Greenheck KSQ - User Manual

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Rooftop Supply Mixed Flow Fans 1

Document 486132

Model KSQ Direct Drive

Rooftop Supply Mixed Flow Fans

Installation, Operation and Maintenance Manual

Please read and save these instructions for future reference. Read carefully before attempting to assemble, install,

operate or maintain the product described. Protect yourself and others by observing all safety information. Failure

to comply with these instructions will result in voiding of the product warranty and may result in personal injury

and/or property damage.

General Safety Information

Only qualiﬁed personnel should install this fan.

Personnel should have a clear understanding of these

instructions and should be aware of general safety

precautions. Improper installation can result in electric

shock, possible injury due to coming in contact with

moving parts, as well as other potential hazards. If more

information is needed, contact a licensed professional

engineer before moving forward.

1. Follow all local electrical and safety codes, as well as

the National Electrical Code (NEC) and the National

Fire Protection Agency (NFPA), where applicable.

Follow the Canadian Electric Code (CEC) in Canada.

2. The rotation of the wheel is critical. It must be free

to rotate without striking or rubbing any stationary

objects.

3. Motor must be securely and adequately grounded.

4. Do not spin fan wheel faster than max cataloged fan

RPM. This could cause catastrophic wheel failure.

Adjustments to fan speed signiﬁcantly affects motor

load. If the fan RPM is changed, the motor current

should be checked to make sure it is not exceeding

the motor nameplate amps.

5. Do not allow the power cable to kink or come in

contact with oil, grease, hot surfaces or chemicals.

Replace cord immediately if damaged.

6. Verify that the power source is compatible with the

equipment.

7. Never open access doors to a duct or fan while the

fan is running.

8. Never remove covers protecting electrical

components while fan is energized.

Rooftop Supply Mixed Flow Fans

Fans are direct-driven with mixed ﬂow wheels and feature rigid

construction, high efﬁciency, and low sound levels. These fans

are designed for ﬁltered roof supply applications such as providing

non-tempered make-up air. The fans are available in twelve sizes

and feature permanent, washable aluminum ﬁlters.

Units that ship fully assembled: Horizontal intake sizes 7 through 24,

bottom intake sizes 7 through 22

Units that ship with hood knockdown for ﬁeld assembly: Horizontal intake

sizes 27 through 33, bottom intake sizes 24 through 33

DANGER

Always disconnect, lock, and tag power source before

installing or servicing. Failure to disconnect power

source can result in fire, shock, or serious injury.

CAUTION

When servicing the fan, motor may be hot enough

to cause pain or injury. Allow motor to cool before

servicing.

DANGER

Pour écarter les risques d’incendie, de choc électrique

ou de blessure grave, veiller à toujours débrancher,

verrouiller et étiqueter la source de courant avant

l’installation ou l’entretien.

ATTENTION

Lors de toute intervention sur la soufflante, le moteur

peut être suffisamment chaud pour provoquer une

douleur voire une blessure. Laisser le moteur refroidir

avant toute maintenance.

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This document describes the installation, operation, and maintenance of Rooftop Supply Mixed Flow Fans.

Function Description

The Rooftop Supply Mixed Flow Fans are designed for rooftop installation to supply air. They are available in various sizes and configurations, including horizontal and bottom intake/discharge. The fans are designed to provide efficient air performance and are suitable for commercial and industrial applications.

Important Technical Specifications

The fans come in various sizes, from 7 to 33, with corresponding dimensions and weights.

