GO FAN YOURSELF VividAir Z-Tech3 User manual

Z-TECH3™ FAN
INSTALLATION & TECHNICAL OPERATIONS GUIDE
GO FAN YOURSELF, INC. | 1032 NATIONAL PARKWAY | SCHAUMBURG, IL 60173 | www.gofanyourself.com | 1-844-GOFANME (463-2663) OR 1-847-648-4920
GO FAN YOURSELF, INC. | 1032 NATIONAL PARKWAY | SCHAUMBURG, IL 60173 | www.gofanyourself.com | 1-844-GOFANME (463-2663) OR 1-847-648-4920
GO FAN YOURSELF, INC. | 1032 NATIONAL PARKWAY | SCHAUMBURG, IL 60173 | www.vividairmovement.com | 1-844-GOFANME (463-2663) OR 1-847-648-4920
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VividAir
1032 National Parkway
Schaumburg, IL 60173
1-844-GOFANME (463-2663)
1-847-648-4920
www.vividairmovement.com
Company:
Address:
City/State/Zip:
Email:
Contact Name:
Phone:
1. Contractor and customer have reviewed the scope of work/layout including: fan placement, controller placement, and power supply panel(s) to be used.
3. Contractor and customer have reviewed the installation schedule and any site specific safety rules and regulations (i.e., specific requirements, gear, certifications,
Additional Comments:
Customer Signature:
Printed Name:
Date:
Installation crew supervisor and facility manager are to complete checklist after completing installation.
Customer Signature:
Printed Name:
Date:
Contractor Signature:
Printed Name:
Date:
INSTALLATION CHECK IN
Installation crew supervisor and facility manager are to complete checklist prior to entering the jobsite or unloading materials.
INSTALLATION CHECK OUT
INSTALLATION CHECK IN / CHECK OUT
Email completed form and required pictures to: [email protected]
2. Contractor and customer have reviewed the fan installation manual for the type of fan mount at each location.
Contractor Signature:
Printed Name:
Date:
lock out/tag out, prohibited areas, secure areas, areas to avoid, special machinery, dangerous conditions or areas and how to detour such places if needed):
1. Fan and controller placement agrees with the check in (above), scope of work and layout.
2. Contractor has reviewed with the customer the breaker location for all fans and the customer understands the lock out/tag out (LOTO) procedure
on all fan controllers.
3. No safety incidents were reported by or on the contractor during the fan installation.
4. All fans are running and the customer has been trained on operation in both directions. The fan operation section of the manual has been reviewed.
5. The customer understands the warranty for each fan and the warranty information in the manual has been reviewed.
6. The customer has been given a copy of the installation manual for all styles of VividAir fans installed as part of this project.
7. The customer is comfortable with fan operation including starting/stopping, speed adjustment, reversing direction, and power disconnect with LOTO.
8. The contractor has taken pictures of all fans individually clearing showing the full fan in the ceiling (required to active the warranty).
9. The contractor has taken pictures of all fans clearly showing the routing and connection of both safety cables (required to active the warranty).
10. The contractor has taken pictures of all fan controllers mounted in their final position (required to activate the warranty).
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Itemized Checklist - Unpacking Your VividAir Fan
Z-TECH3™ FAN
Installation and Technical Operations
Motor Hub Assembly Box
•There are 3 trays
inside the Motor
Hub Assembly Box
(Trays Detailed On Following
Pages)
Blade Box Skid
Down Tubes 3FT
and Longer May
Also Be
Packaged and
Shipped On The
Blade Box Skid
Blade Stabilizer
Box will typically
ship on the Blade
Box skid. Box is
36x6x6 and shown
on page 6.
