General Installation Guide 2-11-10 (Sales)_opt

8 - 24 POWERFOILPLUS, POWERFOIL, & WICKERBILL FANS

WWW.BIGASSFANS.COM 2010 DELTA T CORP. DBA BIG ASS FAN ALL RIGHTS RESERVED

Installation ChecklistDid a structural engineer approve the mounting structure? (See p. 11 for Big Ass Fans approved mounting structures.)

Do you have the correct safety cable? Are you familiar with its use? (See p. 19 for information on properly securing the safety cable.)

Will the fan be installed so that the blades are at least 10 ft (3.05 m) above the floor?

Will the fan be installed so that the blades have at least 2 ft (0.61 m) of clearance from obstructions?

Will the fan be installed so that it is not subjected to high winds (such as from an HVAC system or near a large garage door)? (The distance between the fan and the HVAC equipment (or other air-moving equipment) should be no less than 2x the fans diameter when measured from the center of the fan to the equipment.)

Will the distance between multiple fans be at least 2.5x the fans diameter when measured from the centers of the fans.

If installing to an I-beam, is the upper yoke the correct size? (See p. 11 for more information on installing the fan on an I-beam.)

If you ordered multiple fans, did you keep the parts for each fan together?

Some motors have the factory label, This Unit Factory Wired for 460 VAC. If you have a 200-250V or 100-125V controller, did you rewire the motor for proper use? (See wiring diagrams on pp. 54-55 for additional information.)

Do you have the correct power circuit for the fan controller? (See p. 28 for information on selecting the correct circuit/fuse for the fan controller.)

Customer Service: 1-877-BIG-FANS(International: 1-859-233-1271)

iWWW.BIGASSFANS.COM 2010 DELTA T CORP. DBA BIG ASS FAN ALL RIGHTS RESERVED


Installation Guide8 - 24 PowerfoilPlus, Powerfoil,

& Wickerbill Fans

2425 Merchant StreetLexington, KY 405111-877-BIG-FANSwww.bigassfans.com

May be covered by one or more of the following United States Patents: 6,244,821;

6,589,016; 6,817,835; 6,939,108; 7,252,478; 7,284,960; D607,988; and other patents pending

Installation Guide:110210- Feb. 2010

The C-UL-US mark from Underwriters Laboratory applies only to Big Ass Fans electrical control panels.

This product was manufactured in a plant whose Management System is certified as being in conformity with ISO 9001:2000.

3128438Conforms to ANSI/UL STD 507Certified to CAN/CSA C22.2 No.113

See p. 71.



IMPORTANT SAFETY INSTRUCTIONSREAD AND SAVE THESE INSTRUCTIONS

WARNINGTO REDUCE THE RISK OF FIRE, ELECTRIC SHOCK, OR INJURY TO PERSONS, OBSERVE THE FOLLOWING:a) Installation work and electrical wiring must be done by qualified person(s) in accordance with all applicable codes and

standards.b) When cutting or drilling into wall or ceiling, do not damage electrical wiring and other hidden utilities.

CAUTION: The installation of a Big Ass Fan must be in accordance with the requirements specified in this installation manual and with any additional requirements set forth by the national electric code (NEC), ANSI/NFPA 70-1999, and all local codes. Code compliance is ultimately YOUR responsibility!

WARNING: The fan controllers contain high voltage capacitors which take time to discharge after removal of mains supply. Before working on the fan controller, ensure isolation of mains supply from line inputs at the fan controllers disconnect (L1, L2/N, L3). Wait 3 minutes for capacitors to discharge to safe voltage levels (note: darkened display LEDs are not an indication of safe voltage levels). Failure to do so may result in personal injury or death.

CAUTION: Exercise caution and common sense when powering the fan. Do not connect the fan to a damaged or hazardous power source. Do not attempt to resolve electrical malfunctions or failures on your own. Contact Big Ass Fans at 1-877-BIG-FANS if you have any questions regarding the electrical installation of this fan.

Suitable for use with solid-state speed controls.

WARNINGTo reduce the risk of fire, electric shock, and injury to persons, Big Ass Fans must be installed with Big Ass Fan supplied controllers that are marked (on their cartons) to indicate the suitability with this model. Other parts cannot be substituted.

CAUTION: When service or replacement of a component in the fan requires the removal or disconnection of a safety device, the safety device is to be reinstalled or remounted as previously installed.

WARNING: Risk of fire, electric shock, or injury to persons during cleaning and user-maintenance! Disconnect the appliance from the power supply before servicing.

WARNINGTO REDUCE THE RISK OF FIRE, ELECTRIC SHOCK, OR INJURY TO PERSONS, OBSERVE THE FOLLOWING:a) Use this unit only in the manner intended by the manufacturer. If you have questions, contact the manufacturer.b) Before servicing or cleaning unit, switch power off at service panel and lock the service disconnecting means to prevent

power from being switched on accidentally. When the service disconnecting means cannot be locked, securely fasten a prominent warning device, such as a tag, to the service panel.

CAUTION: Do not bend the blades when installing, adjusting, or cleaning the fan. Do not insert foreign objects in between rotating fan blades.

WARNING: Stay alert, watch what you are doing, and use common sense when installing fans. Do not install fans if tired or under the influence of drugs, alcohol, or medication. A moment of inattention while installing fans may result in serious personal injury.

CAUTION: The installation of this fan requires the use of some power tools. Follow the safety procedures found in the owners manual for each of these tools and do not use them for purposes other than those intended by the manufacturer.

CAUTION: The Big Ass Fans product warranty will not cover equipment damage or failure that is caused by improper installation.



ContentsIntroduction Thank You 1

About Big Ass Fans 1About this Fan 2Whats in the Box 3

Pre-Installation Parts Included 4Tools Needed 5Important Weights 5Recommended Torque 5Fan Diagram 6Allen-Bradley Controller Diagram (Optional) 7Preparing the Work Site 8Understanding Airflow Patterns 9

Mounting Method 1: I-Beam

1. Attach Upper Yoke (to I-Beam) 11

Mounting Method 2: Angle Irons

1. Select Proper Angle Irons 122. Pre-drill Angle Irons 133. Fasten Angle Irons Together (if span is longer than 8) 134a. Fasten Single Angle Irons to Roof Structure Mounting Points 144b. Fasten Double Angle Irons to Roof Structure Mounting Points 155a. Attach Upper Yoke (to Angle Irons) 165b. Attach Motor Frame (to Angle Irons) 17

Hanging The Fan 1. Attach Extension Tube (to Upper Yoke) 182. Secure Safety Cable 193. Attach Lower Yoke (to Extension Tube) 204. Attach Motor Frame (to Lower Yoke) 20

Installing Guy Wires 1. Attach Eyebolt to Motor Frame 212. Attach Beam Clamp 213. Route Guy Wire Through Gripple 224. Install Three Remaining Guy Wires 22

Replacing Oil Plug Replace Oil Plug on Bonfiglioli Motors 23Replace Oil Plug on Bonfiglioli Motors (24 ft Fans) 24Replace Allen Head Plug on Baldor Motors 25

Installing Airfoils 1. Attach Winglets (Powerfoil, PowerfoilPlus) 262. Attach Airfoils to Hub 26

Electrical Installation Electrical Installation Safety 27Electrical Installation Overview 27Power Requirements for Big Ass Fan Controllers 28Controller Dimensions 29Mounting Controller 30Controller Storage 30Input Power Conditioning 30Power Wiring Guidelines 31Conduit/Piping Guidelines 32Installation Techniques: Single Fan Controls 33Installation Techniques: Multiple Fan Controls 34Grounding 35Standard Grounding for Powerflex 4 Controller 36Standard Grounding for Powerflex 4M Controller 37Shielded Motor Cable Grounding for Powerflex 4 Controller 38Shielded Motor Cable Grounding for Powerflex 4M Controller 39Multi-Fan Grounding for Powerflex 4 Controller 40



Electrical Installation RFI/EMI Grounding for Powerflex 4 Controller 41RFI/EMI Grounding for Powerflex 4M Controller 42Ungrounded Distribution Systems 43Wiring: KBDA Controller (200-250V Single Phase) 44Wiring: KBDA (200-250V & 400-480V 3 Phase) 45Wiring: Powerflex 4 Controller (100-125V Single Phase) 46Wiring: Powerflex 4 Controller (200-250V Single Phase) 47Wiring: Powerflex 4 Controller (200-250V 3 Phase) & (400-480V 3 Phase) 48Wiring: Powerflex 4 Controller (575-600V 3 Phase) 49Wiring the Motor: Bonfiglioli Motor (100-125 & 200-250 Volts) 50Wiring the Motor: Bonfiglioli Motor (400-480 Volts) 50Wiring the Motor: Reliance/Baldor Motor (400-480 Volts) 51Wiring the Motor: Reliance/Baldor Motor (200-250 Volts) 51Start-up Procedures For KBDA Controllers 52Short (75 ft (22.9)) Motor Lead Adjustment 53Start-up Procedures For Allen-Bradley Controllers 55Start-up Procedures For Multi-Fan Controllers 56

