

(approximately 285 feet total length for 14 gauge wire;

455 feet total length for 12 gauge wire). If the resis-

tance exceeds 0.75 ohms, an industrial-style plug-in

relay should be wired in place of the remote switch.

The relay must be rated for at least 5 amps and have

a 120 VAC coil. Failure to comply with these guidelines

may cause motor starters to chatter or not pull in, re-

sulting in contactor failures and/or motor failures.

1. The unit’s nameplate states the voltage and the

unit’s MCA. The main power lines to the unit should

be sized accordingly. The nameplate is located on

the outside of the unit on the control panel side.

2. Install eld electrical wires through the provided

holes.

3. Connect the main power lines to the disconnect

switch and main grounding lug(s). Torque eld con-

nections to 20 in.-lbs.

4. Wire the optional convenience outlet. The conve-

nience outlet requires a separate 115V power supply

circuit. The circuit must include short circuit protec-

tion which may need to be supplied by others.

Single Phase

T-1

T-4

Ground B

Ground A

Line

When ground is required, attach to ground A or B with no. 6

thread forming screw. To reverse, interchange T-1 and T-4.

Three Phase

456

789

12 3

Low Voltage

208/230 Volts

High V

oltage

460 Volts

3 Phase, 9 Lead Motor

Y-

Connection

6789

456

12 3

Low Voltage

208/230 V

olts

High V

oltage

460 Volts

L1L3

3 Phase, 9 Lead Motor

Delta-Connection

A complete wiring diagram is attached on the in-

side of the control center door(s). It is also avail-

able in the HMD Wiring Diagram Supplement.

Gas

All gas piping must be installed in accordance with

local codes, or in the absence of local codes, in ac-

cordance with the National Fuel Gas Code, ANSI

2223.1/NFPA 54, or the CAN/CSA B149.1 Natural

Cas and Propane Installation Code.

NOTICE! When a duct work system is attached to the

inlet of the heater purge the volume of the duct system

with at least four air changes prior to an ignition

attempt.

6. Apply sealant around the perimeter of the weather-

hood to prevent water penetration and drafts into the

building.

Curb Arrangement

1. Position curb on the roof. Verify that unit supports are lev-

el, shim if necessary.

2. Attach curb to roof, ash in place

3. Attach ductwork to unit using self-tapping screws

Good duct practices should be followed for all duc-

twork. Ductwork should be installed in accordance

with SMACNA and AMCA guidelines, NFPA 96 and

any local codes.

4.Apply an appropriate sealant around the perimeter of

the curb and duct adapter(s) to isolate fan vibration and

prevent water penetration

5. Use the 4 lifting lugs to lift and place unit on the curb. A

crane with a spreader bars is required.

6. NOTICE! Do not include a wood nailer. Use self-tapping

sheet metal screws to fasten the unit to the curb support.

7. The weatherhood can now be assembled and attached to

the unit.

8. Using an appropriate sealant, seal the seam between the

weatherhood and the unit.

Curb Mount Example

Wiring

In Canada, all wiring should be done in

accordance with the Canadian Electrical Code.

NOTICE! The equipment must be properly grounded.

Any wiring running through the unit in the airstream

must be protected by metal conduit, metal clad cable

or raceways.

NOTICE! If any of the original wire as supplied with

the heater must be replaced, it must be replaced with

type TW1 600v wire or its equivalent.

NOTICE! Field-wiring having a temperature rating of

at least 105ºC shall be used and supply circuit wiring

shall have a minimum size of 14 AWG.

NOTICE! High voltage electrical input is needed for

this equipment.

An electric disconnect switch having adequate am-

pacity (see marking on the heater for voltage and

ampacity), if not provided as part of the heater,

shall be installed in accordance with Article 430 of

the National Electrical Code, ANSI/NFA 70.

4HMD IO&M B51242-002

4. Compare the supplied voltage,

hertz, and phase with the unit

and motor’s nameplate infor-

mation.

