BIG ASS FANS 8’-24’ Powerfoil X Installation Manual
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BIG ASS FANS 8’-24’ Powerfoil X Installation Manual

BIG ASS FANS 8’-24’ Powerfoil X Installation Manual

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INSTALLATION GUIDE
8'-24' Powerfoil® X

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Summary of Contents for BIG ASS FANS 8’-24’ Powerfoil X

  • Page 1 INSTALLATION GUIDE 8’-24’ Powerfoil® X...
  • Page 2 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)? Big Ass Fans recommends that a fan be installed at a distance (from HVAC equipment) no less than 2x the fan’s diameter when measured from the center of the fan to the equipment.
  • Page 3 8’ - 24’ POWERFOIL® X Installation Guide 8’-24’ Powerfoil® X Installation Guide: May be covered by one or more 2425 Merchant Street 170511- May 2011 of the following United States Patents: 6,244,821; Lexington, KY 40511 Rev. B 6,589,016; 6,817,835; 6,939,108; 7,252,478; 7,284,960; 1-877-BIG-FANS D607,988;...

  • Page 4: Important Safety Instructions

    FANS if you have any questions regarding the electrical installation of this fan. WARNING—To reduce the risk of fire, electric shock, and injury to persons, Big Ass Fans must be installed with Big Ass Fan supplied controllers. Other parts cannot be substituted.

  • Page 5: Table Of Contents

    8’ - 24’ POWERFOIL® X Contents Introduction Thank You About Big Ass Fans About this Fan What’s in the Box Pre-Installation Parts and Hardware Tools Needed Recommended Torque Fan Diagram Preparing the Work Site Understanding Airflow Patterns Mounting Method 1: 1.
  • Page 6 Cooling Season User Servicing Annual Preventive Maintenance Troubleshooting General Troubleshooting Optional Parts Optional Parts Order Form Warranty Big Ass Fans Warranty Policy Warranty Claim Form Instructions Acknowledgment & Return Instructions Warranty Claim Form Responsibility Agreement Annual Maintenance Annual Maintenance Checklist Checklist...

  • Page 7: Thank You

    Thank You Thank you and congratulations on your Big Ass Fans 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.

  • Page 8: About This Fan

    Add 5 lbs more for large upper yoke. **The distance of the fan from the ceiling should be measured from the top of the winglet to the ceiling. CAUTION—Big Ass Fans requires that the Powerfoil X fan be supplied from one of the following types of transformers:...
  • Page 9 Add 5 lbs more for large upper yoke. **The distance of the fan from the ceiling should be measured from the top of the winglet to the ceiling. CAUTION—Big Ass Fans requires that the Powerfoil X fan be supplied from one of the following types of transformers:...

  • Page 10: What's In The Box

    8’ - 24’ POWERFOIL® X What’s in the Box The 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 3 ft or shorter in length) with attached safety cable, winglets (Powerfoil® or Powerfoil®Plus), hub cover (with junction box and center cap), wall control (with wall control mounting plate), and hardware.

  • Page 11: Parts Included

    The Hub Cover Hardware is packed in the hub cover box. Guy wires are designed to constrain fan’s lateral movement and are only included in some fan packages. Big Ass Fans recommends using guy wires if the fan’s extension tube is 4 ft or longer, if the fan is exposed to high winds, or if the fan is close to any building fixtures.

  • Page 12: Tools Needed

    8’ - 24’ POWERFOIL® X Tools Needed Mechanical Installation Electrical Installation Standard Wrench Set Phillips and Flat Head Screwdriver Standard Socket Set with Ratchet 1/4” Nut Driver Torque Wrench capable of 40 ft·lb (54.2 N·m) 5/16” Nut Driver Phillips and Flat Head Screwdriver Pair of #10 to #14AWG Crimpers Standard and Metric Allen Wrench Set Pair of Medium Size Channel Locks...

  • Page 13: Fan Diagram

    8’ - 24’ POWERFOIL® X 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.

  • Page 14: Preparing The Work Site

    • Big Ass Fans can only be hung from an I-beam or angle irons. If mounting from an I-beam, the I-beam must be part of the existing building structure. For specific requirements, see installation instructions starting on p. 11. Do not mount the fan to a single purlin, truss, or bar joist.

