Loren Cook Gemini Manual

®
Gemini
Ceiling and cabinet fans
INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
This publication contains the installation, operation and
maintenance procedures for standard units of the Gemini
- Ceiling and Cabinet Fans. Carefully read this publication
prior to installation.
Carefully read this publication and any
supplemental documents prior to any
installation or maintenance procedure.
Loren Cook Company’s Gemini catalog 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 [phone],
extension 166; by FAX at [phone]; or by e-mail at
[e-mail].
For information and instructions on special equipment,
contact Loren Cook Company at [phone].
Receiving and Inspection
Carefully inspect the fan and accessories for any
damage and shortage immediately upon receipt of fan.
• Turn the wheel by hand to ensure it turns freely and
does not bind.
• Inspect dampers (if included) for free operation of
all moving parts.
• Remove mounting brackets from packing insert &
install mounting brackets (Gemini 100 only).
• Remove shipping tape.
• Record on the Delivery Receipt any visible sign of
damage.
Handling
Lift fan by the outside housing (box) or by the blower
mounting brace. Never lift by the shaft or motor.
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
Motor Installation
All Gemini units are shipped with motors mounted at
the factory.
Gemini 100 Inline to Ceiling Conversion
The Gemini 100 series can be converted from inline
to ceiling by ordering the Inline to Ceiling Conversion Kit
from Loren Cook Company (Part Number 797180). The
kit includes all parts required, plus detail instructions on
how to convert the Gemini 100.
Gemini 100 Ceiling to Inline Conversion
The Gemini 100 series can be eld converted from
ceiling to inline by following these steps:
1. Remove and discard the inlet box end plate.
2. Install the inline cover panel with sheet metal
screws as shown on the following page.
Ceiling to Inline Conversion Kit can be ordered from
Loren Cook Company (Part Number 797181), or
fabricate the required part using the following sketch.
Gemini 100
1
Rotating Parts & Electrical Shock Hazard:
Disconnect electric power before working on unit.
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 emergency 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.
Failure to follow these instructions could result in
death or serious injury.

Exhaust
Duct Collar
Side
Panel
Intake
Outlet
Box
Mounting
Brackets
Side
Panel
Mounting
Brackets Intake
Side Discharge
Exhaust
Duct Collar
SEE NOTE
Mounting
Bracket
Grille
Screw
SEE NOTE
Screw
Grille
Filter
Mounting
Bracket
Allow 3/8"
for filter
Optional
2
Figure 1
Figure 2
Figure 3. Note: Allow for ceiling thickness.
Suggested Installation: Unit without lter.
Figure 4 Note: Allow for ceiling thickness.
Suggested Installation: Unit with lter.
Inline
Cover
Panel
1-7/16
14-1/16
11-15/16
F
o
rm
ed
Vi
e
w
s
16-3/4
13-15/16 1-3/8
11-15/16
13-5/16
Break up at 90
Fl
at
P
atte
rn Vi
e
w
18 Ga. Galvanized Steel
Direction of Discharge (200-900 Series)
The duct collar (damper frame), for fastening a
standard duct, is located so discharge will be from the
top, as shown in gure 1. When discharge from the side
is desired, follow these steps:
1. Remove the side panel and install with the duct
collar in the side position, as shown in gure 2.
2. Move the mounting bracket from the top discharge
to the side discharge position for securing the
housing to the joists.
See in gure 2.
Fan Installation
1. Adjust housing, using the adjust mounting bracket
provided, to allow for the thickness nished ceiling
and grille. Refer to gure 3. If a unit is furnished
with lters allow 3/8” for lters. Refer to gure 4.
2. Fasten duct work to the outside of the duct collar
(damper frame) using sheet metal screws. Make
sure sheet metal screws are placed where they do
not interfere with damper operation.
3. Fasten the housing to the bottom of the joists
through the holes provided in the mounting bracket.
Refer to gures 1 and 2.
For Ceiling Radiation Damper Installation see
separate document “Gemini/CRD Installation
Supplement.”

