boss 52 installation & operation guide

BOSS 52" Installation & Operation Guide PNEG - 1450 March 2005

Airstream Ventilation Systems Model: F52CL16GA Size: 52” Fiberglass Housing and Cone Voltage: 115v / 230v Amps: 13.0 / 6.5 Frequency: 50/60 Hz Single Phase

You have just Fans in the indvelocity airflowelectrical usagthrough this maproper installatio

FEATURES

28,000 cfm

Limited LifeCone

Whisper Qu

Patented Ve

Corrosion F

Easy Assem

On-Site Se

T A B L E O F

1 Warranty

2 Safety and

3 Unpacking

4 Installation

5 Wiring

6 Operation

7 Maintenan

8 Troublesho

9 Parts List

10 Exploded D

Congratulations! purchased one of the best Ventilation ustry, designed to give years of high

while saving hundreds of dollars in e. Please take some time to read nual and familiarize yourself with the n methods and operation of the fan.

@ .05”

time Warranty on the Housing and

iet Operation

nturi Design

ree

bly and Maintenance

rvice and Support

BOSS 52" Installation and Operation Guide - 1 -

C O N T E N T S

Warnings

ce

oting

iagram


Warranty

Airstream Ventilation Systems (AVS) a member of the GSI Group warrants all parts manufactured and sold by AVS to be free of defects in materials and workmanship under usual and customary service, including a reasonable maintenance program. AVS’s only obligation is to repair or replace products returned on a prepaid basis within 12 months after retail sale, and, in the opinion of AVS, found to be defective due to material or workmanship. If defective, the product will be repaired or replaced without charge, F.O.B. factory, this constituting and fulfilling our warrant obligation. Expenses incurred without written authorization of AVS shall be the sole responsibility of bearer; under no circumstances will AVS be liable for any kind of special or consequential damages, nor will the liability ever exceed the selling price of the product. Limited Lifetime Warranty, this lifetime warranty includes Fiberglass Fan housings, Discharge Cones, and Composite Propellers. All other fan components, attachments, and accessories are excluded from this Lifetime Warranty, but are covered under the normal Product Warranty.

AVS shall not be liable for any consequential damage which the purchaser may suffer or claim to have suffered as a result of any defect in the product. “Consequential” or “Special” damages as used herein include, but are not limited to, lost or damaged products, cost of transportation, loss of sales, loss of orders, loss of income, increased overhead, labor costs, cost of operational inefficiencies and any other incidental costs.

This warranty does not cover products which may have been damaged by negligent use, misuse, lack of maintenance, alteration, or accident. All products supplied by outside manufacturers are warranted separately by the respective manufacturer. This warranty is exclusive and in lieu of all other warrants, expressed or implied. AVS reserves the right to make design or specification changes at any time without any contingent obligation to purchasers of product already sold.

AVS assumes no responsibility for field modifications or installation defects which create structural problems. If any field modifications are necessary which are not specifically covered by the contents of this manual, contact AVS for recommendations and approval. Any unauthorized modification or installation defect which affects the normal and intended use of the AVS product will be cause for immediate nullification of the product warranty.

All instructions shall be construed as recommendations only, as the actual installation may vary according to local conditions and AVS assumes no liability for results arising from the use of such recommendations or from recommendations provided without complete information on the local conditions and intended use of products.


G E N E R A L S A F E T Y I N F O R M A T I O N Users Manual

This manual contains information and instructions essential to the safe installation and use of the BOSS Fan. This manual should be read thoroughly before attempting any installation or use of the fan. Keep this manual in a location that it can be readily accessed. Failure to read the manual and it’s safety instructions constitutes misuse of the product.

Safety in Handling the Boss Fan

This unit should be installed and maintained by a qualified technician familiar with the use and function of Ventilation Fans. This will prevent situations leading to damaged components and/or injury. Whenever possible use mechanical lifting equipment when lifting or moving the fan during installation. Where manual handling is required seek assistance from other people.

