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P.O. Box 848 Kearney, NE 68848 USA Phone (308) 237-3186 Fax (308) 237-2650

Part Number 740548Bulletin 441GEffective 1/2/2006

OWNERS MANUAL

INSTALLATION AND OPERATION INSTRUCTIONS FOR AXIAL FLOW FANS

This manual is for installation, operation, and maintenance of all Caldwell axial fans with serial numbers 06A__________ and up.

WARNING! Read this manual thoroughly before installing or operating fan. Keep this manual in a location for quick access and reference.

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TABLE OF CONTENTS

LIST OF FIGURES 4 LIST OF TABLES 5 INTRODUCTION 6 SAFETY 7 SERVICE NOTICE 10 PACKING LIST 11 MODEL SPECIFICATIONS 12-13 MOUNTING PAD 12 AXIAL SPECIFICATIONS 13 INSTALLATION INSTRUCTIONS 14-19 FOUNDATION 14 INSTALLATION 14 ELECTRICAL INSTALLATION 15 LEVELING 17 ACCESSORIES 17 INSTALLATION CHECK 17 AXIAL DIMENSIONS 18 ELECTRICAL SERVICE 19 OPERATING INSTRUCTIONS 20-21 PRELIMINARY 20 STARTING FAN 21 MAINTENANCE 22 FAN OPERATION OFF SEASON 22 FAN CONTROL 22 FAN LUBRICATION 22 BLADE CLEANING 22 WIRING DIAGRAM 23-28 AF12-751 23 AF18-11 24 SINGLE PHASE 230 VOLT 25 THREE PHASE 230 VOLT 26 THREE PHASE 460 VOLT 27 THREE PHASE 575 VOLT 28 FAN SERVICE 29-33 GENERAL INFORMATION 29 CONVERTING DUAL VOLTAGE FANS 29-30 TROUBLE SHOOTING 31 FAN REPLACEMENT PARTS 34-36 FAN PARTS 34-35 MOTORS 36 CONTROL PARTS 35 WARRANTY/SERVICE POLICY 37 NOTES 38

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LIST OF FIGURES

Figure 1. Warning Label Locations 7

Figure 2. Danger High Voltage 8

Figure 3. Warning Rotating Blade 8

Figure 4. Warning to Prevent Roof Damage 9

Figure 5. Serial Number Plate 10

Figure 6. Fan Mounting Pad Location for Drying Transition 12

Figure 7. Fan Mounting Pad Location for Wall Adaptor with Angle Flange 12

Figure 8. Screen Guard Location 14

Figure 9. Field Power Installation Single Phase 16

Figure 10. Field Power Installation Three Phase 16

Figure 11. Motor Connection for Single Phase 17

Figure 12. Correcting Fan Rotation Three Phase 17

Figure 13. End and Side View of Axial Fan 18

Figure 14. Toggle Switch 21

Figure 15. Push Button Switch 21

Figure 16. Wiring Schematic for AF12-751 23

Figure 17. Wiring Schematic for AF18-11 Fan 24

Figure 18. Wiring Schematic for 230 Volt Single Phase Axial Fan 25

Figure 19. Wiring Schematic for 230 Volt Three Phase Axial Fan 26



Figure 22. Conversion 230/460 Volt 29

Figure 23. Conversion 460/230 Volt 30

Figure 24. Axial Fan Parts Disassembled 34

Figure 25. Control Enclosure Disassembled 36

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LIST OF TABLES

Table 1. Fan Pad Distance from Bin Wall for use with Caldwell Drying Transition 12

Table 2. Fan Pad Distance from Building for use with Caldwell Wall Adaptor 12

Table 3. Fan Model Specifications for Tube Axial Aeration & Drying Fans 13

Table 4. Axial Fan Housing Dimensions 18

Table 5. Electrical Service for Single Phase Operation 230 Volt 19

Table 6. Electrical Service for Three Phase Operation 230/460 Volt 19

Table 7. Electrical Service for Three Phase Operation 575 Volt 19

Table 8. Normal Time for Switchless Motor to Reach Full Speed for 230 Volt 20

Table 9. Housing, Screen Guard, Control Enclosure Replacement Parts 34

Table 10. Motor, Blade Replacement Parts 35

Table 11. Contactor or Holding Coil for Converting from 460Volt to 230Volt 35

Table 12. Control Enclosure Parts (Furnas/Siemens Parts) 36

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TO OUR VALUED CUSTOMER

The Chief Industries product you have recently purchased has been engineered and manufactured to the highest possible standards. This unit has been assembled by caring and trustworthy individuals who live in the plains of Nebraska and have your best interests in mind. Each Caldwell assembled product has been 100% quality control inspected plus field simulated stress tested to assure optimum dependability for you and your operation.

Before using your fan, it is your responsibility to read, understand and follow all of the safety instructions in your operator's manual. Also make sure that EVERYONE operating or near your fan understands and follows all of the safety instructions in the manual. Remember, a safety-minded, informed operator is the most important safety aspect of your fan. Accidents can be avoided. Do not risk injury or death -- be certain that every operator of your fan is well acquainted with all the safety recommendations and operating instructions in the manual. The table below will aid you in making sure

all employees or family members know the proper operation of your Chief Industries product. After completely reading the manual, the table should be filled in.

DATE OPERATOR SIGNATURE OWNER SIGNATURE

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Figure 1 . Warning Label Locations

Safety Notice - Important - Read This!

Safety Alert Symbol

This symbol means ATTENTION! BE ALERT! YOUR SAFETY IS AT STAKE!

The Safety Alert Symbol identifies important safety messages in this document and on your fan. Make yourself familiar with the messages identified for you with

the Safety Alert Symbol. When you see this symbol, be alert to the possibility of serious injury or death. Follow the safety instructions given in this manual and on your fan.

