VIVIDAIR ConZumer120 User manual

ConZumer120 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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Itemized Checklist - Unpacking Your VividAir Fan
ConZumer120 FAN
Installation and Technical Operations
You should receive two skids with your ConZumer120 fan shipment:
A Motor Hub Assembly skid with the motor housing assembly, control, and hardware.
A blade box skid with a box containing the blades and blade stabilizer plates.
Blade Box Skid
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Verify You Received All Components
(2) Beam
Clamp Plates
(2) Beam Clamp
Plate Shims
(4) Truss
Mount Washers
(1) Upper Yolk
Weldment
(2) Lower Yolk
Plates
(1) Down Tube
Assembly
With Z-Tech
SS safety
Straps (3) Blade
Stabilizer Plates
(1) Shackle to
secure upper
Z-Tech SS safety
straps
Hardware Pack C
Motor to Lower Yolk
Hardware Pack B
Down Tube
Hardware Pack A
Blade Connection
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ConZumer120 FAN
Installation and Technical Operations

Itemized Checklist - ABB VFD Controllers, Blade Box, Blade Stabilizer Box
Itemized Checklist - Fan Blade Box
Blade Set (3 Blades)
Blade Stabilizer Plates (3 Plates)
VividAir VFD Controller or
ABB ACS255 Controller
120VAC 1 Phase 20 Amp Receptacle Required
Control Is factory wired Line In
The 50' cable factory wired to the motor
needs to be wired on site by the installer to
Line Out of the controller.
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ConZumer120 FAN
Installation and Technical Operations

Structural
Support of
the Building
Fan Frame
Optional Guy Wire Mounting Holes
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
Upper Yoke Weldment and
Down Tube Assembly
(2) 1/2"-13 x 5" Grade 8 Bolts
(4) 1/2" Grade 8 Flat Washers
(2) 1/2"-13 Grade 8 Nylock Nuts
Lower Yoke and
Down Tube Assembly
(2) 1/2"-13 x 5" Grade 8 Bolts
(4) 1/2" Grade 8 Flat Washers
(2) 1/2"-13 Grade8 Nylock Nuts
(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-TechSSTM Upper Safety
Strap Assembly - Wrap as
tightly as possible around
building support and fan
structure to minimize slack.
1ft Down Tube
Z-TechSSTM Lower Safety
Strap Assembly
Motor
Gearbox
Hub
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ConZumer120 FAN
Installation and Technical Operations

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Table of Contents
1. Tools Required to Install Product..........................................................................................................................................8
2. Required Steps Before Installation .......................................................................................................................................8
3. Different Mounting Applications ...........................................................................................................................................8
“I” Beam Mounting Fig.2.....................................................................................................................................................8
Bottom Chord Angle Iron Mount Fig.3......................................................................................................................9
Top Chord Angle Iron Mount Fig.4............................................................................................................................10
“L-Bracket” Mounting Fig.5......................................................................................................................................................11
“Z-Purlin” Mounting Fig.6..............................................................................................................................................12
4. Standard Mount .............................................................................................................................................................................13
What is included in the mount package ..........................................................................................................................13
What standard mounts are available Fig.7....................................................................................................................13
How to install the standard mount Fig.8. .........................................................................................................................13
5. Down Tube .........................................................................................................................................................................................14
What is included in the down tube package ...................................................................................................................14
How to install the down tube, upper safety cable, and lower yoke assembly.............................................14
Typical safety cable routing Fig11......................................................................................................................................14
6. Main Hub and Drive Assembly ................................................................................................................................................ 15
What is included in the main hub and drive assembly Fig.12 .............................................................................. 15
How to install the assembly Fig 13. .................................................................................................................................... 15
Installing the lower safety cable (Reference Fig.11 page #14)............................................................................. 15
7. Optional Guy Wires ....................................................................................................................................................................... .16
What is included in the optional guy wires .................................................................................................................... 16
How to install the optional guy wires:
Fig.14 ........................................................................................................................................................................................ 16
Fig.15 ........................................................................................................................................................................................ 16
Fig.16 ........................................................................................................................................................................................ 16
Fig.17 ......................................................................................................................................................................................... 17
8. Blade Assembly ............................................................................................................................................................................... 17
What is included with the blades ......................................................................................................................................... 17
How to install the blades Fig.18. ............................................................................................................................................ 17
9. Leveling the fan & Removing the Oil Vent Plug on the Motor.....................................................................................18
Electrical Installation ................................................................................................................................................................................ 19
Electrical Connections.................................................................................................................................................................. 20
ESFR Wire Connections.......................................................................................................................................................21-22
Operations Instructions for the Controller................................................................................................................23-24
Maintenance Schedule.............................................................................................................................................................................. 26
Safety Precautions .................................................................................................................................................................................... 27
Recommended Maintenance Checklist ............................................................................................................................................ 28
Warranties and Liabilities ................................................................................................................................................................34-37
Troubleshooting Guides....................................................................................................................................................................29-33
Locate Your VividAir Fan (Recommended Clearances)................................................................................................7
Fan Operation Best Practices................................................................................................................................................................ 25
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ConZumer120 FAN
Installation and Technical Operations

