INSTALLATION / MAINTENANCEGUIDE

MODEL FWT-Fanwall Technology® Retrofit

Improper installation, adjustment, alteration service or maintenancecan cause property damage, injury or death. Read the installation,operating and maintenance instructions thoroughly before installingor servicing this equipment.

FOR YOUR SAFETY

TABLE OF CONTENTS

GENERAL DESCRIPTION ........................................................................................................... 1

INSTALLATION CODES / PRECAUTIONS ................................................................................ 1

INSTALLATION

ELECTRICAL CONNECTIONS ........................................................................................ 2

FANWALL ASSEMBLY

FAN MOTOR CARTRIDGE ALIGNMENT ....................................................................... 3

SECURING FAN MOTOR CARTRIDGE.......................................................................... 3

WIRING ............................................................................................................................ 4

MAINTENANCE

FANWALL OPTION - FAN WHEEL/MOTOR REPLACEMENT ...................................... 5

FANWALL OPTION - FAN CARTRIDGE REPLACEMENT ............................................ 7

LONG TERM STORAGE (Over 1 Month) .......................................................................... 8

MONTHLY, YEARLY MAINTENANCE ............................................................................. 8

TROUBLESHOOTING .................................................................................................................. 9

START-UP INSPECTION REPORT ............................................................................................. 10

WARRANTY .................................................................................................................................. 11

PAGE

© Copyright 2007, HUNTAIR, Inc.

ALL RIGHT RESERVED. NO PART OF THIS BOOK MAY BE REPRODUCED,STORED IN A RETRIEVAL SYSTEM, OR TRANSMITTED IN ANY FORM BY ANELECTRONIC, MECHANICAL, PHOTOCOPYING, RECORDING MEANS OROTHERWISE WITHOUT THE WRITTEN PERMISSION OF HUNTAIR, INC.COPYRIGHT 2007.

The manufacturer reserves the right to modify the materials and specifications resulting from a continuing program ofproduct improvement or the availability of new materials.

GENERAL DESCRIPTION

1

INSTALLATION CODES

Electrical characteristics are shown on the unit rating plate.

The unit shall be carefully installed in accordance with thestandards of the National Fire Protection Association (Na-tional Electrical Code). Authorities having jurisdiction shouldbe consulted before installations are made to verify localcodes and installation procedures.

INSTALLATION PRECAUTIONS

1. The services of qualified field service personnel aremandatory for safe and proper installation of this equip-ment.

2. Air volumes and external static pressures that do notcoincide with those listed on the rating plate will ad-versely affect the performance of the unit. Pleaseconsult the factory if either of these values change.

3. The following clearances from combustible materials areto be maintained: Top - 6", control side - 48", oppositecontrols - 6", bottom - 0". If roof curb is provided byothers, it must be at least 4" high and constructed fromnon-combustible material.

4. This unit is designed for installation on a level surface.This is especially true if provided with an evaporativecooler.

5. Do not locate the supply inlet opening within 10' of anyexhaust discharge point or within 24" of any obstruction.

INSTALLATION CODES / PRECAUTIONS

Follow all safety codes. Wear safety glasses and workgloves. Use quenching cloth for brazing operations. Havefire extinguisher available. Read these instructions thor-oughly.

WARNINGBefore installing or servicing system, always turn offmain power to system. There may be more than onedisconnect switch. Turn off accessory heater power ifapplicable. Electrical shock can cause personal injuryor death.

CAUTION: Before proceeding, make sure all electricalservice to unit is locked in “Off” position.

GENERAL DESCRIPTION

Huntair Fanwall Technology® is a fan-array approach to airhandler design that that uses several smaller fans to replaceone larger fan, providing design flexibility, reducing mainte-nance costs, and increasing energy savings.

Safety Considerations

Installing and servicing air conditioning equipment can behazardous due to system pressure and electrical compo-nents. Only trained and qualified service personnel shouldinstall or service air conditioning equipment.

Untrained personnel can perform basic maintenance, suchas cleaning and replacing filters. All other operationsshould be performed by trained service personnel. Whenworking on air conditioning equipment, observe precau-tions in literature and on tags and labels attached to unit.

