Cook Fce series User manual

1FCE/FCRU IO&M B51150-003

FCE/FCRU

Fiberglass Roof Exhausters

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Receiving and Inspection

Carefully inspect the fan and accessories for any dam-

age and shortage immediately upon receipt of the fan.

• Turn the wheel by hand to ensure it turns freely and does not

bind.

• Check dampers (if supplied) for free operation of all moving

parts.

• Record on the Delivery Receipt any visible sign of damage.

Handling

Lift the fan by the base.

NOTICE! Never lift by the shaft, motor or housing.

Storage

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

tion, completely ll the bearings with grease or moisture-

inhibiting oil (refer to Lubricants, page 6). Rotate the wheel

several revolutions every three to ve days to keep a coat-

ing of grease on all internal bearing parts.

Store the fan in its original crate and protect it from dust,

debris and weather.

FCE FCRU

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 off, in case of an emer-

gency and in order that maintenance personnel are pro-

vided 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 con-

tact 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 build-

ing code for the site. The local code ofcial may require

variations from the recognized code based on local data.

The licensed engineer of record will be responsible for pre-

scribing the correct attachment based on construction ma-

terials, code requirements and environmental effects spe-

cic to the installation.

This publication contains the installation, operation and

maintenance instructions for standard units of the FCED,

FCEB, FCRUD and FCRUB Fiberglass Roof Exhausters.

Carefully read this publication and any

supplemental documents prior to any

installation or maintenance procedure.

Loren Cook catalog, Fiberglass, provides additional

information describing the equipment, fan performance,

available accessories and specication data.

For additional safety information, refer to AMCA Publi-

cation 410-96, Safety Practices for Users and Installers of

Industrial and Commercial Fans.

All of the publications listed above can be obtained from:

• lorencook.com

• [email protected]

• 417-869-6474 ext. 166

For information and instructions on special equipment,

contact Loren Cook Company at 417-869-6474.

2FCE/FCRU IO&M B51150-003

1. Remove the top cap which covers the motor assembly

by unbolting the lid.

2. For internal wiring, run the electrical wire and conduit

through the opening drilled in the damper shelf (refer

to Damper Installation), then through the wiring con-

duit in the ventilator base to the motor compartment.

For external wiring, run the wires through the horizon-

tal conduit on upblast units, or under top cap in down-

blast units.

3. Pull the wires through and complete the wiring. For

further information. Refer to Wiring Diagrams on page

Final Installation Steps

1. Ensure fasteners and set screws, particularly fan

mounting and bearing fasteners are tightened accord-

ing to the recommended torque shown on the table

below.

2. Inspect for correct amperage with an ammeter and

correct voltage with a voltmeter.

3. Ensure that all accessories are installed.

4. Test the fan to be sure the rotation is the same as indi-

cated by the arrow marked “Rotation.”

NOTICE! Do not allow the fan to run in the wrong

direction. This will overheat the motor and cause

serious damage. For 3-phase motors, if the fan is

running in the wrong direction, check the control

switch. It is possible to interchange two leads at

this location so that the fan is operating in the cor-

rect direction.

5. Inspect wheel-to-inlet clearance. Wheels may shift in

shipment. To realign wheel-to-inlet, shift upper bearing

so there is an equal radial clearance between the wheel

and inlet. Refer to Wheel to Inlet Clearance, page 6.

Recommended Torque for Setscrews/Bolts on Metal (IN-LB)

Setscrews Hold Down Bolts

Size

Key Hex

Across

Flats

Recommended

Torque Size Recommended

Torque

Min. Max.

#8 5/64” 15 21 3/8”-16 324

#10 3/32” 27 33 1/2”-13 780

1/4 1/8” 70 80 5/8 ”-11 1440

5/16 5/32” 140 160 3/4”-10 2400

3/8 3/16” 250 290 7/8”-9 1920

7/16 7/32” 355 405 1”-8 2700

1/2 1/4” 560 640 1-1/8”-7 4200

5/8 5/16” 1120 1280 1-1/4”-7 6000

3/4 3/8” 1680 1920 - -

7/8 1/2” 4200 4800 - -

19/16” 5600 6400 - -

Recommended Torque for Setscrews/Bolts on FRP (FT-LB)

Size (inches) 18-8 SST Hardware Torque

No. 10 7

1/4” 12

5/16” 20

3/8” 30

7/16” 41

1/2” 54

5/8” 86

3/4” 128

To maintain good working condition of the fan when it is

stored outdoors, follow the additional instructions below.