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 solid
walls
E. Distance from obstructions
F. Proximity of fan tip to roof with pitch
or other obstruction
G. Heat source or exhaust fan
Guidelines
Fan Clearances
A. Minimum of 3ft clearance above the fan blades to the
solid roof surface for optimal performance.
B. Nominal 12ft.
C. Blades must be a minimum of 10ft from the floor.
D. Minimum 12ft for optimal airflow.
E. Minimum 18" of clearance from obstructions.
F. Minimum 2ft clearance.
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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Recommended VividAir
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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 ConZumer120 Fan is to be installed.
•Each person installing the ConZumer120 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 ConZumer120 Fan must be met and followed.
“I” Beam Mounting
Fig.2
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. Go Fan Yourself
® hereby denies any liability resulting from the lack of verification
or from the use of any materials or hardware than those supplied by Go Fan Yourself
® or otherwise indicated within
these installation instructions.
Start your installation
3. Standard 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 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.
3. Standard 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 installer 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
A B C B D
3"x3"x1/4" Steel Angles
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Installation and Technical Operations

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3. Standard Mounting Applications (continued)
***NOTE*** Hardware A, B, and C below are installer 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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Installation and Technical Operations

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“Wood Beam” Mounting
(Refer to Wood Beam Installation Guide
received with your fan)
A local structural engineer should be
consulted to verify all Wood Beam
Mounting applications.
3. Optional Mounting Applications
GFY's Wood/Concrete Beam Kit Must Be Ordered
Secure L-Brackets
As shown below secure the L-Brackets and Safety
Clips with Quick Links to the mounting structure
with installer-supplied hardware.
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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ConZumer120 FAN
Installation and Technical Operations

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“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 Nm).
3. Optional Mounting Applications (continued)
GFY's Z-Purlin Kit Must Be Ordered
Fig.6
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Installation and Technical Operations

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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 Nm). (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
4. Standard Mount
The mount will accomodate 6"-10" I-Beams and is
also used with the optional Z-Purlin Kit and Wood/
Concrete Beam Kit.
An XL Mount is available for 12"-15" I-Beams
The package includes:
(2) mfg “I” Beam Clamp Plates.
(2) mfg “I” Beam Shims (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
Optional Shim
Upper Yoke Weldment
Structural Flat Washer
(4) 1/2"x13 Grade 8 Steel Nylock Nut
Tighten the bolts to a minimum 40 ft-lbs (54.2 Nm)
Insert optional shims 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 Weldment and are secured with the
mounting hardware provided.
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Installation and Technical Operations

| 14
5. Down Tube
This package includes:
(1) 1ft Down Tube
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
(2)Z-TechSSTM Upper Safety Straps
(fastened to Down Tube from the factory,
wrap tightly around the building structure
and secure with 3/8" quick link provided)
Installing:
•Down Tube
•Z-TechSSTM Upper Safety Straps
•Lower Yoke Assembly
•Z-TechSSTM Lower Safety Straps
1. Slide the upper end of the Down Tube (end with the
Z-TechSSTM Upper Safety Straps factory installed)
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. Wrap the Z-TechSSTM Upper Safety Straps (per Fig. 11)
as tightly as possible around the building structure
and fasten the loops with the 3/8" quick link or shackle
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).
Fig.11
Fig. 10
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Installation and Technical Operations

| 15
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)
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. The
Z-TechSSTM Lower Safety Straps will
be factory assembled to the motor
mount bolts. Secure opposite end of
both straps to the Down Tube with the
hardware provided:
a. (1) 3/8" x 16 x 5" Grade 8 bolt
b. (2) 3/8" Grade 8 washers
c. (1) 3/8" x 16 nylock nut
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.
5.
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ConZumer120 FAN
Installation and Technical Operations