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Itemized Checklist - Motor Assembly Box Tray #1 - Top Tray
Z-TECH3™ FAN
Installation and Technical Operations
Down Tube
1FT or 2FT Down Tubes Only. Longer Down
Tubes will Be Packaged Separately Upper Yoke Weldment &
Beam Clamp Plates
ACS355 or ACS255 VFD Controller
ACS255 Controller Shown
Accessory Area
Typical Items Packed Here Will Include:
•Z-Purlin Mounting Kit
•Wood Beam Mounting Kit
•Guy Wire Kit
Your Fan May Include Other Optional Accessories
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Itemized Checklist - Motor Assembly Box Tray #2 - Middle Tray
Z-TECH3™ FAN
Installation and Technical Operations
Truss Mount Kit (4)
Square Washers
Z-TechSSTM
3/8" Quick Link
Manual & Optional
Accessories
Hardware Packs
ACS355 or
ACS255 VFD
Controller
(ACS255 Shown)
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| 5
Itemized Checklist - Motor Assembly Box Tray #3 - Bottom Tray
Z-TECH3™ FAN
Installation and Technical Operations
Fan Mount Shims
To Keep The Beam Clamp Plates
Near Level When Clamping To
Thicker I-Beams. Add Additional
Shims If Required.
Lower Yoke Plates
Motor Hub Assembly
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Itemized Checklist - VFD Controllers, Blade Box, Blade Stabilizer Box
Itemized Checklist - Fan Blade Box
Blade Set (3 Blades) 8ft, 10ft , 12ft, 16ft, 20ft, 24ft
Z-TECH3™ FAN
Installation and Technical Operations
Itemized Checklist - Fan Blade Stabilizers Packed With Motor
ABB ACS355 Controller
200-240VAC 3 Phase
400-480VAC 3 Phase
ABB ACS255 Controller
200-240VAC 1 Phase
VividAir VFD Controller
200-200-240V 1 Phase
200-200-240V 3 Phase
400-480V 3 Phase
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Structural
Support of
the Building
Upper Yoke Weldment
Down Tube
(ordered to length)
Lower Yoke Assembly
Fan Frame
Guy Wire Mounting Holes
Hub
Gearbox
Z-TechSSTM Lower Safety
Strap Assembly
16,000 lb Break Strength
Motor
Z-TechSSTM Upper Safety
Strap Assembly
16,000 lb Break Strength
Lower Safety
Cable Assembly
Fan Mount
Assembly
(4) 1/2"-13 x 2" Grade 8 Bolts
(8) 1/2" Grade 8 Flat Washers
(4) 1/2"-13 Grade 8 Nylock Nuts
(2) 1/2"-13 x 5" Grade 8 Bolts
(4) 1/2" Grade 8 Flat Washers
(2) 1/2"-13 Grade 8 Nylock Nuts
(2) 1/2"-13 x 5" Grade 8 Bolts
(4) 1/2" Grade 8 Flat Washers
(2) 1/2"-13 Grade8 Nylock Nuts
Fan Mounting Plate
(Top of Motor Hub Assembly)
(4) 1/2"-13 x 1.5" Grade 8 Bolts
(8) 1/2" Grade 8 Flat Washers
(4) 1/2"-13 Grade 8 Nylock Nuts
Z-TECH3™ FAN
Installation and Technical Operations
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Table of Contents
1. Tools Required to Install Product........................................................................................................................................10
2. Required Steps Before Installation .....................................................................................................................................10
3. Different Mounting Applications .........................................................................................................................................10
“I” Beam Mounting Fig.2................................................................................................................................................................11
Bottom Chord Angle Iron Mount Fig.3................................................................................................................................11
Top Chord Angle Iron Mount Fig.4.......................................................................................................................................12
“L-Bracket” Mounting Fig.5....................................................................................................................................................................13
“Z-Purlin” Mounting Fig.6..........................................................................................................................................................14
4. Standard Mount .............................................................................................................................................................................15
What is included in the mount package ......................................................................................................................................15
What standard mounts are available Fig.7................................................................................................................................15
How to install the standard mount Fig.8. .....................................................................................................................................15
5. Down Tube ........................................................................................................................................................................................16
What is included in the down tube package ...............................................................................................................................16
How to install the down tube, upper safety cable, and lower yoke assembly.....................................................16
Typical safety cable routing Fig11...................................................................................................................................................16
6. Main Hub and Drive Assembly ................................................................................................................................................ 17
What is included in the main hub and drive assembly Fig.12 ........................................................................................ 17
How to install the assembly Fig 13. ................................................................................................................................................. 17
Installing the lower safety cable (Reference Fig.11 page #11)........................................................................................ 17
7. Guy Wires .......................................................................................................................................................................................... .18
What is included in the guy wires ..................................................................................................................................................... 18
How to install the guy wires:
Fig.14 ...................................................................................................................................................................................................... 18
Fig.15 ...................................................................................................................................................................................................... 18
Fig.16 ...................................................................................................................................................................................................... 18