5. Open the blower access door

and run the blower momentarily

to determine the rotation. Ar-

rows are placed on the blower

scroll to indicate the proper di-

rection.

NOTICE! If the blower is rotating in the wrong direc-

tion, the unit will move some air, but will not perform

as designed. Be sure to perform a visual inspection to

guarantee the correct blower rotation.

• To reverse the rotation on three phase units,

disconnect and lock-out the power, then interchange

any two power leads.

• To reverse the rotation on single phase units,

disconnect and lock-out the power, then rewire the

motor per the motor manufacturer’s instructions.

6. Check for unusual noise, vibration or overheating of

the bearings. Reference the Troubleshooting sec-

tion for corrective actions. Excessive vibration may

be experienced during the initial start-up. Left un-

checked, it can cause a multitude of problems in-

cluding structural and/or component failure. Gener-

ally, fan vibration and noise is transmitted to other

parts of the building by the ductwork. To minimize

this undesirable e󰀨ect, the use of heavy canvas duct

connectors is recommended.

7. Measure the motor’s voltage, amps and RPM.

Compare to the specications. Motor amps can be

reduced by lowering the motor RPM or increasing

system static pressure. Additional starters and over-

loads may be provided in the make-up air control

center for optional exhaust blowers. Any additional

overloads must be checked for proper voltage and

amps.

8. Measure the unit’s air volume (cfm) and compare it

with its rated air volume. If the measured air volume

is wrong, adjust the fan’s RPM by changing/adjust-

ing the drive. The most accurate way to measure

the air volume is by using a Pitot traverse method

downstream of the blower. Changing the air volume

can signicantly increase the motor’s amps. If the

air volume is changed, the motor’s amps must be

checked to prevent overloading the motor. To ensure

accuracy, the dampers are to be open when measur-

ing the air volume.

9. Adjust the settings on the optional components. See

the Control Center Layout in the Reference section

for location of optional components.

• Heating Inlet Air Sensor:

Typical setting: 60-70ºF

• Building Freeze Protection:

Typical setting: 45ºF

• Dirty Filter Gauge:

Typical setting: Settings vary greatly for each unit.

Do not connect the unit to gas types other than what

is specied and do not connect the unit to gas pres-

sures that are outside of the pressure range shown on

the label.

When connecting the gas supply, the length

of the run must be considered in determining

the pipe size to avoid excessive pressure drop.

Refer to a Gas Engineer’s Handbook for gas

pipe capacities.

Refer to the heater rating plate for determining

the minimum gas supply pressure for obtain-

ing the maximum gas capacity for which this

heater is specied.

1. Determine the supply gas requirements by looking

at the unit’s nameplate on the outside of the unit on

the control center side.

2. When the supply gas pressure exceeds the maxi-

mum gas pressure shown on the nameplate, an ad-

ditional regulator (by others) is required to reduce

the pressure. The regulator must have a listed leak

limiting device or it must be vented to the outdoors.

The regulator located inside the unit is used to adjust

the unit’s maximum output temperature.

3. If an optional vent line is located between the safety

shuto󰀨 valves it must be piped to the outdoors.

Reference the National Fuel Gas Code for

additional vent line requirements.

4. Test the system for leaks.

Operation

Pre Start-Up

Follow the pre start-up list before proceeding. Follow

the procedure in the exact order that it is presented.

Failure to do so could result in serious injury or death

and damage to equipment.

Pre Start-Up

General

1. Get voltage & amperage meter, thermometer, micro amp

meter, u-tube manometer and tachometer.

2. Perform a gas leak check during heater start-up, to verify

the gas tightness of the heater’s components and piping

under normal operating conditions.

3. Disconnect and lock-out all power and gas.

Blower

1. Check the housing, blower, and ductwork for any foreign

objects before running the blower.

2. Rotate the fan wheel by hand and make sure no parts are

rubbing. Check the V-belt drive for proper alignment and

tension (a guide for proper belt tension and alignment is

provided in the Belt Maintenance section).

3. Check fasteners, set screws and locking collars on the

fan, bearings, drive, motor base, and accessories for tight-

ness.