  • Page 15: Understanding Airflow Patterns

    8’ - 24’ POWERFOIL® X Understanding Airflow Patterns View Airflow in an Open Area The airflow moves from the fan toward the floor. Side View 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.
  • Page 16 8’ - 24’ POWERFOIL® X Understanding Airflow Patterns (cont.) Powerfoil®Plus The PowerfoilPlus hybrid airfoil creates a jet of air that flows outward from the fan at a 45° angle, ignoring floor obstructions and delivering airflow in a much broader pattern. The airflow generated from a 24-ft PowerfoilPlus fan can effectively maintain an operative temperature in an area up to 168 ft away from the fan.

  • Page 17: Attach Upper Yoke (To I-Beam)

    8’ - 24’ POWERFOIL® X Mounting Method 1: I-Beam Big 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.

  • Page 18: Select Proper Angle Irons

    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.

  • Page 19: Pre-Drill Angle Irons

    8’ - 24’ POWERFOIL® X Mounting Method 2: Angle Irons (cont.) 2. Pre-drill Angle Irons Drill two Ø 9/16”(1.4 cm) holes exactly 5-3/8” (13.7 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 Ø...

  • Page 20: 4A. Fasten Single Angle Irons To Roof Structure Mounting Points

    8’ - 24’ POWERFOIL® X Mounting Method 2: Angle Irons (cont.) 4a. Fasten Single Angle Irons to Roof Structure Mounting Points If installation requires double angle irons (i.e., span is greater than 8 ft [2.4 m]), proceed to step 4b. CAUTION: Do not install the fan from a single purlin, truss, or bar joist.

  • Page 21: 4B. Fasten Double Angle Irons To Roof Structure Mounting Points

    8’ - 24’ POWERFOIL® X Mounting Method 2: Angle Irons (cont.) 4b. Fasten Double Angle Irons to Roof Structure Mounting Points CAUTION: Do not install the fan from a single purlin, truss, or bar joist. 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.

  • Page 22: Attach Upper Yoke (To Angle Irons)

    8’ - 24’ POWERFOIL® X Mounting Method 2: Angle Irons (cont.) 5. Attach Upper Yoke (to Angle Irons) 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.

  • Page 23: Attach Extension Tube (To Upper Yoke)

    8’ - 24’ POWERFOIL® X Hanging the Fan ATTENTION: If installing a VESDA system, refer to the VESDA Installation Guide BEFORE hanging the fan. 1. Attach Extension Tube (to Upper Yoke) Fasten the extension tube to the upper yoke with the Single Pivot Hardware as shown.

  • Page 24: Attach Lower Yoke (To Extension Tube)

    8’ - 24’ POWERFOIL® X 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. Tighten the bolts to 40 ft·lb (54.2 N·m) using a 3/4” socket with torque wrench.

  • Page 25: Attach Locking Carabiner To Motor Assembly

    8’ - 24’ POWERFOIL® X Installing Guy Wires Guy wires may not be included in your fan order. They are intended to constrain the fan’s lateral movement and are included with fans that have extension tubes 4 ft (1.2 m) or greater in length. ATTENTION: If installing a VESDA system, do not install airfoils until all VESDA piping is installed.

  • Page 26: Route Guy Wire Through Gripple

    8’ - 24’ POWERFOIL® X Installing Guy Wires (cont.) 3. Route Guy Wire Through Gripple ® Gripple Route the guy wire through the Gripple, the carabiner on the motor, 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.

  • Page 27: Attach Winglets To Airfoils

    8’ - 24’ POWERFOIL® X Installing Airfoils Fans recommends completing electrical installation (p. 24) before installing the airfoils. WARNING: Disconnect power to the fan before installing the airfoils. ATTENTION: If installing a VESDA system, do not attach airfoils until all VESDA piping is installed. 1.

  • Page 28: Attach Airfoils To Hub

    8’ - 24’ POWERFOIL® X 3. Attach Airfoils to Hub WARNING: Disconnect power to the fan before installing the airfoils. Attach the 10 airfoil retainers using the Airfoil Hardware. Moving clockwise around the fan hub, position the airfoil retainers end over end as shown.