45
Cooking
Equipment
Floor
45
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 nameplate. Refer to Wiring Diagrams.
Lock off all power sources before unit is wired to power
source.
Follow the wiring diagram in the disconnect 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).
Note: Insulate Unused Leads. Fan plug box is designed
for single speed operation, using an FSC to vary speed if
required. Do not wire to more than two leads.
Wiring Diagrams
Gemini 100 Series:
White
(Common)
Wire Red
(Low Speed)
Wire
White
(Common)
Wire
Black
(High Speed)
Wire
Plug
options
Snap either the red wire, low-speed plug or the black
wire, high-speed plug into the eld wiring compartment
as shown. Low speed: Connect red and white wires to
line. Red wire, low-speed plug is for Model 122, 142, 162
and 182. High speed: Connect black and white wires to
line. Black wire, high-speed plug is for Model 124, 144,
164 and 184.
Gemini 200 - 300 and 600 - 700 Series:
White Line
Line
Black (High)
Red (Low)
Electrical Shock & Fire Hazard:
Insulate Unused Lead
Failure to follow these instructions could result in
death or serious injury.
Gemini 400 - 500 Series:
White Line
Black Line
Gemini 800 - 900 Series:
White Line
Line
Black (High)
Blue (Medium)
Red (Low)
Electrical Shock & Fire Hazard:
Insulate Unused Leads Separately
Failure to follow these instructions could result in
death or serious injury.
Gemini 1000:
White Line 2
Line 1
Yellow
Purple
Orange Insulate
Brown
Yellow Line 2
Line 1
Brown
Purple
Orange
Insulate
Insulate
White
1 PH / 60 HZ / 115V
MARATHON 6.0 AMPS
1 PH / 60 HZ / 208-230 V
MARATHON 2.8-3.0 AMPS
White Line 2
Line 1
Red
Black
Blue Insulate
Orange
Yellow
Line 2
Line 1
Insulate
Blue
Purple
Orange
White
1 PH / 60 HZ / 115V
MAGNETEK 8.0 AMPS
1 PH / 60 HZ / 208-230 V
MAGNETEK 4.1 AMPS
Gemini 1000 is continued on the next page.
3
Notice! Do not install above or inside
shaded area