CORRECT USE OF YOUR BOSS FAN

The Fan is designed solely for the purpose of ventilating agricultural buildings. Use of the Fan in any other way is a misuse and may endanger yours or another person’s safety and health.

In the installation and use of the Boss Fan only genuine AP/GSI parts are to be used. Use of other non-genuine parts is a misuse and may lead to dangerous situations.

This Fan is not designed for use in atmospheres where the risk of explosion is foreseen. Such environments may include enclosed areas of high dust concentrations, gas, vapors, and fumes. Use in such an environment is prohibited. If in doubt contact GSI or your dealer.

SAFETY GUARDS

The Boss Fan contains moving and electrical parts which would cause serious injury, even death if touched. Guards are placed on the Fan to protect you. Operating the Fan at any time with guards removed or incorrectly fitted is a serious misuse of the Fan and endangers you and others safety.

SAFETY IN MAINTENANCE

While the Boss Fan is designed to keep maintenance to a minimum, some items such as greasing the bearings and belt replacement will be required over the life of the fan. Do not attempt any maintenance or repairs on the fan unless you are competent to do so. Remember that the Fan may in

certain situations operate under automatic control and will start without warning. Never attempt any work on the Fan without first isolating it from the power supply and locking out the isolator so that only you can turn the power back on. For your safety follow the guidelines given in the maintenance section of this manual.

Before re-starting the Fan ensure that all electrical enclosures are locked closed and all guards and other safety measures are correctly fitted. If in doubt contact your dealer or GSI for assistance.

ELECTRICAL SAFETY

Provisions for an adequate and safe power supply to the Fan unit is essential to your safety. GSI recommends that a competent and qualified electrician undertake all electrical wiring. All wiring is to be installed to in accordance with National, State, and Local electrical codes. Fans used to ventilate livestock buildings and other rooms where continuous air movement is essential should be connected to individual electrical circuits with a minimum of two circuits per room.

We strongly recommend the installation of supplementary natural ventilation as well as a back-up thermostat . There should also be an alarm system on at least one cooling stage. For connection requirements refer to the diagram on the motor nameplate and also to information enclosed with the AVS fan control used.

For single phase Fans motor overload protection should be provided for each fan. A Circuit Breaker or Slow Blow Motor type fuse must be used. A safety cut-off switch should be located adjacent to each fan. Contact your local distributor for the correct cut-off switch.

The motor must be securely and adequately grounded. This can be accomplished by wiring with a grounded conduit or a separate ground wire attached to the motor’s ground lug. Do not attempt operation unless the motor is sufficiently grounded.

Do not kink power cable and never allow cable to come in contact with oil, grease, hot surfaces, or chemicals.

Remember, electrical safety is your responsibility!

S A F E T Y G U I D E L I N E S This manual contains information that is important for you, the owner/operator, to know and understand. This information relates to protecting personal safety and preventing equipment problems. It is the responsibility of the owner/operator to inform anyone operating or working in the area of this equipment of these safety guidelines. To help you recognize this information, we use the symbols that are defined below. Please read the manual and pay attention to these sections. Failure to read this manual and it’s safety instructions is a misuse of the equipment and may lead to serious injury or death.


This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

NOTE indicates information about the equipment that you should pay special attention to.

I N S T A L L & O P E R A T E E L E C T R I C A L E Q U I P M E N T

P R O P E R L Y

Electrical controls should be installed by a qualified electrician and must meet the standards set by the national electrical code and all local and state codes. Disconnect and lock out all power sources before installing wires/cables or servicing equipment .

K E E P H A N D S A W A Y F R O M M O V I N G P A R T S

DO NOT put hand or arm in fan. Rotating parts can crush and dismember.

DO NOT put any kind of tool inside fan to try and clear debris while the fan is running. Damage to the equipment will result. ALWAYS turn off and lock out all power sources before servicing equipment.


Electric Shock Hazard

Rotating Fan Blade R E A D A N D O B E Y P R O D U C T L A B E L S

Read and obey all labels and instructions for products used in the fan.