• Coat the shaft with grease or a rust preventative

compound.

• Wrap bearings for weather protection. Cover the inlet

and outlet to prevent the accumulation of dirt and mois-

ture in the housing.

• Periodically rotate the wheel and operate dampers (if

supplied). Periodically inspect the unit to prevent dam-

aging conditions.

Installation

If the fan was delivered with the motor unmounted, see

the maintenance section for belt and pulley installation.

Damper Installation

If your fan is supplied with dampers, follow the directions

below. If your fan does not include dampers, proceed to

Belt and Pulley Installation.

1. Place the damper inside the curb or inside the duct

work. Ensure the damper will open freely for the cor-

rect direction of the airow.

2. Secure to curb at the damper shelf.

3. Drill hole in the curb shelf for conduit needed for mo-

tor wiring.

4. Operate the dampers manually to ensure the blades

move freely.

5. Install fan over curb while aligning the conduit location

with the conduit hole in the curb.

Wiring Installation

NOTICE! All wiring should be in accordance with

local ordinances and the National Electrical Code,

NFPA 70. Ensure the power supply (voltage, fre-

quency, and current carrying capacity of wires) is

in accordance with the motor nameplate (see page

3 for diagram). Fan must be grounded to prevent

electrical discharge.

For Units Without A Junction Box:

An approved metal eld wiring compartment must be

secured to the unit with two screws in order that the box

does not rotate. All wires must be protected from abrasion

where they enter and exit the wiring compartment.

The green ground wire from the motor must be secured

under the green ground screws inside the eld wiring

compartment using a closed loop connector. Complete

connections in accordance with the wiring diagram on the

motor.

For Units With A Junction Box:

Pull wires through the appropriate conduit. Protect wires

from abrasion where they enter the eld wiring compart-

ment and complete connections in accordance with the

diagram on the motor.

Leave enough slack in the wiring to allow for motor

movement when adjusting belt tension. Some fractional

motors have to be removed in order to make the connec-

tion with the terminal box at the end of the motor.

NOTICE! Follow the wiring diagram in the discon-

nect switch and the wiring diagram provided with

the motor. Correctly label the circuit on the main

power box and always identify a closed switch to

promote safety (i.e., red tape over a closed switch).

3FCE/FCRU IO&M B51150-003

Wiring Diagrams

Single Speed, Single Phase Motor

T-1

T-

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.

2 Speed, 2 Winding, Single Phase Motor

Ground A

Ground B

T-1

T-

Low Speed

High Speed

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 leads.

Single Speed, Single Phase, Dual Voltage

Ground B

J-10

T-5

Ground A

Link A

Link B

Low Voltage

Line

Ground A

Link A & B

Line

Ground B

T-5

J-10

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

forming screw. To reverse, interchange T-5 and J-10 leads.

Typical Damper Motor Schematic

Fan

Motor

Damper

Motor*

Second

Damper

Motor

ansformer** Transformer*

For 3 Phase, damper motor voltage should be the same between L1and

L2. For single phase application, disregard L3.

*Damper motors may be available in 115, 230 and 460 volt models. The

damper motor nameplate voltage should be veried prior to connection.

**A transformer may be provided in some installations to correct the

damper motor voltage to the specied voltage.

3 Phase, 9 Lead Motor

456

L1L2L3

456

789

12 3

L1L2L3

Low Voltage

208/230 Volts

High Voltage

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

To reverse, interchange any 2 line leads.

2 Speed, 1 Winding, 3 Phase Motor

Motor

Together

High Speed

Line

Open

Low Speed

Line

Motor

To reverse, interchange any 2 line leads. Motors require magnetic

control.

2 Speed, 2 Winding, 3 Phase

T3Low Speed

Low Speed

High Speed

Motor

T13

T12

T11

L2Line

To reverse: High Speed-interchange leads T11 and T12. Low Speed-in-

terchange leads T1and T2. Both Speeds-interchange any 2 line leads.