Fan Sizes and Dimensions (Horizontal Intake):
- Size 7: 32-1/2 A, 17 B, 16-3/8 C, 11-3/8 D, 15-1/4 E; Max. Fan Weight: 85 lbs
- Size 9: 36-1/2 A, 19 B, 20-7/8 C, 16 D, 19 E; Max. Fan Weight: 106 lbs
- Size 12: 43-1/2 A, 22-1/2 B, 23-1/4 C, 18-1/4 D, 22-1/8 E; Max. Fan Weight: 144 lbs
- Size 15: 54-3/4 A, 29-1/4 B, 27 C, 22 D, 25-7/8 E; Max. Fan Weight: 212 lbs
- Size 16: 57 A, 30-3/8 B, 29 C, 24 D, 28 E; Max. Fan Weight: 236 lbs
- Size 18: 59-1/4 A, 31-1/2 B, 31-5/8 C, 26-5/8 D, 30-1/2 E; Max. Fan Weight: 285 lbs
- Size 20: 64-3/4 A, 34-1/2 B, 64-1/4 C, 29-1/4 D, 33 E; Max. Fan Weight: 394 lbs
- Size 22: 71-1/4 A, 38-1/8 B, 37 C, 32 D, 36 E; Max. Fan Weight: 447 lbs
- Size 24: 78-1/2 A, 42 B, 40-1/2 C, 35-1/2 D, 39-3/8 E; Max. Fan Weight: 498 lbs
- Size 27: 86 A, 46 B, 44 C, 39 D, 42-7/8 E; Max. Fan Weight: 712 lbs
- Size 30: 94-1/2 A, 50-1/2 B, 48 C, 43 D, 46-7/8 E; Max. Fan Weight: 799 lbs
- Size 33: 103-3/4 A, 55-3/8 B, 52-1/4 C, 47-1/4 D, 41-1/4 E; Max. Fan Weight: 922 lbs
Fan Sizes and Dimensions (Bottom Intake):
- Size 7: 36 A, 20-3/8 B, 16-3/8 C, 15-1/4 E; Max. Fan Weight: 85 lbs
- Size 9: 41-3/4 A, 24-1/4 B, 20-7/8 C, 19 E; Max. Fan Weight: 106 lbs
- Size 12: 50 A, 29 B, 23-1/4 C, 22-1/8 E; Max. Fan Weight: 144 lbs
- Size 15: 62-1/8 A, 36-1/2 B, 27 C, 25-7/8 E; Max. Fan Weight: 212 lbs
- Size 16: 65-1/4 A, 38-3/4 B, 29 C, 28 E; Max. Fan Weight: 236 lbs
- Size 18: 69 A, 41-1/4 B, 31-5/8 C, 30-1/2 E; Max. Fan Weight: 285 lbs
- Size 20: 75-1/2 A, 45-1/4 B, 34-1/4 C, 33 E; Max. Fan Weight: 394 lbs
- Size 22: 82-3/4 A, 49-5/8 B, 37 C, 36 E; Max. Fan Weight: 447 lbs
- Size 24: 91-1/2 A, 54-7/8 B, 40-1/2 C, 39-3/8 E; Max. Fan Weight: 498 lbs
- Size 27: 100-1/8 A, 60-1/8 B, 44 C, 42-7/8 E; Max. Fan Weight: 712 lbs
- Size 30: 100-1/4 A, 66-1/4 B, 48 C, 46-7/8 E; Max. Fan Weight: 799 lbs
- Size 33: 121-3/8 A, 72-7/8 B, 52-1/4 C, 41-1/4 E; Max. Fan Weight: 922 lbs
Mounting Dimensions (Horizontal Discharge):
- F Sq. (Fan Size 7-33): Ranges from 11-3/8 to 47-1/4 inches.
- G (Hole Spacing): Ranges from 6-1/2 to 11-1/4 inches.
- H (Holes per side): Ranges from 3 to 6.
Mounting Dimensions (Bottom Discharge):
- J: Ranges from 9-1/2 to 40-1/2 inches.
- K: Ranges from 6-3/4 to 40-1/2 inches.
Curb Cap Dimensions:
- L (Length): Ranges from 14-1/4 to 47 inches.
- M (Width): Ranges from 11-1/2 to 47-1/2 inches.
Recommended Duct/Damper Size (Horizontal Discharge):
- Ranges from 9-1/2 x 6-3/4 (Size 7) to 40-1/2 x 40-1/2 (Size 33).
Recommended Roof Opening (Horizontal Discharge):
- Ranges from 13-1/4 x 10-1/2 (Size 7) to 46 x 46 (Size 33).
Filter Sizes:
- Size 7: 18-1/4 x 10-1/2 (Qty 1)
- Size 9: 22 x 14-1/4 (Qty 1)
- Size 12: 26-3/4 x 17-1/2 (Qty 1)
- Size 15: 34-1/2 x 21-1/4 (Qty 1)
- Size 16: 36-1/2 x 23-1/4 (Qty 1)
- Size 18: 39-1/4 x 25-3/4 (Qty 1)
- Size 20: 28-1/2 x 21-1/2 (Qty 2)
- Size 22: 31-1/4 x 23-3/4 (Qty 2)
- Size 24: 34-3/4 x 26-1/2 (Qty 2)
- Size 27: 38-1/4 x 29 (Qty 2)
- Size 30: 40 x 21-1/4 (Qty 3)
- Size 33: 40 x 23-1/2 (Qty 3)
Fastener Torque Recommendations:
- Self-Drilling Sheet Metal Screw (#12): 25-30 in-lb (2-2.5 ft-lb) for Outdoor Panels.
- Hex Bolt/Thumb Screw (1/4 in.): 96-108 in-lb (8-9 ft-lb) for Ductwork and Accessory Mounting.
- Cap Screw (1/4 in. x 20): 120 in-lb (10 ft-lb) for QT Bushing (Size 7-24).
- Cap Screw (1/4 in. x 20): 108 in-lb (9 ft-lb) for SD Bushing (Size 27-33).
- Semi-Gimlet Bolt (5/16 in.): 132-144 in-lb (11-12 ft-lb) for Fan Construction.
- Serrated Flange Bolt/Nut (3/8 in.): 252-288 in-lb (21-24 ft-lb) for Motor Mount.
- Serrated Flange Bolt/Nut (1/2 in.): 564-636 in-lb (47-53 ft-lb) for Motor Mount.