6.Z-TechSSTM Saftey System Makes VividAir the safest fan on the market! Ships with all
VividAir orders. A retrofit version is also available for existing ConZumer120 fans.
| 15A
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 3/8" 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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Installation and Technical Operations

| 16
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 snug.
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.
Tighten cable clamp hardware
to a minimum 4.5 ft-lbs (6.1
N.m)
7. Optional Guy Wires
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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Installation and Technical Operations

| 17
1.
2.
3.
4.
5.
Determine mounting position on ceiling and
establish the angle between 45º-60º for the
cable. Determine correct location on the I-
Beam to anchor the eye bolt. If the guy wire
anchor points on the fan are 3' 4" (101.6 cm)
down from the I-Beam or Steel Angles the
cables should anchor at least 3' 4" (101.6 cm)
away from the fan
Fasten all eye bolts with nuts and washers as
per Fig. 14.
Measure the run of cable required and cut a
minimum of 2 FT longer. NOTE: runs longer
than 18 FT will require additional cable. Secure
it with 1 thimble and 2 cable clamps (Fig.16).
Repeat using the other 3 pieces of guy wire
cable, thimbles and cable clamps(Fig.15).
Guy wires should be tight. Allow fan to self-
level and recheck level as you tighten each guy
wire. They should also be approximately 90º
apart (Fig.17).
8. Z-TechTM Blade Assembly
(3) Blades
(3) Blade Stabilizer Plate
(15) 3/8"x16x3.5" Grade 8 Hex Cap Screw
(30) 3/8"x0.812" Grade 8 Flat Washer (15)
3/8"x16 Grade 8 Nylock Nut
Installing the Blade Assembly
Fig.17
NOTE: Fans hanging lower than 10ft from
where the guy wires will mount may require
additional cable (provided by the installer).
Fig.18
Installing the Guy Wires
1. Clamp blade between blade stabilizer
plate and hub.
2. Continue until all 3 blades have been
fastened and tighten to:
30 ft-lbs +/-2 ft-lbs
(40.7 N.m = 30 ft-lbs) or
(38 N.m to 43.4 N.m)
3. Turn the fan by hand and verify
minimum clearance exists for all
blades from all obstructions.
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Installation and Technical Operations

| 18
9. Leveling the Fan
1. After your fan is installed, check the level again by placing your level vertically on the
vertical post of the fan frame. Adjust as required.
2. Once leveled, tighten hardware to a mimimum 40 ft-lbs (54.2 Nm) to secure the Down Tube into
the Upper Yoke. Verify fan level once hardware is tightened.
For proper electrical connection, please consult the Wire Connections (Motor) page later in this document.
ATTENTION! YOU MUST REMOVE THE VENT STOPPER FROM THE GEARBOX!!!!!
Failure to remove the vent stopper will cause gearbox failure (if equipped)!!
NORD Gearbox - Pull rubber out of breather Dodge Gearbox - Remove rubber stopper
Rubber
Stopper
shown
removed
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Installation and Technical Operations

| 19
Electrical Installation &
Operation Manual
All installation wiring must confirm to your National Electrical Code and local guides.
While we believe that using VividAir controls and following our instructions will result
in an installation that meets those requirements, we cannot guarantee it. Code
compliance is ultimately the installer’s and/or user’s responsibility.
Subject to change without notification.
IMPORTANT
Contact VividAir for all outdoor applications and any application
where the fan may be hit directly by the wind.
Safety Precautions
•All installations must be installed by a qualified person.
•Do not work on live equipment. Use lock out/tag out
procedures.
CRITICALLY IMPORTANT!!
Upon completion of the installation you MUST complete the
VividAir Check In/Close Out Form and take two pictures:
1)The overall fan installation.
2) Close up of the fan mount clearly showing both safety straps routed properly, snug,
and secured with the hardware provided.
Please send the completed VividAir Check In/Close Out form and pictures to :
[e-mail]
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ConZumer120 FAN
Installation and Technical Operations