Schwank MonsterFan Series Operating and maintenance manual

1
Use Instruction
Schwank GmbH ▪Bremerhavener Str. 43 ▪D 50735 Cologne
Tel: [phone] Fax: [phone]
www.monsterfans.com [email protected]
Language: English
Date: 01/2021
Revision: v1.4

www.monsterfans.com [e-mail] 2
Table of content:
1 Introduction .............................................................................................................. 3
1.1 Specifications........................................................................................................ 3
2 Safety Instructions..................................................................................................... 3
2.1 Placement & Distances........................................................................................ 4
2.2 Checklist ................................................................................................................ 5
3 Parts Overview MonsterFans ................................................................................... 6
3.1 Bill of Materials ...................................................................................................... 6
3.2 Required Tools....................................................................................................... 8
4 Installation & Mounting............................................................................................ 8
4.1 Safety Clearances................................................................................................ 8
4.2 Safety Distances to Ventilation Systems ............................................................. 9
4.3 Required Installation Environment....................................................................... 9
4.4 Mounting Sets ..................................................................................................... 10
4.5 Extension Elements ............................................................................................. 11
4.6 Wire rope clamps & Thimbles ............................................................................ 11
4.7 Installation of MonsterFans................................................................................. 12
4.8 Electric Connections .......................................................................................... 14
4.9 Oil Check and Oil Safety Pin.............................................................................. 15
5 Frequency Inverter................................................................................................. 16
6 Commissioning ....................................................................................................... 17
6.1 Test Run................................................................................................................ 17
6.2 Warnings.............................................................................................................. 17
6.3 Troubleshooting .................................................................................................. 17
6.4 Frequency Inverter Error Messages ................................................................... 18
7 Warranty & Maintenance ..................................................................................... 19
8 Packaging Units...................................................................................................... 20
9 Acceptance Report for Installation & Commissioning........................................ 21
10 Acceptance Report of Maintenance.................................................................. 22
11 Declaration of Conformity .................................................................................... 23
MonsterFans Assembly Video:

www.monsterfans.com [e-mail] 3
1Introduction
Congratulations on your MonsterFan purchase.
The High Volume, Low Speed fans (HVLS) of the MonsterFans series are energy-saving units
with high comfort and diameters from 3.6 m (12ft.) to 7.3 m (24 ft.). They move big amounts
of air at low rotational speed. The blades are streamlined and ideally engineered according
to the principles of aerodynamics.
With a power rating of 1.5 kW, the aluminium blades can move large air masses over a large
area and create a comfortable breeze. MonsterFans cool by lowering the ambient
temperature. In winter MonsterFans can effectively be used for destratification. Please also
note the warning notices for destratification.
1.1 Specifications
Diameter
3.6 m (12 ft)
4.9 m (16 ft)
6.1 m (20 ft)
7.3 m (24 ft)
Article no.
195 80 200
195 80 204
on request
195 80 212
Type
MF-C12
MF-C16
MF-C20
MF-C24
Max. Air Volume
621,000
m3/h
675,000
m3/h
729,000
m3/h
783,000
m3/h
Rounds per Minute
10-95 RPM
10-75 RPM
10-65 RPM
10-55 RPM
Weight*
104 kg
113 kg
124 kg
132 kg
Motor Power
1.5 kW / 2 hp
Max. Electrical
Consumption
3.23 A
3.23 A
3.23 A
3.23 A
Supply Voltage
3~400 V, 50 Hz
Max. Coverage Range
630 m2
850 m2
1.380 m2
1.800 m2
Recommended Range
150 - 400 m2
250 - 550 m2
400 –800 m2
500 –1200 m2
Sound Pressure Level
55 dB
measured at max. rotational speed at 5 m distance
*Notes: The weight specifications refer to the fan without controller and without mounting set or
further extension tube.
2Safety Instructions
Read these use instructions carefully before starting the fan. Clear the operating
area of the fan from all obstacles to have enough space for the fan.
Before installation and maintenance work on the fan, ensure that the power
supply is disconnected.
Ensure that all safety precautions and instructions are followed when installing,
operating and maintaining the fan. Failures caused by disregarding these safety
precautions can result in serious injury or death. If you do not understand the
instructions, please contact your customer service.
Installation, power supply, commissioning, maintenance and repairs may only be
carried out by a qualified specialists who are familiar with national and local
guidelines for electrical installations and building regulations.