Additional Input Power Considerations

Input Voltage Irregularities 58Delta Secondary 58Branch Circuit Protection 59KBDA Controller Specifications and Environmental Ratings 60Allen-Bradley Controller Specifications and Environmental Ratings 61Baldor or Reliance - 3 Lead, Single Voltage Wye for 600V Installations 62NORD - 3 Lead, Single Voltage Wye for 600V Installations 62

Operating the Fan Heating Season 63Cooling Season 63

User Servicing Annual Preventive Maintenance 65

Troubleshooting General Troubleshooting 66Troubleshooting KBDA Controllers 67Troubleshooting Allen-Bradley Controllers 68

CE Compliant Instructions CE Compliant Instructions 71Declaration of Conformity 72Fan Mounting Height Requirements 73Fan Airborne Noise Emissions 73Electrical Installation 73CE Compliant Grounding for Powerflex 4 Controller 74CE Compliant Grounding for Powerflex 4M Controller 75

Warranty Big Ass Fans Warranty Policy 77Warranty Claim Form Instructions 79Acknowledgment & Return Instructions 80Warranty Claim Form 81Responsibility Agreement 82

Annual Maintenance Checklist

Annual Maintenance Checklist 83

Big Ass Fan Certified Installers

Check-In Procedure 85Close-Out Procedure 86

1WWW.BIGASSFAN.COM 2010 DELTA T CORP. DBA BIG ASS FAN ALL RIGHTS RESERVED


IntroductionThank YouThank you and congratulations on your Big Ass Fan purchase! You now have an efficient and cost-effective way to stay cool in the summer and warm in the winter. The sleek revolutionary design of our fans will look great in any commercial or industrial setting. More importantly, you can rest assured that you have a product that is backed by extensive research, thorough testing, and quality manufacturing.

If you have any questions or comments, contact us at 1-877-BIG-FANS or visit our web site at www.BigAssFan.com.

Who We Are and What We DoFOUNDED IN 1999, Lexington, KY-based Big Ass Fan Company is the preeminent designer and manufacturer of high volume/low speed (HVLS) ceiling and vertical fans designed to improve facility and worker comfort in large commercial, industrial, agricultural, and institutional buildings worldwide.


WWW.BIGASSFAN.COM 2010 DELTA T CORP. DBA BIG ASS FAN ALL RIGHTS RESERVED

2



About this FanThe specifications of the fan depend on the size and model. The table below lists the specifications for the Powerfoil model.

Specifications (Powerfoil)Fan Size Motor Max Amp

Speed (At 60hz)

Air Displacement(At Max Speed)

Airfoil Length Weight

1 Suggested Distance From Ceiling2

8 (2.4 m)

1 HP, 1750 RPM, 208/230/460V

3.8@208V, 3.4@230V, 1.7@460V 112 RPM

39,015 cfm (18,413 L/S)

40 (102 cm)

170 lbs (77 kg) 3 (0.61 m)

10 (3 m)

1 HP, 1750 RPM, 208/230/460V

3.8@208V, 3.4@230V, 1.7@460V 103 RPM

74,122 cfm (34,982 L/S)

52 (132 cm)

183 lbs (83 kg) 3 (0.61 m)

12 (3.6 m)

1 HP, 1750 RPM, 208/230/460V

3.8@208V, 3.4@230V, 1.7@460V 81 RPM

101,579 cfm (47,940 L/S)

64 (163 cm)

200 lbs (91 kg) 3 (0.61 m)

14 (4.3 m)

1.5 HP, 1725 RPM, 208/230/460V

5.3@208V, 5.0@230V, 2.5@460V 71 RPM

113,829 cfm(53,721 L/S)

76 (193 cm)

220 lbs (100 kg) 4 (0.91 m)

16 (4.9 m)

1.5 HP, 1725 RPM,208/230/460V

5.3@208V, 5.0@230V, 2.5@460V 63 RPM

147,569 cfm (69,645 L/S)

88 (224 cm)

239 lbs (108 kg) 4 (0.91 m)

18 (5.5 m)

1.5 HP, 1725 RPM,208/230/460V

5.3@208V, 5.0@230V, 2.5@460V 55 RPM

178,568 cfm (84,275 L/S)

100 (254 cm)

256 lbs (116 kgs) 4 (0.91 m)

20 (6.1 m)

1.5 HP, 1725 RPM,208/230/460V

5.3@208V, 5.0@230V, 2.5@460V 47 RPM

223,572 cfm (105,515 L/S)

112 (284 cm)

290 lbs (132 kg) 5 (1.22 m)

24 (7.3 m)

2 HP, 1725 RPM, 208/230/460V

6.3@208V, 5.8@230V, 2.9@460V 42 RPM

337,774 cfm (159,412 L/S)

136 (345 cm)

328 lbs (149 kg) 5 (1.22 m)

1. Weight includes weight of Powerfoil airfoils and motor hub, and does not include the weight of any extension tubes, mounting yokes, other customized mounting hardware, or other airfoil styles. For more information, see Important Weights on p. 5.

2. Add additional 2 ft for PowerfoilPlus fans.

Motor 1 to 2 HP motor NEMA Design B 208/230/460 Volts AC 1725 RPM 60Hz, 3 Phase Insulation: Class F Rating: 40 C Ambient-Continuous

Reduction Gear Concentric Helical Gear Reducer Gear Hardened to 58-62 Rockwell C Precision finished for low noise and long service life Double seals keep oil in and contaminant out Lubricated for life with synthetic oil



3



(10) Airfoils

Airfoil Box

Whats in the BoxThe fan is shipped in multiple boxes. The larger box contains the motor/hub assembly, upper yoke (with beam clips and spacers), lower yoke, extension tube (if less than 4 in length) with attached safety cable, winglets (Powerfoil or PowerfoilPlus models only), control panel, and mounting hardware. The smaller box contains the airfoils. If the extension tube is over 3, it will also be shipped in a separate box.

CAUTION: If you ordered multiple fans, be sure to keep the components of each fan together. The fans each have differently rated components that are not interchangeable.

NOTE: Dashed lines indicate internal boxes. Drawings below are not to scale.

(2) Lower Yoke(2) Beam Clip &

(2) Spacer Upper Yoke (10) Winglet2

Extension Tube3 & Safety Cable4

Main Box

Controller5Motor & Hub

1. Airfoil retainers packed in bag with Installation Guide; winglet hardware packed in winglet box; guy wires (if ordered) are bagged separately in main box.

2. Powerfoil or PowerfoilPlus models only.3. Only included if ordered. If extension tube is over 3, it will be shipped in a separate box. 4. Safety cable is attached to extension tube or packed separately if extension tube was not ordered.5. Either the small (24D) or large (29) KBDA controller is included with the fan. Allen Bradley controller is optional.

(2) Hardware1

OL

JOG

REM

FWD REV STOP LOC/REM

PGM

Hz

AC MOTOR SPEED CONTROL

RUNSTOP RESET

JOGLOC/REM

PROGRAMDISPLAY

READENTER

OL

JOG

REM


PGM

Hz


RUNSTOP RESET

JOGLOC/REM

PROGRAMDISPLAY

READENTER



4



Mounting

(2) Beam Clip & (2) Spacer

Upper Yoke (2) Lower Yoke

Motor & Hub Extension Tube, Safety Cable2, & Shackle3

Hardware

Beam Clip Hardware(4) 1/2-13 x 2 GR 8 Bolt(8) 1/2 Flat Washer(4) 1/2-13 Nylock Nut

Single Pivot Hardware(2) 1/2-13 x 5 GR 8 Bolt (4) 1/2 Flat Washer(2) 1/2-13 Nylock Nut

Lower Yoke Hardware(2) 1/2-13 x 5 GR 8 Bolt(4) 1/2 Flat Washer(2) 1/2-13 Nylock Nut

Motor Hub Hardware(4) 1/2-13 x 1 3/4 GR 8 Bolt(8) 1/2 Flat Washer(4) 1/2-13 Nylock Nut

Winglet Hardware(10) 10-24 x 1/2 Bolt(10) 10-24 x 3/4 Barrel

Airfoil Hardware(20) 5/16-18 x 2 GR 8 Bolt(40) 5/16 Flat Washer(20) 5/16-18 Nylock Nut

(4) Gripple/Eyebolt Hardware1(1) Locking Caribiner(1) 1/4 Beam Clip(1) 1/4-20 x 1 Eyebolt (1) 1/4-20 Hex Nut

(1) Gripple(1) Guy Wire(2) Wire Rope Clip

Parts IncludedNOTE: Drawings below are not to scale.