Signal Words Danger: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Warning: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury and property damage. Caution: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

Fan Information:

A.) The unit utilizes electricity as the source of energy. When the power is installed properly, and protective covers are in place, the unit poses no direct hazard.

WHEN INSTALLING OR SERVICING THE ELECTRICAL COMPONENTS, ALWAYS SHUT THE POWER OFF AT THE FAN DISCONNECT, AND LOCK THE FAN DISCONNECT IN THE OFF POSITION, SO NO POWER CAN BE DELIVERED TO THE FAN WHILE YOU ARE SERVICING THE UNIT. IN PERFORMING ELECTRICAL CHECKS WITH THE POWER ON, USE A VOLTMETER AND BE CAREFUL NOT TO CONTACT LIVE PARTS.

B.) The unit, when operating, has a fan blade turning at high speed, and when guarded

with the screen guard, poses no direct hazard.

MAKE SURE THE SCREEN GUARD IS SECURELY FASTENED IN PLACE. WHEN SERVICING THE FAN BLADE, MAKE SURE THE ELECTRICAL POWER IS SHUT OFF AT THE FAN DISCONNECT, AND LOCK THE FAN DISCONNECT IN THE OFF POSITION.

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Safety Decals READ AND BE CERTAIN THAT YOU FULLY UNDERSTAND THE MEANING OF ALL SAFETY DECALS BEFORE OPERATING YOUR FAN. Keep safety decals clean and readable at all times. Replace any safety decals that become unreadable or are missing. If a part with an attached safety decal is replaced, make sure the proper safety decal is attached in the proper location on the replacement part. You may obtain new decals from your local dealer. The following are representative of the safety decals on your Axial fans:

I.) Danger High Voltage:

II.) Warning Rotating Fan Blade:

Figure 2. Danger High Voltage

Figure 3. Warning Rotating Blade

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Figure 4. Warning To Prevent Roof Damage.

III.) Warning Roof and Wall Damage of Structure:

Read and follow the safety instructions before starting your Axial fan:

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CALDWELL AXIAL FAN INSTALLATION AND OPERATION MANUAL

THIS MANUAL IS FOR THE INSTALLATION OPERATION AND MAINTENANCE OF ALL AXIAL FANS WITH SERIAL NUMBER 06A_____ AND UP. READ MANUAL THOROUGHLY BEFORE INSTALLING OR OPERATING THE FANS. KEEP THIS MANUAL IN A LOCATION FOR QUICK ACCESS AND REFERENCE. SPECIAL SERVICE NOTICE If you are unable to remedy any service problem after thoroughly studying this manual, contact the dealer from whom you purchased the unit. YOUR DEALER IS YOUR FIRST LINE OF SERVICE. GIVE THEM THE INFORMATION REQUESTED BELOW AND EXPLAIN YOUR PROBLEM. If they are unable to remedy the problem, refer to the factory. When calling the factory for service, ask for the Customer Service Department. Give the information requested below and explain your problem. If adequate information relating to the problem is given, the Customer Service Department should be able to pin-point the problem and suggest an immediate remedy. THE CHIEF AGRI/INDUSTRIAL DIVISION SERVICE POLICY IS INCLUDED AT THE END OF THIS MANUAL.

1.) *Fan Model Number __________________________

2.) *Fan Serial Number __________________________

3.) Size of Bin Diameter __________________________

4.) Type of Grain __________________________

5.) Grain Depth __________________________

6.) Line Voltage (Measured)__________________________

7.) *Dealer Purchased From__________________________

8.) *Date Purchased __________________________

* fill in these items at date of purchase THE ABOVE INFORMATION MUST BE AVAILABLE BEFORE CONTACTING THE DEALER OR FACTORY FOR SERVICE.

Figure 5. Serial Number Plate.

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PACKING LIST

The shipment should contain the following items. Check carefully when unpacking and before installing. In case of any shortage or damage while in shipment, file a claim with the carrier. QUANTITY COMPONENT DESCRIPTION 1 FAN FAN ASSEMBLY 1 BOLT BAG ASSEMBLY 1 MANUAL BULLETIN 441G 1 AUTHORIZED MOTOR SERVICE CENTER BULLETIN FAN ACCESSORIES AVAILABLE

1.) A humidistat is available to cycle the fan according to ambient relative humidity conditions. The Humidistat model NHC-2 (Part#736280) can be used with any fan that has 230Volt magnetic controls.

2.) Rainhoods are available to reduce the addition of rain water into the fan.

3.) Standard Drying Transitions are available for all fans used with full floors. Refer to the fan location

information on Page 12 when drying transitions are used.

4.) Electric Humidity Controllers are available for most fans. The Humidity Controller will supply a small amount of heat to lower the relative humidity of the drying air and aid in grain storage.

5.) Gas Fired Heaters are available for most fans. The gas fired heater is used when a large temperature

rise is required. The Gas Fired Heater is a direct combustion unit and should not be used in inhabited areas.

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AXIAL FAN BF18 30"F24 42"F28 46"

AXIAL FAN DF18 3"F24 3"

Table 1. Fan Pad Distance from Bin Wall for use with Caldwell Drying Transition.

Table 2. Fan Pad Distance from Building Wall for use with Caldwell Wall Adaptor

with Angle Flange.

Figure 6. Fan Mounting Pad Location for Drying Transition.

Figure 7. Fan Mounting Pad Location for Wall Adaptor with Angle Flange.

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Table 3. FAN MODEL SPECIFICATIONS FOR TUBE AXIAL AERATION & DRYING FANS

FAN MODEL NO.