www.monsterfans.com [e-mail] 4
All electrical components are pre-programmed at the factory and ready for use.
Follow these installation instructions during installation. Please do not make any
changes to components. Install the device completely before putting the device
into operation.
To avoid the risk of electric shock, note the following:
a) Use this device only as intended by the manufacturer. If you have any
questions, please contact the manufacturer or your local service partner.
b) Always disconnect the unit from the power before maintenance or cleaning
work.
The mounting of the suspension elements must be carried out by a qualified
specialist. The fan´s wings have to be installed at least 3.5 m above the floor.
Do not operate or install a big fan or individual parts that are damaged. If the fan
does not work properly or if there are any unusual movements of the fan, switch
off the power supply and contact your customer service.
Make sure that the replacement of in particular safety-related parts, is carried out
by the manufacturer, its customer service or a qualified specialist.
Install the safety cables on each fan according to the installation instructions. The
MonsterFans must never be operated without a properly installed safety cable. In
an emergency, the safety ropes additionally secure the fan. Proper installation of
the ropes is also required for the stabilisation during operation. The fan shall not be
operated in windy surroundings.
We recommend also securing the floor under the assembly so that attention is
drawn to the work on the ceiling. Review all relevant guidelines to ensure that
building regulations are followed in accordance with product certifications.
We always recommend having a structural engineer check who confirms the
strength of the building and ceiling structure in advance.
If MonsterFans are located in closed rooms with heaters with indirect exhaust gas
systems (unflued), the parallel operation must be prevented by interlocking it!
2.1 Placement & Distances
Before installing the fans, check compliance with all guidelines for fire alarm systems, sprinkler
systems and fans. We strongly recommend consultation with your local safety expert.
If sprinkler systems are installed, the fans must not interfere with the proper operation of these
sprinklers. The control unit can also be connected to a fire alarm system so that the fan stops
in an emergency.
The digital inputs and the Modbus interface of the control units are used for switching off and
interlocking. If possible, do not mount the fan directly under lights to avoid adverse lighting
effects from rotating wings.
If the building has a mezzanine, fans should be installed in the way that they are not
accessible to people. HVLS fans should not be installed in the immediate vicinity of air supply
outlets or suction inlets of other heating, ventilation, or air conditioning units, see chapter 4.2.

www.monsterfans.com [e-mail] 5
2.2 Checklist
☐Do you have the right mounting set for your mounting position?
The standard mounting set supplied with this fan for I-beam, allows the fan to be hung on
steel beams. Do not mount the fan on a purlin or a framework.
If you are unsure, please contact customer service.
☐Has a structural engineer checked and approved the assembly position?
The assembly structure must withstand the forces generated by the fan.
☐The fan is NOT used in parallel with heaters with indirect exhaust gas systems (unflued).
Otherwise, parallel operation must be prevented by interlocking it.
☐The fan is at a minimum distance from the ceiling in accordance with the specified safety
distances.
☐The fan´s wings are installed at least 3.5 m above the floor.
☐The fan is installed with a minimum distance of 2 times the fan diameter from obstacles and
building structure, measured from the fan centre.
☐The distance between several fans is at least 2.5 times the fan diameter, measured from
the fan centre.
☐The fan is installed that it is not exposed to strong winds and maintains a safety distance of
at least 1 times the fan diameter from other heating, ventilation, air conditioning systems or
from gates.
☐The supply voltage is selected correctly.
☐The fan can be secured with the supplied safety ropes
There are mounting points available for the safety ropes.
If your fan application does not meet the above requirements, proper operation is at risk.
Please contact your customer service.

www.monsterfans.com [e-mail] 6
3Parts Overview MonsterFans
1. Steel structure
2. Safety rope ring
3. Steel structure fastening
4. Extension tube
5. Motor housing
6. Winglets of fan blades
7. Fan blades
8. Turnbuckle & clamps
9. Safety steel rope
10. I-type safety adapting piece
3.1 Bill of Materials