Operation

Pre-Start Checks

1. Lock out all the primary and secondary power sources.

2. Inspect and tighten fasteners and setscrews, partic-

ularly fan mounting and bearing fasteners. Refer to

Torque Chart.

3. Inspect belt tension and pulley alignment. Refer to Belt

and Pulley Installation, page 5.

4. Inspect motor wiring. Refer to Wiring Installation.

5. Ensure belt touches only the pulleys.

6. Rotate the wheel to ensure it rotates freely.

7. Ensure fan and ductwork are clean and free of debris.

8. Close and secure all access doors.

9. Restore power to fan.

Start-Up

Turn on the fan. In variable speed units, set the fan to its

lowest speed. Inspect for the following:

• Direction of rotation

• Excessive vibration

• Unusual noise

• Bearing noise

• Improper belt alignment or tension (listen for squealing)

• Improper motor amperage or voltage

If a problem is discovered, immediately shut the

fan off. Lock out all electrical power and check for

the cause of the trouble. Refer to Troubleshooting

on page 7.

4FCE/FCRU IO&M B51150-003

Bearings should be relubricated in accordance with the

condition chart below.

Conditions Chart

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

120-200 2 weeks

Any Speed < -30 Consult Factory

Any Speed > 200 1 week

For moist or otherwise contaminated installations, divide the interval

by a factor of 3. For vertical shaft installation, divide the interval by a

factor of 2

For best results, lubricate the bearing while the fan is in

operation. Pump grease in slowly until a slight bead forms

around the bearing seals. Excessive grease can damage

seal and reduce life through excess contamination and/or

loss of lubricant.

In the event that the bearing cannot be seen, use no more

than three injections with a hand operated grease gun.

Motor Bearings

Motor bearings without provisions for relubrication will

operate up to 10 years under normal conditions with no

maintenance. In severe applications, high temperatures or

excessive contaminates, it is advisable to have the mainte-

nance department disassemble and lubricate the bearings

after 3 years of operation to prevent interruption of service.

For motors with provisions for relubrication, follow inter-

vals of the following table.

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 month

NOTICE! 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 verti-

cal shaft installations.

Inspection

Inspection of the fan should be conducted at the rst 30

minute, 8 hour and 24 hour intervals of satisfactory op-

eration. During the inspections, stop the fan and inspect

as per the chart below.

30 Minute Interval

Inspect bolts, setscrews, and motor mounting bolts. Adjust

and tighten as necessary.

8 Hour Interval

Inspect belt alignment and tension. Adjust and tighten as

necessary.

24 Hour Interval

Inspect belt tension. Adjust and tighten as necessary.

Maintenance

Establish a schedule for inspecting all parts of the fan.

The frequency of inspection depends on the operating

conditions and location of the fan.

Inspect fans exhausting corrosive or contaminated air

within the rst month of operation. Fans exhausting con-

taminated air (airborne abrasives) should be inspected ev-

ery three months.

It is recommended the following inspections be

conducted twice per year:

• Inspect bolts and setscrews for tightness. Tighten as

necessary. Refer to Torque chart.

• Inspect belt wear and alignment. Replace worn belts

with new belts and adjust alignment as needed. Refer to

Belt and Pulley Installation, page 5.

• Bearings should be inspected as recommended in the

Conditions Chart.

• Inspect for cleanliness. Clean exterior surfaces only.

Removing dust and grease on motor housing assures

proper motor cooling.

Fan Bearings

NOTICE! The fan bearings are provided

prelubricated. Any specialized lubrication

instructions on fan labels supersedes information

provided herein. Bearing grease is a petroleum

lubricant in a lithium base conforming to a NLGI #2

consistency. If user desires to utilize another type

of lubricant, they take responsibility for ushing

bearings and lines, and maintaining a lubricant that

is compatible with the installation.

A NLGI #2 grease is a light viscosity, low-torque, rust-

inhibiting lubricant that is water resistant. Its temperature

range is from -30°F to 200°F and capable of intermittent

highs of 250°F.

