PennBarry Zephyrette Manual

1401 North Plano Road, Richardson, Texas 75081
Phone: [phone] Fax: [phone]
Receiving and Handling
PennBarry fans are carefully inspected
before leaving the factory. When the unit
is received, inspect the carton for any
signs of tampering. Inspect the unit for
any damage that may have occurred dur-
ing transit and check for loose, missing or
damaged parts. Mishandled units can
void the warranty provisions. PennBarry
is not responsible for damages incurred
during shipment.
Avoid severe jarring and/or dropping.
Handle units with care to prevent damage
to components or special finishes.
Storage
Long-term storage requires special atten-
tion. Units should be stored on a level,
solid surface, preferably indoors. If out-
side storage is necessary, protect the
units against moisture and dirt by encas-
ing the cartons in plastic or some similar
weatherproof material.
Unpacking
Place carton in an upright position and
remove staples or use a sharp (knife
edge) tool to CAREFULLY cut or scribe
the sealing tape on both sides at the top
of the carton. Open carton flaps. Remove
any cardboard and wooden filler pieces,
as well as loose components or acces-
sories shipped with the unit.
Carefully remove the unit from the carton.
Inspect the unit for any damage that may
have occurred during transit and check
for loose, missing or damaged parts.
Installation
WARNING
To reduce the risk of
fire, electric shock, or
injury to persons - observe the following:
A. Use this unit only in the manner
intended by the manufacturer.
If you have questions, contact
the manufacturer.
B. Before servicing or cleaning unit,
switch power off at service panel
and lock the service panel to
prevent power from being switched
on accidentally. When the service
disconnecting means cannot be
locked, securely fasten a prominent
warning device, such as a tag,
to the service panel.
To reduce the risk of
fire, electric shock, or
injury to persons observe the following:
A. Installation work and electrical wiring
must be done by qualified person(s)
in accordance with all applicable
codes and standards, including fire
rated construction.
B. Sufficient air is needed for proper
combustion and exhausting of gases
through the flue (chimney) of fuel
burning equipment to prevent back
drafting. Follow the heating
equipment manufacturer’s guideline
and safety standards such as
those published by the National Fire
Protection Association (NFPA),
the American Society for Heating,
Refrigeration and Air Conditioning
Engineers (ASHRAE), and the local
code authorities.
C. When cutting or drilling into wall or
ceiling, do not damage electrical
wiring and other hidden utilities.
D. Duct fans must always
be vented to the outdoors.
E. If this unit is to be installed over a
tub or shower it must be marked as
appropriate for this application.
F. Never place a switch where it can
be reached from a tub or shower.
For general ventilating
use only. This product
is not to be used to exhaust hazardous or
explosive materials and vapors.
3.Follow all local electrical and
safety codes, as well as the
National Electrical Code (NEC)
and the Occupational Safety
and Health Act (OSHA).
4. Always disconnect the power
source before working on or near
a fan or motor.
Operation & Maintenance Manual
Zephyrette & Zephyr Jr. Ceiling Exhaust Ventilators
Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by
observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain
instructions for future reference.
Printed in the USA Feb 2006
PART #59620-1
Description
PennBarry ceiling exhaust ventilators employ direct drive centrifugal blower wheels
powered by a 1200 RPM, 115V, 60 Hz sleeve bearing shaded pole motor. See specifi-
cations for CFM and sone ratings. Air deliveries are based on AMCA test codes. Units
have molded plastic grill and shatterproof backdraft damper. Motor and blower assem-
bly can be removed from heavy gauge steel housing for cleaning. Adjustable mounting
brackets and hardware included. UL and CSA listed.
Figure 1: Dimensions
1-1/2"
13-3/4"
3-1/4"
1-1/2"
9-7/8"
6-5/8"
12"
1-1/4"
PLEASE READ AND SAVE THESE INSTRUCTIONS.