www.monsterfans.com [e-mail] 7
Bill of Materials - MonsterFans
1. Motor Housing 2. Top-Plate 3. Spacer 4. Beam clip
2x 2x
5. Turnbuckle 4x 6. I-type fan 7. Fastener M5 x 12 mm 8. Bottom plate
& 1x replacement blade retainer 5x 3x
9. Safety steel rope 10. Steel wire lock 11. Fastener 12. Fastener
40m length 55x M12 x 80 mm M16 x 55 mm
10x 4x
13. Fastener 14. Metal joint on 15. Controller Box 16. Techn. Manual
M16 x 120 mm Controller Box MonsterFans
4x 2x
17. Techn. Manual 18. Fan blades 19. Extension Tube 20. 3-Pole switch-
Danfoss VFD 5x 1m length disconnector
21. Thimbles
16x

www.monsterfans.com [e-mail] 8
3.2 Required Tools
Spanner Set
Socket Wrench
Set
Screwdriver
Cross & Slot
Spirit Level
Wire rope
shear
Cable Shears
Wire Stripper
Multimeter
Distance Meter
Threadlocker
Glue
Please also note the necessary safety precautions for the use of a scissor lift and the general
safety precautions. Two specialists are required for the installation.
4Installation & Mounting
4.1 Safety Clearances

www.monsterfans.com [e-mail] 9
4.2 Safety Distances to Ventilation Systems
If the air supply outlet of a ventilation system is below the blades, a minimum distance of 1
times or larger the fan diameter from the blade tip is sufficient.
If the air supply outlet of a ventilation system is located above the blades, a minimum
distance of 2 times or larger the fan diameter from the blade tip is necessary.
4.3 Required Installation Environment
Installation Environment
Conditions
Installation Location
Inside
Temperature Range
-15 + 55 °C
Do not use the product in environments with strong temperature
fluctuations.
The product must not be exposed to frost.
Humiditiy
Below 95% relative humidity
Surrounding
The fan and controller must not be exposed to flammable or
corrosive gases. Metal powder, oils, water and other foreign
objects must not get into the controller.
Distances to hot sources e.g. heaters must be maintained. Please
note the manufacturer's safety clearances.
If MonsterFans are located in closed rooms with heaters with
indirect flue gas systems (unflued), parallel operation must be
prevented by interlocking it.

www.monsterfans.com [e-mail] 10
4.4 Mounting Sets
The fans are usually connected to an I-beam
Accordingly, this element as standard is included in every packaging unit.
Optional mounting set for concrete structure
Optional mounting set for side mount on concrete
Optional mounting set for bent structure
Standard Mounting Set
(for I-Beam)
Article no
19580220
Weight: 14 kg
Mounting Set
for
concrete structure
Article no.
19580222
Weight: 26 kg
Mounting set for
side mount
on concrete
Article no.
19580223
Weight: 16 kg
Mounting Set
for bent stucture
Article no.
19580224
Weight: 26 kg

www.monsterfans.com [e-mail] 11
4.5 Extension Elements
The MonsterFans fans are delivered ex-works with a hanging element of standard 1m.
Optionally, we offer another 1 m and 2 m extension element and a connection piece to
connect two extension elements.
The max. length of these extension elements must not exceed 3 m consisting of max. 2
elements. Likewise, only one connection set may be used to connect two extension
elements. Otherwise the stability of the fan can be influenced.
Extension tube Optional Extension tube 1,5 m length
1 m standard length Article no 19580231
Article no: 19580230 Weight: 12 kg
Weight: 8 kg
Optional Extension tube 2 m length
Article no 19580232
Weight: 16 kg
Connecting piece for extension tubes incl. bolts & screws:
Article no. 19580239
Weight: 3 kg
4.6 Wire rope clamps & Thimbles
EN 13411-5:2009-02 stipulates the use of at least 3 wire rope clamps and thimbles for end
connections for steel wire ropes of nominal size 5 mm.
The first wire rope clamp should be attached directly to the thimble. The clamp should
always be attached to the loaded part of the rope.
The distance "e" between the wire rope clamps should be at least 1.5 "t" and not more than 3
"t", where "t" is the width of the clamp jaw.
When making the connection and before commissioning, the collar nuts should be tightened
to a torque of 2 Nm. The recommended tightening torque applies to wire rope clamps where
the contact surfaces and threads of the nuts have been lubricated.
After the first application of the load the tightening torque should be checked again and
corrected if necessary.

