Cook Vcr Installation and operating instructions

Centrifugal Roof and Wall Exhausters

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

This publication contains the installation, operation

and maintenance procedures for standard units of the

VCR/VCRD/VCR-HP/VCRD-HP/VCR-XP/VCRD-XP -

Centrifugal Roof and Wall Exhausters. Carefully read

this publication prior to installation or maintenance

procedure.

Loren Cook catalog, VCR, provides additional informa-

tion describing the equipment, fan performance, available

accessories and specification data.

For additional safety information, refer to AMCA publica-

tion 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, exten-

sion 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.

Receiving and Inspection

Immediately upon receipt of a VCR fan, carefully inspect

the fan and accessories for damage and shortage.

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

does not bind.

• Record on the Delivery

Receipt any visible sign of

damage.

Handling

Lift the fan by the lifting lugs

provided under top cap. Never lift

by the shaft, motor or housing.

Storage

If the fan is stored for any

length of time prior to installation,

store it in its original shipping

crate and protect it from dust,

debris and the weather.

Installation

If the fan was delivered with the motor unmounted, see

the maintenance sections for belt and pulley installation.

If the fan was purchased as a wall mount unit and a

grease terminator or grease trough was not purchased, a

WARNING

This fan has rotating parts. Safety precautions

should be exercised at all times during installation,

operation, and maintenance.

ALWAYS disconnect power prior to working on fan.

1-1/16 inch diameter drain hole should be inserted on the

bottom side of the unit for drainage.

Fan Installation

a. Ensure the fan discharge is a minimum 40 inches

above the roof surface and a minimum of 10 foot from

any building air intake in order to comply with NFPA 96.

b. Minimum exhaust velocity in the duct should be 1500

FPM in accordance with NFPA 96.

c. If the fan is installed on a surface that is not level, install

the fan in a position that places the drain tube at the

lowest position.

d. Secure the fan to the roof curb at all four corners using

a minimum of four anchor bolts, lag screws or other

suitable fastener.

Personal Safety

Disconnect switches are recommended. Place

the disconnect switch near the fan in order that

the power can be swiftly cut off in case of an

emergency, and in order that maintenance per-

sonnel are provided complete control of the

power source.

VCR

VCR/VCRD

Lifting Lugs

Wiring Installation

All wiring should be in accordance with local ordinances

and the National Electrical Code, NFPA 70. Ensure the

power supply (voltage, frequency, and current carrying

capacity of wires) is in accordance with the motor name-

plate. Refer to the Wiring Diagrams, next page.

Do not use cooling tubes for electrical connections.

Upblast units have two wiring conduits. Upblast units have

two wiring conduits. The vertical conduit comes plugged.

The horizontal conduit is directly above vertical conduit.

! CAUTION ! Do not use vertical conduit if fan will be used

in a grease and/or heat exhaust application, use of the verti-

cal conduit does not conform to NFPA 96 and UL 762.

Lock off all power sources before the fan is wired to

power source.

Follow the wiring diagram in the disconnect switch

and the wiring diagram provided with the motor. Cor-

rectly 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).

Fan With a Junction Box

a. Wire the motor using the junction box located on the

outside of the fan.

b. Reinstall the junction box cover and ensure that the

gasket forms a complete seal.

Fan Without a Junction Box

A field wiring compartment must be installed for wire con-

nections. Wire the motor by pulling the electrical wire

through the conduit. For further information refer to the

National Electrical Code and the wiring diagram provided on

the motor.

WARNING

All wires must be protected from abrasion when

passing through the opening of a field wiring com-

partment.

Personal Safety

Disconnect switches are recommended. Place

the disconnect switch near the fan in order that

the power can be swiftly cut off in case of an

emergency, and in order that maintenance per-

sonnel are provided complete control of the

power source.

Grease Terminator Installation

Final Installation Steps

a. Ensure fasteners and setscrews, particularly fan

mounting and bearing fasteners, are tightened accord-

ing to the recommended torque shown in the table

below, Recommended Torque for Setscrews/Bolts.

b. Inspect for correct voltage with voltmeter.

c. Ensure all accessories are installed.

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

cated by the arrow marked Rotation.

Do not allow the fan to run in the wrong direction.

This will overheat the motor and cause serious dam-

age. For 3-phase motors, if the fan is running in the

wrong direction, check the control switch. It is possi-

ble to interchange two leads at this location so that the

fan is operating in the correct direction.

e. 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.