Fig.17 ....................................................................................................................................................................................................... 19
8. Blade Assembly ............................................................................................................................................................................... 19
What is included with the blades ....................................................................................................................................................................................... 19
How to install the blades Fig.18 ............................................................................................................................................................................................ 19
9. Leveling the fan & Removing the Oil Vent Plug on the Motor................................................................................... .20
Fig.19 ............................................................................................................................................................................................................................................................... .20
Electrical Installation ............................................................................................................................................................................... 21
Safety Precautions ............................................................................................................................................................................................................................ 21
Wire Requirements ........................................................................................................................................................................................................................... 22
Maximum Power Cable Length ........................................................................................................................................................................................... 23
Power Requirements ......................................................................................................................................................................................................................24
Wire Locations & VFD Connections.................................................................................................................................................................................. .25
ESFR Wire Connections......................................................................................................................................................................................................26-27
Wire Connections (Motor). .....................................................................................................................................................................28
Operation Instructions for the VFD (3 phase & 1 phase applications).................................................................29-30
Recommended Maintenance Schedule & Saftey Precautions....... ....................................................................................... 32
Fan Clearances......... .................................................................................................................................................................................. 33
VividAir Annual Performance Plan.....................................................................................................................................................34
VividAir Annual Performance Plan Record. ................................................................................................................................... 35
Warranties and Liabilities ...............................................................................................................................................................43-46
Z-TECH3™ FAN
Installation and Technical Operations
Troubleshooting Guides...................................................................................................................................................................36-42
Locate Your VividAir Fan (Recommended Clearances)................................................................................................9
Fan Operation Best Practices................................................................................................................................................................ 31
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A
B
E
D
G
F
C
Legend
A. Distance from the ceiling
B. Distance of fan from tip to tip
C. Distance from the floor
D. Distance from fan blades to outer
walls
E. Distance from obstructions
F. Proximity of fan tip to roof with pitch
or other obstruction
G. Heat Source
Guidelines
Recommended VividAir
Fan Clearances
A. Clearance from solid roof surfaces or solid trusses:
i. 8, 12 & 16ft fans = 4ft
ii. 20 & 24ft fans = 5ft
Open trusses do not need to be considered for air flow restriction.
B. Diameter of fan from tip to tip.
C. Fan diameter minus 4' (nominal). Blades must be a
minimum of 10' from the deck.
D. Should be equal to the diameter of the fan from tip to
tip.
E. Should have at least 18" of clearance from obstructions.
F. Should not be less than 2 feet with any fan diameter.
G. The best practice is to keep blade tips 20' from any
heat source or exhaust fan whenever possible.
H. Per NFPA fans must be centered between (4) sprinkler
heads if the location is equipped with sprinklers.
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Z-TECH3™ FAN
Installation and Technical Operations
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1. Tools Required to Install Product
•Level
•High torque 1/2" impact gun with impact socket set
•Torque wrench capable of 30 ft-lbs +/- 2 ft-lbs
•Standard socket set
•Standard wrench set
•Scissor or Boom Lift
2. Required Steps Before Installation
•Check to see if you have all the tools required for the installation.
•Verify that all fan components were received.
•Check drawings and layouts provided to locate where the Z-TechTM Fan is to be installed.
•Each person installing the Z-TechTM Fan must use a safety harness at all times.
•Other safety requirements may be required for installation.
•All workspace safety requirements and lock out/tag out procedures provided by the customer
for the assembly and installation of the Z-TechTM Fan must be met and followed.
“I” Beam Mounting
Fig.2
Z-TECH3™ FAN
Installation and Technical Operations
Follow the Factory Mutual Insurance Company (FM Global) standards, Heating equipment manufacturer’s guideline
and safety standards such as those published by the National Fire Protection Association (NFPA), and the American
Society for Heating, Refrigeration and Air Conditioning Engineers (ASHRAE), and local code authorities.