1. Guy wires are designed to constrain fans lateral movement and are only included in some fan packages. Big Ass Fans recommends using guy wires if the if the fans extension tube is 4 or longer, if the fan is exposed to high winds, or if the fan is close to any building fixtures. Gripple/Eyebolt hardware is bagged separately from hardware boards.

2. Safety cable is attached to extension tube or packed separately if extension tube was not ordered.3. Shackle included on hardware boards.4. Powerfoil model only.5. PowerfoilPlus model only.

Airfoils

(10) Airfoils

(10) PowerfoilWinglets4

(10) PowerfoilPlusWinglets5

(10) Airfoil Retainers



5



Recommended Torque

Application Thread Size TorqueMounting Bolts 1/2-13 UNC 98 ftlbf (133 Nm)

Airfoil Bolts 5/16-18 UNC 29 ftlbf (39 Nm)

Important Weights

Part Weight Part Weight

Single Pivot Mounting Kit (7/10) 32 lbs (14 kg)

8 Wickerbill foils 52 lbs (23 kg)8 Standard foils 52 lbs (23 kg)

Single Pivot Mounting Kit (10/15) 37 lbs (16 kg)

8 Powerfoil foils 62 lbs (28 kg)10 Wickerbill foils 67 lbs (30 kg)

1 Extension 4 lbs (2 kg) 10 Standard foils 67 lbs (30 kg)2 Extension 8 lbs (4 kg) 10 Powerfoil foils 80 lbs (36 kg)3 Extension 13 lbs (6 kg) 12 Wickerbill foils 78 lbs (35 kg)4 Extension 17 lbs (8 kg) 12 Standard foils 78 lbs (35 kg)5 Extension 21 lbs (10 kg) 12 Powerfoil foils 94 lbs (42 kg)6 Extension 25 lbs (11 kg) 14 Wickerbill foils 91 lbs (41 kg)7 Extension 29 lbs (13 kg) 14 Standard foils 91 lbs (41 kg)8 Extension 33 lbs (15 kg) 14 Powerfoil foils 110 lbs (49 kg)9 Extension 37 lbs (17 kg) 16 Wickerbill foils 105 lbs (47 kg)10 Extension 42 lbs (19 kg) 16 Standard foils 100 lbs (45 kg)

KBDA-24D Controller 6 lbs (2.7 kg) 16 Powerfoil foils 127 lbs (57 kg)KBDA-29 Controller 11 lbs (5.9 kg) 18 Wickerbill foils 116 lbs (52 kg)

24 Wickerbill foils 160 lbs (72 kg)24 Standard foils 150 lbs (68 kg)24 Powerfoil foils 195 lbs (88 kg)

Tools Needed

Mechanical Installation Electrical InstallationStandard Wrench Set Phillips and Flat Head ScrewdriverStandard Socket Set with Ratchet 1/4 Nut DriverTorque Wrench capable of 98 ftlbf (133 Nm) 5/16 Nut DriverPhillips and Flat Head Screwdriver Pair of #10 to #14AWG CrimpersStandard and Metric Allen Wrench Set Pair of Medium Size Channel Locks

Multimeter



6



Fan Diagram

A. Safety Cable. A redundant safety feature that secures the fan to the mounting structure.

B. Upper Yoke. Secures the fan to the mounting structure and allows the fan to adjust its center of gravity.

C. Extension Tube. Extends the fan from the ceiling.

D. Lower Yoke. Connects motor & hub assembly to mounting assembly.

E. Motor (see p. 2 for details)

F. Airfoil. Provides air movement. In the event of a collision, safety retainers secure the airfoils to the fan hub.

G. Winglet. Improves the efficiency of the fan by reducing drag. Winglets are only included with Powerfoil and PowerfoilPlus models (PowerfoilPlus winglets not shown).



7



Allen-Bradley Controller Diagram (Optional)

A. VFD. The Variable Frequency Drive (VFD) controls AC power to the motor.

B. Fuses. Protects the system from power surges and over-current.

C. Disconnect. Emergency disconnect for the fan controller.

D. Load Reactor (AB575 only)



8



Preparing the Work SiteMechanical Installation A 24 (7.3 m) Powerfoil fan (our largest model) weighs, at maximum, 415 lbs (188 kg). A scissor lift, or other suitable means for

lifting the weight of the fan and up to two installation personnel, will be required. Big Ass Fans can only be hung from an I-beam or angle irons. For specific requirements, see installation instructions starting on p.

11. Do not mount the fan to single purlins, trusses, or bar joists. Consult a structural engineer for installation methods not covered in the manual.

CAUTION: Mount fan only to an angle iron or I-Beam.

Angle Iron

I-Beam

To reduce the risk of injury to persons, install the fan so that the blades are at least 10 (3.05 m) above the floor. The fan installation area must be free of obstructions such as lights, cables, sprinklers, or other building structure. The fan blades

should have at least 2 (0.61 m) of clearance from any obstructions. Do not install the fan where it will be continuously subjected to high winds (e.g., under a high velocity HVAC system). The distance

between the fan and the HVAC equipment (or other air-moving equipment) should be no less than 2x the fans diameter when measured from the center of the fan to the equipment.

The distance between multiple fans should be no less than 2.5x the fans diameter when measured from the centers of the fans. The mounting system must be able to withstand the torque forces generated by the fan. A 24 diameter fan generates nearly 300

ftlbf (406.7 Nm) of torque during operation. Fans mounted on lightweight I-beams (common in steel buildings) could cause the beam to flex and the fan to move significantly

during operation. If this flexing causes a clearance problem we suggest installing a stiffening strut to a nearby beam. If the fans extension tube is 4 (1.2 m) or longer, the fans lateral movement must be secured using guy wires (see p. 21 for more

information). If the fan is close to any building fixtures it is recommended to secure the fan with guy wires as a safety measure.

Electrical Installation To reduce the risk of electric shock, wiring should be performed by a qualified electrician! Incorrect assembly can cause electric

shock or damage the motor and the controller! The installation of a Big Ass Fan must be in accordance with the National Electrical Code, ANSI/NFPA 70-1999, and all local codes. Acceptable Unshielded Cable Types: Stranded THHN / THNW, rated for 600V & 158F-194F (75-90C) in metallic conduit. Acceptable Shielded Cable Types: RHH / RHW-2, rated for 600V & 158F-194F (75 to 90C); Belden 29501 through 29507; RHH

/ RHW-2, tray rated for 600V & 158F-194F (75-90C); Shawflex 2ACD / 3ACD or equivalent. MC cable (stranded or solid core) may not be used for fan output/motor input leads. The motor leads from the fan control to the fan can not be greater than 400 (121.9 m). The fan must be visible from its controller unless a suitable means of disconnect is used at the motor. The output/motor leads cannot share the same conduit or piping as the AC power supply. AC supply feeds for one fan controller

may share the same conduit with AC supply feeds for one or more controllers. AC supply feeds for a fan controller and the output/motor leads for the same fan may not share a conduit. AC supply feeds for one fan controller may not share conduit with output/motor leads from one or more controllers/VFDs. All unused conductors that share a conduit with the AC supply feeds must be grounded on both ends. Controller output/motor input leads may not share a conduit with any other controllers output/motor leads. Controller output/motor input leads may not share a conduit with any other controllers AC supply feed.



9



Understanding Airflow Patterns

Airflow with Streamlined ObstructionObstructions on the floor tend to block the horizontally moving air. Thin or streamlined obstructions do not block much airflow, regardless of size. The air tends to flow smoothly around these obstructions, losing little momentum, and leaving only a small stagnant area behind the obstruction.

Airflow with Wide, Blunt ObstructionA wide, blunt, or flat-faced obstruction forces the air to change direction, turning upward and outward. There is a stagnant area behind these obstructions that is wider and higher than the obstructions themselves.

Airflow in an Enclosed AreaThe floor jet radiates outward until it reaches the walls. The walls deflect the jet upward. The ceiling then turns the upward flow inward, back toward the low pressure area above the fan where it is pulled back toward the floor. This creates a convection-like air current that gathers momentum. Once this current is established, the fan begins to move air outside of the current as well and escalates the cooling effects of the fan.

Airflow in an Open AreaThe airflow moves from the fan toward the floor. Once the airflow hits the floor, it moves outward in all directions. When airflow is deflected off of the floor it is called a floor jet. The depth of this floor jet varies depending on the size and speed of the fan. A 20 (6 m) Big Ass Fan at standard speed creates a floor jet 9 (2.7 m) deep.

Airflow with Multiple FansWhere there are multiple fans appropriately spaced, the expanding jets of adjacent fans meet to create a pressure zone. The pressure zone acts like a wall, causing each fan to behave more like a single enclosed fan. Typically, a single fans performance will increase when working in conjunction with other fans.