Sealing Nut

Fan Inlet Side

Lid

Terminator

VCR with Terminator

PVC

Extension

Sealing Nut

Recommended Torque for Setscrews/Bolts (IN/LB.)

Setscrews

Hold Down Bolts

Size Key Hex

Across

Flats

Recommended

Torque

Min. Max. Size Wrench

Torque

No.10 3/32” 28 33 3/8”-16 240

1/4” 1/8” 66 80 1/2”-13 600

5/16” 5/32” 126 156 5/8”-11 1200

3/8” 3/16” 228 275 3/4”-10 2100

7/16” 7/32” 29 348 7/8”-9 2040

1/2” 1/4” 42 504 1”-8 3000

5/8” 5/16” 92 1104 1-1/8”-7 4200

3/4” 3/8” 120 1440 1-1/4”-7 6000

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 Volts High Voltage

460 Volts

L1L3

3 Phase, 9 Lead Motor

Delta-Connection

Wiring Diagrams Wiring Diagrams

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

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

Ground A

Line

T-1

T-4

Ground B

Single Speed, Single Phase Motor

To reverse, interchange any 2 line leads.

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

screw. To reverse, interchange T-1 and T-4 leads.

T-1

T-4

Ground B

Ground A High Speed

Low Speed

L2Line

2 Speed, 2 Winding, Single Phase Motor 2 Speed, 1 Winding, 3 Phase Motor

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

Together

Open

Low SpeedHigh Speed

Motor Motor

Single Speed, Single Phase, Dual Voltage 2 Speed, 2 Winding, 3 Phase

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

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

Link A

Low Voltage

Ground A

Ground B

T-5

J-10

Line T-5

J-10

Ground A

Ground B

Link A & B

High Voltage

Line

Link B

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

Low Speed-interchange leads T1and T2. Both Speeds-interchange any 2

line leads.

T11

T12

T13

Low Speed

High Speed

Motor

Line

Operation

Pre-Start Checks

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

b. Inspect and tighten fasteners and setscrews, particu-

larly fan mounting and bearing fasteners. Refer to

Torque chart.

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

and Pulley Installation, page 5.

d. Inspect motor wiring. Refer to Wiring Installation, page

e. Ensure belt touches only the pulleys.

f. Rotate the wheel to ensure it rotates freely.

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

h. Close and secure all access doors.

i. Restore power to fan.

Start Up

Turn the fan on. 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, page 6.

VCRD with Shade Pole or PSC Motors

White Line

Line

Black (High)

Red (Low)

Line

VCRD with 2-Speed PSC Motors

White Line

NOTE: Insulate Unused Lead

Black

*See VCR Wiring Diagram for correct lead.

†

Locate away from heat.

VCR

FAN*

WHITE

BLACK

FSC - 115 VOLT 10 AMP

FSC



VCR

FAN*

a period of ten years. However, it is advisable to have your

maintenance department remove and disassemble the

motor, and lubricate the bearings after three years of opera-

tion in excessive heat or in a contaminated airstream con-

sisting of airborne abrasives.

Fan Bearings

Fan bearings are lubricated through the grease fitting and

should be lubricated by the schedule, Conditions Chart,

shown below.

For best results, lubricate the bearing while the fan is rotat-

ing. Slowly pump grease into the bearing until a slight bead

forms around the bearing seals. Excessive grease can burst

seals thus reduce bearing life.

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

three injections with a hand-operated grease gun.

Motor Services

Should the motor provedefective within a one-year period,

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 the fan speed, perform the

following:

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

key, if equipped.

b. 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.

c. After adjustment, inspect for proper belt tension.

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 main-

tained.

Conditions Chart

RPM Temperature Fan

Status Greasing

Interval

100 Up to 120°F Clean 6 to 12 months

500 Up to 150°F Clean 2 to 6 months

1000 Up to 210°F Clean 2 weeks to 2 months

1500 Over 210°F Clean Weekly

Any

Speed Up to 150°F Dirty 1 week to 1 month

Any

Speed Over 150°F Dirty Daily to 2 weeks

Any

Speed Any Temperature Very Dirty Daily to 2 weeks

Any

Speed Any Temperature Extreme

Conditions Daily to 2 weeks

Inspection

Inspection of the fan should be conducted at the first 30

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

tion. During the inspections, stop the fan and inspect as

instructed 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 con-

ditions and location of the fan.

Inspect fans exhausting corrosive or contaminated air

within the first month of operation. Fans exhausting con-

taminated air (airborne abrasives) should be inspected

every three months.

Regular inspections are recommended for fans exhaust-

ing non-contaminated air.