FAN HORSE POWER

MOTOR PHASE & VOLTAGE

R.P.M. FAN DIAMETER

INCHES

UNIT AMPERAGE

MAX. F12-751 0.75 SINGLE-115/230V 3450 12 7.0/3.5

F12-753 0.75 THREE-230/460V 3450 12 2.6/1.3 F14-11 1.00 SINGLE-115/230V 3450 14 9.2/4.6 F14-13 1.00 THREE-230/460 3450 14 3.6/1.8

DOMESTIC UNITS

F18-11 1.50 SINGLE-230V 3450 18 6.5 AF12-751 0.75 SINGLE-115/230V 3450 12 7.0/3.5

AF18-11 1.5 SINGLE-230V 3450 18 6.5 F18-13 1.5 THREE-230/460V 3450 18 4.6/2.3

F18-135 1.5 THREE-575V 3450 18 1.6 F18-31 3.0 SINGLE-230V 3450 18 13.2

F18-33 3.0 THREE-230/460V 3450 18 8.4/4.2 F18-335 3.0 THREE-575V 3450 18 3.6

F24-51 5.0 SINGLE-230V 3450 24 28 F24-53 5.0 THREE-230/460V 3450 24 16/8

F24-535 5.0 THREE-575V 3450 24 6.4 F24-71 7.5 SINGLE-230V 3450 24 35

F24-73 7.5 THREE-230/460V 3450 24 22.4/11.2 F24-735 7.5 THREE-575V 3450 24 9.0

F24-101 10.0 SINGLE-230V 3450 24 38 F24-103 10.0 THREE-230/460V 3450 24 25/12.5

F24-1035 10.0 THREE-575V 3450 24 10.4 F28-121 12.5 SINGLE-230V 3450 28 51

F28-123 12.5 THREE-230/460V 3450 28 33/16.5

CSA LISTED UNITS

F28-1235 12.5 THREE-575V 3450 28 13.2

NOTE: Fan models F12-751, AF12-751, F14-11, F18-11, and AF18-11 have automatic overload protection. All other fan models, except F12-753 and F14-13, have internal thermal protection. Fan models F12-753 and F14-13 do not have internal motor protection. All Single Phase Fans utilize a Permanent-Split Phase Capacitor Start Motor.

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INSTALLATION INSTRUCTIONS

1. FOUNDATION FOR THE FAN

For proper operation of your fan, the unit is to be mounted on a level pad. The fan should not be anchored to the pad but allow to float on the pad. The fan pad should be at the same elevation as the floor of the bin or 1.50” below the floor of a building.

A. PAD LOCATION FOR DRYING TRANSITION

When the Axial Fan is to be used with a standard Caldwell Drying Transition, locate the fan pad as indicated in Figure 6 and Table 1 referred to on Page 12.

B. PAD LOCATION FOR WALL ADAPTOR WITH ANGLE FLANGE

When the Axial Fan is used with a standard Caldwell Wall Adaptor with an angle flange, locate the fan pad as indicated in Figure 7 and Table 2 referred to on Page 12.

2. INSTALLATION OF THE FAN

a) PHYSICAL SIZE OF THE FAN Figure 13 on Page 18 illustrates the physical size of the fan. Use the illustration and the dimensions in Table 4 in determining the position of the fan when installed.

b) MECHANICAL CHECK

Rotate the fan blade to be sure it revolves freely and does not hit the housing. If there is interference, the motor will need to be shimmed per the instructions on page 29. Check all the fasteners on the fan to make sure they are tight. If any are loose, check for proper clearance and retighten.

c) AIR FLOW DIRECTION INSTALLATION In most applications fans are installed to force air up through the stored grain. This operating condition is referred to as a “Positive” aeration system. For this operation condition the screen guard is mounted on the end of the fan opposite the blade. The axial fans can be installed to pull air down through the stored grain. This operating condition is referred to as a “Negative” aeration system. For this operation condition the screen guard needs to be moved to the blade end of the fan housing.

d) FASTENING THE FAN TO A FLANGED

ADAPTOR On the end of the fan housing opposite the

screen guard mount the fan to the transition or aeration wall adaptor with the fasteners provided in the bolt bag. (Eight 5/16” x 3/4” capscrews and 5/16” whiz nuts are provided.)

Figure 8. Screen Guard Location.

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3. ELECTRICAL INSTALLATION OF THE FAN

A. GENERAL INSTRUCTIONS The electrical installation must be performed by a certified electrician, in accordance with the appropriate national and local electrical codes.

(CAUTION: ANY VIOLATION OF ELECTRICAL WIRING CODES COULD JEOPARDIZE THE CALDWELL STANDARD LIMITED WARRANTY.)

B. ELECTRICAL SERVICE INSTALLATION

Check the type of electrical service and make sure the fan to be wired is manufactured to operate on the electrical service. Table 3 on Page 13 titled “Fan Model Specifications” indicates the electrical service the fan is designed to utilize in the column labeled “Motor Phase & Voltage”. The electrical service must match this specification. Note that the Caldwell Three Phase 230V and 460V fans can be wired for either voltage, and if you need to convert either of these models to the other voltage refer to Page 29. The components to connect the electrical service to the fan need to be sized for the electrical service present. Tables 5, 6 and 7 located on Page 19 illustrate the sizing information for Single Phase 230 Volt, Three Phase 230 and 460 Volt, and Three Phase 575 Volt respectively. Use the appropriate table and size the following electrical service components: 1.) TRANSFORMER

The transformer size for the fan only is indicated in a KVA rating. Example: For an F18-312 Fan, Table 5 would be used. The KVA rating for the 3 horsepower motor is 4.5 KVA. This KVA rating is for the fan only. Your electrician will need to add the KVA requirements for the other electrical components of the system in sizing the transformer.

2.) FAN DISCONNECT

A disconnect for the fan needs to be sized to handle the recommended cartridge type fusetron size. Example: For an F18-312 Fan, Table 5 would be used, and the fusetron size is 30 amp. Install the fusetron recommended in the disconnect. Note that a circuit breaker can be used, however, the circuit breaker or any fuse used, must be a time delay type sized to provide the equivalent current in-rush of the fusetron fuse to allow the initial starting in-rush current to the fan.