Electrical Connections

All electrical wiring and connections including electricalgrounding must be made in accordance with the latestedition of the National Electric Code (or the edition yourauthority having jurisdiction has adopted). There may alsobe local ordinances that apply.

a. The FWT nameplate and the drawings in Appendix Astate the line voltage and minimum ampacity require-ments for this unit. A separate line voltage power supplyshould be run directly from the building distribution panelto the electrical panel provided on the side of the FWTunit. The quantity of wires and the connection terminalsare identified on the wiring diagram in Appendix A. Allexternal wiring must be within approved conduit and havea minimum temperature rating of 90°C.

b. IMPORTANT: If any of the original wire supplied with theunit must be replaced, it must be replaced with typeTHHN 90°C wire or its equivalent, except for miscella-neous 120 volt control wiring that must be type SJO90°C.

c. Refer to Appendix A for other control interface connec-tions.

INSTALLATION

2

FANWALL ASSEMBLY

3

BOLTINGFLANGES

FANCARTRIDGE

Fanwall Assembly

DANGER! Risk of Electric Shock

Always disconnect power to the fan control panel

before maintenance. Follow all lockout and tag

out procedures.

1. To assemble fanwall, first disconnect power to

the existing fan at the main control panel.

2. Make note of all wire locations for reinstallation later.

3. Disconnect existing fan motor power cable from termi-nal located in motor J-Box and conduit fitting f r o mJ-Box as shown in the demolition drawings.

4. Remove existing fan/motor assembly and clean thearea thoroughly.

5. Make sure that floor on airhandler is level and rigid.

6. Find the center line of the fan cabinet air inlet openingand mark it on the air handler floor to help align thefirst fan cartridge.

7. Align the first fan cartridge frame needed at the centerbottom for the fanwall (inlet side). See drawings for fanarray. Align the next fan cartridge needed on either sideof the first cartridge and bolt together using the boltingflanges and supplied bolts, washers, and lock washers.

8. When the base fan cartridges are aligned properly andbolted together, use tek screws and washers to securethe bases to the floor. To further secure the bases to thefloor, mount the blank-offs for the floor with tek screws.

9. Lift the next row of fan cartridges in to place and bolttogether at the bolting flanges, both side-to-side and top-to-bottom. Follow the same procedure until the entirefanwall is complete.

10. To secure the fanwall to the cabinet, secure blank offpanels to the fan cartridge frame and the air handlercabinet using tek screws. Apply caulking to blank-offpanels and fan cartridges where needed.

MOUNTING BOLTS

BOLTING FLANGES

BLANK-OFFS

INLET SIDE VIEW

BOLTINGFLANGES

FANWALL ASSEMBLY

4

Fanwall Electrical Installation

DANGER! Risk of Electric Shock

Always disconnect power to the fan control panel

before maintenance. Follow all lockout and tag

out procedures.

1. Verify fanwall is in place.

2. Layout conduit run from fan(s) to enclosureor j-box. See installation design drawings.

3. Attach FMC ( flexible metal conduit ) to motor j-box( Pecker head ), one J-box per motor.

4. Size wire ( per NEC code ) and pull from motor(s) toenclosure/j-box.

5. Wire internal motor connection.

A. Crimp on ring terminals.

B. Bolt terminals together for what ever voltage you areusing (see motor nameplate).

C. First layer wrap with Friction tape ( 3M VarnishedCambric ).

D. Second layer with rubber splicing tape ( 3M 130C ).

E. Third layer use vinyl tape ( 3M Super33 ).

Note: 3 wraps on all taped layers.

6. Hi-pot wires.

7. Connect wires to Enclosure / j-box.

Flexible MetalConduit

Enclosure J~Box

Standoffs

Flexible MetalConduit from J-Box

to Motor J-Box

Conduit run fromJ-Box to Enclosure

J-Box

Flexible Metal Conduitto motor J-Box

Ring Terminals

All grounds are pulled continuously thrufanwall j-boxes without splicing to accomodatefor box fill calculations.

ELECTRICAL NOTE

MAINTENANCE

5

2. Set the motor pedestal rail onto the structural anglebrackets that run front to back along the cell (see fig-ure 1).

3. Line the four pedestal bolt holes up with the bolt holeson the angle bracket.a. Insert ½” bolts into the holes, make sure to use a

standard washer on the bolt side and a standardwasher and lock washer on the nut side. Handtighten the bolts for now (see figure 1).

