Installation General CAUTION: Sheet metal parts, screws, clips and similar items inherently have sharp edges, and it is necessary that the installer and service personnel exercise caution. The installation of this equipment shall be in accordance with the regulations of authorities having jurisdiction and with all applicable codes. This equipment is to be installed by an experienced installation company and fully trained personnel. The mechanical installation of the inline centrifugal fan consists of making final connections between the unit, building services, and duct connections. 1. These units have been run at the factory to insure excellent operation. 2. Before installing unit in ductwork (if damper is to be used) make sure the damper is correctly installed. Refer to Table 6 for correct damper size. 3. Connect supply leads to the disconnect switch. 4. Check power supply to insure it is proper for the motor supplied. 5. Determine if wheel is free to rotate and not subject to misalignment in shipping or installation. 6. Install belts and adjust tension and lock capscrew in slot. Tension should be checked and reset, if necessary, after 48 hours of operation. (BSI models only.) 7. Apply power and check wheel for proper rotation. Also check unit RPM, motor volts and amperes, to insure proper operation. Check, Test & Start Procedure WARNING Electric shock hazard. Could cause severe injury or death. Failure to bond the frame of this equipment to the building electrical ground by use of the grounding terminal provided or other acceptable means may result in electrical shock. Disconnect electric power before servicing equipment. Service to be performed only by qualified personnel. BEFORE STARTUP: Disconnect power to this unit before servicing the unit. 1. Check to verify that the wheel is free to rotate. 2. Verify that supply voltage on the line side of disconnect agrees with voltage on unit identification plate and is within the utilization voltage range as indicated in Table 1. Table 1. Utilization Voltage Ranges SYSTEM VOLTAGE/ UTILIZATION VOLTAGE UNIT NAMEPLATE MIN. MAX. 115/60/1 104 127 208-230/60/1 or 208-230/60/3 187 253 230/60/1 or 230/60/3 207 253 277/60/1 249 305 200/60/3 180 220 380/60/3 342 418 460/60/3 414 506 575/60/3 517 633 110/50/1 99 121 220/50/1 198 242 380-415/50/3 342 456 440/50/3 396 484 3. On three-phase units check and calculate phase unbalance as follows: % Voltage Unbalance = 100 x max. voltage deviation from avg. voltage avg. voltage Example: Determine the percent voltage unbalance given voltages of 220, 216 and 213. How To Use The Formula: a. Avg. Voltage = 220 + 216 + 213 = 649 3 = 216 b. Max. Voltage Deviation From Avg. Voltage = 220 216 = 4 c. % Voltage Unbalance = 100 x (4 216) = 1.8% Voltage unbalance should not exceed 2%. 4. Apply power to unit and check rotation of wheel with the directional arrow on the unit. WARNING: All units run in a clockwise direction when viewed from the air intake. If allowed to operate in the wrong direction, the motor will be overloaded and burn out. WARNING: Special attention should be paid to checking three-phase units for rotation. For three-phase, rotation can be changed by interchanging any two of the three line leads. If unit is installed on temporary wiring, it should be rechecked when permanently installed. Motor burn-out or tripped overload protection devices are usually the result of incorrect rotation. 5. Electrical Input Check: Perform check of fan ampere draw and verify that motor nameplate amps are not exceeded. Take account of the service factor range if motor is nameplated above a 1.0 service factor. 6. Fan RPM Check: Fan the RPM should be checked and verified with a tachometer. Refer to Table 2 for maximum fan RPM values. WARNING: Running the fan at an RPM greater than the maximum RPM value in Table 4 will overload the fan motor and lead to premature motor failure. WARNING: Do not replace motor sheave with one larger in diameter. Do not replace fan sheave with one smaller in diameter. The sheave ratios are set so that the motor will not be overloaded within the range of the adjustable sheave. 2 Twin City IM 4205