Usage Features

Receiving and Unpacking: Upon delivery, all items should be checked against the packing list, and any shipping damage or shortages should be reported immediately to the local representative. Physical damage after acceptance is not the manufacturer's responsibility. All required parts and quantities must be verified upon unpacking.
Handling: Fans should be lifted carefully by the isolator holes on top of the unit or by the skid using a forklift. A minimum of four lifting straps should be used. Care should be taken to avoid scratching or chipping the coating.
Storage: If not installed immediately, fans should be stored indoors, above grade, in a low humidity environment (30° to 110°F or -1° to 43°C) to prevent deterioration. Units should be stored at least 3-1/2 inches (89 mm) off the floor on wooden blocks covered with moisture-proof paper. Aisles should be provided for air circulation and inspection.
Pre-Start-Up Checks:
- All fasteners, especially cap screws in the wheel bushing, must be checked for tightness.
- The fan wheel must rotate freely without rubbing and be aligned as shown in Figure 1. Adjust the radial gap between the wheel cone and inlet cone for even distribution. Adjust wheel position by loosening the wheel hub from the motor shaft.
Operation:
- Before connecting power, ensure the fan wheel does not strike the inlet cone or any obstacles.
- Start and immediately shut off the fan to check wheel rotation. Counterclockwise rotation (viewed from the fan inlet) is critical for proper air performance and to prevent motor overloading. If rotation is incorrect, switch two wiring leads for 3-phase power or check motor wiring for single-phase power. Verify RPM with a tachometer.
- Observe operation for unusual noises.
- Measure current input to the motor with the system in full operation and all ductwork attached, comparing it to the nameplate rating to ensure safe load conditions.
- Keep inlets and approaches clean and free from obstruction.
Installation Steps:
- Roof Opening (bottom discharge units only): Cut an appropriately sized hole in the roof surface.
- Install Roof Curb: Position and install the curb on the roof, ensuring a watertight seal.
- Install Ductwork (bottom discharge units only): Follow SMACNA and AMCA guidelines. Ductwork should extend above the roofline and have approximately three duct diameters of straight duct for cataloged performance. A duct adapter is recommended for alignment.
- Apply Sealant: Apply sealant around the perimeter of the supply duct before installing the unit to isolate the fan and minimize vibration.
- Install Unit: Use a crane with spreader bars to lift and center the unit on the curb. Fasten the unit to the curb using self-tapping sheet metal screws. Use all four lifting holes when using a sling.
- Assemble Filter Tracks: For horizontal intake sizes 7-24 and bottom intake sizes 7-22, the hood ships installed. Otherwise, retrieve the ship-loose intake hood/cover package. Align holes on filter tracks and install spring nuts.
- Fasten Filter Tracks to Side Panels: Install a 1/4 inch thumb screw and bolt in the slot and hole to tighten into spring nuts. Position filter tracks on the opposite side of the side panel flanges.
- Install Side Panels: Apply sealant to the mating surface of the inlet panel. Install both side panels to the inlet of the fan with filter tracks facing each other using 5/16 inch fasteners (do not fully tighten initially).
- Install Top Panel: For horizontal intake, place the top panel on top of both side panels and against the inlet panel. Attach with 5/16 inch fasteners to the inlet of the fan and sheet metal screws to the side panels. Fully tighten all fasteners. Apply sealant to corners. For bottom intake, install the first panel with a single return flange using self-tapping sheet metal screws, then the second top panel by hinging it around the first panel. Mount the second panel with self-tapping sheet metal screws.
- Install End Caps: Align half-moon cutouts on the end cap with screws on the inlet and outlet. Fasten with self-tapping sheet metal screws (DO NOT OVER-TIGHTEN).
- Install Side Mullions (Sizes 27-33 only): Install left and right side mullions using two self-tapping sheet metal screws per side.
- Mount Disconnect Switch (if applicable): Determine ideal location and install per manufacturer's suggestions.
- Install Conduit: Connect flexible metal conduit (FMC) to the power junction box. Route the conduit to the hole in the end cap. Insert the liquid-tight connector into the hole and screw into the female connector. Cut and install liquid-tight conduit from the elbow to the disconnect switch or power supply.
- Route Wiring to Junction Box: Route wiring from the junction box to the disconnect through all conduit. Plug unused end cap holes.
- Install Top Panel(s) of Cover: For size 24, install the top panel of the outdoor cover to the fan using self-tapping sheet metal screws. For sizes 27-33, install the first top panel with a single return flange, then the second top panel by hinging it around the first panel. Mount the second panel with self-tapping sheet metal screws.
- Install Filter(s): Loosen thumb screws on the intake hood and drop filter tracks. Aluminum washable filters are standard; MERV13 pleated filters are optional. Return filter tracks to operating position and tighten thumb screws.