10Understanding Airflow Patterns (cont.)

Overhead View

Overhead View

Side View

PowerfoilPlusThe PowerfoilPlus hybrid airfoil creates a jet of air that flows outward from the fan at a 45 degree angle, ignoring floor obstructions and delivering airflow in a much broader pattern. The airflow generated from a 24 PowerfoilPlus fan can effectively cool an area up to 168 away from the fan.

The same principles of airflow apply to the PowerfoilPlus, but must account for its much larger coverage area as illustrated in the diagrams to the left.

TipsBelow are some techniques that can make a dramatic difference in congested areas of your facility. You can treat air like water and scoop, direct, and channel it right where you need it most. If you are using a PowerfoilPlus fan, you will notice that it delivers air from a much higher angle, resolving many of the obstacles outlined below.

Make sure people are not hidden behind structures that would block air flow. This may seem obvious, but work areas are routinely blocked by shelving, crates, and machinery.

Position large obstructions so that their smallest profile is perpendicular to the direction of air movement. For example, a sheet metal press brake might have five times the frontal area if its facing the airflow rather than if its turned sideways.

Wherever possible, position welding curtains, partitions, sheet materials, etc. in such a way as to scoop air into the work area rather than deflect it away.

Take advantage of the air moving near the floor by creating ground level openings in your work area. It is better to have a work area blocked by materials stacked to the ceiling with an opening below than to have low stacks 3 (0.9 m) to 6 (1.8 m) high sitting on the floor.

11



Mounting Method 1: I-BeamBig Ass Fans can only be hung from an I-beam or angle irons. See the following page for angle iron mounting instructions. Consult a structural engineer for installation methods not covered in this manual.

WARNING: Big Ass Fans should not be installed unless the structure on which the fan is to be mounted is of sound construction, undamaged, and capable of supporting loads up to 635 lbs (293 kg). A structural engineer should verify that the structure is adequate prior to fan installation. Verifying the stability of the mounting structure is the sole responsibility of the customer and/or end user, and Big Ass Fans hereby expressly disclaims any liability arising therefrom, or arising from the use of any materials or hardware other than those supplied by Big Ass Fans or otherwise specified in these installation instructions.

1. Attach Upper Yoke (to I-Beam)

Measure the flange width of the I-beam from which the fan will be hung. Consult the tables and diagram below to determine what size upper yoke is included with your fan package. Select the upper yoke mounting holes that match the flange width of the I-beam.

CAUTION: Install the spacers only if the thickness of the I-beam flange exceeds 3/8 (1 cm). The mounting holes on the spacer are closer to one side than the other. Make sure this side is facing the I-beam.

Secure the upper yoke to the I-beam with the Beam Clip Hardware as shown. Tighten the bolts to 98 ftlbf (133 Nm) using a 3/4 socket with torque wrench.

Proceed to Hanging the Fan (p. 18).

Beam Clip Hardware (BAF-Supplied):a. (4) 1/2-13 x 2 GR 8 Boltb. (8) 1/2 Flat Washerc. (4) 1/2-13 Nylock Nutd. (2) Beam Clampe. (2) Spacer

Small Upper Yoke 13 1/4 (33.7 cm) x 9 5/8 (24.4 cm)

I-Beam Flange Width

Upper Yoke Mounting Holes

5 (12.7 cm) - 6 5/8 (16.8cm) inner holes

>6 5/8 (16.8 cm) - 8 1/4 (21 cm) middle holes

>8 1/4(21 cm) - 9 7/8(25 cm) outer holes

Large Upper Yoke 18 (45.7 cm) x 9 5/8 (24.4 cm)

I-Beam Flange Width

Upper Yoke Mounting Holes

9 7/8 (25 cm) - 11 3/8 (28.9 cm) inner holes

>11 3/8 (28.9 cm) -13 (33 cm) middle holes

>13 (33 cm) - 14 5/8 (37.1 cm) outer holes

Upper Yoke (top view)

outer holemiddle hole

inner hole

outer holemiddle holeinner hole

Upper Yoke (top view)

outer holes

inner holesmiddle holes

Side View

b

a

c

b

e

d



12



1. Select Proper Angle Irons

NOTE: Angle irons and angle iron hardware are not included with the fan.

CAUTION: Do not install the fan from a single purlin, truss, or bar joist.

CAUTION: Unsupported angle iron spans should not exceed 12 (3.7 m).

Follow the table below when selecting angle irons for fan installation.

Height

Width

9/16 (1.4 cm)

Thickness: 1/4 (6 mm)

Angle Iron Side View(see table for dimensions)

Thickness

Angle Iron Span(between mounting points)

Minimum Angle Iron Dimensions (W x H x T)

Number of Angle Irons Needed

6 (1.8 m) or less 2.5 (6.4 cm) x 2.5 (6.4 cm) x .25 (0.6 cm) 2over 6 (1.8 m) - 8 (2.4 m) 3 (7.6 cm) x 3 (7.6 cm) x .25 (0.6 cm) 2

over 8 (2.4 m) - 12 (3.7 m) 3 (7.6 cm) x 3 (7.6 cm) x .25 (0.6 cm) 4**2 pairs of angle irons. Pairs should be placed back to back and fastened in center (see step 2).

Mounting Method 2: Angle IronsIf you are installing the fan to an I-beam and have attached the upper yoke (p. 11), proceed to Hanging the Fan (p. 18).

WARNING: Big Ass Fans should not be installed unless the structure on which the fan is to be mounted is of sound construction, undamaged, and capable of supporting loads up to 635 lbs (293 kg). A structural engineer should verify that the structure is adequate prior to fan installation. Verifying the stability of the mounting structure is the sole responsibility of the customer and/or end user, and Big Ass Fans hereby expressly disclaims any liability arising therefrom, or arising from the use of any materials or hardware other than those supplied by Big Ass Fans or otherwise specified in these installation instructions.

WARNING: Never use beam clamps when mounting the fan to angle irons! Beam clamps are only intended for I-beam installations.



13



Mounting Method 2: Angle Irons (cont.)

3. Fasten Angle Irons Together (if span is longer than 8)

If the angle iron span is 8 (2.4 m) or less, proceed to step 4a on the following page.

If the angle iron span is longer than 8 (2.4 m), it is necessary to use double angle irons.

Locate the center of the angle iron length. Drill 9/16 (1.4 cm) hole through the center of the vertical wall of the angle iron. Drill a total of four (4) angle irons.

Place two drilled angle irons back to back. Fasten the angle irons together with customer-supplied Grade 8 hardware.

Align the angle irons to each other and tighten the bolts to 98 ftlbf (133 Nm) using a 3/4 socket with torque wrench.

Repeat step for remaining two angle irons.

Proceed to step 4b.

Grade 8 Hardware (Customer-Supplied):a. (2) 1/2-13 Bolt b. (4) 1/2 Washersc. (2) 1/2 Nut

Side View

ab bc

2. Pre-drill Angle Irons

Determine the mounting method that will be used for your fan. If the fan will be mounted with an extension tube, drill two 9/16(1.4 cm) holes exactly 5 3/8 (13.7 cm) apart in the centers of two angle irons. If the motor frame will be mounted directly to the angle irons, drill two 9/16 (1.4 cm) holes exactly 5 1/2 (14 cm) apart in the centers of two angle irons.

Measure the distance between the mounting points of the roof structure that the angle irons will span. Measure the same distance on the angle irons and drill 9/16 (1.4 cm) holes through each end of the angle irons. Drill holes in two angle irons if span is 8 (2.4 m) or less. Drill holes in four (4) angle irons if span is greater than 8 (2.4 m).



14



4a. Fasten Single Angle Irons to Roof Structure Mounting Points

If installation requires double angle irons (i.e., span is greater than 8 (2.4 m)), proceed to step 4b.


CAUTION: The angle irons must be fastened to the roof structure at each end.

Fasten the angle irons to the roof structure mounting points at each end with customer-supplied Grade 8 hardware as shown.

ATTENTION: Do not tighten the hardware until the fan has been mounted to the angle irons.

Proceed to step 5.

Grade 8 Hardware (Customer-Supplied):a. (4) 1/2-13 Bolt b. (8) 1/2 Washersc. (4) 2.5 Square Washer (see diagram)d. (4) 1/2 Nut

2.5 (6.4cm)

2.5 (6.4cm)

9/16 (1.4cm)

Thickness: 1/4 (6mm)

Square Washer

b

a

c

b

d




15



4b. Fasten Double Angle Irons to Roof Structure Mounting Points


CAUTION: The angle irons must be fastened to the roof structure at each end.

Fasten the angle irons to the roof structure mounting points at each end with customer-supplied Grade 8 hardware as shown.