It is recommended the following inspections be con-

ducted 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, page 4.

• Inspect for cleanliness. Clean exterior surfaces only.

Removing dust and grease on motor housing assures

proper motor cooling.

Grease Terminator

Regular inspections of the Grease Terminator 2 are rec-

ommended. Depending on the amount of grease dis-

charged through the fan, the Grease Terminator 2 should

be changed every 30 to 45 days to ensure proper opera-

tion. Any buildup of grease is easily seen during a visual

inspection of the clear canister. However, if the Grease Ter-

minator 2 becomes saturated, grease will no longer be

absorbed.

To replace the Grease Terminator, simply unscrew the

used canister and screw on a new one.

Lubricants

Loren Cook Company uses petroleum lubricant in a lith-

ium base conforming to NLGI grade 2 consistency. Other

grades of grease should not be used unless the bearings

and lines have been flushed clean. If another grade of

grease is used, it should be lithium-based.

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

rust-inhibiting lubricant that is water resistant. Its tempera-

ture range is from -30°F to +200°F and capable of intermit-

tent highs of +250°F.

Motor Bearings

Motor bearings are pre-lubricated and sealed. Under nor-

mal conditions they will not require further maintenance for

Replacing Pulleys and Belts

a. Clean the motor and fan shafts.

b. Loosen the motor plate mounting bolts to relieve the

belt tension. Remove the belt.

c. Loosen the pulley setscrews and remove the pulleys

from the shaft.

If excessive force is required to remove the pul-

leys, 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.

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

oil on the bores.

e. Remove grease, rust and burrs from the pulleys.

f. 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.

g. After the pulleys have been correctly placed back onto

their shafts, tighten the pulley setscrews.

Belt and Pulley Installation

Belt tension is determined by the sound of the belts when

the fan is first 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 efficiency and

damage can occur.

Do not change the pulley pitch diameter to change tensi-

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

a. Loosen motor plate adjustment bolts and move motor

plate so that the belts easily slip into the grooves on

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

rim of the pulley.

b. Slide the motor plate back until proper tension is

reached. For proper tension, a deflection of approxi-

mately 1/4” per foot of center distance should be

obtained by firmly pressing the belt. Refer to Figure 1.

c. Lock the motor plate adjustment bolts in place.

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

Pulley Alignment

Pulley alignment is adjusted by loosening the motor pul-

ley setscrew and by moving the motor pulley on the motor

shaft.

Figure 2 indicates where to measure the

allowable gap for the drive alignment toler-

ance. All contact points (indicated by

WXYZ) are to have a gap less than the tol-

erance shown in the table. When the pul-

leys are not the same width, the allowable

gap must be adjusted by half of the differ-

ence in width. Figure 3 illustrates using a

carpenter’s square toadjust the position of

the motor pulley until the belt is parallel to

the longer leg of the square.

Bearing Replacement

The fan bearings are pillow block type ball bearings.

a. Remove the old bearing.

b. Remove any burrs from the shaft by sanding.

c. Slide new bearings onto the shaft to the desired loca-

tion and loosely mount bearings onto the bearing sup-

port. Bearing bolts and setscrews should be loose

enough to allow shaft positioning.

1 foot

1/4 inch

Figure 1

OFFSET ANGULAR OFFSET/ANGULAR

CENTER

DISTANCE

(CD)

GAP GAP

Figure 2

Tolerance

Center Distance Maximum

Gap

Up thru 12” 1/16”

12” up through 48 1/8”

Over 48” 1/4”

Figure 3

Maximum RPM

VCR

Size Maximum RPM VCR-HP

Size Maximum RPM

Standard Reinforced Standard Reinforced

100 2002 - 150 1952 -

120 1671 - 165 1728 -

135 1574 - 180 1829 -

150 1520 - 195 1570 -

165 1295 - 210 1626 -

180 1546 - 225 1435 -

195 1353 - 245 1185 1234

210 1227 - 270 1025 1049

225 1086 - 300 980 1046

245 901 - 330 830 912

270 766 - 365 735 872

300 837 877

330 716 748

365 624 659

402 539 560

445 463 473

490 360 403

Maximum RPM

VCR-XP

Size Maximum RPM VCR-XP

Size Maximum RPM

Standard Standard

165 2508 245 1616

180 2396 270 1656

195 2100 300 1391

210 2126 330 1182

225 1879 365 1132

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

inlet cone bolts and repositioning the inlet cone.