Read ALL Labels


P R E P A R E F O R E M E R G E N C I E S Be prepared if fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

W E A R P R O T E C T I V E C L O T H I N G

E Y E P R O T E C T I O N

Wear close fitting clothing and safety equipment appropriate to the job.

G L O V E S

Safety glasses should be worn at all times to protect eyes from debris.

S T E E L T O E B O O T S

Wear gloves to protect your hands from sharp edges on plastic or steel parts.

R E S P I R A T O R

A respirator may be needed to prevent breathing potentially toxic fumes and dust.


U N P A C K I N G Before beginning installation, check the condition of the fan. Remove the overwrap and packing materials and examine all parts and components for shipping damage. Any damage incurred must be reported immediately to the freight carrier.

I N S T A L L A T I O N Construct the opening frame to the correct size ( 58 ½ ” L x 55 ½ ” W ) as illustrated below in Figure 1

Remember, framing must be able to support the weight of the Fan assembly. Ensure the load bearing portion of the bottom sill is rigid and properly supported. Position the Fan in front of the opening from the inside. Using a minimum of 2 people lift Fan housing into opening and fasten Flanges to framework with the mounting screws provided. The Fan housing should now be flush and level inside of the framing. Important: When installing more than one Fan, maintain a minimum of 11” – 12” between rough openings to ensure clearance of Cones outside of Buildings. The Cone largest Diameter is 65” and allowances must be made to keep the cones separated. If not sure of sufficient clearance, contact your local distributor for more information. See Below:

58 1/2” Tall

55 1/2” Wide

66” minimum

11 – 12” minimum

C O N E A N D G R I L L E G U A R D A S S E M B L Y Next assemble the N=4 Cone panels using the hardware provided (Use Cone / Guard Hardware Kit ). See Figure 2 below. Overlap Slotted Flange and Bolt together outside portion of Cone using 1 5/16” x 1” SS Flange Bolt, 1 5/16” SS Flange Nut and 2 5/16” x 1 ½” Fender Washers. Repeat for other 7 locations. Use washers on both sides before tightening nuts to prevent cracking Fiberglass panels. When complete the Cone Assembly should look like the Cone in Figure 3. Once assembled, position Cone Assembly outside the building and lift into position on the Fan Housing. Push completely onto Orifice and line up the inner holes of the Orifice with the holes of the Cone. Bolt the Cone to the Housing Orifice using 8 5/16” SS Flange Bolts, 8 5/16” Flange Nuts and 16 5/16” x 1 ½” Fender Washers. Insert Bolts from the inside of orifice through the Cone as shown below in Figure 2. Tighten all bolts and nuts securely.

Next insert the Grille Guard inside of the Cone, push back towards the Prop until the Grille fits snug against the inner portion of the Cone. Using the eyelets of the Grille as the template mark n=4 locations. Drill through the marks with a 5/16” drill bit. Re-install the Grille and bolt securely 4 5/16” x 1” SS Flange Bolts, 4 5/16” SS Flange Nuts and 8 5/16” x 1 ¼ “ Fender Washers. The Fan is now ready to wire up to the Power Source.

Figure 2 Figure 3

E L E C T R I C A L H O O K U P As previously mentioned, All wiring should be installed in accordance with National, State and local electrical codes. A certified electrician should complete this portion of the installation to ensure Safety and that the wiring is correct for the application.

First, remove the back cover of the motor exposing the wiring block. See Figure #4 below:

Ground Lug Hole for Conduit

Figure 4 Gusset for Wire ( Remove Rubber Plug )


The motor is designed to use either a solid clamping conduit on the side of the motor or the supplied wire with a 3 prong plug attached. In either case, it is important to attach the ground wire to the Ground Lug as depicted in Figure #4. For correct motor rotation ( CCW ), the Red wire should be located on the L2 connection as depicted. If this is not the case, switch the Red and Black wires. Refer to the Wiring Diagram on the side of the motor for correct wiring for 115V and 230V supply.