Operation & Maintenance Manual Zephyrette & Zephyr Jr. Ceiling Exhaust Ventilators
2 PENNBARRY 1401 North Plano Road, Richardson, Texas 75081
Phone: [phone] Fax: [phone]
5. Make certain the power source con-
forms to the requirements shown in
the performance chart.
6. Protect the power cord from
coming in contact with sharp
edges or other objects.
7. Do not kink the power cord or allow
it to come in contact with oil, grease,
hot surfaces or chemicals.
CAUTION
1. For general ventilating use only.
Do not use to exhaust hazardous
or explosive materials and vapors.
2. To avoid motor bearing damage
and noisy and/or unbalanced
impellers, keep drywall spray, con-
struction dust, etc. off power unit.
3. Please read specification label
on product for further information
and requirements.
ELECTRICAL CONNECTIONS
1. Connect motor per nameplate
to correct power supply.
2. Install all wiring, protection and
grounding in accordance with
the National Electrical Code (NEC)
and all local requirements.
3. Follow all local electrical and
safety codes, as well as the
National Electrical Code (NEC)
and the Occupational Safety
and Health Act (OSHA).
Make the necessary
connections by using
two wire nuts. A separate ground
wire must be connected to the
grounding screw. Replace the cover
of the junction box.
To reduce the risk of
injury of person, install
fan at least seven feet above the floor, if no
guard or grill is supplied.
BEFORE A CEILING IS INSTALLED
WITH ACCESS FROM BELOW
Figure 2: Wiring Diagram
1. Disconnect motor cord and plug
from internal terminal and receptacle
before starting installation
(see figure 2).
2. Assemble adjustable flanges to fan
housing with four self-tapping metal
screws (provided). Adjustable
flanges should be located as
illustrated in Figure 3.
3. Secure the adjustable flanges to
each joist. Attach a properly sized
duct to the duct sleeve mounted on
the fan housing. Connect this duct
system to the appropriate size wall
cap or roof cap (see Figure 3).
4. Before wiring is attempted, Always
lock out the primary and secondary
power source. Utilizing the pre-
punched hole found at the terminal
box on the fan housing, insert a 3/8"
electrical connector. All wiring should
be in strict accordance with the
National Electrical Code and local,
state and federal standards.
5. If building out is necessary, an
appropriate piece(s) of wood should
be utilized. Nail wood spacer(s)
to joist(s) at the point where the fan
will be installed; the fan housing
should fit between the two joists
(or between the built-out spacers)
with approximately 1/2" clearance.
spacers should be sized according
to the fan housing dimensions
(see Figure 4).
6. Complete installation by cutting
an 11-7/8" x 13-3/4" ceiling opening
for the unit. Use care not to
exceed this dimension when
installing the fan.
7. The egg crate ceiling grill should be
installed by screwing the grill into the
fan housing using the two 2" plastic
bolts supplied with each unit.
8. Automatically operated thermal
protector to reduce risk of injury;
disconnect power supply
before servicing.
WITH CEILING IN PLACE
1. Disconnect motor cord and
plug from internal terminal
box and receptacle before
starting installation.
2. Assemble adjustable flanges
to fan housing with four self-tapping
metal screws (provided). Adjustable
flanges should be located as
illustrated in Figure 5. Install the
duct and electrical service in
accordance with the instructions
listed in the previous section.
SUSPENDED CEILING SYSTEMS
Installation of ceiling fans in suspended
ceiling systems require a minimum 10
gauge solid wire for hanging or suspend-
ing the ceiling fan. Four wires per unit
should be connected to the pre-punched
holes of the adjustable mounting flanges
(after the flanges have been mounted to
the fan housing as outlined above).
Figure 4: Using Spacers
Blower Scroll Housing
Adjustable
Flanges
Finished Ceiling
Removable Deluxe Face Grill
Duct-To
Outside
Duct Sleeve
Electrical
Leads
for
Conduit
Fan
Housing
Joist
Motor
115 volt
Thermoprotected
Plug
Receptacle
Junction Box
Wire
Nut
White
Ground
Screw
Ground Wire
Black
Wire
Nut
Joist ‘A’Joist ‘B’
Finished
Ceiling
Wood Spacer
1/2"
Figure 3: Typical Ceiling Installation
Adjustable Mounting Flanges
Backdraft
Damper