Table 2. Maximum Fan RPM (BSI) MODEL MOTOR MAXIMUM BSI HP FAN RPM 1/4 2250 1/3 2500 080 1/2 2860 3/4 3260 1 3590 1/4 2015 1/3 2230 090 1/2 2550 3/4 2920 1 3205 1/4 1565 1/3 1725 100 1/2 1980 3/4 2255 1 2480 1/4 1290 1/3 1420 1/2 1630 120 3/4 1865 1 2045 1-1/2 2345 1/4 1450 1/3 1600 1/2 1840 120HP 3/4 2105 1 2315 1-1/2 2655 1/4 1075 1/3 1190 1/2 1370 135 3/4 1565 1 1720 1-1/2 1970 1/4 1200 1/3 1350 1/2 1550 135HP 3/4 1765 1 1945 1-1/2 2225 1/4 920 1/3 1020 1/2 1170 150 3/4 1335 1 1465 1-1/2 1680 2 1845 1/3 1140 1/2 1320 3/4 1510 150HP 1 1660 1-1/2 1900 2 2090 1/3 875 1/2 1005 3/4 1150 165 1 1260 1-1/2 1445 2 1590 3 1820 1/2 1130 3/4 1290 1 1415 165HP 1-1/2 1620 2 1785 3 2040 MODEL MOTOR MAXIMUM BSI HP FAN RPM 1/3 750 1/2 865 3/4 985 180 1 1085 1-1/2 1240 2 1365 3 1560 1/2 970 3/4 1105 1 1215 180HP 1-1/2 1390 2 1530 3 1750 1/3 630 1/2 720 3/4 825 210 1 905 1-1/2 1040 2 1140 3 1305 1/2 810 3/4 925 1 1015 210HP 1-1/2 1165 2 1280 3 1465 1/3 520 1/2 600 3/4 685 1 750 225 1-1/2 865 2 950 3 1085 5 1285 3/4 785 1 860 1-1/2 985 225HP 2 1085 3 1240 5 1470 1/2 505 3/4 575 1 630 1-1/2 725 245 2 795 3 910 5 1080 7-1/2 1235 1 730 1-1/2 835 2 915 245HP 3 1050 5 1245 7-1/2 1425 1/2 420 3/4 480 1 525 1-1/2 605 270 2 665 3 760 5 900 7-1/2 1030 MODEL MOTOR MAXIMUM BSI HP FAN RPM 1 605 1-1/2 695 2 760 270HP 3 870 5 1030 7-1/2 1185 1 450 1-1/2 515 2 565 300 3 645 5 770 7-1/2 880 1 515 1-1/2 590 2 650 300HP 3 745 5 880 7-1/2 1010 1 380 1-1/2 435 2 475 330 3 545 5 650 7-1/2 745 10 820 1-1/2 500 2 550 3 630 330HP 5 745 7-1/2 855 10 940 1 320 1-1/2 370 2 405 365 3 465 5 550 7-1/2 630 10 695 1-1/2 420 2 460 3 530 365HP 5 625 7-1/2 720 10 790 1-1/2 310 2 340 3 390 402 5 465 7-1/2 535 10 585 1-1/2 355 2 390 3 445 402HP 5 530 7-1/2 605 10 670 15 765 Twin City IM 4205 3
Speed Control (Field Installed Only) DSI Models (Optional) Speed control is available for DSI models using 115/60/1 open type PSC or shaded pole motors. The speed controllers are of solid-state (tri-ac) design. The speed control features include RFI filter, minimum speed trim adjustment capability, and built-in on/off line switch. The controller is designed to start motor on high speed for better start-up characteristics. Installation Connect speed controller in series with motor and AC line (115V only). Never connect speed controller across AC line. See Figure 2. Minimum Speed Setpoint All controls are factory set to 65V±3V output as standard with an input voltage of 120V. If different minimum speed is desired, the control may be adjusted by turning minimum speed pot clockwise to decrease minimum speed and Table 3. Speed Controller Size (DSI Models) counterclockwise to increase minimum speed. Refer to Figure 1. Warning: If minimum speed is readjusted, verify unit ampere draw does not exceed motor nameplate amps. Do not operate unit in range where amp draw exceeds motor nameplate. Warning: Certain failure modes of solid-state controls such as half-waving can cause high levels of DC, motor overheating and motor burn-out. Therefore, a thermal overload protection (integral with motor) is required to limit the maximum motor temperature under such a failure. Caution: These motors operate more efficiently in the ranges set from the factory. Operating motors outside these ranges may cause motors to run hotter and substantially shorten motor life. Note: Lowering the minimum speed setpoint may adversely affect motor start-up characteristics. MOTOR DSI MOTOR PART NO. SPEED CONTROLLER RPM HP MODEL ODP TE PART NO. AMP 1075 1/6 080, 090, 100, 120, 135N 73505106 1/4 135, 150N 73500214 73505210 66805601 5 1/2 150, 165N 73500413 73505408 3/4 165 73500510 73505506 66805701 10 1/4 080, 090 73500215 66805601 5 1/3 100 73500316 73505311 1/2 120 73500415 73505409 66805701 10 1650 1 135 73500610 73505606 66806001 15 3/4 135N 73500509 73505507 66805701 10 1 1/2 150 73500705 73505606 1 150N 73500610 73505706 66806001 15 Figure 1. Low End Setpoint Adjustment Figure 2. Connection Diagram, Speed Control SPEED CONTROLLER SETPOINT ADJUSTMENT SCREW SWITCH AC LINE (115V) TRI-AC MOTOR 1. The motors in these units are equipped with permanently sealed ball bearings. They require no lubrication for the life of the motor. 