Nextek Fanworks Vari-Cyclone User manual

Toll free: 1 (877) 24-VOLTS
Web: nextekpower.com
Email: [e-mail]
Installation Instructions For
Vari-Cyclone Ceiling Fans
Installation Instructions For Vari-Cyclone Ceiling Fans
Vari-Cyclone Ceiling Fans DC powered fans designed
to operate on 12 or 24 vdc only!
Toll free: 1 (877) 24-VOLTS
Web: nextekpower.com
Email: [e-mail]
Installation Instructions For
Vari-Cyclone Ceiling Fans

Installation Instructions For Vari-Cylone Ceiling Fans | | Installation Instructions For Vari-Cyclone Ceiling Fans
For more information: Nextek Power Systems Tel: [phone] nextekpower.com
461 Burroughs Street Toll free: 1 (877) 24-VOLTS
Detroit, Michigan 48202 Fax: [phone] [e-mail]
For more information: Nextek Power Systems Tel: [phone] nextekpower.com
461 Burroughs Street Toll free: 1 (877) 24-VOLTS
Detroit, Michigan 48202 Fax: [phone] [e-mail]
CAUTION:
1. Readentireinstructionscarefullybefore
beginninginstallation.
2. Toavoidpossibleelectricalshock,becertain
electricityisshutoffatmainpanelbefore
wiring.
3. Allwiringmustbeinaccordancewith
nationalandlocalelectricalcodes.Ifyou
areunfamiliarwithwiring,youshouldusea
qualiedelectrician.
WARNING:
1. Toreducetheriskofreorelectricalshock,
donotuseasolidstatespeedcontrolwith
thisfan.UseNextekcontrolsonly.
2. Toreducetheriskofpersonalinjury,donot
bendthebladebracketswheninstallingthe
bracketsorcleaningthefan.Donotinsert
foreignobjectsinbetweenrotatingfan
blades.
3. Toreducetheriskofpersonalinjury,install
thefanonlytothebuildingstructure
accordingtotheseinstructions,anduseonly
thehardwaresupplied.
Step 1: Pre-Installation Instructions
A. Select installation site. Check to see
that in normal use no object can come
in contact with the rotating fan blades.
The mounting site should also meet the
precautions listed in Step 3 below.
B. Installation hardware is included for a
standard drywall or plaster ceiling. You
will need a 4” x 1-1/2” or a 4” x 1/2”
outlet box and wire nuts (2) which can
be purchased from any hardware store
or electrical supply house.
C. The fan blades must be mounted at least
7’ above the oor. For maximum Step 3:
!
2 11
WARRANTY:
All fan bodies and fan motors are
warranted against defect for one (1) year
from time of sale. Please keep any dated
invoices or sales receipts for proof of
purchase.
DISCLAIMER:
All DC powered ceiling fan motors are
rated for one (1) amp maximum input.
All warranties on the motor and body
part are voided if the power input to the
motor exceeds one (1) amp.
PLEASE NOTE:
When operating an DC powered ceiling
fan directly from a Photo Voltaic (PV)
panel, without a battery in the circuit, be
sure the output of the panel does not
exceed 20 watts at 12 or 24 Vdc.
This will void your warranty. I
IMPORTANT INFORMATION :
It is recommended that all Nextek
Fanworks DC ceiling fans be used in
conjunction with a reversible speed control
12/24 V.
If using a photovoltaic you must use a
Nextek reversible speed control 12/24 V.
The Nextek DC ceiling fans can be
operated above 24 Vdc but not to exceed
48 Vdc. 48 Vdc can be special ordered. The
12/24 V speed control is designed to work
between 12 and 24 V.
MY FAN MAKES A RUBBING SOUND WHEN RUNNING:
Turn your fan off, when the blades have stopped turning, spin the fan with your hand, if you hear the
rubbing sound, it is most likely that the fan’s hub is rubbing against the motor housing.
Loosen the hub’s set screw; remove the decorative knob covering the fan’s motor shaft. Using a at
bladed screw driver, pry the safety push nut away from the hub (about 1/8 inch) Try spinning the fan
again, if the rubbing sound is gone, then re-tighten the set screw and replace the decorative knob.
MY FANS BLADES SEEM TO GO UP AND DOWN AS THE FAN SPINS:
Turn fan off, gently rotate hub by hand, look for the high and low movement of the blades. Grab the
hub at the high spot with one hand, with your other hand, grab the low spot, then “gently” push the
low side of the hub up while pulling down on the high side. Spin the hub again and see if the up/down
wobble is gone, if not, repeat the procedure until problem is xed.