CAUTION: The angle irons with fan mounting holes should be positioned on the inside, facing each other.

ATTENTION: Do not tighten the hardware until the fan has been mounted to the angle irons.

Grade 8 Hardware (Customer-Supplied):a. (8) 1/2-13 Bolt b. (16) 1/2 Washersc. (8) 2.5 Square Washer (see diagram)d. (8) 1/2 Nut

A

b

a

c

bd




16



5a. Attach Upper Yoke (to Angle Irons)

If you are mounting the fan motor frame directly to angle irons, proceed to step 5b.

Secure the upper yoke directly to the angle irons with the Beam Clip Hardware as shown. Consult the diagrams below for distances between the angle irons.

CAUTION: The angle irons should be aligned with the outermost holes of the upper yoke.

Tighten the bolts to 98 ftlbf (133 Nm) using a 3/4 socket with torque wrench.

CAUTION: After attaching the upper yoke to the angle irons, tighten all the bolts securing the angle irons to the roof structure to 98 ftlbf (133 Nm) using a 3/4 socket with torque wrench.

Proceed to Hanging the Fan (p. 18).

Beam Clip Hardware (BAF-Supplied):a. (4) 1/2-13 x 2 GR 8 Boltb. (8) 1/2 Flat Washerc. (4) 1/2-13 Nylock Nut


NOTE: Dashed lines represent angle irons.

Side View

a

b

c

b



17



After attaching the motor frame to angle irons, proceed to Secure Safety Cable (p. 19).


5b. Attach Motor Frame (to Angle Irons)

Attach the motor frame directly to the angle irons with the Motor Hub Hardware as shown. Consult the diagram below for distances between the angle irons.

CAUTION: The motor frame is heavy. Use caution when raising it.


CAUTION: After attaching the upper yoke to the angle irons, tighten all the bolts securing the angle irons to the roof structure to 98 ftlbf (133 Nm) using a 3/4 socket with torque wrench.

Proceed to Secure Safety Cable (p. 19).

Motor Hub Hardware (BAF-Supplied):a. (4) 1/2-13 x 1 3/4 GR 8 Boltb. (8) 1/2 Flat Washerc. (4) 1/2-13 Nylock Nut

b

b

c

a

NOTE: Dashed lines represent angle irons.



18



Hanging the Fan1. Attach Extension Tube (to Upper Yoke)

Fasten the extension tube to the upper yoke with the Single Pivot Hardware as shown.

Before tightening the bolts, allow the extension tube to hang freely and balance itself.


Single Pivot Hardware (BAF-Supplied):a. (2) 1/2-13 x 5 GR 8 Boltb. (4) 1/2 Flat Washerc. (2) 1/2-13 Nylock Nut

ba

cb



19



2. Secure Safety Cable

WARNING: The safety cable is a crucial part of the fan and must be installed correctly. If you have any questions, please contact Customer Service at 1-877-BIG-FANS.

ATTENTION: If your fan installation includes an extension tube, the safety cable is already attached to the extension tube. If you are mounting the fan without an extension tube, the safety cable is packed separately.

Hanging the Fan (cont.)

Shackle

I-Beam MountSecure the safety cable by wrapping it around the I-beam and connecting the looped ends with the shackle as shown. The cable must be drawn tightly around the I-beam, leaving as little slack as possible. If possible, the shackle should be on the topside of the I-beam. Securely tighten the shackle.

Proceed to step 3.

Angle Iron Mount (with Extension Tube)Secure the safety cable by wrapping it around the angle irons and connecting the looped ends with the shackle as shown. The cable must be drawn tightly around the angle irons, leaving as little slack as possible. If possible, the shackle should be on the topside of the angle irons. Securely tighten the shackle.

Proceed to step 3.

Angle Iron Mount (no Extension Tube)Route the cable through the motor frame and around the angel irons as shown. Connect the looped ends of the cable with the shackle. The cable must be drawn tightly around the angle irons leaving as little slack as possible. If possible, the shackle should be on the topside of the angle iron. Securely tighten the shackle.

Proceed to Replacing Oil Plug (pp. 23-25).



20



Hanging the Fan (cont.)

3. Attach Lower Yoke (to Extension Tube)

Attach the lower yoke to the bottom of the extension tube with the Lower Yoke Hardware as shown.


Lower Yoke Hardware (BAF-Supplied):a. (2) 1/2-13 x 5 GR 8 Boltb. (4) 1/2 Flat Washerc. (2) 1/2-13 Nylock Nut

ba

c b

4. Attach Motor Frame (to Lower Yoke)

Attach the motor frame to the lower yoke with the Motor Hub Hardware as shown.

CAUTION: The motor frame is heavy. Use caution when raising it.


Motor Hub Hardware (BAF-Supplied):a. (4) 1/2-13 x 1 3/4 GR 8 Boltb. (8) 1/2 Flat Washerc. (4) 1/2-13 Nylock Nut

a

b

c

b



21



Installing Guy WiresGuy wires may not be included in your fan order. They are intended to constrain the fans lateral movement and are included with fans that have extension tubes 4 ft (1.2 m) or greater in length.

If you are not installing guy wires, proceed to Replacing Allen-Head Plug (pp. 23-25).

1. Attach Locking Carabiners to Motor Frame

Secure the locking carabiner to the motor frame as shown.

Gripple/Eyebolt Hardware (BAF-Supplied):a. (4) Carabiners

2. Attach Beam Clamp

Attach the beam clamp to an I-beam or angle iron. The guy wire must be at a 30o-45o angle from the roof to the extension tube. Place the beam clamp accordingly.

Fasten the small eyebolt and nut onto the beam clamp (the nut will be on the outside of the beam clamp).

Loop the guy wire through its crimped end to secure it to the eyebolt as shown.

Gripple/Eyebolt Hardware (BAF-Supplied):a. 1/4 Beam Clampb. 1/4-20 x 1 Eyeboltc. 1/4-20 Hex Nutd. Guy Wire

Beam Clamp

a

dc

b



22



4. Install Three Remaining Guy Wires

Follow steps 1-3 to install the three remaining guy wires.

CAUTION: The guy wires should be spaced evenly around the fan and clear of the path the fan blades will rotate.

Evenly cinch all four guy wires into place using the Gripples. The wires should be taut.

CAUTION: Over-tightening the guy wires could throw the fan off balance.

Once all of the guy wires are taut, secure their loose ends with the wire rope clips as shown.

Wire Rope Clip

3. Route Guy Wire Through Gripple

Route the guy wire through the Gripple, the carabiner on the motor frame, and back through the Gripple as shown.

ATTENTION: To back the guy wire out of the Gripple, insert 1/16 (1.5 mm) Allen wrench into the small hole on the Gripple.

ATTENTION: Do not tighten the Gripple until the remaining guy wires have been installed.

Installing Guy Wires (cont.)

Gripple



23



Replacing Oil Plug on Bonfiglioli Motors(8-20 Powerfoil/Wickerbill and 10-20 PowerfoilPlus Models Only)

CAUTION: The oil plug on the fan models listed above must be replaced with the oil vent cap to optimize performance. The proper brass oil vent cap is packaged in a bag attached to the motor unit.

If your fan model does not require an oil vent cap, proceed to Installing Airfoils (p. 26).

1. Replace Oil PlugCAUTION: Do not remove oil plug until fan is properly mounted! If the oil plug is removed before the fan is mounted, oil in the gear reducer may spill out.

For 8-20 Powerfoil/Wickerbill and 10-20 PowerfoilPlus models only, Remove the oil plug as shown.

Install the oil vent cap as shown. Screw the cap into place by hand and being careful not to strip the threads.

Vent Cap

Oil Plug



24



Replacing Oil Plug on Bonfiglioli Motors(24 Powerfoil/Wickerbill and PowerfoilPlus Models Only)

CAUTION: The oil plug on the fan models listed above must be replaced with the oil vent cap to optimize performance. The proper brass oil vent cap is packaged in a bag attached to the motor unit.


1. Replace Oil PlugCAUTION: Do not remove oil plug until fan is properly mounted! If the oil plug is removed before the fan is mounted, oil in the gear reducer may spill out.

NOTE: These instructions apply to 24 Powerfoil/Wickerbill and PowerfoilPlus models only!

Remove the oil plug and install the oil vent cap as shown. Screw the cap into place by hand, being careful not to strip the threads.

Vent Cap

Oil Plug



25



Replacing Allen-Head Plug on Baldor Motors(20-24 Powerfoil/Wickerbill and 18-24 PowerfoilPlus Models Only)

CAUTION: The oil plug on the fan models listed above must be replaced with the oil vent cap to optimize performance. The proper oil vent cap is packaged in a bag attached to the motor unit for these fans. It is black and labeled OIL.