Maintenance
Disconnect power
source before working
on unit. Maintenance should be done
yearly or as conditions warrant.
CLEANING BLOWER WHEEL,
HOUSING & GRILL
1. The blower wheel, housing and
grill can be cleaned of dust and
grease if required.
a. Remove the grill. Using a vacuum
cleaner with appropriate attach-
ments, vacuum dust from the grill.
Wash the grill with a warm, soapy
solution of water. Allow the grill to
dry thoroughly before re-installing.
b. To clean blower wheel(s) and hous-
ing, unplug blower motor from inte-
gral terminal box. Unscrew the self-
tapping screws which secure the
motor and blower support plate.
Carefully remove entire blower/
motor assembly. Vacuum blower
wheel. If necessary, the wheel can
be washed. Wipe blower wheel dry
with an absorbent cloth. Before
replacing blower/motor assembly,
wipe out interior of housing. Replace
blower/motor assembly and secure
with self-tapping screws. Plug in
blower motor to terminal box.
Do not allow water
to enter motor.
MOTOR LUBRICATION
Oil every six months with 2 drops of
SAE 20 oil.
Parts Replacement
If replacing parts, do so with properly
selected components which duplicate the
original parts correctly. Incorrectly sized
parts can damage the fan.
PARTS LIST (SEE FIGURE 6)
1. Main Housing
2. Venturi (motor support plate)
3. Housing Bracket
4. Cover Plate (junction box)
5. Damper
6. Blower Housing
7. Grill
8. 1/4" - 20 x 2" Nylon Bolt
9. Duct Sleeve
10. Motor and Plug / Disconnect
11. Wheel
12. Electric Receptacle Device
13. 1/4" x 3/4" Screw (housing bracket)
14. Polyurethane Damper Stop
15. Damper Pivot Pin
16. Electric Grounding Screw
17. #14-1/2" Screw SM
18. Junction Box
19. #8-1/4" Screw SM
20. U-Clip Speed Nut
Operation & Maintenance Manual
Zephyrette & Zephyr Jr. Ceiling Exhaust Ventilators
PENNBARRY 3
1401 North Plano Road, Richardson, Texas 75081
Phone: [phone] Fax: [phone]
Figure 5: Maintenance Diagram
Figure 6: Parts Diagram

Operation & Maintenance Manual Zephyrette & Zephyr Jr. Ceiling Exhaust Ventilators
4 PENNBARRY 1401 North Plano Road, Richardson, Texas 75081
Phone: [phone] Fax: [phone]
Troubleshooting Checklist
Note: Care should be taken to follow all local electrical, safety and building codes. Provisions of the National Electric Code (NEC), as wells as the Occupational Safety
and Health Act (OSHA) should be followed.
All motors are checked prior to shipment. If motor defects should develop, prompt service can be obtained from the nearest author-
ized service station of the motor manufacturer while under warranty. Exchange, repair or replacement will be provided on a no
charge basis if the motor is defective within the warranty period. The PennBarry representative in your area will provide a name and
address of an authorized service station if requested. WARNING: Motor guarantee is void unless overload protection is provided in
motor wiring circuit.
Symptom Possible Cause(s) Corrective Action
Excessive noise
1. Defective or loose motor bearings 1. Replace motor with same frame size, RPM, HP
2. Ventilator base not securely anchored 2. Reset properly
3. Loose or unbalanced wheel/propeller 3. Tighten screws, remove build-up,
balance wheel/propeller
4. Misaligned pulleys or shaft 4. correct alignment
5. Loose or damaged wheel/propeller 4. Replace wheel/propeller
6. Wheel running in wrong direction 6. Reverse direction
Fan inoperative
1. Blown fuse or open circuit breaker 1. Replace fuses or circuit breaker
2. Loose or disconnected wiring 2. Shut off power and check wiring
for proper connections
3. Defective motor 3. Repair or replace motor
4. Broken belts 4. Replace belts
Insufficient airflow
1. Open access doors or loose sections of ducts 1. Check for leakage
2. Clogged filters 2. Clean filters
3. Operation in wrong direction 3. Correct rotation of wheel/propeller
4. Insufficient make-up air direction 4. Add make-up fan or louver opening
Water leaking
into ductwork or
collection of grease
under fan
1. Fan installed with slope in the wrong direction
1. Slope should be fitted in the direction of the
drainage opening or grease collection box and
drain spout
2. Clogged drain spout 2. Clean drain spout
3. Cooling tube or motor dome top removed 3. Install new cooling tube
with gasket and dome top
4. Grease container full 4. Empty grease box
Motor overheating
1. Belt slippage 1. Adjust tension or replace bad belts
2. Overvoltage or under voltage 2. Contact power supply company
3. Operation in wrong direction 3. Reverse direction of motor
4. Fan speed too high 4. Slow down fan by opening variable pitch
pulley on motor shaft
5. Incorrect motor (service factor 1.0,
low ambient temperature)
5. Replace motor with correct open,
NEMA service factors (1.15 or higher)
with 40 degrees ambient
6. Blocked cooling tube or leaky gasket 6. Remove blockage and seal cooling tube in place
7. Insufficient airflow to kitchen hood fan operating
on low speed with kitchen in full operation
7. Check airflow under hood and adjust
kitchen equipment output
8. Undersized motor 8. Check motor ratings with catalog speed
and air capacity chart