WARNING: A structural engineer will need to verify that the structure is suitable prior to the installation of the fan.
The fan should not be installed unless the structure on which the fan will be mounted is securely constructed, without
damages, and can support the load of the fan. It is the sole responsibility of the customer/end user to have the
stability of the mounting structure verified. VividAir hereby denies any liability resulting from the lack of verification
or from the use of any materials or hardware than those supplied by VividAir or otherwise indicated within these
installation instructions.
Start your installation
3. Different Mounting Applications
Note: The following mounting applications
are representations only and are subject to
change without notice. Contact your sales
representative or the VividAir office for
complete mounting instructions.
Insert optional shims (found in bottom
tray of your fan packaging) to keep
Beam Clamp Plates near level if I-Beam is
thicker than the bend in the Beam Clamp
Plate. Shims insert on top of the Upper
Yoke Assembly and are secured with the
mounting hardware. See picture above
and following pages for additional
details.
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Bottom Chord Angle Iron Mount
Drill holes in angle iron and direct mount in
place of using Beam Clamp Plates.
Z-TECH3™ FAN
Installation and Technical Operations
3. Different Mounting Applications
NOTE: The 3"x3"x1/4" steel angles must be supplied
by the installer. Hardware used to secure the angles
to the mounting structure is not included.
NOTE: If the truss span is wider than 8 FT (4) steel
angles are required. Contact VividAir for additional
instructions.
***NOTE*** Hardware A, B, and C below are contractor supplied.
A - (4) 1/2"x13x1.5" longer than the lower chord of the truss Grade 8 Cap Head Screw
B - (8) 1/2" Grade 8 Flat Washer
C - (4) 1/2"x13 Grade 8 Steel Nylock Nut
D - (1) VividAir Truss Mount Kit will be included with your fan (kit consists of (4) large
square washers). Tighten all hardware to a minimum 40 ft lbs (54.2 N
. m).
•Face angle irons as shown.
•Once mounted use Upper Yoke Weldment and mark
mounting holes on the angle irons.
•Drill (2) holes in each angle iron and direct mount the
Upper Yoke Weldment to the angle irons.
•The Beam Clamp Plates and shims are not used in this
application.
Fig.3
3"x3"x1/4" Steel Angles
A B C B D
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Z-TECH3™ FAN
Installation and Technical Operations
3. Different Mounting Applications (continued)
***NOTE*** Hardware A, B, and C below are contractor supplied:
A - (4) 1/2"-13x(chord height + 1.5") Grade 8 Cap Head Screw
B - (8) 1/2" Grade 8 Flat Washer
C - (4) 1/2"-13 Grade 8 Steel Nylock Nut
D - (1) VividAir Truss Mount Kit will be included with your fan
(kit consists of (4) large square washers).
Tighten all hardware to a minimum 40 ft lbs (54.2 N.m).
NOTE: The 3"x3"x1/4" steel angles
must be supplied by the installer.
Hardware used to secure the angles to
the mounting structure is not included.
NOTE: If the truss span is wider than
8' (4) steel angles are required. Contact
VividAir for additional instructions.
•Face angle irons as shown.
•Once mounted use Upper Yoke Weldment and mark
mounting holes on the angle irons.
•Drill (2) holes in each angle iron and direct mount the
Upper Yoke Weldment to the angle irons.
•The Beam Clamp Plates and shims are not used in this
application.
Top Chord Angle Iron Mount
Drill holes in angle iron and direct mount in
place of using Beam Clamp Plates.
Fig.4
C D B A 3"x3"x1/4" Steel Angles
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“L-Bracket” Mounting
(Refer to L-Bracket Installation Guide received
with your fan)
A local structural engineer should be consulted
to verify all L-Bracket Mounting applications.
Secure L-Brackets
As shown below secure the L-Brackets and Safety
Clips with Quick Links to the mounting structure with
installer-supplied hardware.