1. Replace Allen-Head PlugCAUTION: Do not remove oil plug until fan is properly mounted! If the oil plug is removed before the fan is mounted, oil in the gear reducer may spill out.

For 20-24 Powerfoil/Wickerbill and 18-24 PowerfoilPlus models only, Remove the oil plug as shown, using an 8mm Allen head wrench.

Install the oil vent cap as shown. Screw the cap into place by hand and being careful not to strip the threads.

Vent Cap

Allen-Head Plug



26 Installing AirfoilsBig Ass Fans recommends completing electrical installation (p. 27) before installing the airfoils.

WARNING: Disconnect power to the fan before installing the airfoils.

a

b

1. Attach Winglets to Airfoils (Powerfoil, PowerfoilPlus Only)

Attach the winglet to the airfoil using the Winglet Hardware as shown. You will need to use both a Phillips head and flat head screwdriver to properly secure the fasteners.

ATTENTION: The Powerfoil winglets and PowerfoilPlus winglets will be attached the same way, using the same hardware kit.

Attach winglets to all ten (10) airfoils before attaching the airfoils to the fan.

Winglet Hardware Kit (BAF-Supplied):a. (10) 10-24 x 1/2 Boltb. (10) 10-24 x 3/4 Barrel

2. Attach Airfoils to Hub

WARNING: Disconnect power to the fan before installing the airfoils.

Slide the airfoils onto the tabs of the fan hub. An airfoil will only attach to the fan hub in one direction. Do not force an airfoil into place.

Attach the ten (10) airfoil retainers using the Airfoil Hardware. Moving clockwise around the fan hub, position the airfoil retainers end over end as shown. Hole A should be positioned over top of Hole B. Do not tighten the bolts until all the airfoil retainers have been attached!

First, tighten the bolts along the outside perimeter to 29 ftlbf (39 Nm) using a 1/2 socket with torque wrench.

Second, tighten the bolts along the inside perimeter to 29 ftlbf (39 Nm) using a 1/2 socket with torque wrench.

Airfoil Hardware Kit (BAF-Supplied):a. (20) 5/16-18 x 2 GR 8 Boltb. (40) 5/16 Flat Washerc. (20) 5/16-18 Nylock Nut

b

c

a

b

Hole B

Hole A

Airfoil Retainer

27



Electrical Installation Electrical Installation Safety

WARNING: To reduce the risk of electric shock, wiring should be performed by a qualified electrician! Incorrect assembly can cause electric shock or damage the motor and the controller! Hazard of electrical shock!

WARNING: The installation of a Big Ass Fan must be in accordance with the requirements specified in this installation manual and with any additional requirements set forth by the national electric code (NEC), ANSI/NFPA 70-1999, and all local codes. Code compliance is ultimately YOUR responsibility!

WARNING: The fan controllers contain high voltage capacitors which take time to discharge after removal of mains supply. Before working on the fan controller, ensure isolation of mains supply from line inputs at the fan controllers disconnect if installed (L1, L2/N, L3). Wait 3 minutes for capacitors to discharge to safe voltage levels (note: darkened display LEDs are not an indication of safe voltage levels). Failure to do so may result in personal injury or death.

CAUTION: An incorrectly installed controller can result in component damage or reduction in the fans life. Wiring or application errors such as under-sizing the controller, incorrect or inadequate AC supply, or excessive ambient temperatures may result in a malfunction of the fan system. Verify correct voltage, phase, and horsepower before beginning installation!

WARNING: Exercise caution and common sense when powering the fan. Do not connect the fan to a damaged or hazardous power source. Do not attempt to resolve electrical malfunctions or failures on your own. Contact Big Ass Fans at 1-877-BIG-FANS if you have any questions regarding the electrical installation of this fan.

CAUTION: For use with manufacturer supplied variable frequency drive only. Not for use with other speed control devices!

CAUTION: Shielded cable, if applicable, must be landed on motors ground terminal!

CAUTION: To avoid a short circuit, be very careful not to get metal chips in the control!

CAUTION: The Big Ass Fans product warranty will not cover equipment damage or failure that is caused by improper installation.

Electrical Installation OverviewIt is the sole responsibility of the installer to verify the operating voltage of the fan system prior to installation! It is also mandatory that the installer verify that fan blades, motor hub assemblies, and fan controllers are matched properly at the time of installation, especially where multiple fan systems will be installed.

The electrical installation section is intended for a professional electrician. If you are unfamiliar or uncomfortable with installing electrical components, do not attempt to install the fan alone. Serious personal injury or damage to the fan and other equipment could result.

The guide provided here is a merely a recommendation of proper installation. Adhering to national and local electrical codes is your responsibility.

The following sections of this chapter will outline how to prepare for the electrical installation, including which cables to select and how to properly route the cabling through conduit, how to properly ground the fan system, how to properly wire the fan controller, how to properly wire the fan motor, and proper startup procedures.

Power Requirements for Big Ass Fans ControllersCAUTION: It is the sole responsibility of the installer to verify the operating voltage of the fan system prior to installation! It is also mandatory that the installer verify that fan blades, motor hub assemblies, and fan controllers are matched properly at the time of installation, especially where multiple fan systems will be installed.

The power requirements for all Big Ass Fans controllers are listed in the chart on the following page. If multiple controls are connected to one feeder circuit, the circuit required is the sum of the feeder circuit requirements listed on the chart. For example, if two MC, 230-3-KB-1-2.0 controllers are connected to a single feeder circuit, that circuit needs to be rated for 30 Amps. This type of installation will also require that each fan control be installed downstream of a dedicated over-current protection device.



28



Pow

er R

equi

rem

ents

for B

ig A

ss F

an C

ontr

olle

rs

Fan

Size

Con

trol

ler M

odel

N

umbe

rR

ated

HP

(kW

)N

omin

al A

C L

ine

Inpu

t Vol

tage

Phas

e In

put (

)

Rec

omm

ende

d M

inim

um

Feed

er S

ize

Nom

inal

O

utpu

t Vo

ltage

, 3

*

Max

imum

Con

t. O

utpu

t Cur

rent

(a

s pr

ogra

mm

ed)*

*

10 P

ower

foilP

lus,

8-1

2 P

ower

foil,

8

-12

Wic

kerb

ill,

8-2

4 S

tand

ard

MC

, 230

-1-K

B-1

-1.0

2 (1

.5)

200-

250

120

A23

03.

4 A

MC

, 230

-3-K

B-1

-1.0

2 (1

.5)

200-

250

315

A23

03.

4 A

MC

, 460

-3-K

B-1

-1.0

2 (1

.5)

400-

480

310

A46

01.

7 A

MC

, 120

-1-A

B-1

-1.0

1 (0

.75)

100-

125

130

A23

03.

4 A

MC

, 230

-1-A

B-1

-1.0

1 (0

.75)

200-

250

115

A23

03.

4 A

MC

, 230

-3-A

B-1

-1.0

1 (0

.75)

200-

250

310

A23

03.

4 A

MC

, 460

-3-A

B-1

-1.0

1 (0

.75)

400-

480

310

A46

01.

7 A

MC

, 575

-3-A

B-1

-1.0

1 (0

.75)

575-

600

310

A57

51.

1 A

12-1

8 P

ower

foilP

lus,

14-2

0 P

ower

foil,

14

-20

Wic

kerb

ill

MC

, 230

-1-K

B-1

-1.5

2 (1

.5)

200-

250

120

A23

05.

6 A

MC

, 230

-3-K

B-1

-1.5

2 (1

.5)

200-

250

315

A23

05.

6 A

MC

, 460

-3-K

B-1

-1.5

2 (1

.5)

400-

480

310

A46

02.

8 A

MC

, 120

-1-A

B-1

-1.5

1.5

(1.0

)10

0-12

51

40 A

230

5.6

AM

C, 2

30-1

-AB

-1-1

.52

(1.5

)20

0-25

01

20 A

230

5.6

AM

C, 2

30-3

-AB

-1-1

.52

(1.5

)20

0-25

03

15 A

230

5.6

AM

C, 4

60-3

-AB

-1-1

.52

(1.5

)40

0-48

03

10 A

460

2.8

AM

C, 5

75-3

-AB

-1-1

.52

(1.5

)57

5-60

03

10 A

575

1.7

A

20-2

4 P

ower

foilP

lus,

24 P

ower

foil,

24

Wic

kerb

ill

MC

, 230

-1-K

B-1

-2.0

2 (1

.5)

200-

250

120

A23

06.

4 A

MC

, 230

-3-K

B-1

-2.0

2 (1

.5)

200-

250

315

A23

06.

4 A

MC

, 460

-3-K

B-1

-2.0

2 (1

.5)

400-

480

310

A46

03.

2 A

MC

, 230

-1-A

B-1

-2.0

2 (1

.5)

200-

250

120

A23

06.