3.) CONDUCTOR SIZE FOR THE FAN DISCONNECT TO FAN WIRING

The conductor size for the fan needs to be sized according to the distance between the fan and disconnect. Example: For an F18-312 Fan located 200’ from the disconnect, use Table 5 to determine the conductor size to be a #6 AWG. The proper sized wiring must be used to make sure a voltage drop is not developed.

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C. ELECTRICAL CONNECTION AT THE FAN

1. SINGLE PHASE When a 115 Volt accessory is to be used with the Axial Fan a 4-wire system should be provided for fans to be operated on single phase power. The four wires consist of the two current carrying conductors, a grounded neutral, and a ground. When any 115 Volt accessory equipment will not be used a 3-wire system can be used. In this case the grounded neutral wire is not required. The current carrying conductors are connected securely to terminals L1 and L2 of the contactor as illustrated in Figure 9. The contactor is located in the control enclosure. The ground wire is secured to the terminal in the control enclosure labeled “G”.

2. THREE PHASE When a 115 Volt accessory is to be used with the Axial Fan a 5 wire system should be provided for fans to be operated on three phase 230Volt power. The five wires consist of three current carrying conductors, a grounded neutral and a ground. A 4-wire system should be provided for fans to be operated on 460 Volt or 575 Volt three phase power or when any 115 Volt accessory equipment will not be used. The four wires consist of three current carrying conductors and a ground. The current carrying conductors are connected securely to terminals L1, L2, and L3 of the contactor as illustrated in Figure 10. The contactor is located in the control enclosure. The grounded neutral for 230 Volt systems is required for application of any 115 Volt accessories. The ground wire is secured to the terminal in the control enclosure labeled “G”.

Figure 9. Field Power Installation Single Phase.

Figure 10. Field Power Installation Three Phase.

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4. LEVELING OF THE FAN

A. AXIAL FAN When fastened to the transition the fan legs should be evenly supported on the concrete pad for smooth trouble free operation. If not, use shims under the fan leg, so the fan cannot generate a natural frequency to vibrate.

5. INSTALLATION OF ACCESSORIES

For the proper installation of a humidistat, gas fired heater, or humidity controller, refer to the installation instructions provided with each accessory.

6. INSTALLATION CHECK

When the fan is completely installed, the unit will need to be checked for proper rotation. Provide power to the fan controls and start the fan momentarily. Make sure that the blade rotation develops airflow in the direction that the decal on the fan housing illustrates. If the blade is rotating the wrong direction, have your electrician correct as follows:

A. SINGLE PHASE SYSTEM

With the power “LOCKED OUT AND TAGGED OUT” at the fan disconnect, the motor lead wires will need to

be exchanged and then securely connected to the outlet terminal of the contactor T1 and T2 as illustrated in Figure 11. Note that this figure illustrates the proper connection of the motor lead wires for the counterclockwise rotation of the fan blade. The location of lead wires is based on the lead wire marking for motor labeled per the NEMA standard. Refer to the motor nameplate for the specific wiring connections and which wires are interchanged to reverse rotation direction. The unit will then need to be rechecked for proper rotation.

B. THREE PHASE SYSTEM With the power “LOCKED OUT AND TAGGED OUT” at the fan disconnect, exchange the location

of the current carrying conductors at terminals L1 and L3 of the contactor as illustrated in Figure 12. The unit will then need to be rechecked for proper rotation.

Figure 11. Motor Connection for Single Phase.

Figure 12. Correcting Fan Rotation Three Phase.

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Table 4. Axial Fan Housing Dimensions.

NOTE A: On the F12 and AF12 fan, four slots are used in the angle ring for mounting located at 12:00, 3:00, 6:00, and 9:00. NOTE B: On the F14 fan, four slots are used in the angle ring for mounting located midway between the 12:00, 3:00, 6:00, and 9:00 locations. NOTE C: On the F18, AF18, F24, and F28 fans, eight slots are used in the angle ring for mounting located at 45 degree increments with the first slot at the top of the fan housing. NOTE D: The fan is placed on level concrete slab. Anchoring to the fan pad is not required.

Fan Model

"L" Fan

Length "H" Fan

Diameter "C" Bolt Circle

Bolt Size

"A" Base Location

"B" Spacing

"D" Base Length

AF12, F12 14" 14 7/8” 13 1/8” 1/4" 0” 6” 1 1/4” F14 14" 17 1/4” 15 3/8” 1/4" 0” 6” 1 1/4”

AF18, F18 18" 21 3/4” 19 3/4” 5/16" 3 5/8” 14 1/4” 8” F24 24" 27 1/2” 25 7/8” 5/16" 9 1/2” 18 1/2” 8” F28 24" 31 7/8” 30” 5/16" 4 3/4” 21 3/8” 10”

Figure 13. End and Side View of Axial Housing.

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TABLE 5. Electrical Service For Single Phase Operation 230 Volt

COPPER WIRE SIZE DISTANCE MOTOR TO DISCONNECT IN FT. UP TO MOTOR H.P.

TRANSFORMER SIZE (NOTE B)

(MINIMUM) 0'-50' 100' 200' 300'

CARTRIDGE TYPE FUSETRON OR EQUIVALENT

TIME DELAY FUSE AMP

1.5 2.5 KVA 14 12 10 8 15 3 4.5 KVA 12 10 6 5 30 5 8.5 KVA 8 6 4 3 50

7.5 10.0 KVA 6 6 3 1 60 10 13.0 KVA 6 4 2 1/0 70

12.5 16.0 KVA 4 2 00 000 80

TABLE 6. Electrical Service for Three Phase Operation 230/460 Volt

COPPER WIRE SIZE DISTANCE MOTOR TO DISCONNECT IN FT. UP TO

CARTRIDGE TYPE

FUSETRON OR EQUIVALENT TIME DELAY FUSE AMP

0'-50' 100' 200' 300'

MOTOR H.P.