Installation Instructions For Vari-Cylone Ceiling Fans | | Installation Instructions For Vari-Cyclone Ceiling Fans
For more information: Nextek Power Systems Tel: [phone] nextekpower.com
461 Burroughs Street Toll free: 1 (877) 24-VOLTS
Detroit, Michigan 48202 Fax: [phone] [e-mail]
For more information: Nextek Power Systems Tel: [phone] nextekpower.com
461 Burroughs Street Toll free: 1 (877) 24-VOLTS
Detroit, Michigan 48202 Fax: [phone] [e-mail]
10 3
efciency, they should not have any
obstruction (walls, posts, etc.) within
24” of the blade tips. See Figure 1 for
mounting distances.
Step 2: Inspection of Fan
A. Unpack the fan carefully to avoid any
damage to the components.
B. Check for any shipping damage to the
motor and the fan blades. If more than
one fan is being installed, keep the
matched and balanced fan blades in sets,
as they were shipped. Should one of
the fan blades become damaged during
shipment, return all blades in the set for
replacement.
C. Check contents to be certain it contains
a bag of parts.
Step 3: Installation of Outlet Box and
Rough-In Wiring
CAUTION:
Yourceilingfanwithaccessoriescanweigh
upto35lbs.Thefollowingprecautionsmust
betakenforsafetyandtoensurethatyour
fanissecurelymountedtotheceiling.
• Becertainelectricityis“off ”atfusepanel
wheninspectingorrepairinginstallation
site.
• Allwiringmustmeetlocalandnational
electricalcodes.
• Donotmountdirectlytoanunsupported
ceilingortoanelectricaloutletbox.
Mountingmustsupporta35lb.fanwith
accessories.
!
Figure1
Figure3
!
TROUBLE SHOOTING:
The following are tips that may help x a problem that you are having with a Nextek Power Systems
Fanworks DC powered ceiling fan.
FAN DOESN’T RUN:
Check all connections to make sure you have power, use a volt meter or multi tester to conrm
that the voltage is correct. If fan still doesn’t run, try connecting the fans leads directly to the
battery (no switches or speed controls) If fan still won’t run, please contact Nextek Power Systems
Fanworks, not your dealer.
FAN MOTOR IS HOT TO THE TOUCH:
Turn off fan immediately, and contact Nextek Power Systems Fanworks.
FAN MAKES “CLICKING” NOISE:
The “clicking” noise is usually a bur on one or both brushes. First try reversing the fan (i.e.: make it
run backwards) this can be done by reversing the polarity of the fans wires at the battery. If your fan
has a speed control but no reversing switch, reverse the leads that run from the speed control to
the fan. In either case, let the fan run at least 24 hours in reverse, then try running the fan in forward
and see if the noise is gone.
The second option, if your fan is not too high up, is to take a broom handle and give a sharp upward
rap to the decorative nut at the center of the fan hub. (Do this while the fan is running)
Please note: Fans in summer cottages or in places where the fan is not run for long periods of time
are more prone to developing a bur on the brushes. Before starting fan, gently spin the blades by
hand, and then turn on fan.
If problem persists, please contact Nextek Power Systems Fanworks.
MY FAN WOBBLES WHEN RUNNING:
Most fans mounted with a down rod will have a slight wobble (less than 1 inch from the center)
depending on how long the down rod is.
All Nextek Power Systems Fanworks fans come from the factory with balanced blades and blade
arms.
Make sure that the when the hub was placed on the fan shaft, that the at on the shaft matched the
at on the hub’s center hole.
Check that all the blade arms have the same pitch. (Lay them in line on a at surface and check
that all the blade arms lay at the same angle.) If the pitch on one of the blade arms is different, try
twisting the arm until it matches the rest of the arms.
Most large hardware stores, Home Depot, Lowes, Ace, etc, that sell ceiling fans, have blade balancing
kits. These are very inexpensive and have good instructions, if the above ideas don’t work, pick up a
kit and try it.
A. Secure metallic outlet box 4” x 1-1/2”
or 4” x 1/2” deep to 2 x 4 cross brace
between two ceiling joists as shown
in Figure 2. The outlet box must be
recessed into the ceiling by 1/16”
minimum. Secure the outlet box to the
cross brace by drilling (2) pilot holes no
larger than the minor diameter of the
wood screws (5/64”) and use two #8 x
1-1/2” wood screws and washers. Use
the innermost holes for securing the
box. Orient the box so the outermost
holes will be used in Step 4B.
CAUTION:
Donotusealubricantonscrews.