4 A

MC

, 230

-3-A

B-1

-2.0

2 (1

.5)

200-

250

315

A23

06.

4 A

MC

, 460

-3-A

B-1

-2.0

2 (1

.5)

400-

480

310

A46

03.

2 A

MC

, 575

-3-A

B-1

-2.0

2 (1

.5)

575-

600

310

A57

52.

2 A

* O

utpu

t vol

tage

will

not

exc

eed

Inpu

t vol

tage

, with

the

exce

ptio

n of

120

Vol

t mod

els.

All

cont

rolle

rs p

rodu

ce 3

o

utpu

t pow

er, r

egar

dles

s of

inpu

t ph

ase.

** T

his

valu

e m

ay v

ary

due

to in

put v

olta

ge c

ondi

tions

.



29



Controller DimensionsKBDA Controllers NEMA Type 4X (IP65) Unit

Allen-Bradley Controller (Optional) NEMA Type 1 (IP20) Unit A controller with a different environmental rating will differ from dimensions shown below. If a controller with a rating other than

NEMA Type 1 (IP20) is required, contact Big Ass Fans at 1-877-BIG-FANS.

Allen-Bradley

KBDA-24D

OL

JOG

REM


PGM

Hz


RUNSTOP RESET

JOGLOC/REM

PROGRAMDISPLAY

READENTER

OL

JOG

REM


PGM

Hz


RUNSTOP RESET

JOGLOC/REM

PROGRAMDISPLAY

READENTER

8.85

(2

2.5

cm)

9.53

(2

4.2

cm)

5.51 (14 cm)

9.8

(24

.9 c

m)

9.25

(2

3.5

cm)

7.55 (19.2 cm)

1 (2.5 cm)KBDA-29

12 (30.5cm)

20 (50.8cm)

460 VOLT

Three Phase

11.5 (29.2cm)

9.13 (23.2cm)

Depth: 8.62 (21.9cm)

Depth: 7.25 (18.4cm)

11.5 (29.2cm)

9.13 (23.2cm)

Depth: 7.25 (18.4cm)

9.25 (23.5cm)

7.15 (18.1cm)

Depth: 7.25 (18.4cm)

11.5 (29.2cm)

9.13 (23.2cm)

460 VOLT

Three Phase

12 (30.5cm)

20 (50.8cm)

Depth: 8.62 (21.9cm)

460 VOLT

Three Phase



30



Mounting ControllerKBDA Controller Mount to a wall using suitable hardware with a bolt or screw diameter of 1/4 (0.64 cm). KBDA fan controllers are provided with knock outs on the bottom only. Do not drill the top and/or sides of the enclosure.

Allen-Bradley Controller (Optional) Mount to a wall using suitable hardware with a bolt or screw diameter of 1/4 (0.64 cm). For single fan controllers, the mounting hole pattern is 7 x 17 7/8 (17.8 cm x 45.4 cm). For multi-fan controllers, the mounting hole

pattern is 11 x 17 7/8 (27.9 cm x 45.4 cm). If mounting to a vertical column use a strut, spring nuts and beam clamps with 1/4-20 hardware (not provided). The Allen-Bradley controllers do not provide pre-punched conduit knock-outs. Big Ass Fans recommends the use of a hole punch

to create conduit knock-outs. Before drilling top and/or sides of enclosure, cover the VFD with a protective material to prevent loose metal shards from entering controller.

General Mounting Guidelines Do not mount any controller adjacent to or above a heat source or heat producing equipment. For Allen-Bradley controller, ambient temperature shall be between 14 F (-10 C) and 104 F (40 C). For KBDA controllers,

ambient temperature shall be between 14 F (-10 C) and 122 F (50 C). Do not expose the controller to a corrosive atmosphere, moisture, or direct sunlight. When mounting the controller, keep in mind that the fan should be visible from the controller. A minimum distance of 6 (15.2 cm) should be maintained between fan controllers.

Controller Storage

Store within an ambient temperature range of -40 to +85 degrees Celsius. Store within a relative humidity range of 0 to 95%, non-condensing. Do not expose to a corrosive atmosphere. If the controller has been in storage or powered down for more than one year, the user should apply AC supply power to the

controller for a period of two hours prior to operation in order to recondition the internal DC bus capacitors.

Input Power ConditioningLine reactors should be installed if AC supply is subject to any of the following: Low line impedance Frequent power interruptions Phase-to-ground voltage in excess of 125% nominal phase-to-phase voltage Distribution system exceeds established kVA limit for your specific model (contact Big Ass Fans for more information). Power factor correction capacitors Intermittent noise spikes (lightning)



31



Power Wiring GuidelinesWARNING: National Codes and standards (NEC, VDE, BSI, etc.) and local codes outline provisions for safely installing electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection and disconnecting devices. Failure to do so may result in personal injury and/or equipment damage.

WARNING: To avoid a possible shock hazard and/or nuisance tripping caused by induced voltages, unused wires in the conduit must be grounded at both ends. For the same reason, fan controller output wires should not share a conduit with another fan controllers output leads, or other power circuits (lighting, motors, etc.).

CAUTION: MC or Metal clad cable may not be used for controller output/motor leads. Both stranded and solid core varieties must be avoided. Do not use solid core cable of any size or insulation class for motor wiring. Use of such types of cabling may result in nuisance tripping or premature equipment failure.

GeneralA variety of cable types are acceptable for variable frequency drive installations. For many installations, unshielded cable is adequate, provided it can be separated from sensitive circuits. In all cases, parallel runs of control and motor cabling should be avoided when unshielded cable is being used. Do not use cable with an insulation thickness of less than 15 mils.

UL installations in 50C ambient must use 600V, 75C or 90C wire. UL installations in 40C ambient should use 600V, 75C or 90C wire.

Acceptable Unshielded TypesTHHN, THNW or similar wire is acceptable for drive installations in dry environments provided adequate free air space and/or conduit fill rate limits are provided. Do not use THHN or similarly coated wire in wet areas. Any wire chosen must have a minimum insulation thickness of 15 mils and should not have large variations in insulation concentricity.

Acceptable Shielded TypesNote: The drain conductor included with shielded cables must be connected to both the motor frame and the PE/Ground terminal of the Variable Frequency Drive.

Location Rating / Type DescriptionStandard (Option 1) 600V, 75C or 90C (167F or 194F)

RHH/RHW-2 Four tinned conductors with XLPE insulation Foil shield and tinned copper drain wire with 85% braid

coverage PVC JacketBelden 29501-29507 or equivalent

Standard (Option 2) Tray rated 600V, 75C or 90C (167F or 194F) RHH/RHW-2

Three tinned copper conductors with XLPE insulation 5 mil single helical copper tape (25% overlap min.) with

three bare copper grounds in contact with shield PVC JacketShawflex 2ACD/3ACD or equivalent

Class I & II; Division I & II Tray rated 600V, 75C or 90C (167F or 194F) RHH/RHW-2

Three bare copper conductors with XLPE insulation with impervious corrugated continuously welded aluminum armor

Black sunlight resistant PVC jacket overall Three copper grounds on #10 AWG and smaller

Maximum Cable LengthsTo prevent nuisance trips the following cable length limitations shall be observed: All Single Fan Systems - Distance between controller and fan should not exceed 400 (122 m). All Multi-fan Systems - Distance between controller and fans should not exceed 1200 (366 m) in total.

Output DisconnectsA device that routinely disconnects then reapplies the output power to the motor for the purpose of starting and stopping the motor, such as a contactor, shall not be used.

ATTENTION: In order to satisfy some code requirements, it may be necessary to install a manual disconnect at the fan motor location when the fan assembly is not within line-of-sight from the fan controller. A non-fused, 600V, 3 Phase, Blade style disconnect shall be used to satisfy this line-of-sight requirement.

Recommended Wire SizeA minimum of 14AWG is acceptable for motor leads. Warning: 14AWG applies to motor leads only. Power feeders to controllers shall be governed by the fuse size included with the fan controller and/or required circuit breaker (see p. 28).



32



Conduit/Piping GuidelinesThe nature of Variable Frequency Drive systems must be considered prior to and during the installation of Big Ass Fans. Due to high frequency electrical noise on the output side of the fan controller, measures must be taken to ensure that wires and cabling are routed in a manner consistent with recommendations made in this section. Big Ass Fans controllers rely on motor feedback through the cabling to sense motor speed, slip, etc.

CAUTION: The presence of foreign signals on a drives output wiring greatly reduces the controllers ability to control current and speed regulation of the fan. Any wiring practice that would allow this kind of cross-talk must be avoided. Failure to do so may result in nuisance tripping, and/or premature equipment failure. Sources of foreign signals that could induce such signals include another VFDs output circuit, long across-the-line motor circuits, and lighting circuits.