Z-TECH3™ FAN
Installation and Technical Operations
3. Optional Mounting Applications
VividAir Wood/Concrete Beam Kit Must Be Ordered
Required Contractor Supplied Hardware:
(2) 1/2"-13 x 1 1/2" longer than the support
structure Grade 8 Hex Cap Screw
(4) 1/2" Grade 8 Flat Washer
(2) 1/2"-13 Grade 8 Steel Nylock Nut
Tighten all hardware to a minimum
40 ft lbs (54.2 N.m).
Fig.5
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| 14
“Z-Purlin” Mounting
(Refer to Z-Purlin Installation
Guide received with your fan for
additional details).
1) Drill the Z-Purlins using the backer plate as
a template and anchor the backer plate to
the Purlin Bracket with supplied hardware.
Tighten to 40 ft lbs (54.2 N
.m).
2) Measure and pre-drill the angle irons for
the fan mount using the mount as a
template.
3) Finger tight the angle irons facing outward
to hold them in place and attach the fan
mount.
4) Tighten both the fan mount hardware and
the angle iron hardware to a minimum
40 ft lbs (54.2 N
.m).
Mounting Hardware Supplied
a. (16) 1/2"-13 x 2” Grade 8 Hex Head Cap
Screw
b. (32) 1/2" Grade 8 Flat Washer
c. (16)1/2" Grade 8 Nylock Nut
Tighten all hardware to a minimum
40 ft lbs (54.2 N
. m).
Z-TECH3™ FAN
Installation and Technical Operations
3. Optional Mounting Applications (continued)
VividAir Z-Purlin Kit Must Be Ordered
Fig.6
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1. Secure the I-Beam or OWSJ Beam between
the mfg I-Beam Clamps and the Upper Yoke.
Insert the mfg I-Beam Spacers if required.
2. Insert the bolts, washers and tighten to a
minimum 40 ft-lbs (54.2 N.m). (Fig 8)
Fig. 8
Fig.7
Installing the Mount
Upper Yoke Mounting Hardware:
(4) 1/2"x13x2" Grade 8 Hex Cap Screw
(8) 1/2" ASTM F436 Type 1 Mechanical Galvanized Steel
Beam Clamp Plates
Upper
Yoke
Weldment
Down
Tube
Lower
Yoke
Assembly
Z-TECH3™ FAN
Installation and Technical Operations
4. Standard Mount
A Standard Mount is used for 6"-10" I-Beams and
all optional mounting kits. Down Tube is ordered
to length.
An optional XL Mount is used for 12"-15" I-Beams
and truss angle iron mounts when the truss span is
greater than 8ft. This requires (4) 3"x3"x1/4" steel
angles. Contact VividAir for more information.
The package includes:
(2) mfg I-Beam Clamp Plates.
(2) mfg I-Beam Spacers (may or may not be
required for assembly)
(1) Upper Yoke Weldment*
*Down Tube and Lower Yoke are shown as a preview of the fan mount
assembly
Beam Clamp Plate
Shim
Upper Yoke Assembly
Structural Flat Washer
(4) 1/2"x13 Grade 8 Steel Nylock Nut
Tighten the bolts to a minimum 40 ft-lbs (54.2 N .m)
Insert optional shims (found in bottom tray of your
fan packaging) to keep Beam Clamp Plates near
level to the mounting surface of the I-Beam when
the I-Beam is thicker than the bend in the Beam
Clamp Plate. Shims insert on top of the Upper Yoke
Assembly and are secured with the mounting
hardware.
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| 16
Hardware Pack:
(4) 1/2"x13x5" Grade 8 Hex Cap Screw
(8) 1/2"x1.375" Thru Hardened General
Purpose Flat Washer
(4) 1/2"x13 Grade 8 Steel Nylock Nut
5. Down Tube
This package includes:
(1)Down Tube
(standard 1ft, ordered to length).
(2)Z-TechTM SS Upper Safety
Straps Break strength = 16,000
lbs.
***NOTE*** The Guy Wire Kit must be used to stabilize
the fan during normal operation.
Installing Down Tube, Upper Z-TechTM SS Safety
Strap System, & Lower Yoke Assembly
1. Slide the upper end of the Down Tube (end with the Z-
TechTM SS straps attached) into the Upper Yoke.