TRANSFORMER SIZE (NOTE B)

(MINIMUM)

230 460 230 460 230 460 230 460 230 460

1.5 2.5 KVA 14 14 14 14 12 14 10 12 10 5 3 4.5 KVA 14 14 12 14 10 12 8 10 15 8 5 8.5 KVA 12 14 10 12 6 10 4 8 30 15

7.5 10.0 KVA 10 14 8 12 6 8 4 6 40 20 10 13.0 KVA 10 12 8 10 4 8 2 6 50 25

12.5 16.0 KVA 48 12 6 10 2 6 1 4 60 30

TABLE 7. Electrical Service for Three Phase Operation 575 Volt

COPPER WIRE SIZE DISTANCE MOTOR TO DISCONNECT IN FT. UP TO

MOTOR H.P. TRANSFORMER SIZE (NOTE B)

(MINIMUM) 0'-50' 100' 200' 300'

CARTRIDGE TYPE FUSETRON

OR EQUIVALENT TIME DELAY FUSE AMP

1.5 2.5 KVA 14 14 14 14 4 3 4.5 KVA 14 14 12 12 8 5 8.5 KVA 14 12 10 8 10

7.5 10.0 KVA 14 12 8 8 15 10 13.0 KVA 12 12 8 6 20

12.5 16.0 KVA 12 10 6 4 25

NOTE A: Always check current local, state, and national codes on electrical requirements before installing any electrical equipment.

NOTE B: Transformer size is based on current draw from the fan only. Your electrician

will need to add the KVA requirements for other components of the system in sizing the transformer.

NOTE C: Copper wire (rated 75°C) is sized for the fan service. The wire size from the transformer to the disconnect service will be determined from the fan and the other electrical equipment requirements.

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OPERATING INSTRUCTIONS

1. PRELIMINARY TO STARTING THE FAN

When the fan is to be started for the first time, or after the fan has been idle for months, the following checks should be made prior to starting the fan.

A. FAN BLADE

With the power locked out and tagged out at the disconnect switch, rotate the fan blade to make sure it revolves easily and does not rub on the housing.

B. FASTENERS Check all the fasteners to make sure they are tight. If any are loose, check for proper clearance and retighten fasteners. Make sure the screen guard is fastened securely.

C. ELECTRICAL With power locked out and tagged out at the disconnect switch, check all electrical connections to make sure they are tight. Inspect the current carrying wires to make sure they are not grounded. Make sure the control enclosure cover is secured in place.

D. WIRING Refer to the wiring diagram on Pages 23 through 28 and make sure the fan is wired correctly.

2. STARTING THE FAN

IMPORTANT INFORMATION

The single phase axial fans listed in the chart below use a permanent-split phase capacitor start motor. The start switch and start capacitors have been eliminated for trouble free operation. The permanent-split phase capacitor start motor is referred has a “slow start” motor because it comes up to speed much slower than a capacitor start single phase motor. When the fan is started, allow the motor time to accelerate to full speed without turning the power off according to the table below.

WARNING: DO NOT CONTINUE SHORT MULTIPLE STARTS AS OVERHEATING OF THE MOTOR COULD RESULT.

Fan Model Time to Start F12-751 5 Seconds F14-11 8 Seconds F18-112 8 Seconds F18-312 8 Seconds F24-512 8 Seconds F24-712 10 Seconds F24-1012 10 Seconds F28-1212 16 Seconds

Table 8. Normal Time for Switchless Motor to Reach Full Speed for 230 Volt Power Supply

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A. STARTING AXIAL FAN

1. 230/460 VOLT FAN On 230 Volt and 460 Volt units, the fan is started by moving the toggle from the “OFF” position through the “RUN” position up to the “START” position. When the fan begins to start the switch should be released. The switch is designed to return to the “RUN” position. In this position the fan will continue to operate until the toggle is moved from the “RUN” to the “OFF” position, or unit the internal motor thermal protection interrupts the power by opening the circuit. With the motor thermal protection in the open position the fan cannot be started by moving the toggle into the “START” position. When the motor thermal protector closes, the fan will not restart by itself, the toggle will need to be moved to the “START” position to start the unit again. Note that if the motor thermal protector opens to shut off the fan refer to the Service Section for determining the cause of the thermal protector opening.

2. 575 VOLT FAN On 575 Volt units, the fan is started by pushing in the switch button marked “START”. When the fan begins to start the button should be released. The fan will continue to operate until the “STOP” button is pushed in, or until the internal motor thermal protection interrupts the power by opening the circuit. With the motor thermal protection in the open position the fan cannot be started by pushing the “START” button in. When the motor thermal protector closes, the fan will not restart by itself, the “START” button will need to be pushed in to start the unit again. Note that if the motor thermal protector opens to shut off the fan refer to the Service Section for determining the cause of the thermal protector opening.

3. SHUTTING THE FAN OFF

When shutting the fan down for the season, shut off the power at the fan disconnect rather than at the fan controls to provide additional protection from unauthorized personnel operating the fan, and potential damage to the fan from a lightning strike. Refer to the Maintenance Section for off season operation recommendations.

Figure 14. Toggle Switch.

Figure 15. Push Button Switch.

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MAINTENANCE

1. FAN OPERATION IN OFF SEASON

During the off season, the fan blade should be allowed to turn freely. Also, during the off season, OPERATE THE FAN FOR APPROXIMATELY 30 MINUTES EVERY THREE WEEKS. The operation of the fan keeps the lubricant more evenly distributed within the bearing cavity and dries out any condensation that could be in the motor.