  • Page 29: Attach Hub Cover (To Junction Box)

    8’ - 24’ POWERFOIL® X Installing Hub Cover If your fan order included accessories (e.g., light, camera, etc.), consult the instructions packaged with those accessories. WARNING: Disconnect power to the fan before installing the hub cover. 1. Attach Hub Cover (to Junction Box) Attach the hub cover to the junction box using the four (4) screws.

  • Page 30: Electrical Installation Safety

    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.

  • Page 31: Wiring Data Cable For Wall Control

    8’ - 24’ POWERFOIL® X Wiring Data Cable for Wall Control WARNING: Failure to install the adapter cable may result in damage to the fan or controller and void all warranty! ATTENTION: To avoid damage to the VFD and fan controller, test the VFD and fan controller with a test cable before wiring the CAT 5 cable! The controller cable to be installed between wall controller and the fan...

  • Page 32: Delta Secondary

    8’ - 24’ POWERFOIL® X Delta Secondary There are many different arrangements available for industrial and commercial power distribution in the United States. The three most common are: • 480/277V Three Phase (Wye secondary), which provides 480V between phases, and 277V from each phase to Neutral / Ground. •...

  • Page 33: Branch Circuit Protection

    8’ - 24’ POWERFOIL® X Branch Circuit Protection CAUTION: The fan controllers do not include fuses for branch short circuit protection. These fan controller models should be installed with a dedicated fusible disconnect and/or input circuit breaker (see p. 27). National and local industrial safety standards and/or electrical codes may determine additional requirements for these installations.

  • Page 34: Wiring: Fan Controller (200-250V & 400-480V Three Phase)

    8’ - 24’ POWERFOIL® X Wiring: Fan Controller (200-250V & 400-480V Three 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. •...
  • Page 35 8’ - 24’ POWERFOIL® X Wiring: Fan Controller with EMI Filter (200-250V & 400-480V Three 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. •...

  • Page 36: Wiring: Fan Controller (200-250V & 400-480V Three Phase)

    8’ - 24’ POWERFOIL® X Wiring: Fan Controller (200-250V & 400-480V Three 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. •...
  • Page 37 8’ - 24’ POWERFOIL® X Wiring: Fan Controller with EMI Filter (200-250V & 400-480V Three 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. •...

  • Page 38: Wiring: Fan Controller (200-250V Single Phase)

    8’ - 24’ POWERFOIL® X Wiring: Fan 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. •...

  • Page 39: Wall Control Operation

    8’ - 24’ POWERFOIL® X Wall Control Operation Understanding Wall Control Operation Wall Controller Upon initial power-up of the fan, the wall controller display appears as shown to the left. The wall control is preprogrammed to show the fan’s current running speed in RPM (or “U” for “user”) on the LED display.

  • Page 40: Toggling The Fan's Command Source

    8’ - 24’ POWERFOIL® X Toggling the Fan’s Command Source To select the command source of the fan, press the PU (Programmer/User) button. The fan controller is programmed at the factory to accept digital and analog inputs from customer automation systems for start/stop and speed commands, or to be directly controlled from the wall control unit.

  • Page 41: Understanding And Clearing Fan Faults

    ATTENTION: Under no circumstances should an operator attempt to change or alter the programming of the Powerfoil X fan’s controller without the assistance of an authorized Big Ass Fans installer, the Big Ass Fans Customer Service Department, or the Big Ass Fans Engineering Department.

  • Page 42: Daisy Chaining

    2 conductor shielded cable, will follow command references provided by the Master controller. See the following pages for detailed wiring diagrams. Limit 2 conductory shielded cable runs to 200 ft (61 m) or less. Consult Big Ass Fans Customer Service Department at 1-877-BIG-FANS for conversion to 4-20 mA current loop.
  • Page 43 8’ - 24’ POWERFOIL® X Daisy Chaining RS-485 1:Reserved 2:EV 3:GND 4:SG- 5:SG+ 6:Reserved 7:Reserved 8:Reserved Digital Input (MI1 Master Fan STOP REV EXT Digital Input (MI2 Controller Digital Input (MI3 MODE Digital Input (MI4 Digital Input (MI5 Digital Input (MI6 PROG DATA STOP...