www.monsterfans.com [e-mail] 12
4.7 Installation of MonsterFans
Start by installing the mounting element on the ceiling.
Attachment of the
suspension &
extension element
Pull your electrical cable through the extension tube.
Then attach the safety steel rope (parts list no 9) and secure it with the steel wire lock (no 10).
Observe the notes on wire rope clamp connections.
Mount the motor housing with the motor on the extension element.
Use the M16 x 120 mm screws for this. Pay attention to an exactly horizontal alignment.

www.monsterfans.com [e-mail] 13
Note: The safety steel ropes must be aligned symmetrically for the same load, then tightened
evenly, use the turnbuckles and a threadlocker glue at the end.
Connect the motor supply cable to the motor terminal box. Observe the instructions in
chapter 4.8 Electrical connections.
Now assemble the fan blades. Use the M10 x 100 mm screws. Pay attention to an exact
alignment of the rotor blades and use threadlocker glue. When assembling, make sure to
connect all retaining brackets (parts list no.6) to each other. Then install the bottom plate
(parts list no 8) with the screws M5 x 12 mm (no 7).

www.monsterfans.com [e-mail] 14
Now wire the cable to the Controller box.
Use your own electrical cable for this.
Now install the Controller Box. We recommend installing it at a height of approx. 1.6 m.
The 3-pole switch disconnector (parts list no. 20) must be mounted and integrated in the
direct vicinity of the Controller Box. Operation is only permitted with an emergency stop
mechanism! The switch-disconnector may only be operated in emergency situations. An
interruption of the power supply during operation can damage the frequency inverter as
well as the motor!
Use a adequately dimensioned and EMC-compliant power cable for the motor connection,
such as: LAPP ÖLFLEX® CLASSIC 110 CY 4 G 2.5 [or equivalent].
4.8 Electric Connections
Apply the supply voltage, 3 ph + PE, to the "control supply line" terminals. The motor supply
cable is connected directly to the frequency Inverter, the shielding next to the strain relief is
connected to the PE. The start command of the frequency inverter can be brought out and
interrupted via the remote release contact.
Figure: Controller Connection Figure: Inverter connection

www.monsterfans.com [e-mail] 15
To connect the motor please remove the MonsterFans cover from the motor housing above
the motor terminal box and unscrew the cover from the motor terminal box. Lead the motor
connection cable through the EMC gland and pay attention to the position of the shielding
braid.
Figure: LAPP Skintop MS-SC EMC Cable Gland Schematic Shielding Connection
For the motor wiring, please remove the MonsterFans cover from the motor housing above
the motor connection box. Then wire the motor in star cabling according to the connection
diagram above. The fan is operated exclusively with 3 phases, 400 volts AC.
Nord Motor Wiring Clamps with a Star Connection Stud Wiring Fan Motor
4.9 Oil Check and Oil Safety Pin
Please also check the oil level before starting up. There is a safety pin on the
bleed screw. The safety pin must be removed before the initial start-up. The
engine is operated with synthetic oil (lubricant: Synth ISO VG 680, 3.1 litres).
The safety pin is provided with a cable tie ex works to make the safety pin visible and to
make it easier to remove the safety pins.

www.monsterfans.com [e-mail] 16
After proper cabling and checking, you can turn on the power. The area around the fan
must be free of obstacles. Start with a test run of 10 minutes.
If the operation of the fan works properly, instruct the operator and please use the handover
protocol for a formal handover.
5Frequency Inverter
A variable frequency drive is integrated in the MonsterFans Controller Box. You will find
detailed technical instructions from the manufacturer attached. The frequency Inverter is
pre-programmed at the factory and ready for operation.
You will also find the following Wiring Diagram (3~400V, 50 Hz) printed inside the
Controller Box.