Size Maximum

Overlap Size Maximum

Overlap

100

5/8”

300

1”

120 330

135 365

150 402

165 445

180 490

1-1/4”

195 540

210 3/4” 600

225 660

245 730

270

Wheel/Inlet Overlap

Radial Clearance Overlap

d. Correctly position the wheel and tighten the bearing

bolts securely to the bearing support.

e. Align setscrews bearing to bearing and secure tightly

to the shaft.

Never tighten both pairs of setscrews before secur-

ing bearing mounting bolts. This may damage the

shaft.

f. Inspect the wheel position again. If necessary, readjust

by loosening the bearing bolts and setscrews and

repeat from step e.

g. Test run the fan.

h. Retighten setscrews on bearings, sheave and wheel.

Recheck belt tension and adjust as needed.

Wheel Replacement

a. Drill two holes approximately centered between the

shaft and the edge of the hub OD with the following

dimensions:

• 1/4” diameter

• 3/8” to 1/2” deep

• 180° apart in face of hub

b. Tap 1/4” holes to 5/16” thread with the 5/16” hole tap.

Do not drill or tap any larger than recommended.

c. Screw the puller arms into the tapped holes full depth

of threads (3/8” to 1/2” approximately). Align center of

puller with center of shaft. Make certain all setscrews

in hub (normally a quantity of two) are fully removed.

Work puller slowly to back wheel off the shaft

Recommended Puller

Lisle No. 45000 Sterling Wheel Puller. This puller is avail-

able at most automotive parts retail outlets.

Wheel-to-Inlet Clearance

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

fan performance. This clearance should be verified 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

Wheel Replacement Components

Above - Drilled hole placement.

Right - Wheel puller.

Troubleshooting

Problem and Potential Cause

Low Capacity or Pressure

•Incorrect direction of rotation. Make sure the fan rotates in same di-

rection 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 di-

rection 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 di-

rection 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.

Part

No. VCRD/VCRD-HP/VCRD-XP Parts Description

100-195

1a Top Cap Lid

1b Top Cap Cylinder

2 Top Cap Clip (4)

3 Motor

4 Spun Motor Plate

5Baffle

6 Wheel Assembly

7 NEMA 3 Junction Box

8Base

9 Conduit

11 Upper Post (4)

12 Lower Post (4)

13 Wind Band

14 Brace (4)

15 Vent Tube (2)

16 Grommet (4)

Part

No. VCR/VCR-HP/VCR-XP Parts Description

100-225 245 270-490

1a Top Cap Lid Top Cap Lid Top Cap Lid

1b Top Cap Cylinder Top Cap Cylinder Top Cap Cylinder

2 TopCap Clip (4) Top Cap Clip (4) Top Cap Clip (8)

3 Motor Motor Motor

4 Spun Motor Plate Spun Motor Plate Spun Motor Plate

5 Baffle Baffle Baffle

6 Wheel Assembly Wheel Assembly Wheel Assembly

7BaseBaseBase

8 Conduit Conduit Conduit

9 Isolator (4) Isolator (4) Isolator (4)

10 Upper Post (4) Upper Post (4) Upper Post (8)

11 Lower Post (4) Lower Post (4) Lower Post (8)

12 Wind Band Wind Band Wind Band

13 Brace (4) Brace (4) Brace (8)

14 Power Assembly Power Assembly Power Assembly

15 Shaft Shaft Shaft

16 Bearing (2) Bearing (2) Bearing (2)

17 Drive Sheave Drive Sheave Drive Sheave

18 Driven Sheave Driven Sheave Driven Sheave

19 Belt Set Belt Set Belt Set

20 Vent Tube Vent Tube Vent Tube

21 Grommet (2) Grommet (2) Grommet (2)

22 — Cut Off (HP & XP Only ) Cut Off (HP & XP Only )

23 Insulation Insulation Insulation

24 NEMA 3 Junction Box NEMA 3 Junction Box NEMA 3 Junction Box

Parts List

VCR/VCR-HP/VCR-XP Parts

VCRD/VCRD-HP/VCRD-XP Parts

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 war-

ranty 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 modified 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 Offices, 2015 East

Dale Street, Springfield, Missouri 65803-4637, explaining in writing, in detail, your complaint and referring to the specific model and serial numbers of your fan. Upon

receipt by Loren Cook Company of your written complaint, you will be notified, 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 adjustment 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 specifically the right. You may have other legal

rights which vary from state to state.

Corporate Offices: 2015 E. Dale Street Springfield, MO 65803 417.869.6474

lorencook.com VCR IOM - October 2007

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