5B51242-002HMD IO&M

Testing Inspection

All components of this or any other gas-red heating

unit must be leak tested prior to placing the unit into op-

eration. The factory piping has been checked for leaks

but should be rechecked due to shipping & installation

issues. The eld-installed shuto󰀨 valve should also be

checked.

A soap & water solution should be used to perform this

test.

Never test for gas leaks with a ame.

When leak testing pressures that are less than or equal

to 14 in. wc (3.5 kPa), rst close the eld-installed shut-

o󰀨 valve to isolate the unit from gas supply line.

When leak testing pressures that are more than 14 in.

wc (3.5 kPa), close the eld-installed shuto󰀨 valve, dis-

connect the furnace & gas train from the gas supply line

& plug the supply line before testing.

All piping should be clean & free of any foreign matter,

which may damage the valves, regulators or burner.

Control Panel

Control Panel Parts

1. Contactor

2. Overload

3. Three phase

transformer #A

4. 120 - 24v

transformer #B

5. Ignition control

6. High Temp Overload

7. Mild weather thermostat to

damper

8. Damper motor

9. Terminal blocks

10. Circuit breaker

11. Override switch

12. 120v spark ignitor

13. Pressure sensing probe (high)

14. Pressure sensing probe (low)

15. Temperature controller

16. Thermostat to blower

17. Safety Shut o󰀨 valve

18. Pressure gauge

19. Gas valve

20. Modulating gas valve

21. Pressure gauge

22. Safety Shut o󰀨 valve

23. Optional V.F.D. here

2 3 4 5

912

10 11

16 18

20 21

Gas

1. Check the supply gas pressure and compare it with

the unit’s nameplate pressure requirements. Adjust

the supply regulator as needed until the supply gas

pressure is within the specied range (see below).

The nameplate is located on the outside of the unit

on the control panel side.

2. Check the settings on the optional high and low gas

pressure switches. The high pressure setting is typi-

cally 8 inches wc (2 kPa) and the low pressure is set-

ting is typically 3 inches wc (0.7 kPa). The switches

are set at the factory and should not need adjust-

ment. Adjust the setting only if needed. The pur-

pose of the high and low gas pressure switches is

to automatically shut down the burner if the inlet gas

pressure is too low for the burner to safely light, or

if the manifold pressure is too high for the burner to

operate properly. Proper air velocity over the burner

is critical on direct red gas units. If the air velocity

is not within the unit specications, the unit will not

operate e󰀩ciently, may have sporadic shutdowns,

and may produce excessive carbon monoxide (CO)

or other gases.

6HMD IO&M B51242-002

Tolerance

Center Distance Maximum Gap

Up thru 12” 1/16”

12” up through 48 1/8”

Over 48” 1/4”

NOTICE! Premature or frequent belt failures can

be caused by improper belt tension, or misaligned

sheaves. Abnormally high belt tension or drive mis-

alignment will cause excessive bearing loads and

may result in failure of the fan and/or motor bearings.

Abnormally low belt tension will cause squealing on

start-up, excessive belt utter, slippage, and overheat-

ed sheaves.

1. V-belt drives must be checked on a regular basis for

wear, tension, alignment, and dirt accumulation.

2. Check the tension by measuring the deection in the

belt as shown here.

3. Check the alignment by using a straight edge across

both sheaves. The drawings below show where to

measure the allowable gap for the drive alignment

tolerance. All contact points (indicated by WXYZ) are

to have a gap less than the tolerance shown in the

table. When the pulleys are not the same width, the

allowable gap must be adjusted by half of the di󰀨er-

ence in width.

Snow Accumulation

Clear snow away from roof mounted units. Keep the

snow clear of the intake and access doors.

Motors

Motor maintenance is generally limited to cleaning and

lubrication (where applicable). Cleaning should be limited

to exterior surfaces only. Removing dust and grease build-

up on the motor assures proper motor cooling.

Motors supplied with grease ttings should be greased

in accordance with the manufacturer’s recommendations.