2. Loosely fasten the Down Tube into the Upper Yoke
by tightening the hardware only enough to engage
the nylock nut. This keeps the hardware in place
while allowing the self-leveling feature of the Upper
Yoke to work for you. Do NOT tighten until the Motor
Hub Assembly has been securely fastened to the
Lower Yoke on the bottom end of the Down Tube.
3. Position the Upper Z-TechTM SS straps per Fig. 11,
fasten the loops with the connecting shackle or 3/8"
quick link provided.
4. Assemble the Lower Yoke onto the bottom of the
Down Tube. Tighten hardware to a minimum
40 ft-lbs (54.2 N.m).
5. The Lower Safety Cable will be routed and secured
with the Z-TechTM SS safety strap (see details next
page) once the Motor Hub Assembly is secured in
place.
Fig.11
Fig. 10
Z-TECH3™ FAN
Installation and Technical Operations
3/8" Quick Link Shackle
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6. Z-TechTM SS Saftey System Makes VividAir the safest fan on the market! Ships
with all VividAir orders. A retrofit version is also available for existing fans.
| 16A
Z-TECH3™ FAN
Installation and Technical Operations
Secure the lower straps to the Down
Tube with the hardware provided and tighten to
a minimum of 40 ft-lbs (54.2 N .m)
Route upper straps around building support
wrapped as tightly as possible and secure
with the shackle or3/8" quick link provided.
Hardware List:
(1) 3/8" x 5" Grade 8 Bolt
(2) 3/8" Grade 8 Flat Washers
(1) 3/8" x 16 Grade 8 Nylock Nut
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| 17
6. Main Hub and Drive Assembly
The package includes:
(1) Hub
(1) Fan frame
(1) Motor
(1) Gearbox
Installing the Main Hub & Drive Assembly
1.
2.
3.
4.
Raise the fan and align the Mounting
Plate with the Lower Yoke Assembly.
Fasten the top plate of the Fan Frame
to the Lower Yoke and tighten to a
minimum 40 ft-lbs (54.2 N.m)
Position the safety cable as per Fig.
11. (page #11) and secure with the
connecting shackle.
Verify fan level by checking both
directions on the vertical post of the
fan frame.
Tighten the Upper Yoke/Down Tube
hardware to a minimum 40 ft-lbs
(54.2 N.m) to secure the fan level.
Fig.12
Fig.13
Mount & Upper Yoke
Down Tube & Lower Yoke
Motor Hub Assembly
Hardware Pack Includes:
(4) 1/2"x13x1.5" Grade 8 Hex Cap Screw
(8) 1/2" ASTM F436 Type 1 Mechanical Galvanized Steel
Structural Flat Washer - Grade 8
(4) 1/2"x13 Grade 8 Steel Nylock Nut
Check fan level by placing the
level on the front and side of
either vertical post of the fan
frame.
Z-TECH3™ FAN
Installation and Technical Operations
5.
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| 18
Fig.16
Fig.14
I-Beam Nut
Washer
Nylock Nut
Washer
Eye Bolt
Thimble
Cable Clamps
Guy Wire Cable
Fig.15
Ceiling/Roof Deck
Guy Wire cables
should be tight.
Recheck fan level
after tensioning
Guy Wires.
45 to 60o
When placing cable clamps on
the wire it is critical the U-Bolt
side of the clamp is placed on
the short, turn-back end and
the saddle goes on the long
end running from the anchor
point to the fan (see detail
below).
To the anchor point.
Z-TECH3™ FAN
Installation and Technical Operations
7. Required Guy Wires
Tighten cable clamp hardware
to a minimum 4.5 ft-lbs (6.1 N.m)
The package includes:
(4) Cable 1/8” Stainless Steel (4 @ 20 FT provided)
(8) Thimbles 1/4" Stainless Steel
(16) Cable Clamps 1/8” (Use 2 per anchor location)
(4) Turnbuckles 3/8” x 6” 1200# Galvanized eye to eye
(4) Quick Links 3/8"
Contractor Supplied Hardware For Anchor Points:
(4) 3/8" eyebolts (1 1/2" longer than the thickness of the anchor point)
(4) Nuts 3/8"
(8) Washers 3/8"
(4) Nylock Nuts 3/8"
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