2. FAN CONTROL MAINTENANCE

During the off season, make sure the control enclosure cover is secured to the control enclosure. Before operating, the magnetic contactor should be inspected to make sure all contact points are clean and unobstructed. Also, check points for pitting and replace the magnetic contactor if the points are defective.

3. FAN MOTOR LUBRICATION

The life of a motor is very dependent on the life of the bearings. Before lubricating the bearings, inspect the bearings to make sure they are still in good condition. If not, the bearings will need to be replaced. The fan motor uses sealed bearings, however, the bearing cavity should still be lubricated. The motor should be lubricated once a year prior to the operating season per the following instructions.

A. AXIAL FAN

1. To lubricate a motor with filler and drain holes, remove both plugs and clean the

holes of any hardened lubricants. Approximately three standard pumps of Shell Dolium R or Chevron SRI-2 lubricant should be added. Allow the motor to run for approximately 10 minutes before reinstalling the drain plug.

2. To lubricate a motor without filler and drain holes, first clean out any hardened

grease, and then add the Shell Dolium R or Chevron SRI-2 lubricant to fill ¾ of the cavity of the end bell.

CAUTION: The lubricants listed above are designed to operate at high temperature and have a rust inhibitor for extended bearing life. DO NOT MIX OTHER GREASES WITH THE GREASE IN THE BEARINGS. DO NOT OVERLUBRICATE THE BEARINGS AS THE LUBRICANT WILL WORK ITS WAY INTO THE MOTOR AND CAUSE PREMATURE MOTOR FAILURE.

4. FAN BLADE CLEANLINESS

Either once a year, or if vibration develops, clean the fan blade so the unit runs smoothly. Also check the fan to make sure it is mounted properly. Refer to the installation instructions on Page 17 for instructions on leveling the fan.

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Figure 16. Wiring Schematic for AF12-751 Fan.

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Figure 17. Wiring Schematic for AF18-11 Fan.

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Figure 18. Wiring Schematic for 230 Volt Single Phase Axial Fan.

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Figure 19. Wiring Schematic for 230 Volt Three Phase Axial Fan.

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START/STOP SWITCH

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FAN SERVICE

1. GENERAL INFORMATION WHEN SERVICING FAN

A. MOTOR AUTHORIZED SERVICE CENTERS A Web site of authorized service centers for the motor on your fan has been provided with this manual. The authorized service center can perform all inspections for warranty claims and correct any motor problems. Refer to the bulletin provided and select the authorized service center closest to your location. (Web site information was placed with this manual at the time of shipment.)

B. POSITIONING OF FAN BLADE IN FAN HOUSING

If, in servicing the fan, you determine that the fan blade will need to be removed from the motor shaft, refer to the following instructions to make sure the reassembled fan will perform properly.

1. AXIAL FAN

a. When reassembling the fan blade onto the motor shaft make sure the blade is centered in the fan housing. Shim motor to center the fan blade if required.

b. Start the securing of the bolts in the tapered bushing to the blade by

tightening the bolts gradually by continually working in a circle turning each fastener slightly. Finally, torque the bolts securing the tapered bushing for the F12 and F14 fan to 60 in.-lb.; the F18-1 fan to 80 in.-lb.; and the F18-3, F24, and F28 fans to 100 in.-lb.

2. CONVERTING THREE PHASE DUAL VOLTAGE

FANS

A. CONVERTING FROM A FAN WIRED FOR 230 VOLT TO A FAN WIRED FOR 460 VOLT When an Axial Fan is wired for 230 Volt, but because the electrical service available is 460 Volt, the fan can be converted to 460 Volt as follows: 1. MAKE SURE TO LOCK OUT AND TAG OUT

THE POWER TO FAN SO NO POWER IS PRESENT WHEN REWIRING.

2. Disconnect the motor leads attached to the

contactor terminals T1, T2 and T3. Break the connection of the motor leads 4, 5 and 6 so that each motor lead is separate. Refer to the 230 Volt illustration in Figure 22.

3. Remove the contactor from the control enclosure

disconnecting the wires connecting the contactor to the toggle switch and to the motor thermal protector.

4. Disassemble the contactor as illustrated in

Figure 25 on Page 36.

Figure 22. Conversion 230/460 Volt.

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5. The holding coil will need to be replaced. Order holding coil #164064 (Furnas Siemens), for all axial fans.

6. When you have obtained the 460 Volt Holding Coil, reassemble the contactor as

illustrated in Figure 25 on Page 36.

7. The contactor is then reinstalled into the control enclosure, and the toggle switch wires and the motor thermal protection are wired per Figure 20 on Page 27.

8. Connect the motor leads to the output terminal of the contactor per the illustration in

Figure 23. Note that the motor lead wire pairs (4 and 7), (5 and 8), (6 and 9) are secured together using a wire nut.

9. Refer to the Electrical Service Installation Instructions on Page 15 for sizing the

electrical service on 460 Volt Three Phase operations.

B. CONVERTING FROM A FAN WIRED FOR 460 VOLT TO A FAN WIRED FOR 230 VOLT When an Axial Fan is wired for 460 Volt, but because the electrical service available is 230 Volt, the fan can be converted to 230 Volt as follows: 1. MAKE SURE TO LOCK OUT AND TAG OUT

THE POWER TO FAN SO NO POWER IS PRESENT WHEN REWIRING.

2. Disconnect the motor leads attached to the

contactor terminals T1, T2 and T3. Break each of the paired motor lead connections (4 and 7), (5 and 8), and (6 and 9), so that each motor lead is separate. Refer to the 460 Volt illustration in Figure 23.

3. Remove the contactor from the control enclosure

disconnecting the contactor to the toggle switch and to the motor thermal protector.

4. The holding coil or complete contactor will need

to be replaced. Refer to Table 11 on Page 35, and order the 230 Volt Holding Coil or contactor indicated for the fan model being converted.