T4 Insulate
P4
T5 Insulate
P6
T6 Insulate
P6
T1
T7
T2
T8
T3
T9
3 PH / 60 HZ / 208-230 V
MARATHON 2.2-2.0 AMPS
MAGNETEK 2.2-2.0 AMPS
Line
2
Line 1
Line
3
T4 Insulate
T7
T6 Insulate
T9
T5 Insulate
T8
T1
T2
T3
P4
P5
P6
3 PH / 60 HZ / 460 V
MARATHON 1.0 AMP
MAGNETEK 1.0 AMP
Line
2
Line 1
Line
3
Insulate
Insulate
Insulate
Gemini 2000:
Brown
Line 2
Line 1
Blue
Purple
White
Insulate
Black
Brown
Line 2
Line 1
Blue
Orange
White
Insulate
Insulate
Black
1 PH / 60 HZ / 115V
MARATHON 10.8 AMPS
1 PH / 60 HZ / 208-230 V
MARATHON 6.0-5.4 AMPS
P2
Line 2
Line 1
T3
P1
T2
Insulate
T4
T5 T5
P2
Insulate
Line 1
Insulate
T3
P1
Line 2
T2
T4
1 PH / 60 HZ / 115 V
LEESON 10.2 AMPS
1 PH / 60 HZ / 208-230 V
LEESON 5.2 AMPS
T4 Insulate
P4
T5 Insulate
P6
T6 Insulate
P6
T1
T7
T2
T8
T3
T9
Line 2
Line 1
Line 3
3 PH / 60 HZ / 208-230 V
MARATHON 4.1-4.2 AMPS
LEESON 3.4 AMPS
T4 Insulate
T7
T6 Insulate
T9
T5 Insulate
T8
T1
T2
T3
P4
P5
T6
3 PH / 60 HZ / 460 V
MARATHON 2.1 AMPS
LEESON 1.7 AMPS
Line
2
Line
1
Line
3
Insulat
e
Insulat
e
Insulat
e
FSC:
White
Fan
Black
FSC
Time Delay Switch:
White
Black
Red
Blue
Fan
light
Switch
Final Installation Steps
1. Inspect fasteners and setscrews, particularly fan
mounting fasteners, and tighten as required.
2. Inspect for correct amperage and voltage with an
ammeter and voltmeter.
3. Ensure blower is secured to duct work.
4. Ensure all accessories are installed.
5. Inspect wheel-to-inlet clearance. Make sure wheel
does not rub against the inlet.
6. Test the fan to be sure the rotation is the same as
indicated by the arrow marked Rotation.
Grille installation is described after the operation
and inspection sections.
Operation
Pre-Start Checks
1. Lock out all the primary and secondary power
sources.
2. Inspect fasteners and setscrews, particularly those
used for mounting the fan, and tighten if necessary.
3. Inspect motor wiring.
4. Ensure fan and ductwork are clean and free of
debris.
5. Test the fan to ensure the rotation of the wheel is
the same as indicated by the rotation label.
6. Restore power to unit.
Start Up
Before attaching the grille, turn the fan on and inspect
for the following:
• Direction of rotation.
• Excessive vibration.
• Unusual noise.
• Motor noise.
• Improper motor amperage or voltage.
If a problem is discovered, immediately shut off the fan.
Lock out all electrical power and check for the cause of
the trouble — refer to the ‘Troubleshooting’ section.
4

Inspection
Inspection of the fan should be conducted at the rst
30 minute interval of satisfactory operation. During the
inspection, stop the fan and inspect as per directions
below.
• Inspect bolts, setscrews, and motor mounting bolts.
• Adjust and tighten as necessary.
Grille Installation
Attach the grille by hand-tightening the knurled screws.
When the unit is furnished with a lter, place the knurled
screws through the hole in the grille. Install the lter
through the holes provided in the lter frame.
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.
Fans exhausting contaminated air (airborne abrasives)
should be inspected every three months.
Regular inspections are recommended for fans
exhausting non-contaminated air.
It is recommended the following inspections be
conducted twice per year.
• Inspect bolts and setscrews for tightness. Tighten
as necessary.
• Inspect for cleanliness. Clean exterior surfaces
only. Removing dust and grease on motor housing
assures proper motor cooling.
Access
Gemini 100:
To inspect, clean or repair refer to gure 6 and follow
these steps:
1. Remove grille.
2. Remove blower assembly from housing:
1. Disconnect the motor from electrical supply
2. Remove the mounting bolts on the inlet plate
assembly and remove the motor/wheel assembly
3. Remove the blower wheel with an allen wrench
Electrical Supply
Junction Box & Cover
Grill Mount
Holes
Inlet Plate
Mounting Bolts (4)
Gemini 200 - 700 series
To inspect, clean, or repair, refer to gure 7 and follow
these steps:
1. Remove grille.
2. Remove blower assembly from housing:
1. Disconnect the motor from electrical supply.
2. Remove mounting bolts.
3. Slide discharge ange out of spring clip and
remove motor/blower assembly from box.
3. Remove inlet ring from blower housing.
4. Remove blower wheel with an allen wrench.
Blower Mounting Brace Wheel
Unit
Mounting
Bracket
Adjustment
Bolts
Duct Collar
Damper
Blade
Motor
Wiring
Box
Mounting Bolts
5

