gemini - Loren Cook Company

gemini - Loren Cook Company
GEMINI
Ceiling and Cabinet Fans
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
®
This publication contains the installation, operation and
maintenance instructions for standard units of the Gemini:
Ceiling and Cabinet Fans.
Carefully read this publication and any
supplemental documents prior to any
installation or maintenance procedure.
Rotating Parts & Electrical Shock Hazard:
Fans should be installed and serviced by qualified personnel only.
Loren Cook catalog, Gemini, provides additional information describing the equipment, fan performance, available accessories and specification data.
For additional safety information, refer to AMCA Publication 410-96, Safety Practices for Users and Installers of
Industrial and Commercial Fans.
All of the publications listed above can be obtained from:
• lorencook.com
• info@lorencook.com
• 417-869-6474 ext. 166
For information and instructions on special equipment,
contact Loren Cook Company at 417-869-6474.
Disconnect electric power before working on unit (prior to
removal of guards or entry into access doors).
Follow proper lockout/tagout procedures to ensure the unit
cannot be energized while being installed or serviced.
A disconnect switch should be placed near the fan, so
power can be swiftly turned off in case of an emergency.
This will also allow maintenance personnel to have complete control of the power source.
Grounding is required. All field-installed wiring must be
completed by qualified personnel. All field installed wiring
must comply with National Electric Code (NFPA 70) and all
applicable local codes.
Fans and blowers create pressure at the discharge and
vacuum at the inlet. This may cause objects to get pulled
into the unit and objects to be propelled rapidly from the
discharge. The discharge should always be directed in a
safe direction and inlets should not be left unguarded. Any
object pulled into the inlet will become a projectile capable
of causing serious injury or death.
When air is allowed to move through a non-powered fan,
the impeller can rotate. This is referred to as windmilling.
This unexpected rotation of components can cause a hazardous condition. Impellers should be blocked in position
or air passages blocked to prevent draft prior to working
on fans.
Gemini 100
Receiving and Inspection
Carefully inspect the fan and accessories for any
damage and shortage immediately upon receipt of fan.
• Turn the wheel by hand to ensure it turns freely and does
not bind.
• Inspect dampers (if included) for free operation of all
moving parts.
• Remove mounting brackets from packing insert & install
mounting brackets (Gemini 100 only).
• Remove shipping tape.
• Record on the Delivery Receipt any visible sign of
damage.
Friction and power loss inside rotating components can
cause them to be a potential burn hazard. All components
should be approached with caution and/or allowed to cool
before contacting them for maintenance.
Under certain lighting conditions, rotating components
may appear stationary. Components should be verified to
be stationary in a safe manner, before they come into contact with personnel, tools or clothing.
Failure to follow these instructions could result in death or
serious injury.
Handling
Lift fan by grasping the outside housing (cabinet) or by
the blower mounting brace. Never lift by the shaft or motor.
GEMINI IO&M
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B51111-002
Storage
If the fan is stored for any length of time prior to
installation, store it in its original shipping crate and protect
it from dust, debris and the weather.
Installation
Motor Installation
All Gemini units are shipped with motors mounted at the
factory.
Gemini 100 Inline to Ceiling Conversion
The Gemini 100 series can be converted from inline
to ceiling by ordering the Inline to Ceiling Conversion Kit
from Loren Cook Company (Part Number 797180). The kit
includes all parts required, plus detail instructions on how
to convert the Gemini 100.
Direction of Discharge (200–900 Series)
Discharge direction can be converted from right angle to
straight line, without a kit, by swapping outer panel and the
inlet/grille: See Figure 1.
1. Remove the side panel, mounting brackets (2) and
grille (if present).
2. Place the side panel where the inlet/grille had been.
Place the mounting brackets on the edge where the
side panel had been. Holes are pre-punched for this
procedure.