5. If coil needs to be replaced. Disassemble the

contactor as illustrated in Figure 25 on Page 36.

6. If the holding coil is being replaced, reassemble

the contactor once you have obtained the holding coil as illustrated in Figure 25 on Page 36.

Figure 23. Conversion 460/230 Volt.

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7. The contactor for the 460 volt control is then reinstalled into the control enclosure, and the toggle switch wires and the motor thermal protections wired per Figure 19 on Page 26.

8. Connect the motor leads to the output terminal of the contactor per the illustration in

Figure 23. Note that the motor lead wires 4, 5 and 6 are secured together with a wire nut.

9. Refer to the Electrical Service Installation Instructions on Page 15 for sizing the

electrical service on 230 Volt Three Phase Operation.

3. TROUBLESHOOTING

When servicing the fan, lock out and tag out the power at the fan disconnect switch. Activate power only when a check is made. The following items will help you pinpoint a possible malfunction of the fan unit and explain the corrective action to take.

WARNING: BE CAREFUL WHEN WORKING WITH ELECTRICITY. USE A VOLTMETER TO MAKE THE NECESSARY CHECK.

The slow start switchless motor used on a single phase fan has a slower, smoother acceleration than a capacitor start motor. Refer to the starting the Fan on Page 20 for information on starting a single phase fan with a slow start switchless motor. Refer to the appropriate diagram on Pages 23 through 28 for the electrical schematic of the controls.

A. SYMPTOM: Turn on toggle switch and nothing happens.

1. Make sure the power is available to the fan unit. 2. Check the overload protection to determine if the control circuit is open or

closed. If the thermostat is open, make sure the overload device has had a chance to cool, if the fan recently shut off. The overload circuit will automatically close when the unit is cooled. If not, the thermostat will need to be replaced in the motor.

a. The thermostat wires (J wires) can be traced from the motor to terminal L1 and the toggle switch.

3. Check the toggle switch. (If switch is defective, replace.)

a. The toggle switch circuit should be checked in the “OFF”, “RUN”, and “START” positions. The top left side and top right side of the toggle switch should be metered to the bottom of the toggle switch and determined if the circuit is open or closed. i. In the “OFF” position, both side should be open. ii. In the “RUN” position, the left side should be closed and the

right side should be open. iii. With the toggle switch held in the “START” position, both

sides should be closed.

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4. Check holding coil. (If coil is defective, replace)

a. Make sure there is power from L2 on the contactor to the holding coil.

b. Make sure there is power going from L1 through the motor

thermostat wires and the toggle switch. If power is available at the coil, the coil is defective.

5. Check to be sure that the contact set is not restricted from closing.

B. SYMPTOM: The fan just hums when turned on.

1. Check to make sure that all leads of your power source have voltage present. If fan unit is not receiving power on all leads, check for a blown fuse, broken wire, or loose connection.

2. Check to see that all contact sets are closing. If one leg of the supply

voltage is not available to the motor, the motor will hum. a. Remove the front cover from the contactor, turn the fan unit on

and watch to see that all contacts close. If all contacts do not close, clean or replace contactor.

3. If power is available at all the motor leads and the motor still hums, then

the motor should be taken to an authorized Service Center for repair or replacement.

a. The power can be hooked directly to the motor leads (for testing), if the motor hums, replace or repair the motor.

C. SYMPTOM: Fan operates when the toggle switch is held in the

“START” position but shuts off when the toggle switch is in the “RUN” position.

1. Check toggle switch as referenced in Symptom A, Number 2. 2. Check the auxiliary switch; locate on the side of the contactor. (If

defective, replace auxiliary switch. Refer to Figure 25 on Page 36 to determine the part required for your fan model.)

a. With the power supply OFF remove the front plate from the contactor the auxiliary switch should be open. Switch should close when the contact sets are pushed in. Circuit is checked by measuring the resistance across the auxiliary switch.

D. SYMPTOM: The Fan only comes up to ½ speed.

1. Take the motor to an Authorized Service Center for repair or replacement.

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E. SYMPTOM: The fan starts and operates for a while and then shuts off.

1. Check the supply voltage. Voltage should be within 10% of rated voltage. For example, a motor rated at 230 Volt should operate in a voltage range of 207 to 253 Volts.

2. Check the supply wire sizes required for the fan unit, Page 19.

3. Check the load on the main circuit to make sure other items on the main

circuit are not overloading the fan circuit. 4. Check the amperage of the fan, if the unit is pulling above nameplate

amperage; take the motor to an Authorized Service Center.

F. SYMPTOM: Fan operates when main power supply is turned on.

1. The top two terminals of the toggle switch should be checked. If the circuit is closed between the two terminals, the toggle switch should be replaced.

2. Check the contact points by removing the front from the contactor to see

if the contacts are locked in or welded in place. If so, the complete contactor should be replaced.

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TABLE 9. Housing, Screen Guard, Control Enclosure Replacement Parts.

FAN ENCLOSURE HOUSING SCREEN GUARD AF12-751 768002 112571 777490 AF18-11 768002 102509 777508

F12 - 112571 777490 F14 - 747303 747519 F18 700968 102509 777508 F24 700984 112580 777516 F28 700984 112600 777524

Figure 24. Axial Fan Parts Disassembled.

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TABLE 10. Motor, Blade Replacement parts. FAN MOTOR BLADE ASSEMBLY

AF12-.751 732404 741355

AF18-11 732420 741371

F12-.751 732404 741355

F12-.753 852152 741355

F14-111 732412 741363

F14-13 748020 741363

F18-112 732420 741371

F18-132 852186 741371

F18-134 852186 741371

F18-135 765073 741371

F18-312 732438 741389

F18-332 852210 741389

F18-334 852210 741389

F18-335 747907 741389

F24-512 774992 741397

F24-532 775007 741397

F24-534 775007 741397

F24-535 765958 741397

F24-712 775015 741405

F24-732 775023 741405

F24-734 775023 741405

F24-735 765917 741405

F24-1012 764282 741413

F24-1032 764761 741413

F24-1034 764761 741413

F24-1035 764894 741413

F28-1212 775056 741421

F28-1232 775064 741421

F28-1234 775064 741421

F28-1235 763128 741421

TABLE 11. Contactor or Holding Coil for Converting of 460Volt Three Phase Fan to 230Volt Three Phase Fan.