2. Fan shaft pillow block bearings on larger units are equipped with grease gun fittings. These bearings are factory lubricated and, with normal operation, will need no lubrication for 3 to 6 months. (BSI models only.) 3. For pillow block bearings, use a low pressure grease gun with Alvania #2 or #3 grease or equivalent. Only a few strokes of the gun are required. Excess grease will be forced out through the bearing pressure relief holes. Use of a high pressure gun, however, is liable to blow the bearing seals. 4. Belt tension is adjusted at the factory. It should be readjusted after a break-in period of 24 hours of actual operation. (BSI models only.) Maintenance 5. To adjust belt tension, loosen the hex head screw in the tab of the motor plate. Snug belts by pulling on the motor with a force of 15 lbs. for single belts and 30 lbs. for double belts. Retighten screw before releasing motor. 6. Belt condition and tension should be checked every 3 to 6 months depending on service. If belt tension is too tight, there is a possibility of overloading the motor as well as causing undue belt wear. If the belt tension is too slack, then the wheel will fall off in RPM, air delivery will decrease and the belts will wear quite rapidly. (BSI models only.) 7. If the air handled by the unit is dust or grease laden, a regular inspection and cleaning of the backdraft damper and the wheel will ensure smooth, efficient operation. 4 Twin City IM 4205
Shown on pages 5 and 6 are the typical dimensions (E and F) for the hanger brackets that are supplied with these units. The 9 16" holes in these brackets can readily be used for Hanger Brackets installing the units. To obtain optimum isolation, the BSI unit should be installed with the motor above or below the fan body. Overhead Mounting Floor Mounting 3.69 2.15 Hanger Rod, Nuts & Washers (By Installer) 3.0 Spring Isolator BSI/DSI Unit Neoprene Isolator 2.72 Hanger Housing Bolt, Nuts & Washers (Included) BSI/DSI Unit 5.25 3.50 Finished Floor 1.50 Hanger Bracket NEOPRENE ISOLATOR SPRING ISOLATOR BSI: Belt Driven Centrifugal Inline Fans MOTOR COVER DISCONNECT SWITCH F MAX. BELT GUARD AIRFLOW 1.13 1.13 C SQ. D A C SQ. B SQ. E B + 3.13 MODEL B C F DAMPER AVG. SHIP A D E BSI SQ. SQ. MAX. SIZE WT. (LBS.) 080 22.50 13.00 11.25 20.19 14.50 12.00 11.00 x 11.00 111 090 23.00 15.25 13.50 20.69 16.75 12.00 13.00 x 13.00 116 100 26.00 17.81 16.06 23.69 19.31 12.00 16.00 x 16.00 135 120/120HP 25.50 19.38 17.62 23.19 20.88 12.00 17.50 x 17.50 151 135/135HP 28.00 21.53 19.75 25.75 23.03 12.00 19.50 x 19.50 161 150/150HP 30.50 23.69 21.94 28.25 25.19 12.00 21.50 x 21.50 200 165/165HP 36.00 26.38 24.62 33.75 27.88 14.50 24.50 x 24.50 232 180/180HP 39.25 28.88 27.12 37.00 30.38 14.50 27.00 x 27.00 266 210/210HP 43.00 32.19 30.44 40.75 33.69 14.50 30.00 x 30.00 300 225/225HP 45.50 34.00 32.25 43.25 35.50 14.50 32.00 x 32.00 385 245/245HP 48.50 37.50 35.75 46.25 39.00 16.00 35.50 x 35.50 468 270/270HP 54.50 40.00 38.25 52.25 41.50 16.00 38.00 x 38.00 551 300/300HP 59.50 44.00 42.25 57.25 45.50 16.00 42.00 x 42.00 634 330/330HP 65.00 48.69 46.94 62.75 50.19 17.00 46.50 x 46.50 792 365/365HP 65.00 50.00 48.25 62.75 51.50 17.00 48.00 x 48.00 892 402/402HP 71.50 55.25 53.50 69.25 56.75 20.00 53.00 x 53.00 1022 DIMENSIONS ARE NOT TO BE USED FOR CONSTRUCTION. Twin City IM 4205 5