  • Page 44: Basic Distributed I/O Interface; Local Control

    8’ - 24’ POWERFOIL® X Basic Distributed I/O Interface; LOCAL Control (RA to Digital Input #1 jumper removed) RS-485 1:Reserved 2:EV 3:GND 4:SG- 5:SG+ 6:Reserved 7:Reserved 8:Reserved FWD / STOP Digital Input (MI1 STOP REV EXT Digital Input (MI2 REV / STOP Digital Input (MI3 MODE Digital Input (MI4...

  • Page 45: Basic Distributed I/O Interface; External Control

    This mode of operation is commonly referred to as “External Control.” About I/O Mode Selection: Big Ass Fans factory defaults for analog and digital inputs are ACI (4-20 mA) and NPN (inputs pulled down to DC Common). If required, the installer may switch these to AVI (0-10 VDC as shown above) and PNP (inputs pulled up to 24 VDC) via the dip switches shown above.
  • Page 46 8’ - 24’ POWERFOIL® X Basic ESFR Interfacing Powerfoil® X Fire Signal Relay Wiring (as Shipped) A contact closure across digital input terminals MI3 and DCM will result in fan shutdown. The relay uses a Normally Open contact (N.O) as shown below. The relay coil must be energized by the FCP for fan shut down. Two additional relay coil leads are provided to facilitate supervision pass-through where required.

  • Page 47: Control Panel

    8’ - 24’ POWERFOIL® X Basic ESFR Interfacing (cont.) Powerfoil® X Fire Signal Relay Wiring (Optional) A contact closure across digital input terminals MI3 and DCM will result in fan shutdown. The relay uses a Normally Closed (N.C.) contact as shown. The relay coil must remain energized by the FCP for fan operation. Two additional relay coil leads are provided to facilitate supervision pass-through where required.

  • Page 48: Basic Timer And Thermostat Interfacing

    8’ - 24’ POWERFOIL® X Basic Timer and Thermostat Interfacing RS-485 1:Reserved 2:EV 3:GND 4:SG- 5:SG+ 6:Reserved 7:Reserved 8:Reserved Digital Input (MI1 STOP REV EXT Digital Input (MI2 Digital Input (MI3 MODE Digital Input (MI4 Digital Input (MI5 Digital Input (MI6 PROG T-Stat or Timer DATA...

  • Page 49: Fan Error Codes

    These three fault codes indicate that the motor has experienced load torque in excess of design limits. Check the fan blades for obstruction and abnormal buildup of debris or dust. Listen for abnormal gear noise while the fan is running. Contact Big Ass Fans Customer Service at 1-877-BIG-FANS for additional troubleshooting. External Fault This fault indicates that a customer-installed fault trigger has been activated on multi-function input terminal 3.

  • Page 50: Cooling Season

    Powerfoil® X should be operated continuously during the heating season and should not be operated in reverse (clockwise). Big Ass Fans are designed to operate efficiently at very low speeds, so turning the fan very slowly in the forward direction (counter-clockwise) will provide enough air movement to circulate the hot air at the ceiling down to the floor without causing drafts.

  • Page 51: Annual Preventive Maintenance

    8’ - 24’ POWERFOIL® X User Servicing Please take a few moments each year to perform the following preventive maintenance inspection to your fan to ensure its safe and efficient operation. If you have any questions, contact Customer Service at 1-877-BIG-FANS. If you require assistance, contact Field Service at 1-877-BIG-FANS to schedule a visit.

  • Page 52: Troubleshooting

    Tighten airfoil fasteners to specified torque. If popping still occurs, verify that the airfoils are not contacting each other. If the airfoils are contacting each other, contact Big Ass Fans Customer Service at 1-877-BIG-FANS. The Fan Is Not Starting •...
  • Page 53 8’ - 24’ POWERFOIL® X Notes WWW.BIGASSFANS.COM ©2011 DELTA T CORP. DBA BIG ASS FAN CO. ALL RIGHTS RESERVED...