Insert Bolts from the inside of Cone

Start up and Operation of Your BOSS Fan

With the Fan de-energized rotate the Prop by turning the Fan Pulley, look for clearance between the Prop Tip and the Housing. Check all fasteners to ensure they are tight. When satisfied, energize the Fan and make note of direction of rotation. The Prop should turn counterclockwise when viewed from inside the house. If not, refer back to Fig. #4 and switch the Black and Red wires as noted after de-energizing the Fan. When satisfied the Fan is operating properly, turn off power and insert the Shutters into the housing. Rotate the button retainers to lock down the Shutters.

Write down the date that your BOSS fan went into service and follow the Maintenance schedule as listed below.

Check the Belt, Pulleys and the Bearings after every 2 months of service. Take note of the Belt Position in the Pulleys, make sure it is slightly raised or flush with the Pulley. If recessed into the grooves, replace the Belt.

The Motor, and Shaft Bearings are lubricated at the factory. The motor bearings should never require lubrication over the life of the fan but the fan Shaft Bearings should be lightly greased after every 2-3 months of use using the Zerks on top of the Pillow blocks. Only a small amount of lithum soap base grease after cleaning the Zerks. Contact your fan distributor for the proper grease.

When cleaning the fans, Do Not Spray Bearings, Tensioner of Motor directly with a Pressure Washer as this Will lead to premature failure of these components. After cleaning the Fan simply wipe these parts with a clean rag to remove dirt and debris. Failure to follow these instructions will void the warranty on these components.

While doing Fan Maintenance, inspect fasteners to ensure they are snug and haven’t vibrated loose. Tighten as necessary.


Information in parenthesis refers to 120 VAC

L1 ( Hot ) L1 ( Hot ) T1 ( Hot ) T1 ( Hot )

L2 ( Neu ) L2 ( Neu ) T2 ( Neu ) T2 ( Neu )

G G

Single PhaseMotor Overload Protection Showing Disconnect

120 or 240 VACPower

Fans used to ventilate livestock buildings or other rooms where continuous air movement is essential should be connected to individual electrical circuits with a minimum of two circuits per room. For connection requirements refer to diagram on the motor nameplate. For single phase fans motor overload protection should be provided for each fan. A safety cutoff switch should be located next to each fan. A Circuit Breaker Switch or Slow Blow Motor Type Fuses must be used. See diagram below. 3 phase Fans require three pole contactors with overload protection.


TROUBLE SHOOTING GUIDE Fan won’t Start

Check the power supplied to the fan at the point closest to the fan.

Check the wiring to the fan.

Override the Controller ( Set to Manual ) and re-check.

Contact your distributor.

Fan turns Slow

Check the Voltage Supplied ( must be within + or – 10% if the nominal voltage )

De-energize the power and check the wiring at the rear of the motor

De-energize the power, remove the belt and rotate both the motor and fan pulleys. Do they turn freely? If not, contact your Distributor.

Fan is Noisy or Vibrates

De-energize the Fan. Check for loose parts,ie; Bolts, Screws, Motor, Pulleys, Prop. Are the Fan Blades even? Turn the Prop inside of the Venturi and look at the Blade Tips as they move past the same location. Do they all three appear even? ( Note: They can be a little different without any problems ). If they are significantly different contact your Distributor for more information.

Is the noise coming from the Bearings? Lubricate per instructions and energize the fan. Did the noise subside? If not, the bearings are probably damaged and in need of replacement.

Airflow Seems Reduced

Clean Shutters after every 2 months to insure maximum Airflow. Dirty Shutters can result in up to 30% less airflow.