5FCE/FCRU IO&M B51150-003

Belt and Pulley Installation

Belt tension is determined by the sound of the belts when

the fan is rst started. The belts will produce a loud squeal,

which dissipates after the fan is operating at full capacity.

If belt tension is too tight or too loose, lost efciency and

damage may occur.

Do not change the pulley pitch diameter to change ten-

sion. The change will result in a different fan speed.

1. Loosen motor plate adjustment bolts and slide motor

plate so that belts easily slip into the grooves on the

pulleys. Never pry, roll, or force the belts over the rim

of the pulley.

2. Slide motor plate until proper tension is reached. For

proper tension, a deection of approximately 1/4” per

foot of center distance should be obtained by rmly

pressing the belt. Refer to Figure 1.

3. Lock the motor plate adjustment bolts in place.

4. Ensure pulleys are properly aligned. Refer to Figure 2.

Tolerance

Center

Distance

Max.

Gap

Up through

12” 1/16”

12” up

through 48” 1/8”

Over 48” 1/4”

OFFSET ANGULAR OFFSET/ANGULAR

CENTER

DISTANCE

(CD)

GAP

Pulley Alignment

Pulley alignment is adjusted by

loosening the motor pulley set-

screw and by moving the motor pul-

ley on the motor shaft.

Figure 2 indicates where to mea-

sure the allowable gap for the drive

alignment tolerance. All contact

points (indicated by WXYZ) are to

have a cap less than the tolerance

shown in the table. When the pul-

leys are not the same width, the al-

low-able gap must be adjusted by

half of the difference in width. Figure 3 illustrates using a

carpenter’s square to adjust the position of the motor pul-

ley until the belt Figure 3 is parallel to the longer leg of the

square.

Motor Services

Should the motor prove defective within a one-year pe-

riod, contact your local Loren Cook representative or your

nearest authorized electric motor service representative.

Changing Shaft Speed

All belt driven ventilators (5HP or less) are equipped with

variable pitch pulleys. To change fan speed, perform the

following:

1. Loosen setscrew on driver (motor) pulley and remove

key, if equipped.

2. Turn the pulley rim to open or close the groove facing.

If the pulley has multiple grooves, all must be adjusted

to the same width.

3. After adjustment, inspect for proper belt tension.

Size Maximum RPM

Standard HP Only

120 4500 4500

150 3600 4300

180 2900 3600

245 2200 2700

270 2000 2400

300 1800 2200

330 1650 2000

365 1500 1800

402 1350 1650

Speed Reduction

Open the pulley in order that the belt rides deeper in the

groove (smaller pitch diameter).

Speed Increase

Close the pulley in order that the belt rides higher in

the groove (larger pitch diameter). Ensure that the RPM

limits of the fan and the horsepower limits of the motor are

maintained.

Replacing Pulleys and Belts

1. Clean the motor and fan shafts.

2. Loosen the motor plate mounting bolts to relieve the

belt tension. Remove the belt.

3. Loosen the pulley setscrews and remove the pulleys

from the shaft. If excessive force is required to remove

the pulleys, a three-jaw puller can be used. This tool,

however, can easily warp a pulley. If the puller is used,

inspect the trueness of the pulley after it is removed

from the shaft. The pulley will need replacement if it is

more than 0.020 inch out of true.

4. Clean the bores of the pulleys and place a light coat of

oil on the bores.

5. Remove grease, rust and burrs from the shaft.

6. Place fan pulley on the fan shaft and the motor pulley

on the motor shaft. Damage to the pulleys can occur

when excessive force is used in placing the pulleys on

their respective shafts.

7. After the pulleys have been correctly placed back onto

their shafts, tighten the pulley setscrews.

8. Install the belts on the pulleys. Align and adjust the

belts to the proper tension as described in Belt and

Pulley Installation.

1 foot

1/4 inch

Figure 1

Figure 2

6FCE/FCRU IO&M B51150-003

Wheel-to-Inlet Clearance

The correct wheel-to-inlet clearance is critical to proper

fan performance. This clearance should be veried before

initial start-up since rough handling during shipment could

cause a shift in fan components. Refer to wheel/inlet draw-

ing for correct overlap.