3. Rotate unit so that the outlet is on top.
Figure 1
Start
Outlet
Gemini 100 Ceiling to Inline Conversion
The Gemini 100 series can be field converted from
ceiling to inline by following these steps:
1. Remove and discard the inlet box end plate.
2. Install the inline cover panel with sheet metal screws
as shown on the following page. Ceiling to Inline
Conversion Kit can be ordered from Loren Cook
Company (Part Number 797181), or fabricate the
required part using the following two sketches.
Remove Parts
x2
Replace Parts
18 Ga. Galvanized Steel
14-1/16
Flat Pattern
12
11-15/16
Bend up at 90o
(Inches)
Inlet
1-7/16
Finished Views
Fan Installation
1. Use the mounting bracket slots to lower the unit
housing by a distance equal to the ceiling thickness.
Refer to Figure 2.
2. Raise the unit, as needed to accommodate accessories and options: With optional filter, raise unit 3/8”.
For both filter and deluxe aluminum grille options,
raise unit 7/8” to compensate for 1/2” grate protrusion of grille. If filter is not present: the grate on the
aluminum grille will fit inside of the unit (except sizes
160 & 180). Other grilles have no protrusion and fit
flush with the fan.
3. Fasten duct work to the outside of the duct collar
(damper frame) using sheet metal screws and foil
tape. Make sure sheet metal screws are placed
where they do not interfere with damper operation.
4. Fasten the housing to the bottom of the joists through
the holes provided in the mounting bracket.
Inline
Cover
Panel
GEMINI IO&M
Outlet
1-3/8
13-5/16
16-3/4
13-15/16
Inlet
For Ceiling Radiation Damper Installation
see separate document, “Gemini/CRD
Installation Supplement.”
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B51111-002
Typical Installation
Roof
Roof jack with damper
or roof cap
Exterior
Wall
Use foil tape
on the joints
to ensure a
good seal.
6” round duct. Insulated duct will help
absorb vibration. Use the shortest runs
possible & long radius elbows.
Joists
Wall cap
with damper
Power
cord
or
Short (1’) piece of flexible duct
will absorb vibration & noise.
Seal around the
unit with caulk.
Insulation around unit.
Also, cover the fan with insulation.
Ensure the power supply (voltage, frequency and current
carrying capacity of wires) is in accordance with the motor
nameplate. Refer to Wiring Diagrams.
Lock out all power sources before unit is wired to power
source.
Follow the wiring diagram in the disconnect
switch and the wiring diagram provided with the
motor. Correctly label the circuit on the main
power box and always identify a closed switch
to promote safety (i.e., red tape over a closed
switch).
Note: Insulate Unused Leads. Fan plug box is designed
for single speed operation, using an FSC to vary speed if
required. Do not wire to more than two leads.
Figure 2
Unit Housing
Joists
Mounting
Bracket
Ceiling
Grate Protrusion (aluminum grille only)
Filter (optional)
Grille
Wiring Diagrams
Notice! Do not install above or around
cooking equipment (shaded area)
Gemini 100 Series:
Cap off wire that is not in use.
45O
45O
Red Wire (Low Speed)
Black Wire (High Speed)
Green Wire
(Ground by COOK)
Cooking
Equipment
White Wire
(Common)
Floor
Ground Screw for
Field Grounding
Wiring Installation
All wiring should be in accordance with local ordinances
and the National Electrical Code, NFPA 70.
GEMINI IO&M
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For fan power supply connection use 4-wire cable
provided in field wiring box shown on above diagram.
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Gemini 1000:
Connect field ground wire to green ground screw located
inside fan electrical box. Connect one supply line to white
wire. Depending on fan speed requirements connect other
supply line to Red wire for Low Speed or Black wire for
High Speed. Insulate unused Red or Black wire. Replace
electrical box cover. Model 126, 146, 166, 186 are Low
Speed. Models 128, 148, 168, 188 are High Speed.
1 PH / 60 HZ / 115V
MARATHON 6.0 AMPS
Purple
White
Yellow
Orange
Brown
Gemini 200, 300, 500, 600 and 700 Series:
White
White
Red (Low)
Red
Blue
Line
Electrical Shock & Fire Hazard:
P4
•Insulate Unused Leads Separately
•Failure to follow these instructions could result in
death or serious injury.
