BIG ASS FANS Powerfoil D User Manual

Quick Installation Guide
Powerfoil
®
X3.0 and Powerfoil
®
D with Ion Technology
ION TECHNOLOGY HARDWARE
The hardware listed below is for installing the components in the Ion Technology kit. For the full fan hardware list, see
the Installation Checklist included with the main fan unit.
All Fans
Static Tube
1. MAIN FAN UNIT
New Fan Installation: Complete all necessary pre-installation and mounting structure preparation steps in the
instructions included with the main fan unit. Mount the fan by completing steps 1–5 in the fan Quick Installation Guide
included with the main fan unit. Do not complete the remaining steps. Return to these instructions to complete the
fan installation.
Fan is Already Installed: Remove the hub cover. If the Airfoil Restraint System is installed, detach the straps from the
hub. Remove the airfoils and winglets. For Powerfoil D, detach the lower safety cables from the extension tube.
x1
Static Tube
Retainer Clip
x9
1/4-20 x 3/4" Socket
Button Head Cap
Screws
x4
10-32 x 1/2" Pan
Head Screws
*Hardware kit 008766. Included only with fans that have the Airfoil Restraint System. The screws
are for attaching the Airfoil Restraint System straps to the fan hub. Spare screws are included.
READ AND SAVE THESE INSTRUCTIONS
TO REDUCE THE RISK OF FIRE, ELECTRIC SHOCK, OR INJURY TO PERSONS, OBSERVE THE FOLLOWING:
WARNING: Disconnect power to the installation locations before installing the fan, controller, and Ion
Technology components. The ion generators are always powered on when the fan is connected to power.
WARNING: Installation work and electrical wiring must be done by qualifi ed person(s) in accordance with all
applicable codes and standards, including fi re-rated construction. Incorrect assembly can cause electric shock
or damage the motor and the controller.
CAUTION: The Big Ass Fans product warranty will not cover equipment damage or failure that is caused by
improper installation or use.
Fans with Ion Technology are suitable for indoor use only.
x4
10-16 x 1/2" Flange Hex
Head Cap Screws
x3
1/4" Two-Tab Male
Quick Connects
x3
12–10 AWG Female Quick
Disconnect Terminals
x3
10-32 x 3/8" Pan Head
Screws with Lock Washer
x4
5/16-12 x 1/2" Flange
Hex Head Cap Screws
x1 Locking Grommet
x2
6-32 x 1/2" Flange Hex
Head Screws
x2
6-32 Serrated
Flange Hex Nuts
Powerfoil X3.0
Hub Connections Bracket
Airfoil Restraint System* VFD and Power Supply
Hub Cover
Powerfoil D
Hub Connections Bracket
VFD and Power Supply

BIG ASS FANS Powerfoil D Specifications

General

Motor	Direct Drive
Weight	Varies by size
Material	Aluminum airfoils
Diameter	8 to 24 feet
Speed	Variable speed

Summary

Read and Save These Instructions

Disconnect Power Before Installation

Ensure power is disconnected to prevent shock or injury during installation.

Qualified Personnel Required

Installation and wiring must be done by qualified personnel per applicable codes.

Warranty Considerations

Improper installation or use may void the product warranty.

Indoor Use Only

Fans with Ion Technology are suitable for indoor use only.

Main Fan Unit Installation

New Fan Installation Steps

Complete pre-installation and mounting preparation, then steps 1-5 of the Quick Installation Guide.

Already Installed Fan Steps

Remove hub cover, detach Airfoil Restraint System straps, remove airfoils and winglets.

Static Tube Installation (Powerfoil X3.0)

Fans Without Motor Frame Weld Nut

Use PFX-R static tube if motor frame lacks a weld nut. See kit instructions.

Fans With Existing Static Tube

Uninstall existing tube, bracket, and clamp. Replace with PFX-R static tube.

Factory-Installed Static Tube

Skip to step 3 if fan has a factory-installed, non-removable static tube.

Static Tube Installation (Powerfoil D)

Static Tube Attachment

Install the static tube with retainer clip, torque to 35 ft-lb (47.4 N·m).

Hub Coupler Installation

Attach Coupler to Static Tube

Attach the coupler to the static tube, ensuring proper alignment.

Tighten Coupler and Set Screw

Tighten coupler and set screw until snug, but do not over-tighten.

Powerfoil X3.0 Coupler Selection

Use shorter white coupler for factory-installed static tubes, taller black for others.

Hub Bracket and Cable (Powerfoil X3.0)

Attach Hub Connections Bracket

Attach the bracket using 5/16-12 x 1/2" Flange Hex Head Cap Screws.

Ensure Long Screw Placement

Verify the long screw on the bracket is inside the slot on the coupler.

Hub Bracket and Cable (Powerfoil D)

Attach Hub Connections Bracket

Attach the bracket using 10-16 x 1/2" Flange Hex Head Cap Screws.

Ensure Long Screw Placement

Verify the long screw on the bracket is inside the slot on the coupler.

Electrical Installation (Powerfoil X3.0)

Install Static Tube Cable and Power Supply

Remove VFD cover, route cables through grommet, and connect power supply wiring.

Connect Power Supply Wiring

Connect brown wire to F1, blue wire to F2/F3, green wire to PE/GND on VFD.

Electrical Installation (Powerfoil D)

Install Quick Connect Tabs

Remove VFD housing cover, loosen cord grip, and attach quick connect tabs to wires.

Install Terminals on Power Wires

Attach 12-10 AWG female quick disconnect terminals to power wires.

Reconnect Power Wires to Terminals

Connect Black/Brown to L1, Red/Black to L2/N, White/Gray to L3.

Electrical Installation (Powerfoil D) - Continued

Connect and Position Cable with Cord Grip

Connect cable with cord grip to static tube cable, routing harnesses between VFD and motor frame.

Install Cord Grip

Install cord grip and nut in back left hole or center hole on VFD housing.

Electrical Installation (Powerfoil D) - Continued

Install and Connect Power Supply

Connect brown wire to L1 and blue wire to L2/N on the power supply.

Install VFD Cover and Lower Safety Cables

Reinstall VFD cover and attach lower safety cables to the extension tube.

Airfoil Assembly

Insert Power Cables

Connect male wiring harness to airfoil with one bolt hole, female to two bolt holes.

Attach Winglets

Orient ion generator brushes upward during assembly to prevent damage.

Airfoil Installation

Position Power Cables

Route cables to exit at the curved, narrow edge of each airfoil and tape them.

Install Airfoils, Cables, and Straps

Connect power cables to hub bracket harness in front of airfoil edges.

Airfoil Installation (Continued)

Secure Airfoils

Attach retainers, tighten outer bolts first, then inner bolts.

Hub Cover Installation

Attach Hub Cover

Secure hub cover using 10-32 x 1/2" Pan Head Screws.

Controller Installation

Install Wall Controller

Install controller, ensuring wiring is routed from fan/VFD to the installation location.