4. Set the motor on the pedestal (see figure 1). Useproper lifting techniques, crane or motor/rail system ifpossible for lifting the motor into position. Once themotor is placed on the pedestal align the bolt holes onthe motor to the bolt holes on the pedestal makingsure that the motor shaft is pointing towards the faninlet wall.a. Next, insert 3/8" bolts into the holes from the

underside, make sure to use a standard washer onthe bolt side, only a locknut is required on the motorside (see figure 1).

b. Square the motor and tighten the bolts to 40 ft-lbs.

5. Locate the fan wheel and cone and associated hardwareand move to the inlet side of the fan wall (see figure 2).a. Install trantorque bushing into hub on fan wheel.

Make sure that the nut pattern on the bushing isfacing towards the fan wheel blades.

b. Place the fan wheel onto the motor shaft throughthe trantorque bushing. Slide the wheel onto theshaft until the trantorque is fully engaged on themotor shaft. Be careful not to push the fan wheel toofar onto the shaft as interference with the pedestalmay occur. Hand tighten the bushing for now (seefigure 2).

DANGER! Risk of Injury

Rotating equipment. Always disconnect power to thefan motor before maintenance.

1. To replace a fan wheel/motor assembly, firstdisconnect power to the FWT at the main control panel.

FAN CONTROLPANEL

Fanwall Option -Fan Wheel/Motor Replacement

This procedure assumes that the fan cell is installed.

DANGER! Risk of Electric Shock

Always disconnect power to the fan control panel

before maintenance. Follow all lockout and tag

out procedures.

MOTOR PEDESTAL

1/2" PEDESTALBOLTS

MOTOR STRUCTUREANGLE BRACKETS

3/8" MOTOR BOLTS

FIGURE 1

FORMED ANGLEBRACKET

CONEFASTENER

INLET CONE

AIRFLOW STRAIGHTNER GRID

FIGURE 2

TRANTORQUEBUSHING

MAINTENANCE

6

Fanwall Option -

Fan Wheel/Motor Replacement (CONTINUED)

6. Temporarily attach the cone to the cell inlet using thescrews and washers provided (see figure 2). Use aminimum of four screws for this step.a. Refer to the fan wheel overlap drawings provided to

determine where to set the wheel with respect to thecone (see figures 4-7).

b. Adjust the amount of overlap by moving the motorpedestal forward or backward to line up the cone withthe wheel (wheel/cone overlap is designed to insertthe cone 50% of the distance of the rolled shroud lipon the wheel). Once you have the wheel approxi-mately located tighten the ½” pedestal bolts to 90ft-lbs.

c. Next make sure that the wheel is located properlyand tighten the trantorque bushing. Once the wheeldepth alignment is verified tighten the trantorquebushing to 70ft-lbs. Please note that a bar or someother device may need to be inserted into the bladeof the fan wheel to hold the wheel while applying thetorque. Please refer to Table 1 for shaft size andassociated socket size to be used to tighten thetrantorque.

7. Center the cone in the wheel shroud. The attachedfigures 4-7 show the proper wheel/cone alignment.a. The cone alignment can be a tedious process as

there are no tools that effectively work to align thecone. It is a hands on process to align the cone.Huntair cones have a running clearance of about1/16" (see figure 3).

b. Start by loosening the four screws that were used tohold the cone for the depth alignment. Hold the conewith one hand and with the other use a drill to attacha screw to hold the cone in place. Feel between thewheel inlet shroud and the cone and set the gap toapproximately 1/16" and tighten the screw in thatlocation (top of the cone is usually the best place tostart). At this point you should be able to move thecone about that screw location, adjust the cone onthe left or right until there is approximately a 1/16"gap.

c. Spin the wheel by hand at this point to check for anyclearance issues. If the wheel spins clear tightenthe remaining screws on the cone. Check that thewheel spins clear after tightening each screw.

8. Attach the inlet airflow straightener using the formedangle brackets (see figure 2).a.Start by loosely installing (don’t tighten screws all

the way) the bottom angle bracket. Set theairflow grid on the angle bracket. Align the side ofthe grid with the end of the bracket.

b.Install either vertical angle bracket loosely andcheck fit up.

c.Install the two remaining brackets and tighten (seefigure 2).