T5
Insulate
P6
T6
Line
Black
Line
Insulate
P6
Series:
Yellow
Brown
Orange
White
T7
T6
Insulate
T9
T5
Insulate
T8
Line 1
Line 2
Insulate
Insulate
1 PH / 60 HZ / 208-230 V
MAGNETEK 4.1 AMPS
Purple
Insulate
Yellow
Blue
Orange
White
T2
T8
T3
T9
3 PH / 60 HZ / 460 V
MARATHON 1.0 AMP
MAGNETEK 1.0 AMP
T1
Insulate
T2
T4
Gemini 500, 700 and 900 with Vari-Flow EC Motor:
Insulate
Purple
3 PH / 60 HZ / 208-230 V
MARATHON 2.2-2.0 AMPS
MAGNETEK 2.2-2.0 AMPS
T1
Insulate
T7
T4
White
Insulate
Line 2
Orange
400
Line 2
1 PH / 60 HZ / 115V
MAGNETEK 8.0 AMPS
Black
Line 1
Line
Black (High)
Gemini
Line 1
1 PH / 60 HZ / 208-230 V
MARATHON 2.8-3.0 AMPS
T3
Line 2
Line 1
Line 1
Line 2
Line 3
Line 1
Line 2
P4
P5
Line 3
Insulate
Insulate
P6
Insulate
Gemini 2000:
1 PH / 60 HZ / 115V
MARATHON 10.8 AMPS
Purple
Brown
For external motor control see
External Control Supplement.
Blue
White
Black
P1
P2
Gemini 800 - 900 Series:
White
T3
T2
Line
T4
T5
Black (High)
Blue (Medium)
Red (Low)
Line
T4
P4
T5
Electrical Shock & Fire Hazard:
P6
T6
•Insulate Unused Leads Separately
•Failure to follow these instructions could result in
death or serious injury.
GEMINI IO&M
P6
4
Line 1
Insulate
Line 2
1 PH / 60 HZ / 115 V
LEESON 10.2 AMPS
Line 1
Insulate
Line 2
1 PH / 60 HZ / 208-230 V
MARATHON 6.0-5.4 AMPS
Orange
Insulate
Blue
White
Insulate
Black
Line 2
1 PH / 60 HZ / 208-230 V
LEESON 5.2 AMPS
P1
Line 1
Insulate
P2
T3
T2
T4
T5
3 PH / 60 HZ / 208-230 V
MARATHON 4.1-4.2 AMPS
LEESON 3.4 AMPS
T1
Insulate
T7
Insulate
Insulate
Line 1
Brown
T2
T8
T3
T9
Insulate
Line 2
Line 1
Line 2
Line 3
B51111-002
Inspection
Gemini 2000 (continued):
3 PH / 60 HZ / 460 V
MARATHON 2.1 AMPS
LEESON 1.7 AMPS
T1
Insulate
T2
T4
T7
T6
Insulate
T8
Line 1
Line 2
T3
Insulate
T9
T5
Inspection of the fan should be conducted at the first
30 minute interval of satisfactory operation. During the
inspection, stop the fan and inspect as per directions
below.
• Inspect bolts, setscrews and motor mounting bolts.
• Adjust and tighten as necessary.
P4
P5
Line 3
Insulate
Insulate
T6
Insulate
Grille Installation
Attach the grille by hand-tightening the grille screws.
When the unit is furnished with a filter, place the screws
through the hole in the grille. Install the filter through the
holes provided in the filter frame. See Figure 2.
FSC:
White
Maintenance
Fan
FSC
Time
light
Black
Delay
Switch:
Fan
h
itc
Blue
Sw
Red
White
Black
Final Installation Steps
1. Inspect fasteners and setscrews (particularly fan
mounting fasteners) and tighten as required.
2. Inspect for correct amperage and voltage with an
ammeter and voltmeter.