Maintenance Features

Inspection and Maintenance During Storage: Inspect fans monthly. Rotate the wheel by hand 10-15 revolutions to distribute lubricant. Address any paint deterioration or rust promptly.
Filters: One-inch washable aluminum mesh filters are standard. Optional two-inch MERV 13 filters may be supplied. Filters should be cleaned/replaced regularly for optimum efficiency. To remove, loosen thumb screws on the intake hood, drop the filter tray, and slide filters out. Aluminum filters can be washed in a mild detergent solution. Adhesive spray can be applied to increase efficiency. Follow manufacturer guidelines for pleated filters.
Motor: Motor maintenance involves cleaning and lubrication. Remove dust buildup on motor housing to ensure proper cooling. Greasing is only needed if fittings are provided. Motors should not be lubricated after installation. Grease should not exceed 104°F (40°C); replace grease after 2,000 hours of running time.
Wheel: Clean the wheel regularly to prevent dirt accumulation, which can cause imbalance.
Tapered Bushing Hub:
- Removal: Loosen the setscrew holding the bushing and shaft key. Loosen socket head cap screws. Take out socket head cap screws and remove them from the visibly threaded holes. Once socket head cap screws are installed, tighten them an eighth of a turn at a time until the bushing comes loose.
- Installation: Clean all surfaces of the hub and bushing. Slide the bushing and shaft key onto the fan shaft. Hold the shaft key and bushing in place (DO NOT overtighten). Install socket head cap screws into the aligned holes by hand. Adjust the axial location of the wheel in the inlet cone. Tighten the socket head cap screws an eighth turn at a time in an alternating fashion to 10 ft-lbs for QT bushings and 9 ft-lbs for SD bushings.
General Maintenance: All fasteners should be checked for tightness during maintenance checks. A proper maintenance program ensures years of dependable service.
Troubleshooting: The manual provides a detailed troubleshooting guide for common issues like inoperative ventilator, insufficient airflow, excessive noise or vibration, and motor overloads or overheating, along with corrective actions.
- Inoperative Ventilator: Blown fuse/breaker, incorrectly wired, defective motor. Corrective action: Replace/repair, shut power OFF and check wiring, replace/repair.
- Insufficient Airflow: Clogged filters, incorrect wheel rotation, excessive dirt buildup, improper wheel alignment, slow fan RPM, closed damper, loose fitting duct sections, high system resistance, accumulation of material on wheel. Corrective action: Clean/replace, correct rotation, clean wheel, center wheel on inlet cone, adjust speed with Vari-Green® control/VFD, inspect/repair damper, check secure duct connections, check system/dampers/obstructions, clean wheel.
- Excessive Noise or Vibration: Loose wheel, improperly aligned/rubbing wheel, out of balance wheel, foreign objects in wheel/housing, not securely anchored ventilator base. Corrective action: Tighten set screws, center wheel on inlet cone, check wheel balance, remove objects, secure properly.
- Motor Overloads or Overheats: Incorrect wheel rotation, shorted motor winding, over/under line voltage. Corrective action: Check motor wiring, replace motor, contact power company.

Safety Information:

Always disconnect, lock, and tag the power source before servicing to prevent fire, shock, or serious injury.
The unit should be made non-functional when cleaning the wheel or housing (fuses removed, disconnect locked off).
Installation and maintenance must be performed by qualified personnel familiar with local codes and regulations.
For units with Variable Frequency Drive (VFD), refer to VFD documentation for installation, start-up, and troubleshooting. Ensure proper VFD cabling and filters if wire length exceeds 100 ft (30.5 m) to prevent premature motor failure.
AMCA Publication 410-96 provides additional safety information for users and installers of industrial and commercial fans.