9. Wire the motor per the electrical schematic provided.Make sure to wire the motors to NEC standards.

10. Bump test the motors and check for proper rotation.

FIGURE 3

TYPICAL FAN~CONECLEARANCE

Table 1

Frame Shaft TranTorque Socket48 0.625 0.87556 0.625 0.875

143T 0.875 1.25145T 0.875 1.25182T 1.125 1.5184T 1.125 1.5213T 1.375 1.75215T 1.375 1.75

Figu

re 4

Figu

re 5

Figu

re 6

Figu

re 7

MAINTENANCE

7

Fanwall Option -

Fan Cartridge Replacement

DANGER! Risk of Electric Shock

Always disconnect power to the fan control panel

before maintenance. Follow all lockout and tag

out procedures.

1. To replace fan cartridge, first disconnectpower to the FWT at the main controlpanel.

2. Remove the safety screens and backdraft damperson discharge side (if equipped) and safety screens orair straightener from inlet side (if equipped).

3. Make note of all wire locations for reinstallationlater.

4. Disconnect motor power cable from terminallocated in motor J-Box and conduit fitting fromJ-Box as shown.

5. Remove all tek screws on both inlet and drive sideblank-off panels around the cartridge you areremoving.

6. Slide and lift the fan cartridge backwards to thedrive side by using the optional overhead motorremoval rail system, if equipped or with amechanical lift to remove cartridge.

7. To reinstall fan cartridge, follow the steps above inreverse. Reapply caulking to blank-off panels andfan cartridges were required.

BOLTINGFLANGES

FANCARTRIDGE

BLANK-OFFS

INLET SIDE VIEW

BOLTINGFLANGES

REMOVE BOLTS

BOLTING FLANGES

BLANK-OFFS

TEK SCREWS

DRIVE SIDE

J -BOX

MAINTENANCE

8

Long Term Storage (Over 1 Month)

All fan and motor bearings equipped with greasee fittingsmust be relubricated as soon as they arrive from thefactory. To prevent corrosion, all bearings should receivegrease and be rotated the first of every month. Turn thewheel by hand while greasing the bearings. A clean 1/16"bead of grease must appear on each side of each bearing.Refer to specific bearing lubricating instructions on the fan.

Monthly

1. Fan and motor bearings equipped with grease fittingsare to be lubricated. Bearings without fittings arepermanently sealed and do not require lubrication.

For normal operation, use Shell Alvania No. 2, MoblithSHC 100 (Mobile), Rykon Prem #2 (Rykon), PremiumRB2 (Texaco), or an equivalent grease. Caution shouldbe used in greasing bearings with a high pressure gunwhich can blow bearing seals and overfill the bearingwith grease. This condition can result in excessivechurning and overheating. For normal operating condi-tions it is a standard practice to fill only 30% of thebearing void with grease. Do not over-lubricate.

For temperatures below 0°F, it is suggested that a lowtemperature lithium grease similar to Beacon #325(humble oil) be used.

Every Six Months

1. Check motor bearings for possible binding, noise oroverheating.

2. Check supply fan and exhaust fan wheels for dirt andgrease accumulation. Clean as necessary. Do not usecaustic cleaning solutions.

Yearly

1. Lightly lubricate damper bushings and associatedlinkage.

2. Lightly lubricate control valve linkage.

Every Two Years

1. Examine unit housing for signs of corrosion. Clean,replace or touch up with paint, as necessary.

Every Four Years

1. Lubricate motor bearings, using CHEVRON BRB #2,ALVANIA #2 (Shell Oil Co.), RYDEKN #2 (Standard OilCo.), or an equivalent grease.

2. For ambient temperatures below 0°F use BEACON#325 low temperature grease or equal

3. Lubricate while motor is warm and at standstill. Re-move and clean plugs, insert grease fitting into upperhole adding a small amount of clean grease with a lowpressure grease gun. Run motor for five (5) minutesbefore replacing plugs.

CAUTION: Excessive amount of grease will overheatthe bearings.

Factory Service

Huntair offers several levels of service to its custom-ers.