Greasing motors is only intended when ttings are provid-

ed. Many motors are permanently lubricated, requiring no

additional lubrication.

NOTICE! Do not allow water or solvents to enter the

motor or bearings. Motors and bearings should never

be sprayed with steam, water or solvents.

3. With all access panels in place, the fan running and

discharging 70ºF (21ºC) air, connect a U-Tube ma-

nometer to the outer sensing probes and measure

the static pressure across the burner. The proper

static pressure should be (check CFM / Static Pres-

sure chart on page tk). If needed, evenly adjust the

ba󰀪es, keeping the burner centered in the opening

until the required pressure is obtained. The pressure

drop was set at the factory and may not need adjust-

ment. When required pressure is obtained, be sure

to reconnect the outer sensing probes. This process

may need to be repeated until the proper pressure is

achieved. This adjustment will change the air quanti-

ty delivered by the unit and therefore the air quantity

delivered should be rechecked. Refer to the Blower

Start-Up section.

• To increase static pressure decrease the opening.

• To decrease static pressure increase the opening.

4. Monitor the unit’s actual temperature rise by placing

a thermocouple in the unit’s inlet and a second in the

discharge, three duct diameters downstream of the

burner. Send the unit to maximum ame by chang-

ing the rotation of the motor pack from left to right.

Use a screw driver on top of modular gas valve.

While monitoring the unit’s temperature rise, set the

maximum ring rate by adjusting the regulator until

the designed temperature rise is achieved. After set-

ting the maximum ring rate, reconnect the wire to

the amplier. Do not set the burner maximum ring

rate based on gas pressure. It should be set based

on the unit’s designed temperature rise shown on

the label. Setting the maximum ring rate during

mild weather conditions may cause the high limit to

trip out during extreme conditions requiring manual

resetting. Gas trains are equipped with a combined

regulator valve. Clockwise rotation increases the

temperature rise; counterclockwise rotation de-

creases the temperature rise. The minimum setting

for the maximum ring rate may be higher than re-

quired. This is acceptable, the burner will modulate

as needed. To convert from Natural Gas to LP or

vice versa follow the instructions associated with the

high re gas valve.

5. Set the operating temperature.

Maintenance - All year

V-Belt Drives

NOTICE! Do not pry belts on or o

the sheave. Loosen belt tension

until belts can be removed by

simply lifting the belts o

the sheaves. When replac-

ing V-belts on multiple

groove drives, all belts

should be changed to

provide uniform drive

loading. Do not install

new belts on worn

sheaves. If the sheaves have grooves worn in them,

they must be replaced before new belts are installed.

1 foot

1/4 inch

7B51242-002HMD IO&M

Relubrication Intervals

Service

Conditions

NEMA Frame Size

Up to and

including 184T 213T-365T 404T and larger

1800

RPM and

less

Over

1800

RPM

1800

RPM and

less

Over

1800

RPM

1800

RPM and

less

Over

1800

RPM

Standard

3 yrs. 6 months 2 yrs. 6 months 1 yr. 3 months

Severe

1 yr. 3 months 1 yr. 3 months 6 months 1 months

Wheels

Wheels require little attention when moving clean air.

Occasionally oil and dust may accumulate on the wheel

causing imbalance. When this occurs the wheel and hous-

ing should be cleaned to assure proper operation.

Bearings

The bearings are carefully selected to match the maxi-

mum load and operating conditions of the specic fan size.

The instructions provided in this manual and those provid-

ed by the bearing manufacturer will minimize any bearing

problems.

Lubricate bearings prior to periods of extended shut-

downs or storage and rotate shaft monthly to aid in corro-

sion prevention. If the fan is stored more than three months,

purge the bearings with new grease prior to start-up.

Motors are provided with a polyurea mineral oil NGLI #2

grease. All additions to the motor bearings are to be with

a compatible grease such as Exxon Mobil Polyrex EM and

Chevron SRI.

The above intervals should be reduced to half for vertical

shaft installations.