Figure2
B. Bring electrical cable into the outlet box
and attach with an approved connector.
Make certain that wiring meets all
national and local electrical codes.
Wire leads should extend at least 6”
beyond outlet box for ease in making
connections. See Figure 3.

Installation Instructions For Vari-Cylone Ceiling Fans | | Installation Instructions For Vari-Cyclone Ceiling Fans
For more information: Nextek Power Systems Tel: [phone] nextekpower.com
461 Burroughs Street Toll free: 1 (877) 24-VOLTS
Detroit, Michigan 48202 Fax: [phone] [e-mail]
For more information: Nextek Power Systems Tel: [phone] nextekpower.com
461 Burroughs Street Toll free: 1 (877) 24-VOLTS
Detroit, Michigan 48202 Fax: [phone] [e-mail]
4 9
Step 4.1: Fan Assembly Close MountVersion
Follow the instructions below for
installation of close mount ceiling fan.
1. Remove mounting bracket (#01) from
mounting cone.(#03) Leave the screws
in the bracket that match up with the
open hole on each side of mounting
cone.
2. Attach mounting bracket to junction
box or directly to ceiling using screws
taped to mounting bracket.
Lead wires through center hole in
bracket.
3. Remove the 4 pan head screws (#04)
around the receptacle (#11) end of the
motor assembly.
4. Attach the mounting cone (#03) to the
receptacle end of the motor assembly
using the 4 screws (#04) just removed.
5. Lift completed motor assembly to
the mounting bracket attached to the
ceiling, and slip one hole on the side of
the mounting cone over the hook on
bracket.
6. With motor and assembly hanging from
hook, connect fan wires to the house
wires using the three (3) wire nuts
included with fan.
White = positive
Black = negative
Green = ground
(Please Note: Fan should only be
operated in a counter clockwise
direction, connect white wire of fan to
the negative power wire, and the black
wire of fan to the positive power wire.
The green wire should be connected
to the ground wire on the mounting
bracket.)
7. After wires are connected, remove
fan from hook, and slip mounting cone
(#03) over mounting bracket (#01).
Align the open holes of cone with the
two screws (#02), and rotate until cone
will stay in place.
Then replace the other two screws in
cone and tighten all four screws rmly.
41228-01 12/95 -2-©1995 HUNTER FAN CO.™
!
Step 5: Painting
1. The Vari-Cyclone can be easily painted
using an acrylic based spray paint.
2. Dark colors (red, blue, green, or brown)
should take only one coat of paint.
3. Light colors (white, yellow, or pastels)
may take two or more coats. Follow the
instructions on the can of spray paint for
applying multiple coats.
4. To disassemble the Vari-Cyclone, look
at the exploded drawing in Parts
Information. This will show you how the
fan comes apart. Be sure to use a bag or
cup for storing screws and pins.
5. There are four (4) parts that are
normally painted: the mounting cone
(part #03), the down rod (part #07),
motor housing (part #12), and the hub
(part #14). Be sure to remove the set
screw from the hub.
6. The receptacle (part #11) and the pivot
ball (part #5) are normally left black.
7. Using soft wire, make 4 long “S” hooks
so each piece may be hung while painting
and drying.
8 Follow the instructions on your can of
spray paint for proper spraying technique
and drying times required.
9. Once the painted parts are dry, you may
re-assemble the fan following the diagram
in Parts Information.

Installation Instructions For Vari-Cylone Ceiling Fans | | Installation Instructions For Vari-Cyclone Ceiling Fans
For more information: Nextek Power Systems Tel: [phone] nextekpower.com
461 Burroughs Street Toll free: 1 (877) 24-VOLTS
Detroit, Michigan 48202 Fax: [phone] [e-mail]
For more information: Nextek Power Systems Tel: [phone] nextekpower.com
461 Burroughs Street Toll free: 1 (877) 24-VOLTS
Detroit, Michigan 48202 Fax: [phone] [e-mail]
8. Turn on power, and check that motor
shaft is turning in a counter clockwise
direction.
Turn power off.
9. Take pre-assembled blade/arm sets
(#14) and attach them to the hub. (#16)
Only remove one pair of the truss head
screws (#15) at a time on the top of the
hub attach a blade/arm set then move
to the next set of screws (be sure the
blade/arm set is attached with the notice
“This side up” facing the ceiling).
10. Lift assembled hub with blades up to
motor shaft (#13).
Align the at side of the motor shaft to
the Allen Screw hole.
Push hub onto shaft until 3/8” (1cm) of
the shaft protrudes from the hub.
Tighten set screw using Allan Wrench
included with fan.