  • Page 54: Optional Parts

    Optional Parts Order Form Fully complete this form, and then fax to Big Ass Fans at 859-967-1695. A Big Ass Fans representative will phone or e-mail you with the total cost of part(s) and shipping. Credit card information will also be obtained at that time.

  • Page 56: Big Ass Fans Warranty Policy

    8’ - 24’ POWERFOIL® X Warranty Big Ass Fans Warranty Policy This warranty is limited solely to products purchased directly from Big Ass Fan Company or from one of its authorized dealers or re- sellers. Under no circumstances will warranty coverage extend to products purchased through eBay, craigslist, or other internet auction or internet-based retail sites.
  • Page 57 8’ - 24’ POWERFOIL® X Big Ass Fans Warranty Policy (cont.) dismantling of the variable frequency drive, and/or removal of any electrical component from the fan controller unit. Misuse, abuse, accidents, unreasonable use, or Acts of God. Incorrect electric current, voltage or supply.

  • Page 58: Warranty Claim Form Instructions

    8’ - 24’ POWERFOIL® X Warranty Claim Form Instructions Complete Warranty Claim Form (see following pages) and Responsibility Agreement (see following pages) and fax them to 859- 967-1695, Attn: Customer Service. These pages will be faxed back to you for your records. The Warranty Claim Form will include our acknowledgment and a Return Materials Authorization (RMA) number.
  • Page 59 8’ - 24’ POWERFOIL® X Replacement of Products Under Warranty Acknowledgment & Return Instructions We have received your request for replacement of a part that failed during normal use and which you believe to be covered under warranty. We are shipping this replacement part to you pursuant to your notice that you will be replacing the original part within 10 days. This replacement part is being shipped to you prior to our receipt of the item that failed and prior to our evaluation of this part to determine the reasons for its failure and whether it is covered under warranty.

  • Page 60: Warranty Claim Form

    8’ - 24’ POWERFOIL® X 2425 Merchant Street Lexington, KY 40511 Phone: 1-877-BIG-FANS Fax: (859) 967-1695 Warranty Claim Form www.bigassfans.com Name (print): Signature: Company: Shipping Address: City/State/ZIP: Phone: Fax: Date of Items Returned: Purchase: Reason(s) for Returning Item (please provide detail, including length of time after fan had been in operation that problem was noticed, nature of problem, any attempts you made to remedy the problem, etc.): ATTENTION: Do not return any item without first being assigned an RMA# by Big Ass Fan Company Customer Service Department.

  • Page 61: Responsibility Agreement

    8’ - 24’ POWERFOIL® X 2425 Merchant Street Lexington, KY 40511 Phone: 1-877-BIG-FANS Responsibility Agreement Fax: (859) 967-1695 www.bigassfans.com To: Big Ass Fan Company The undersigned understands and acknowledges receipt of the Warranty Claim Form and Instructions and agrees that Big Ass Fans (“Big Ass Fan Company”) has the right, upon receipt of returned merchandise, to make final determination as to whether this merchandise should be replaced at no cost under Big Ass Fan Company’s stated warranty policy.

  • Page 62: Annual Maintenance Checklist

    8’ - 24’ POWERFOIL® X Annual Maintenance Checklist Fan Model: Fan Model: Fan Model: Serial #: Serial #: Serial #: Location: Location: Location: Date Initials Date Initials Date Initials WWW.BIGASSFANS.COM ©2011 DELTA T CORP. DBA BIG ASS FAN CO. ALL RIGHTS RESERVED...

  • Page 64: Check-In Procedure

    Check-In document, and Close-Out document. The installation crew will not receive payment until all forms are signed by the facility manager and the supervisor. These documents will then be forwarded to the Field Service Manager at Big Ass Fans. WWW.BIGASSFANS.COM ©2011 DELTA T CORP.

  • Page 66: Close-Out Procedure

    Check-In document, and Close-Out document. The installation crew will not receive payment until all forms are signed by the facility manager and the supervisor. These documents will then be forwarded to the Field Service Manager at Big Ass Fans.
  • Page 72 1001120101 170511 REV B 2425 Merchant Street Lexington, KY 40511 1-877-BIG-FANS...

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