Relubrication Intervals

RPM Temp °F Greasing Interval

Up to 1000 -30 to 120 6 months

120 to 200 2 months

1000 to 3000 -30 to 120 3 months

120 to 200 1 month

Over 3000 -30 to 120 1 month

120 to 200 2 weeks

Any Speed < -30 Consult Factory

Any Speed > 200 1 week

Filter

Filter maintenance is generally limited to cleaning and

replacement.

If aluminum mesh lters are installed, they can be

washed in warm soapy water.

An adhesive spray can be added to aluminum mesh l-

ters to increase their e󰀩ciency.

If disposable lters are installed, they can be checked by

holding up to a light source. If light cannot pass through the

lter, it should be replaced.

When reinstalling lters, be sure to install them with the

airow in the correct direction. An airow direction arrow is

located on the side of the lters.

Replacement lters should be from the same manufac-

turer and the same size as the original lters provided with

the unit.

Maintenance - Beginning of season

Start-Up

Repeat the Blower Start-Up Step #5 and Direct Gas

Start-Up Steps #1, #2 and #3. This will ensure that the gas

and air are set properly before the heating season begins

and should lead to trouble free operation all winter.

High Limit

The high limit switch may have tripped over the summer;

it should be checked and reset if necessary.

Burner

Inspect the burner for accumulation of scales on both

the upstream and downstream sides of the mixing plates.

Any scaling or foreign material should be removed with a

wire brush.

Visually check that all holes in the mixing plates are

clear. If any burner ports are plugged (even partially), clear

them with a piece of wire or another appropriate tool.

Do not enlarge burner ports when clearing a blockage,

performance could be a󰀨ected.

Replace or tighten any loose or missing fasteners on the

mixing plates. Always use zinc plated or stainless steel fas-

teners.

Inspect and clean the ame and spark rod. Occasional

replacement of the ame rod and spark rod may be neces-

sary to ensure optimum unit performance.

Flame rods can last many years, but because of thermal

expansion of the porcelain, ame rods can fail over time.

Gas Train

The gas connections, joints and valves should be

checked annually for tightness. Apply a soap and water

solution to all piping; watch for bubbling which indicates a

leak. Other leak testing methods can be used.

CFM/Static Pressure Chart

Model # Low CFM Low SP High CFM High SP

2400 680 0.05 2400 0.94

3400 2000 0.2 3400 1

4100 3000 0.35 4100 1.1

Parts

To replace parts, contact a COOK representative.

8HMD IO&M B51242-002

Is the proper power

supply at the main

disconnect?

1.Compare the supplied voltage, hertz, and phase with the motor’s

nameplate information.

2.Make sure disconnect switch is on.

Replace 480-120v transformer #A

1.Make sure supply switch is on.

1.Correct supply fan overload if tripped. Check for proper voltage, amps

and RPMs.

2.Check optional exhaust fan interlocks

Is there 120 VAC

between terminals X2 &

X1 on transformer #A?

Is there 120 VAC between

terminal block #2 &

circuit breaker terminal 2?

Is there 120 VAC

between terminal blocks

1 & 5?

Is there 120 VAC

between across A1 &

A2 on supply contactor?

1.Replace fan belt, if broken.

2.Repair or replace motor or capacitor if needed.

3.Repair motor fuse if needed.

4.Repair or replace one or more of the motor

wiring legs, if needed.

At this time the supply contactor

should pull in, passing power to the

supply motor & blower should start.

Yes

1.Install the optional damper limit switch, if not installed. If holding, wait

for actuator to fully open or adjust the limit switch.

2.Repair or replace fan relay if not energizing. Check for loose

connection.

Troubleshooting

Blower does not operate

Refer to the control panel parts list when troubleshooting.

9B51242-002HMD IO&M

Troubleshooting

Motor overamps

Is the air volume too

high?

Adjust drive to

reduce rpm as

needed.

Adjust drive &

increase external

pressure. as needed.

To reverse the rotation on three phase units, disconnect and lock-out the

power, then interchange any two power leads.