- Service scheduling- Recertification or preventative maintenance

scheduling- Additional manual requests or updates- Spare/replacement part ordering

HUNTAIR Customer Service Manager:

Phone: 503-639-0113Fax: 503-639-1269Email: cgooch@huntair.comAddress: 11555 SW Myslony Street

Tualatin, OR 97062

TROUBLESHOOTING

9

SYMPTOM POSSIBLE CAUSE FIELD TEST REMEDY

FAN WILL NOTSTART OR RUN ATALL

1.

2.

3.

4.

No main power.

Faulty control circuitauxiliary contact onunit disconnect switch.

No control transformeroutput.

Tripped overloads onmotor starters.

1.

1A.1B.

2.

3.

3A.

4.

4A.

Check main power fuses with ohm meter.

Check disconnect switch.Use volt meter to check for proper mainvoltage to unit.

Check contact with ohm meter.

Check primary and secondary fuses ontransformer.

Check control transformer primary andsecondary voltages.

Verify overload trip setting is at or slightlyabove the motor nameplate fla.

Reset overloads and measure operatingcurrent of motors.

1.

1A.1B.

2.

3.

3A.

4.

4A.

Correct problem and replace fuses with sizeindicated on electrical diagram.Turn to "On" position.Restore power to unit.

Replace switch if faulty.

Correct problem and replace fuse(s) withsize indicated on electrical diagram.

Replace transformer if faulty.

Adjust overload trip setting (not to exceedmotor fla x 1.15 for ODP motors and not toexceed motor fla for TEFC motors).If current values are above nameplate fla, goto Motor Failure.

MOTOR FAILURE 1.

2.

3.

Improper supplyvoltage.

Motor overloaded.

Motor overheating.

1.1A.

2.

2A.2B.

2C.

3.3A.

Check voltage at motor.Check for proper wiring at motor.

Check amperage at motor.

Check rotation of fan.Check motor shaft for freedom of movement.

Check for excessive cfm and/or staticpressure.

Verify correct supply cfm.Check for temperatures above 110°F.

1.1A.

2.

2A.2B.

2C.

3.3A.

If incorrect, correct to proper value.Wire motor per diagram on motor or insidemotor junction box.If amperage outside of motor nameplatelimits, conduct additional field tests thatfollow.Correct rotation, if necessary.Replace motor or motor bearings ifnecessary.Correct cause of high static pressure andadjust airflow per start-up sectioninstructionsAdjust cfm to unit data plate value.Consult factory for motor heat shield.

SYMPTOM POSSIBLE CAUSE FIELD TEST REMEDY

FAN CAPACITYLOW

1.

2.

3.

4.5.6.

High external staticpressure.Dampers improperlypositioned.

Air leaks in system.

Damaged fan wheel.Incorrect fan rotation.Obstructed inlet.

1.

2.

3.

4.5.6.

Check actual pressure against unit data platepressure.Verify proper position of unit air controldampers (if any) and all externaldampers/diffusers.Check ductwork and duct connections forleaks.Visually inspect wheel.Check wheel rotation with arrow on fan.Inspect inlet.

1.

2.

3.

4.5.6.

Correct static pressure. If not possible,consult factory.Correct damper position.

Repair any leaks.

Replace fan wheel if necessary.Correct rotation if backwards.Clear inlet.

VIBRATION ANDNOISE

1.

2.

3.4.

5.

6.7.

Misalignment ofwheel.Unstable foundation.

Dirty fan wheel.Broken or loose boltsor setscrews.Fan delivering morethan rated capacity.Loose dampers.Shipping bolts and/orbraces not removed.

1.

2.

3.4.

5.

6.7.

Check alignment.

Check roof curb or mounting platform forstability.Inspect fan wheel.Check bolts and setscrews for tightness.

Refer to airflow verification in start-upprocedure section.Inspect dampers.Verify all shipping blocks and braces areremoved.

1.

2.

3.4.

5.

6.7.

Align if necessary.

Correct roof curb or platform installationdeficiency.Clean fan wheel.Replace or tighten as necessary.

Adjust drives per instructions in start-upprocedure section.Tighten dampers if loose.Remove shipping attachments.