Adjust the overlap by loosening the wheel hub and mov-

ing the wheel along the shaft to obtain the correct value.

A uniform radial gap (space between the edge of the

cone and the edge of the inlet) is obtained by loosening

the bearing bolts and set screws which will allow for cor-

rect repositioning.

Size Overlap

120 -165 3/16”

180-245 1/4”

270-300 5/16”

330-365 3/8”

402 7/16”

Spare Parts

Spare parts are not needed for the rst year of opera-

tion. If spare parts are desired, then it is suggested that a

spare motor and impeller be ordered for direct drive fans.

For belt drive fans, in addition to the motor and impeller, it

is suggested that a spare set of bearings, shaft, sheaves

and belts be ordered.

When ordering spare parts, specify the parts desired,

the fan model number and the fan serial number. Contact

your local sales representative for price and delivery.

Bearing Replacement

The fan bearings are pillow block ball bearings.

1. Follow all local lock-out/tag-out procedures, remove

topcap from unit and unwire the units motor.

2. Loosen the bolts holding the motor and remove the

belt. Inspect the belt for signs of wear and set aside.

3. While supporting the motor, either by the lifting eye

or around the base on the motor, loosen and remove

all the bolts holding the motor. Do not lift motor by its

shaft. Caution: Motors with cast frames can be ex-

tremely heavy and should not be lifted without addi-

tional aid. Set motor aside.

4. Locate the 4 to 8 bolts on the at surface of the interior

of the housing. Begin to loosen these bolts and save

the hardware. Note unit may shift during this process.

5. Using the lifting points on the power assembly care-

fully lift the assembly straight up until the wheel clears

all parts of the unit. Set the wheel / shaft / power as-

sembly down in a manner that does not damage the

roof or any component.

6. Measure and record the distance of the wheel from the

support plate.

7. Using a putty knife at the wheel hub, scrape the resin

from the safety plate and retaining bolt.

8. Remove the retaining bolt and safety plate and set

aside.

9. Using either a jewelry screw driver or small drill bit, re-

move the beeswax from the set screw openings and

set screw heads.

10. Remove the wheel and remove the old bearings and

shaft.

11. Install the new shaft to the wheel, safety plate, and re-

taining bolt. Tighten all per the torque values as stated

on page 2.

12. Using a berglass resin repair kit, apply resin per the

manufacture instruction over the safety plate, and re-

taining bolt. Recommend using a Grainger part num-

ber 3RAR9 or equal.

13. Reapply beeswax to protect the set screw heads.

14. Install the new shaft by sliding the bearings to the de-

sired location using the measurement record earlier

and loosely mounting the bearing support. Bearing

bolts and bearing set screws should be loose enough

to allow shaft position later.

15. Follow step 2 through 6 in reserve order to re-assem-

bly unit. Please note the wheel to inlet clear matches

as close as possible the diagram on page below

16. Tighten all hardware per the torque values as stated

on page 2 and follow the Operation Pre-Start Check

and Start-Up listed in this document.

7FCE/FCRU IO&M B51150-003

Troubleshooting

Problem and Potential Cause

Low Capacity or Pressure:

• Incorrect direction of rotation. Make sure the fan rotates

in same direction as the arrows on the motor or belt drive

assembly.

• Poor fan inlet conditions. There should be a straight clear

duct at the inlet.

• Improper wheel alignment.

Excessive Vibration and Noise:

• Damaged or unbalanced wheel.

• Belts too loose; worn or oily belts.

• Speed too high.

• Incorrect direction of rotation. Make sure the fan rotates

in same direction as the arrows on the motor or belt drive

assembly.

• Bearings need lubrication or replacement.

• Fan surge.

Overheated Motor:

• Motor improperly wired.

• Incorrect direction of rotation. Make sure the fan rotates

in same direction as the arrows on the motor or belt drive

assembly.

• Cooling air diverted or blocked.

• Improper inlet clearance.

• Incorrect fan RPMs.

• Incorrect voltage.

Overheated Bearings:

• Improper bearing lubrication

• Excessive belt tension.

8FCE/FCRU IO&M B51150-003

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 Of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