To reverse the rotation on single phase units, disconnect and lock-out the

power, then rewire the motor per the motor manufacturer’s instructions.

Replace motor.

Compare the supplied voltage, hertz, and phase with the unit and

motor’s nameplate information. Correct as needed.

Is the static pressure

lower than rated?

Is the blower rotating in

the wrong direction? If

the blower is rotating in

the wrong direction, the

unit will move some air,

but will not perform as

designed.

Is the motor voltage

correct?

Is the motor horse

power too low?

Shorted winding on the

motor?

Consult factory.

Yes

Measure the unit’s air volume

(cfm) and compare it with its

rated air volume. If the measured

air volume is wrong, adjust the

fan’s RPM by changing/adjusting

the drive. The most accurate

way to measure the air volume

is by using a Pitot traverse

method downstream of the

blower. Changing the air volume

can signicantly increase the

motor’s amps. If the air volume

is changed, the motor’s amps

must be checked to prevent

overloading the motor. To ensure

accuracy, the dampers are to be

open when measuring the air

volume.

Refer to the control panel parts list when troubleshooting.

10HMD IO&M B51242-002

Troubleshooting

Insu󰀩cient airow

Are the dampers not

fully open? This may

take several minutes.

Adjust dampers or replace damper/actuator as needed.

Reduce loss by improving ductwork.

Repair ductwork.

Replace / clean the lters as needed.

Are the system static

losses too high?

Is the blower speed too

low?

Are the lters dirty or

clogged?

Are there leaks in the

ductwork?

Is the belt slipping?

Yes

1.Replace or tighten as needed.

2.Install automatic belt tensioner if possible.

Adjust the drives as needed.

Consult factory.

Measure the unit’s air volume (cfm)

and compare it with its rated air

volume. If the measured air volume

is wrong, adjust the fan’s RPM by

changing/adjusting the drive. The

most accurate way to measure

the air volume is by using a Pitot

traverse method downstream of the

blower. Changing the air volume

can signicantly increase the

motor’s amps. If the air volume is

changed, the motor’s amps must

be checked to prevent overloading

the motor. To ensure accuracy,

the dampers are to be open when

measuring the air volume.

Refer to the control panel parts list when troubleshooting.

11 B51242-002HMD IO&M

Troubleshooting

Too much airow

Is the blower speed too

high?

Are the lters missing?

Is there insu󰀩cient

external pressure?

Yes

Adjust drive & decrease

external pressure. as needed.

Increase external static pressure.

Install lters.

Measure the unit’s air volume

(cfm) and compare it with its

rated air volume. If the measured

air volume is wrong, adjust the

fan’s RPM by changing/adjusting

the drive. The most accurate

way to measure the air volume

is by using a Pitot traverse

method downstream of the

blower. Changing the air volume

can signicantly increase the

motor’s amps. If the air volume

is changed, the motor’s amps

must be checked to prevent

overloading the motor. To ensure

accuracy, the dampers are to be

open when measuring the air

volume.

Consult factory.

Refer to the control panel parts list when troubleshooting.

12HMD IO&M B51242-002

Troubleshooting

Excessive noise or vibration

Is the belt loose or

damaged?

Clean or replace the wheel.

Align sheaves.

Lubricate or replace bearings as needed.

Clean or replace lters as needed.

Are the sheave aligned?

Is the wheel

unbalanced?

Are the lters dirty /

clogged?

Are the bearings worn or

do they need lubrication?

Yes

1.Replace or tighten as needed.

2.Install automatic belt tensioner if possible.

At this time the noise or vibration

should be at acceptable levels

Refer to the control panel parts list when troubleshooting.

13 B51242-002HMD IO&M

Troubleshooting

Heater does not attempt to light. Heater attempts to light, but no ame

Replace 24 VAC transformer.#b

Correct / replace high temp overload switch.

Is there 24 VAC

between terminal blocks

9 & 10?

Is there 120 VAC between

terminal block #10 & high

temp limit switch #2?