3. Ensure blower is secured to duct work.
4. Ensure all accessories are installed.
5. Inspect wheel-to-inlet clearance. Make sure wheel
does not rub against the inlet.
6. Test the fan to be sure the rotation is the same as
indicated by the arrow marked Rotation.
Grille installation is described after the operation and
inspection sections.
Operation
Establish a schedule for inspecting all parts of the fan.
The frequency of inspection depends on the operating
conditions and location of the fan.
Fans exhausting contaminated air (airborne abrasives)
should be inspected every three months.
Regular inspections are recommended for fans
exhausting non-contaminated air. It is recommended the
following inspections be conducted twice per year:
• Inspect bolts and setscrews for tightness. Tighten as
necessary.
• Inspect for cleanliness. Clean exterior surfaces only.
Removing dust and grease on motor housing assures
proper motor cooling.
Access
Gemini 100:
To inspect, clean or repair, refer to the following diagram
and follow these steps:
1. Remove grille.
2. Remove blower assembly from housing:
1. Disconnect the motor from electrical supply
2. Remove the mounting bolts on the inlet plate
assembly and remove the motor/wheel assembly
3. Remove the blower wheel with an allen wrench
Grille Mount Holes
Pre-Start Checks
Electrical Supply
Junction Box & Cover
1. Lock out all the primary and secondary power sources.
2. Inspect fasteners and setscrews (particularly those used
for mounting the fan) and tighten if necessary.
3. Inspect motor wiring.
4. Ensure fan and ductwork are clean and free of debris.
5. Test the fan to ensure the rotation of the wheel is the
same as indicated by the rotation label.
6. Restore power to unit.
Start Up
Before attaching the grille, turn the fan on and inspect
for the following:
• Direction of rotation.
• Excessive vibration.
• Unusual noise.
• Motor noise.
• Improper motor amperage or voltage.
If a problem is discovered, immediately shut off the fan.
Lock out all electrical power and check for the cause of the
trouble—refer to the Troubleshooting section.
GEMINI IO&M
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B51111-002
Gemini 200 - 700 series
To inspect, clean, or repair, refer to the follow diagram
and follow these steps:
1. Remove grille.
2. Remove blower assembly from housing:
a. Disconnect the motor from electrical supply.
b. Remove mounting bolts.
c. Slide discharge flange out of spring clip and
move motor/blower assembly from box.
3. Remove inlet ring from blower housing.
4. Remove blower wheel with an allen wrench.
Blower Mounting Brace
Mounting Bolts
Wheel
Motor
Simply reverse the disassembly instructions. Make sure
the wheel rotates in the same direction as the arrow on the
blower housing. Make sure the wheels do not rub on the
inlet rings. When replacing the motor, make sure the motor
and wheels are properly aligned with the blower housing.
Notice! Ensure that the blower discharge flange is
secured in slot of the cabinet on Gemini 200 - 700
series.
Motor Bearings
Motor bearings are pre-lubricated and sealed. Under
normal conditions they will not require further maintenance
for a period of ten years.
Motor Services
Unit
Mounting
Bracket
Adjustment
Bolts
Wiring
Box
Reassembly
Should the motor prove defective within a one-year
period, contact your local Loren Cook representative or your
nearest authorized electric motor service representative
Troubleshooting
Problem and Potential Cause
Low Capacity or Pressure:
Duct Collar
•Incorrect direction of rotation. Make sure the fan rotates
in same direction as the arrows on the motor or belt
drive assembly.
•Poor fan inlet conditions. There should be a straight
clear duct at the inlet.
•Improper wheel alignment.
•Damper held shut by tape.
•Screw attaching duct work to collar interfering with
damper operation.
Damper
Blade
Gemini 800 - 2000 series:
To inspect, clean, or repair, refer to the diagram below
and follow these steps:
1. Remove grille.
2. Remove blower assembly from housing:
a. Disconnect the motor from the electrical supply.
b. Remove motor plate bolts.
c. Slide motor plate and remove motor/blower
assembly from box.