Parts List

Model # F52CL16GA

Item Component Description Qty Per U/M1 017-1411-2 BELT-V A43 1 EA 2 10-0100 BOSS52 FBGL CONE/GUARD HDW KIT 1 EA 3 10-0105 FG Fan Shutter Mount HW 1 EA 4 91-0042 TURNBUTTON PLASTIC LARG TONGUE 12 EA 5 FH-1309 LOCK NUT 1/2" #401 ARL. 1 EA 6 FH-1310 CONNECTOR 1/2" 1 EA 7 S-7279 WASHER FLAT 3/16 ALUM (.50 OD) 12 EA 8 S-7419 SCRW SDS #10-16x1.25 HWH SS410 12 EA 9 S-7502 SCREW SMS 1/4-14x1 8 EA 10 11-0255WH BOSS52(G) GRILL GUARD 61"WHITE 1 EA 11 11-0262 BOSS52 MOTOR MOUNT PLATE 1 EA 12 11-0265 BOSS52 SS FRAME WELDMENT 1 EA 13 11-0284 PIVOT ROD, MOTOR MOUNT 1 EA 14 12-0154 BOSS52 CONE QUARTER 4 EA 15 12-0168 BOSS52 HOUSING RIGHT SIDE 1 EA 16 12-0169 BOSS52 HOUSING LEFT SIDE 1 EA 17 13-0132 BOSS52(G) GALV BD PROP 1 EA 18 15-0126 MOTOR 1.5HP 1PH 1725RPM50/60HZ 1 EA 19 16-0005 1"X 18" CR SHAFT 1 EA 20 16-0007 PULLEY AL104 X 1" MXB FANS 1 EA 21 16-0027 SHEAVE 1GR 3.75Dx5/8" BORE 1 EA 22 16-0040 SPRING, FOR BELT TENSIONER 1 EA 23 16-0076 BEARING 1" PILLOW BLOCK AVS FA 2 EA 24 DC-1540 DECAL, DANGER/WARNING 2 EA 25 DC-1571 DECAL GREASE INST. ALL BD FANS 1 EA 26 DC-995 DECAL, !WARNING SHEAR POINT 1 EA 27 S-4322 PIN COTTER 3/32X1 ZN GR2 1 EA 28 S-4513 KEY SQ 1/4X1/4X2 LONG KEY 2 EA 29 S-7021 WASHER FLAT 3/8 SS 1 EA 30 S-7082 BOLT ELEV 5/16-18x1 ZN GR2 1 EA 31 S-7447 BOLT FLNG 5/16-18x1 SS SERRATD 21 EA 32 S-8032 NUT FLANGWZ 3/8-16 SS 4 EA 33 S-8140 BOLT FLNGS 3/8-16x1-1/2 SS WHZ 4 EA 34 S-8452 NUT FLANGWZ 5/16-18 SS WAXED 22 EA

EXPLODED DIAGRAM

1) BOSS Fan Housing – 12-0168 – Right Side / 12-0169 – Left Side ( n=1 each ) 2) BOSS Fan Weldment – 11-0265 ( n=1 ) 3) BOSS Fan Cone Panel – 12-0154 ( n=4 ) 4) 1.5 HP Motor – 15-0126 ( n=1 ) 5) Motor Mount Plate – 11-0262 ( n=1 ) 6) Pivot Rod Motor Mount – 11-0284 ( n=1 ) 7) Sheave 1 gr 3.75 Dia x 5/8” Bore – 16-0027 ( n=1 ) 8) Pulley AL104 x 1” Bore – 16-0007 ( n=1 ) 9) Bearing 1” Pillow Block AVS – 16-0076 ( n=2 ) 10) 1” x 18” CR Shaft – 16-0005 ( n=1 ) 11) BOSS Grille Guard 61” White - 11-0255-WH ( n=1 )


1

2

3

4 5

6

7

8

9 10

11


DC-1540 – 5” X 7.5” DANGER HIGH VOLTAGE WARNING STAY CLEAR OF ROTATING BLADE WARNING FLYING OBJECTS HAZARD Located Middle Left Inside Housing / Middle Left Outside Housing

DC-995 – 2.0” X 4.5” WARNING SHEAR POINT Located Middle Left Inside Housing / Middle Left Outside Housing

BOSS 52" Installation and Operation Guide

boss 52 installation & operation guide

Documents