Gemini 800 - 2000 series:
To inspect, clean, or repair, refer to gure 8 and follow
these steps:
1. Remove grille.
2. Remove blower assembly from housing:
1. Disconnect the motor from the electrical supply.
2. Remove motor plate bolts.
3. Slide motor plate and remove motor/blower
assembly from box.
3. Remove inlet rings from blower housing (both
sides).
4. Mark the wheel and housing to ensure correct
replacement of blower wheels (one is clockwise
and the other is counter-clockwise), then remove
the blower wheels with an allen wrench.
Wheel Blower HousingMotor Plate
Motor
Inlet Ring
(Ensure proper clearance between wheel and inlet ring)
Motor Plat e Bolts
Reassembly
Simply reverse the disassembly instructions. Make sure
the wheels do not rub on the inlet rings. When replacing
the motor, make sure the motor and wheels are properly
aligned with the blower housing.
Notice! Ensure that the blower discharge ange is
secured in slot of the cabinet on Gemini 200 - 700
series.
Motor Bearings
Motor bearings are pre-lubricated and sealed.
Under normal conditions they will not require further
maintenance for a period of ten years.
Motor Services
Should the motor prove defective within a one-year
period, contact your local Loren Cook representative
or your nearest authorized electric motor service
representative
Troubleshooting
Problem and Potential Causes:
Low Capacity or Pressure
1. Incorrect direction of rotation. Make sure the fan
rotates in same direction as the arrows on the
motor or belt drive assembly.
2. Poor fan inlet conditions. There should be a straight
clear duct at the inlet.
3. Improper wheel alignment.
4. Damper held shut by tape.
5. Screw attaching duct work to collar interfering with
damper operation.
Excessive Vibration and Noise
1. Damaged or unbalanced wheel.
2. Speed too high.
3. Incorrect direction of rotation. Make sure the fan
rotates in same direction as the arrows on the
motor or belt drive assembly.
4. Motor needs lubrication or replacement.
5. Fan surge.
Overheated Motor
1. Motor improperly wired.
2. Incorrect direction of rotation. Make sure the fan
rotates in same direction as the arrows on the
motor or belt drive assembly.
3. Cooling air diverted or blocked.
4. Improper inlet clearance.
5. Incorrect fan RPMs.
6. Incorrect voltage.
6

Gemini 100 Parts List
Parts
Number
1 Inlet Box End Plate
(Ceiling only)
2 Housing/Scroll
3 Field Wiring Compartment
4 Motor
5 Tinnerman Clip (Grill)
6 Mounting Bracket
7 Backdraft Damper
8 Wheel
9 Motor Mount/Inlet
10 Inlet Box
11 Grille
1
2
34
5
6
7
8
9
10
Air Flow
11
11
Gemini 200 - 900 Parts List
Parts
Number
Gemini 200 -
700
Gemini 800 -
900
1 Backdraft
Damper
Backdraft
Dampers (2)
2 Damper Frame Damper Frame
(2)
3 Mounting Bracket
(2)
Mounting Bracket
(2)
4 Wheel Wheel (2)
5 Grille (Ceiling
and Wall)
Grille (Ceiling
and Wall)
6 Blower Housing Blower Housing
(2)
7 Motor Motor
8 Insulation Insulation
9 Cabinet Cabinet
10 Cabinet Side
Cover
Cabinet Side
Cover
12
3
4
5
6 7 8
Air Flow
9
10
7

Gemini 1000 - 2000 Parts List
Parts
Number
Gemini 200 - 700
1 Grille (ceiling and wall)
2 Backdraft Damper (2)
3 Wheel (2)
4 Blower Housing (2)
5 Motor
6 Insulation
7 Mount Brackets (2)
8 Cabinet
9 Cabinet Side Cover
2
1
3
45
7
6
8
9
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 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 specically the right. You
may have other legal rights which vary from state to
state.
8Gemini IOM - May 2011
Corporate Ofces 2015 E. Dale Street Springeld, MO 65803
Phone [phone] Fax [phone] lorencook.com