FWT START-UP REPORTVFD UNIT MODELS

Unit Nameplate Data:Model No.Serial No.Supply CFM: Supply HP:Exhaust/Return CFM: Exhaust/Return HP:

Mechanical System Checks1 Visually inspect fanwall for damage.

a. On Discharge side look for damage to Fans, Motors, Cells, etc.b. On Inlet side look for damage to inlet straigtening grid and frame as well as cells.

2 Fan Wheel / Motora. Rotate fan wheel by hand to ensure it is properly aligned with inlet cone.b. Check motor bearings as fan wheel is rotating. Bearings should operate freely and be free of noise.c. Check that shaft ground kit is installed correctly.d. Check backdraft damper for smooth operation if supplied. Open damper by hand to ensure a full

range of motion without obstruction.

3 HVAC Systema. Check that all ducts, dampers and registers are set.b. Check that all openings and pentrations are sealed.

Electrical System Checks1 De-Energized

a. Check for any loose connectionsb. Check circuit breaker disconnect mechanisms / Mechanical interlocks operate properlyc. Check VFD size and rating (voltage and horsepower)d. Check and set motor start protectors (MSP) for correct size and setting.e. Ensure all system components are adjusted to proper settings (temperature, amperage)

2 Energizeda. Connect proper input voltage power to line side of panelb. Energize incoming power circuit.c. Check for proper line voltage.d. Check voltage between all neutral terminations and panel ground (should be zero volts) e. Check internal power supplies for proper voltage output(s) and adjust as requiredf. Test and verify proper operations of all GFCI devicesg. Check operation of cabinet cooling fans, adjust thermostat as specified on drawingh. Check and record all voltage readingsi. Energize MSP one at a time to ensure correct motor rotation.j. Ensure that CFM monitoring system is functioning (if applicable).

Comments

Huntair recommends that the following FWT START~UP REPORT be performed on each unit and the results filed with theappropriate facility engineering office.

10

WARRANTY

The materials and methods of construction

for the equipment provided by HUNTAIR are

of the highest quality and will comply

to the project specifications, with the

exception of items identified in HUNTAIR'S

quote for the project.

HUNTAIR warrants its products to be free of

defects in materials and workmanship

under normal use, when installed and

operated in accordance with factory

recommendations, for a period of 18 months

from shipment or 12 months after

initial equipment start-up, whichever occurs

first. Equipment found to be defective will

be replaced, or repaired as determined by

HUNTAIR.

Work or repairs made without HUNTAIR'S

authorization or those items that require

periodic replacement due to wear, such as

fan belts, prefilters, electrical fuses, lamps,

and fan bearings.

Component parts such as electrical

motors, and controls or accessories not

manufactured by HUNTAIR shall be

warranted under the terms and conditions

of the warranty by the manufacturer of said

component parts.

All repairs and replacement parts furnished

under this warranty shall be provided F.O.B.

Huntair, Inc. The party making the warranty

claim shall be responsible for all necessary

freight charges, labor costs for removal and

installation of parts or components, and

all federal, state, or local taxes, unless

specifically stated otherwise and agreed to

in writing by Huntair Inc.

Equipment that is not routinely serviced in

accordance with HUNTAIR'S recommended

maintenance guide as outlined in the O&M

Guide.

Factory Customer Service

HUNTAIR offers several levels of service to its customers.

- Service scheduling

- Recertification or preventative maintenance scheduling

- Additional manual requests or updates

- Spare/replacement part ordering

Please Direct Service Needs To:

HUNTAIR Customer Service Manager:

Phone: (503) 639-0113

Fax: (503) 639-1269

Email: cgooch@huntair.com

Address: 11555 SW Myslony St.

Tualatin, OR. 97062

Items Not Covered By This Warranty

11

HUNTAIR, INC.11555 SW Myslony Street • Tualatin, Oregon 97062 U.S.A.

Phone: 503-639-0113 • Fax: 503-639-1269 • www.huntair.comHUNTAIR® is a registered trademark of HUNTAIR, Inc.®

FANWALL TECHNOLOGY ®and FANWALL® are registered trademarks of Huntair, Inc.

Huntair is a CES GroupTM Company

US Patents 7,137,775 B2 and 7,179,062 B2 Issued and others pending

FORM NO. FWT Retrofit Guide 0907 © COPYRIGHT 2007, HUNTAIR, INC.

Fanwall Technology® Retrofit Guide