Is there continuity

between terminal block

#4 & low pressure switch

normal open?

Yes

1.With all access panels in place, the fan running and discharging 700F

(210C) air, connect a U-Tube manometer to the outer sensing probes

(see below) and measure the stac pressure across the burner. The

proper stac pressure should be (check CFM / Static Pressure chart

on page 8). If needed, evenly adjust the baes, keeping the burner

centered in the opening unl the required pressure is obtained. The

pressure drop was set at the factory and may not need adjustment.

When required pressure is obtained, be sure to reconnect the outer

sensing probes. This process may need to be repeated unl the proper

pressure is achieved. This adjustment will change the air quanty

delivered by the unit and therefore the air quanty delivered should be

rechecked. Refer to the Blower Start-Up secon.

2.To increase the stac pressure decrease the opening.

3.To decrease the stac pressure increase the opening.

Consult factory

No 1.Make sure supply switch is on.

Is there 120 VAC between

terminal block #2 & circuit

breaker terminal 2?

Refer to the control panel parts list when troubleshooting.

14HMD IO&M B51242-002

Troubleshooting

Attempts to light, with visible spark, but no ame

Check the supply gas pressure and compare it with the unit’s nameplate

pressure requirements. Adjust the supply regulator as needed until

the supply gas pressure is within the specied range (see below). The

nameplate is located on the outside of the unit on the control panel side.

With all access panels in place, the fan running and discharging 70ºF

(21ºC) air, connect a U-Tube manometer to the outer sensing probes

(see below) and measure the static pressure across the burner. The

proper static pressure should be (check CFM / Static Pressure chart

on page 8). If needed, evenly adjust the ba󰀪es, keeping the burner

centered in the opening until the required pressure is obtained. The

pressure drop was set at the factory and may not need adjustment.

When required pressure is obtained, be sure to reconnect the outer

sensing probes. This process may need to be repeated until the proper

pressure is achieved. This adjustment will change the air quantity

delivered by the unit and therefore the air quantity delivered should be

rechecked. Refer to the Blower Start-Up section.

To increase the static pressure decrease the opening.

To decrease the static pressure increase the opening.

Purge the air.

Is the inlet gas pressure

between the min and

max?

Is there air in the gas

line?

Is the pressure drop

across the burner

correct? (check chart

on page 8)

Is there still not a proper

spark?

Yes

The wires may be switched. Uncross the spark wires.

Make sure the spark gap is .062 in.

Replace spark the plug.

Consult factory

Refer to the control panel parts list when troubleshooting.

15 B51242-002HMD IO&M

Service Contacts

Dealer:

Installation

Contractor:

Service

Contractor:

Date of Installation:

Name:

Address:

Phone:

Name:

Address:

Phone:

Name:

Address:

Phone:

16HMD IO&M B51242-002

Limited Warranty

Loren Cook Company warrants that your Loren Cook fan was manufactured free of defects in materials and workmanship, to the extent stated herein.

For a period of one (1) year after date of shipment, we will replace any parts found to be defective without charge, except for shipping costs which will be

paid by you. This warranty is granted only to the original purchaser placing the fan in service. This warranty is void if the fan or any part thereof has been

altered or modied from its original design or has been abused, misused, damaged or is in worn condition or if the fan has been used other than for the

uses described in the company manual. This warranty does not cover defects resulting from normal wear and tear. To make a warranty claim, notify Loren

Cook Company, General O󰀩ces, 2015 East Dale Street, Springeld, Missouri 65803-4637, explaining in writing, in detail, your complaint and referring to

the specic model and serial numbers of your fan. Upon receipt by Loren Cook Company of your written complaint, you will be notied, within thirty (30)

days of our receipt of your complaint, in writing, as to the manner in which your claim will be handled. If you are entitled to warranty relief, a warranty ad-

justment will be completed within sixty (60) business days of the receipt of your written complaint by Loren Cook Company. This warranty gives only the

original purchaser placing the fan in service specically the right. You may have other legal rights which vary from state to state. For fans provided with