www.monsterfans.com [e-mail] 17
6Commissioning
6.1 Test Run
Ideally, test the fan for 10 minutes to see if there is any unusual noise, vibration from the
device or from the safety steel ropes.
Also make sure that the fan runs safely with a sufficient safety distance to all possible
obstacles.
6.2 Warnings
•A change in shape or the bending of rotor blades is strictly prohibited.
• Please do not carry out any work or repairs while the device is switched on in order to
avoid an electric shock.
• Please do not change the original technical structure of the fan.
• Please do not open the switch box / controller box during operation to avoid an
electric shock.
• Do not operate devices with malfunctions as this can lead to serious injuries.
• Structural or parameter changes to the electrical control box are strictly prohibited, as
this can lead to equipment damage, injuries or death due to improper use.
• After disconnecting the power supply, there may still be a residual voltage in the
controller box. Wait 2 minutes until the contacts are de-energised. Switching off the
display is not an indication that there is no voltage.
• The installation and laying of the electrical cabling must be carried out by a qualified
specialist.
• Please use the device components enclosed and specified by MonsterFans.
•Do not interrupt the power supply while the fan is running. Otherwise the fan will be
damaged. The power supply may only be switched off, after the rotating blades have
stopped completely.
6.3 Troubleshooting
Common causes of incorrect operation:
• The supply voltage is incorrectly selected or switched off.
• If the fan does not work, please check first if the speed controller is at MIN and check
also the Run/Stopp button.
• Unauthorised personnel must not open the Controller Box. Our local service partner will
send you a trained specialist for repairs or adjustments.
• If you notice, that the fan or Controller Box is damaged or has unusual noises, stop using
it with immediate effect. Switch off the power supply and contact your service partner.
• A damage of the device caused by improper use is not covered by the warranty.
Commissioning;
1. Make sure that the fan can run free of
obstacles.
2. Check the direction of rotation of the blades,
regular operation is counter-clockwise.
3. Make sure that the input voltage is correct and
meets the requirements.
4. Set the speed controller to the minimum
position.
5. Switch on the fan and turn the switch from STOP
to RUN.
6. After the fan has started, set the speed control
knob to the desired speed.
Caution:
1. It is prohibited to interrupt the
power supply during fan
operation.
2. The fan is not designed for reverse
operation.
3. The direction of rotation can only
be changed by phase rotation on
the frequency converter.

www.monsterfans.com [e-mail] 18
6.4 Frequency Inverter Error Messages

www.monsterfans.com [e-mail] 19
7Warranty & Maintenance
Our quality assurance applies to the entire fan.
The warranty period begins on the date of acceptance by the customer after professional
installation and commissioning. This ends with the statutory warranty period. The following
causes are not covered by the warranty:
1. Improper use, incorrect installation, incorrect commissioning and unauthorized
maintenance.
2. Operator assembles / disassembles the product independently.
3. Force majeure (lightning, earthquake, terror, flood etc.).
To ensure a long service life, we recommend regular maintenance and professional
inspection.
Intervals Maintenance Work
Yearly 1. Check the correct rotation of the fan.
Disconnect the fan from power supply for further maintenance work!
Secure the maintenance area on the floor as well.
2. Check all safety bracing devices.
3. Check all fastening screws and connecting elements
4. Check the electrical connections and cabling.
5. Check the gearbox for oil leakage.
6. Check all suspension and connection elements.
7. Check the wing connection bolts under the base plate
8. Check the wings and engine components for damage.
9. Check all fan components for signs of corrosion,
discoloration, pitting and metal spalling.
10. Check the guy wires for damage or abrasion.
11. Removal of dust and dirt particles from wings and motor.
Every five years (or every 20,000 operating hours)
▪Check the oil level, carry out an oil change if necessary.
If a fan runs with strong unusual noises or vibrations, this indicates that the mechanical parts
are damaged. Switch off the fan immediately and carry out a comprehensive inspection
and maintenance.
In the event of faults within the warranty period, please do not try to correct them yourself.
Please contact your manufacturer.

www.monsterfans.com [e-mail] 20
8Packaging Units
A MonsterFan is delivered in two wooden boxes.
Picture: Wooden Box Fan Blades Picture: Wooden Box Motor
Type
Diameter
Dimensions
Weight
Total
MF-C24
7.3 m (24 ft.)
Box Motor:
950 mm*830 mm*520 mm
Box fan blades:
3700 mm*420 mm*450 mm
180 kg
127 kg
307 kg
MF-C20
(on request)
6.1 m (20 ft.)
Box Motor:
950 mm*830 mm*520 mm
Box fan blades:
3100 mm*420 mm*450 mm
180 kg
117 kg
297 kg
MF-C16
4.9 m (16 ft.)
Box Motor:
950 mm*830 mm*520 mm
Box fan blades:
2500 mm*420 mm*450 mm
180 kg
107 kg
287 kg
MF-C12
3.6 m (12 ft.)
Box Motor:
950 mm*830 mm*520 mm
Box fan blades:
2100 mm*420 mm*450 mm
180 kg
97 kg
277 kg