Fan Holding Coil Change to 230 Volt Contactor Change to 230 Volt

F18-134 164048 N/A F18-334 164048 N/A F24-534 N/A 850305

F24-734 N/A 850305 F24-1034 N/A 850305 F28-1234 N/A 754028

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TABLE 12. Control Enclosure Parts (Furnas/Siemens Parts) FAN ENCLOSURE

CONTACTOR PLATE

POWER SWITCH

CONTACTOR/AMP AUXILIARY

SWITCH HOLDING

COIL F18-112 700968 700828 710707 850289 25 165307 164048 F18-132 850297 25 164048 F18-134 420984 25 164064 F18-135 710988 170018 25 164072 F18-312 710707 850289 25 164048 F18-332 850297 25 164048 F18-334 420984 25 164064 F18-335 710988 170018 25 164072 F24-512 700984 700810 710707 850313 40 164048 F24-532 850305 30 164048 F24-534 420984 25 164064 F24-535 710988 170018 25 164072 F24-712 710707 850347 50 164048 F24-732 850305 30 164048 F24-734 420894 25 164064 F24-735 710988 170018 25 164072

F24-1012 710707 850354 60 164048 F24-1032 850305 30 164048

F24-1034 420984 25 164064

F24-1035 710988 170018 25 164072 F28-1212 710707 850362 75 165315 452136 F28-1232 754028 50 165307 164048 F28-1234 420984 25 164064 F28-1235 710988 170018 25 164072

Figure 25. Control Enclosure Disassembled.

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PRODUCT SERVICE: Our top priority is to assure customer satisfaction on all Caldwell products. If a dealer requires assistance from Caldwell, contact our Service Department. The dealer purchasing a product from Caldwell will be responsible for the installation, operation, and service in accordance with Caldwell Service Policy. The dealer will also be responsible for all Standard Limited Warranty procedures in accordance with Caldwell Service Policy.

SERVICE POLICY CALDWELL STANDARD LIMITED WARRANTY: DEALERS HAVE THE RESPONSIBILITY OF CALLING TO THE ATTENTION OF THEIR CUSTOMERS THE FOLLOWING LIMITED WARRANTY, PRIOR TO ACCEPTANCE OF AN ORDER FROM THE CUSTOMER FOR ANY CALDWELL PRODUCTS. THE STANDARD LIMITED WARRANTY POLICY CAN BE FOUND ON OUR INTERNET WEB SITE (www.agr.chiefind.com). THE BASIC WARRANTY IS DETAILED HERE. Caldwell warrants to the purchaser for use that if any part of the product is proven to be defective in material or workmanship with 2 years from date of original invoice from factory, and Caldwell is notified within 15 days after such defect is discovered, Caldwell, will (at company option) either replace or repair said part. This standard limited warranty does not apply to damage resulting from misuse, neglect, material wear, accident or improper installation or maintenance. Said part will not be considered defective if it substantially fulfills performance specifications. THE FOREGOING LIMITED WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OF MERCHANTABILITY, FITNESS FOR PURPOSE AND OF ANY OTHER TYPE, WHETHER EXPRESSED OR IMPLIED. Caldwell neither assumes nor authorizes anyone to assume for it any other obligation or liability in connection with said part and will not be liable for incidental or consequential damages. THE REMEDIES STATED HEREIN SHALL BE THE EXCLUSIVE REMEDIES AVAILABLE UNDER THIS STANDARD LIMITED WARRANTY. CLAIMS UNDER THIS STANDARD LIMITED WARRANTY SHALL BE HANDLED UNDER THE STANDARD SERVICE POLICY. Caldwell will not be responsible for any charges incurred in repairing or servicing any Caldwell products except as such repairs are made at Caldwell or by Caldwell Field Service Personnel or as approved in writing from Caldwell Customer Service. IN WARRANTY REPLACEMENT: The Caldwell Standard Limited Warranty Policy will cover any defective part of the product covered by the Standard Limited Warranty. Equipment involved in a warranty claim under the above Standard Limited Warranty shall have the ORIGINAL WARRANTY REGISTRATIOIN CARD on file in Kearney, Nebraska, and have been properly installed, maintained and operated according to the instructions provided by Caldwell. WARRANTY CLAIM PROCEDURES: When a part failure occurs, that in your judgment meets the conditions of the above Standard Limited Warranty; contact your dealer to make arrangements for the shipment of a replacement item and the return of the defective equipment. ELECTRIC MOTOR WARRANTY: The Manufacturers of all electric motors used by Caldwell carry a warranty for these items. If the motor fails under the conditions of the Caldwell Standard Limited Warranty Policy, and provided it was protected by the proper protective device, the motor manufacturer's nearest authorized service center will repair it. See catalog for motor manufacturers’ service centers. Any in warranty replacement motors not satisfactorily handled by motor manufacturer service centers and within the Standard Limited Warranty period and policy will be covered by Caldwell, Kearney, Nebraska. Contact Caldwell if you have any problems or questions. OUT OF WARRANTY SERVICE: Products requiring Caldwell repair work will be repaired at the standard repair charge plus hourly charges after the first hour. Field service work will require a field service charge plus travel expenses. The repaired part will carry a 30 day limited warranty. Your dealer will be responsible for warranty procedures in accordance with the Caldwell Service Policy. (See Dealer Policy.)

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NOTES:

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