11. Push retaining clip onto motor shaft unit
until it is rmly against the hub.
8 5
Parts Information
01 1 x Mounting Bracket
02 4 x 10/32 x 3/8 P.H. Phillips
03 1 x Mounting cone
04 4 x 10/32 x 3/8” P.H.Phillips
05 1 x Pivot Ball
06 1 x Retaining Pin
07 1 x Down Rod
08 1 x Pin & Clip
09 1 x 10/32 x 3/8 P.H. Phillips
10 4 x 8/32 x 1/2 F.H. Phillips
11 1 x Receptacle
12 1 x Motor Housing
13 1 x Fan Motor
14 Pre-assembled fan blade & arm
15 6 or 8 1/4 x 1/2” Truss Head Screw
16 1 x Hub
17 1 x ¼ 20 set Screw
18 1 x Retaining Clip
19 1 x Retaining Knob
12. Push retaining knob onto motor shaft
until it is rmly against the hub.
13. Your fan is ready to run.

Installation Instructions For Vari-Cylone Ceiling Fans | | Installation Instructions For Vari-Cyclone Ceiling Fans
For more information: Nextek Power Systems Tel: [phone] nextekpower.com
461 Burroughs Street Toll free: 1 (877) 24-VOLTS
Detroit, Michigan 48202 Fax: [phone] [e-mail]
For more information: Nextek Power Systems Tel: [phone] nextekpower.com
461 Burroughs Street Toll free: 1 (877) 24-VOLTS
Detroit, Michigan 48202 Fax: [phone] [e-mail]
6 7
4. Remove pin and clip (#08) from
receptacle.
5. Feed wires from receptacle (#11)
through bottom of down rod (#07) and
out through the pivot ball end.
6. Slip down rod into receptacle, and align
holes of rod with hole in receptacle.
7. Insert pin (#08) through receptacle/
down rod assembly and attach clip.
8. Tighten screw on side of receptacle.
9. Align the hub (#16) with the motor
shaft, be sure the at side of the motor
shaft matches up with the at side of the
hole in the center of the hub.
Press hub onto shaft until 3/8’ (1cm) of
the motor shaft protrudes from the hub.
Tighten set screw with Allan Wrench
included with the fan.
Step 4.2: Fan Assembly Down Rod Version
Follow the instructions below for
installation of down rod ceiling fan.
1. Remove mounting bracket (#01) from
mounting cone.(#03) Leave the screws
in the bracket that match up with the
open hole on each side of mounting
cone.
2. Attach mounting bracket to junction
box or directly to ceiling using screws
taped to mounting bracket.
Lead wires through center hole in
bracket.
3. Put down rod (#07) through mount
cone (#03) (pivot ball end of rod
remains in cone).
Please Note: Down Rod can be
shortened by cutting to length desired
and drilling a 9/32 hole ½’ (13mm) from
end of down rod.
41228-01 12/95 -2-©1995 HUNTER FAN CO.™
White = positive
Black = negative
Green = ground
Please Note: Fan should only be
operated in a counter clockwise
direction, connect white wire of fan to
the negative power wire, and the black
wire of fan to the positive power wire.
The green wire should be connected
to the ground wire on the mounting
bracket.
16. After wires are connected, remove fan
from hook, and slip mounting cone over
mounting bracket.
Align the open holes of cone with the
two screws, and rotate until cone will
stay in place.
Then replace the other two screws in
cone and tighten all four screws rmly.
17. Turn on power, check that the hub is
turning in a counter clockwise direction.
Turn power off.
18. Take pre-assembled blade/arm sets
(#14) and attach them to the hub. (#16)
Only remove one pair of the truss head
screws (#15) at a time on the top of the
hub attach a blade/arm set then move
to the next set of screws (be sure the
blade/arm set is attached with the notice
“This side up” facing the ceiling).
19. Your fan is ready to use.
10. Push retaining clip (#18) onto motor
shaft (#13) until it is rmly against the
hub.
11. Push retaining knob onto motor shaft
until it is rmly against the hub. 12.
Insert retaining pin (#06) into upper
down rod holes. Then slide pivot ball
(#05) up and over retaining pin.
12. Insert retaining pin (#06) into upper
down rod holes. Then slide pivot ball
(#05) up and over retaining pin.
13. Aline mounting cone (#03) slot with
pivot ball key.
14. Lift completed motor and hub assembly
to mounting bracket on ceiling, and slip
one hole on side of mounting cone over
hook on bracket.
15. With motor and assembly hanging from
hook, connect fan wires to the house
wires using the three (3) wire nuts
included with fan.
!