3. Remove inlet rings from blower housing (both sides).
4. Mark the wheel and housing to ensure correct
replacement of blower wheels (one is clockwise and
the other is counter-clockwise), then remove the
blower wheels with an allen wrench.
Wheel
Excessive Vibration and Noise:
•Damaged or unbalanced wheel.
•Belts too loose; worn or oily belts.
•Speed too high.
•Incorrect direction of rotation. Make sure the fan rotates
in same direction as the arrows on the motor or belt
drive assembly.
•Bearings need lubrication or replacement.
•Fan surge.
Overheated Motor:
•Motor improperly wired.
•Incorrect direction of rotation. Make sure the fan rotates
in same direction as the arrows on the motor or belt
drive assembly.
•Cooling air diverted or blocked.
•Improper inlet clearance.
•Incorrect fan RPMs.
•Incorrect voltage.
Motor Plate
Blower Housing
Motor Plate Bolts
Motor
Inlet Ring
(Ensure proper clearance between wheel and inlet ring)
GEMINI IO&M
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B51111-002
Gemini 100 Parts List
Part No.
Gemini 200–900 Parts List
Part Description
1
Inlet Box End Plate (Ceiling only)
2
Housing/Scroll
3
Field Wiring Compartment
4
Motor
5
Tinnerman Clip (Grill) X2
6
Mounting Bracket
7
Backdraft Damper
8
Wheel
9
Motor Mount/Inlet
10
Inlet Box
11
Grille
1
3
Part
No.
Size 200–700
1
Backdraft Damper
Backdraft Dampers (2)
2
Damper Frame
Damper Frame (2)
3
Mounting Bracket (2)
Mounting Bracket (2)
4
Wheel
Wheel (2)
5
Grille (Ceiling and Wall) Grille (Ceiling and Wall)
6
Blower Housing
Blower Housing (2)
7
Motor
Motor
8
Insulation
Insulation
9
Cabinet housing
Cabinet housing
10
Housing Side Cover
Housing Side Cover
2
1
4
Size 800–900
4
2
Air Flow
Air Flow
11
3
5
6
10
6
10
7
8
9
9
11
5
7
8
GEMINI IO&M
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B51111-002
Gemini 1000–2000 Parts List
Part No.
Part Description
1
Grille (ceiling and wall)
2
Backdraft Damper (2)
3
Wheel (2)
4
Blower Housing (2)
5
Motor
6
Insulation
7
Mount Brackets (2)
8
Cabinet housing
9
Housing Side Cover
8
2
3
9
1
4
5
6
7
Limited Warranty
Loren Cook Company warrants that your Loren Cook fan was manufactured free of defects in materials and workmanship, to the extent stated herein.
For a period of one (1) year after date of shipment, we will replace any parts found to be defective without charge, except for shipping costs which will be
paid by you. This warranty is granted only to the original purchaser placing the fan in service. This warranty is void if the fan or any part thereof has been
altered or modified from its original design or has been abused, misused, damaged or is in worn condition or if the fan has been used other than for the
uses described in the company manual. This warranty does not cover defects resulting from normal wear and tear. To make a warranty claim, notify Loren
Cook Company, General Offices, 2015 East Dale Street, Springfield, Missouri 65803-4637, explaining in writing, in detail, your complaint and referring
to the specific model and serial numbers of your fan. Upon receipt by Loren Cook Company of your written complaint, you will be notified, within thirty
(30) days of our receipt of your complaint, in writing, as to the manner in which your claim will be handled. If you are entitled to warranty relief, a warranty
adjustment will be completed within sixty (60) business days of the receipt of your written complaint by Loren Cook Company. This warranty gives only
the original purchaser placing the fan in service specifically the right. You may have other legal rights which vary from state to state.
Corporate Offices: 2015 E. Dale St. Springfield, MO 65803
Phone 417-869-6474 | Fax 417-862-3820 | lorencook.com
GEMINI IO&M
8
March 2017
B51111-002
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