Operation & Maintenance Manual
Zephyrette & Zephyr Jr. Ceiling Exhaust Ventilators
PENNBARRY 5
1401 North Plano Road, Richardson, Texas 75081
Phone: [phone] Fax: [phone]
Notes:

Operation & Maintenance Manual Zephyrette & Zephyr Jr. Ceiling Exhaust Ventilators
6 PENNBARRY 1401 North Plano Road, Richardson, Texas 75081
Phone: [phone] Fax: [phone]
Notes:

Operation & Maintenance Manual
Zephyrette & Zephyr Jr. Ceiling Exhaust Ventilators
PENNBARRY 7
1401 North Plano Road, Richardson, Texas 75081
Phone: [phone] Fax: [phone]
Notes:

Limited Warranty
What Products Are Covered
PennBarry Fans and Ventilators (each, a "PennBarry Product")
One Year Limited Warranty For PennBarry Products
PennBarry warrants to the original commercial purchaser that the PennBarry Products will be free from defects in material and
workmanship for a period of one (1) year from the date of shipment.
Exclusive Remedy
PennBarry will, at its option, repair or replace (without removal or installation) the affected components of any defective PennBarry
Product; repair or replace (without removal or installation) the entire defective PennBarry Product; or refund
the invoice price of the PennBarry Product. In all cases, a reasonable time period must be allowed for warranty
repairs to be completed.
What You Must Do
In order to make a claim under these warranties:
1. You must be the original commercial purchaser of the PennBarry Product.
2. You must promptly notify us, within the warranty period, of any defect and provide us with any substantiation
that we may reasonably request.
3. The PennBarry Product must have been installed and maintained in accordance with good industry practice
and any specific PennBarry recommendations.
Exclusions
These warranties do not cover defects caused by:
1. Improper design or operation of the system into which the PennBarry Product is incorporated.
2. Improper installation.
3. Accident, abuse or misuse.
4. Unreasonable use (including any use for non-commercial purposes, failure to provide reasonable and necessary
maintenance as specified by PennBarry, misapplication and operation in excess of stated performance characteristics).
5. Components not manufactured by PennBarry.
Limitations
1. In all cases, PennBarry reserves the right to fully satisfy its obligations under the Limited Warranties by
refunding the invoice price of the defective PennBarry Product (or, if the PennBarry Product has been discontinued,
of the most nearly comparable current product).
2. PennBarry reserves the right to furnish a substitute or replacement component or product in the event a PennBarry
Product or any component of the product is discontinued or otherwise unavailable.
3. PennBarry's only obligation with respect to components not manufactured by PennBarry shall be to pass through
the warranty made by the manufacturer of the defective component.
General
The foregoing warranties are exclusive and in lieu of all other warranties except that of title, whether written, oral or
implied, in fact or in law (including any warranty of merchantability or fitness for a particular purpose).
PennBarry hereby disclaims any liability for special, punitive, indirect, incidental or consequential damages, including
without limitation lost profits or revenues, loss of use of equipment, cost of capital, cost of substitute products, facilities
or services, downtime, shutdown or slowdown costs.
The remedies of the original commercial purchaser set forth herein are exclusive and the liability of PennBarry
with respect to the PennBarry Products, whether in contract, tort, warranty, strict liability or other legal theory shall not exceed
the invoice price charged by PennBarry to its customer for the affected PennBarry Product at the time the claim is made.
Inquiries regarding these warranties should be sent to: PennBarry, 1401 North Plano Road, Richardson, TX 75081.
1401 North Plano Road, Richardson, Texas 75081
Phone: [phone] Fax: [phone]
1401 North Plano Road, Richardson, Texas 75081
Phone: [phone] Fax: [phone]
8 PENNBARRY
Zephyrette & Zephyr Jr. Ceiling Exhaust Ventilators
Operation & Maintenance Manual