Controller AC Supply Most conventional methods of power distribution and branch circuit installation apply to all models of fan controllers. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection and disconnecting devices. Failure to do so may result in personal injury and/or equipment damage. Refer to Power Requirements (p. 28) for specific ampacities. AC supply feeds for one fan controller may share the same conduit with AC supply feeds for one or more additional controllers. AC supply feeds for a fan controller and output/motor leads for the same fan controller may not share a conduit. AC supply feeds for one fan controller may not share conduit with output/motor leads from one or more additional controllers/VFDs. Any unused conductors that share a conduit with an AC supply feed should be grounded on both ends to prevent risk of electric

shock due to induced voltages.

CAUTION: Recommendations for fan controller output/motor lead routing deem some conventional wiring practices unacceptable. National and/or local code does not differentiate between solid-state and electromechanical systems; however, due to the nature of the Big Ass Fan system, there are additional requirements that must be met to ensure proper operation.

Output/motor leads for a fan controller and AC supply feeds for the same fan controller may not share a conduit. Output/motor leads for one fan controller may not share conduit with AC supply feeds or output/motor leads from one or more

additional fan controllers. Any unused conductors that share a conduit with fan controller output/motor leads should be grounded on both ends to prevent risk

of electric shock due to induced voltages.



33



Installation Techniques: Single Fan Controls

CAUTION: KBDA controllers must be installed on a branch circuit with one fused disconnect per controller and/or circuit breaker per controller.

The total maximum motor lead length for all Big Ass Fan single fan controllers SHALL NOT EXCEED 400 (122 m). MC Cable may not be used for controller output/motor leads! Do not use solid core wiring of any size or insulation class for controller output/motor leads! Acceptable Shielded Cable types (p. 31) may be installed in long parallel runs without risk of cross-talk when properly installed

in a cable tray.

From Electrical Distribution Panel

To Fan To Fan To Fan


To Fan To Fan To Fan



34



Installation Techniques: Multiple Fan Controls

CAUTION: KBDA controllers must be installed on a branch circuit with one fused disconnect per controller and/or circuit breaker per controller.

The total maximum motor lead length for all Big Ass Fan multi-fan controllers SHALL NOT EXCEED 1,200 (366 m). MC Cable may not be used for controller output/motor leads! Do not use solid core wiring of any size or insulation class for controller output/motor leads! Do not connect multiple motors on a common ground return. Motors should each have a dedicated ground return back to the fan

controller. See Grounding on the following page. Acceptable Shielded Cable types (p. 31) may be installed in long parallel runs without risk of cross-talk when properly installed

in a cable tray.

WARNING: This installation method may only be used for control boxes with single VFDs! For control boxes with multiple VFDs, see above diagram. For more information, please contact Customer Service at 1-877-BIG-FANS.

To Fans


To Fans



To Fan

To Fan

To Fan

To Fan

To Fan

To Fan

To Fan

To Fan

To Fan

To Fan

To Fan

To Fan



35



GroundingThe nature of Variable Frequency Drive systems must be considered prior to and during the installation of Big Ass Fans. Due to high frequency content on the output side of the fan controller, measures must be taken to ensure that all grounding connections conform to the recommendations made in this section.

CAUTION: The following information is merely a guide for proper installation. The Big Ass Fans Company cannot assume responsibility for the compliance or the non-compliance to any code, national, local, or otherwise for the proper installation of these fan controllers, fans, or associated equipment. A hazard of personal injury and/or equipment damage exists if codes are ignored during installation.

The fan controllers Safety Ground (PE) must be connected to system ground as shown in the Standard Grounding diagrams on pp. 36-37. Ground impedance must conform to the requirements of national and local industrial safety regulations and/or electrical codes. The integrity of all ground connections should be periodically checked. All ground leads for downstream conduit boxes must be kept separate from the motor ground and terminated on the fan controllers PE terminal as shown in the Standard Grounding diagrams on pp. 36-37.

Motor GroundThe motor ground must be connected to a ground terminal on the VFD as shown in the Standard Grounding diagrams on pp. 36-37. This aids in keeping high frequency electrical noise off of the buildings ground grid.

Shielded Motor Cable TerminationsEither of the safety ground terminals on the drive provides a grounding point for the motor cable shield. The motor cable shield connected to one of the drive terminals must also be connected to the motor frame as shown in the Shielded Motor Cable Grounding diagrams on pp. 38-39. If no drain lead is present, the cable must be stripped back so that the braid can be twisted and soldered to a pigtail for proper termination.

Multi-Fan Grounding RequirementsThe grounding requirements for multi-fan controllers are illustrated in the Multi-Fan Grounding diagrams on p. 40. It is important to follow the wiring and conduit requirements previously outlined to ensure proper operation.

RFI/EMI Filter Grounding Using RFI/EMI filters on BAF fan controllers may result in relatively high ground leakage currents. Therefore, the filter must only be used in installations with grounded AC supply systems and be permanently installed and solidly grounded (bonded) to the building power distribution ground. Grounding must not rely on flexible cables and should not include any form of plug or socket that would permit inadvertent disconnection. Some local codes may require redundant ground connections. The integrity of all connections should be periodically checked. Refer to the RFI/EMI Grounding diagrams on pp. 41-42.

CE Compliant Installations (pp. 71-75)



36



Standard Grounding for Powerflex 4 Controller (Optional)



37



Standard Grounding for Powerflex 4M Controller (Optional)



38



Shielded Motor Cable Grounding for Powerflex 4 Controller (Optional)



39



Shielded Motor Cable Grounding for Powerflex 4M Controller (Optional)



40



Multi-Fan Grounding for Powerflex 4 Controller (Optional)



41



RFI/EMI Grounding for Powerflex 4 Controller (Optional)



42



RFI/EMI Grounding for Powerflex 4M Controller (Optional)



43



Ungrounded Distribution SystemsCAUTION: Allen-Bradley style NEMA type 1 (IP20) fan controllers contain protective MOVs that are referenced to ground. MOVs are protective devices that will fail open in the event of a voltage surge that may otherwise lead to catastrophic failure of the VFD. These devices should be disconnected if the controller is to be installed on an ungrounded distribution system. KBDA NEMA type 4X (IP65) controllers do not provide this option and should only be installed on solidly grounded distribution systems.

Disconnecting MOVsTo prevent controller damage, the MOVs connected to ground shall be disconnected if the controller is installed on an ungrounded distribution system where the Line-to-Ground voltages on any incoming phase could exceed 125% of the nominal Line-to-Line voltage. To disconnect these devices, remove the jumper as shown below.

1. Turn the screw counterclockwise to loosen.2. Pull the jumper completely out of the variable frequency drive chassis.3. Re-tighten the screw after jumper removal.

R/L1S/L2T/L3

1 2 3 4

Three-PhaseAC Input

Jumper

Powerflex 4 Powerflex 4M



44



Wiring: KBDA Controller (200-250V Single Phase)

WARNING: Wait 3 minutes after disconnecting before servicing!

WARNING: Improper installation can cause electric shock or damage to the motor and controller. A qualified electrician should perform the installation.

This diagram is for a KBDA controller, 200-250V using single phase input from AC power supply. See the electrical diagram provided with the controller for detailed voltage, current, and circuit breaker/ fuse requirements. This

information is also found in Power Requirements on p. 28. This fan controller does not contain fusing! Power must be supplied to this controller via a dedicated circuit breaker or properly

fused disconnect! Refer to Power Requirements (p. 28) and Branch Circuit Protection (p. 59).

8.85 (22.5 cm)

5.06 (12.9 cm)

Max Depth:5.86 (14.9 cm)

.275 (7 mm)

Enclosure



45



Wiring: KBDA (200-250V & 400-480V 3 Phase)



This diagram is for a KBDA controller, 200-250V & 400-480V using three phase input from AC power supply. See the electrical diagram provided with the controller for detailed voltage, current, and circuit breaker/ fuse requirements. This

information is also found in Power Requirements on p. 28. This fan controller does not contain fusing! Power must be supplied to this controller via a dedicated circuit breaker or properly

fused disconnect! Refer to Power Requirements (p. 28) and Branch Circuit Protection (p. 59).

8.85 (22.5 cm)

5.06 (12.9 cm)

Max Depth:5.86 (14.9 cm)

.275 (7 mm)

Enclosure



46



Wiring: Powerflex 4 Controller (100-125V Single Phase) (Optional)

Enclosure



This diagram is for an Allen-Bradley Powerflex 4 Controller, 100-125V using single phase input from AC power supply. See the electrical diagram provided with the controller for detailed voltage, current, and circuit breaker/ fuse requirements. This

information is also found in Power Requirements on p. 28. See p. 35 for proper grounding requirements.

460 VOLT

Three Phase


WWW.BIGASSFANS.COM 2010 DE

Documents

General Installation Guide 2-11-10 (Sales)_opt