BlowHard BH-20 User manual

BH-20 Operations Manual v2.2

BH-20 PPV Fan

OPERATIONS MANUAL

WARNING 2

SAFETY INSTRUCTIONS 2

WARRANTY STATEMENT 3

UNPACKING 3

CHARGING PROCEDURE 3

BATTERY MAINTENANCE 3

OPERATING PROCEDURE 6

PRODUCT SPECIFICATIONS 8

TROUBLESHOOTING 12

SERVICE and CONTACTS 13

BH-20 Operations Manual v2.2

WARNING

The following information is important to the proper and safe use of your BlowHard-BH20

Positive Pressure Ventilation (PPV) Fan. Be sure to READ and UNDERSTAND completely the

Operating Manual BEFORE operating the fan. FAILURE TO FOLLOW THESE

INSTRUCTIONS COULD CAUSE PROPERTY DAMAGE or PERSONAL INJURY.

SAFETY INSTRUCTIONS

It is the responsibility of the user to provide proper PPV/PPA Training and provide adequate

Personal Protective Equipment (PPE) i.e. gloves and eye protection for handling this and other

electrical equipment.

This electrical equipment utilizes 110/220V-AC which can cause serious electrical shock if not

properly operated or maintained.

Use Rated and Approved Outdoor Electrical Extension Cord only with this equipment. Do not

submerge this equipment under water. Avoid getting electrical connection wet. Do not come in

contact with wet electrical connections without proper personal protective equipment.

The operating fan is a high speed rotating mechanical device that can cause serious injury if

body parts come into contact with rotating surfaces or material thrown into moving parts.

Although safety grills are installed, they do not block all objects from coming in contact with the

rotating surfaces. Do not push body parts or foreign objects through the grill slots. Do not allow

any object, material, or fluid into the intake or outlet of the fan, or to come into contact with the

fan blade.

Pinch Hazards. The fan is made to fold in and out for storage and operation. Care must be

taken when setting up the equipment for operation, and for storing the unit. Pinch points are at

the hinged sections of the fan. Do not put body parts in the space between opposing parts that

are coming together upon closure or opening of the fan.

Toe Hazards. This equipment may be stowed in elevated compartments and shelves. Safety

handles and shoulder strap are provided for lifting and transporting the equipment. Safety Steel

Toed shoes and boots, gloves should be worn when handling equipment.

Please observe the above warnings which are symbolized and displayed on the yellow Warning

Label on the fan enclosure. Practice Common Sense.

BH-20 Operations Manual v2.2

WARRANTY STATEMENT

Please fill out the enclosed Warranty Registration with your information and return to The

BlowHard Company for our records. All Mechanical Parts are covered for 2 years from date of

purchase under normal operating conditions. All Electrical and Electronic Parts are covered for

1 year from date of purchase under normal operating conditions.

Any intentional misuse or abuse to the unit, accidental damages and anything outside “normal

wear and tear”to the unit will is not covered under this general warranty policy.

Keep your fan Blowing Hard!!

Regular battery maintenance is imperative. Our recommended maintenance is to completely

discharge the battery, and then fully recharge it every 2 weeks for a long and healthy life.

A neglected battery will die, and must be replaced.

UNPACKING PROCEDURES

Unpack and remove the fan from the cardboard boxes.

If possible, keep box and the package braces. If the fan needs to be returned for any reason,

these items will be greatly helpful, and assure there will be no damage in transit.

Visually check to ensure nothing is loose or broken during shipping. Lay the fan flat on the

ground. Lift the shroud part of the fan upright. Once the shroud is vertical, take note of the

location of the Power Knob and Battery Indicator LED on the top right of the enclosure and the

AC Plug on the left side.

CHARGING PROCEDURES

Keep the unit plugged into the truck or wall socket when not in use. This will ensure the

fan is always charged. Remember, there is no charge memory as in NiCad batteries, so

the battery will always be fully charged if kept plugged in.

STEP 1: Make sure the Power Knob is turned to the left and clicked OFF. NOTE: If the LED is

Steady GREEN, then the Fan is in ON Position regardless of whether or not the blades are

moving and must be completely switched off. It will not charge otherwise.

BH-20 Operations Manual v2.2

STEP 2: Plug in the AC Power cord to an approved 120V-AC extension cord. The LED will

start Blinking Slow GREEN during pre-charge, and then switch to either RED/GREEN

alternating (recovery mode), Fast GREEN during fast charge, or Slow GREEN during trickle

charge and maintenance. When the battery is fully charged, the LED will stop blinking and go

OFF.

Charge Time: Expected charge times are 0% - 80% fast charge (fast blink) completed in 1

hour. Slow charge (Slow blink) can take 1 ½ hours longer, 80% - 100%. Battery maintenance

can take a long time, depending upon if cell balancing needs to occur. The fan will continue to

slow blink during this process, but if it has been plugged in for 2 ½ hours, it is fully charged. It is

beneficial to leave the fan plugged in during the maintenance portion to achieve the most

optimal performance, although unplugging it at any point to use it will not damage the fan.

BH-20 Operations Manual v2.2

Battery Maintenance:

The following are good maintenance practice:

The battery has an integrated charging system. The integrated charging system will fully

manage the battery when the fan is plugged in and the power switch is off.

To charge your fan, simply plug it in and turn the power switch counterclockwise to the

off position. The power switch must be in the off position for charging to take place.

Quick Charge –A quick charge will charge your battery to about 80% of full capacity. A

fully discharged battery takes approximately 60 minutes to Quick Charge.

Full Charge –Full charge will trickle charge the battery to full capacity. If possible, leave

the fan plugged in to maintain a full charge at all times. Be sure to complete a Full

charge during maintenance.

Charge Battery after each and every use even for a short period. The early recharging

and constant charging does not damage the LiFePO4 battery. Unlike NiCad batteries,

this battery does not develop memory, and may be charged as often as necessary.

Always keep the battery in charged condition through constant charging or regular

maintenance. This will ensure the readiness operation of the fan and the full capacity of

each operation. It is a good practice to keep the fan plugged into either the truck or a

standard AC outlet.

Trickle charging may take several hours before the Battery Management System (BMS) turns

off, depending on the condition and characteristic of each individual battery cell. Trickle

charging can restart during extended constant charging because the BMS does consume a

small amount of power. The LED does not have to be OFF before using the fully charged

battery.

BH-20 Operations Manual v2.2

Battery Life:

If you have problems with your battery please contact BlowHard at 541-967-0063.

The typical estimated life of the LiFePO4 battery supplied with BH-20 fans ordered with

battery is up to 2,000 full discharge cycles.

When your battery reaches its life cycle the run time of the fan will begin to decrease and

the battery pack will need to be replaced.

Periodically check your run time. After Full Charge your fan should be capable of

running on battery for approximately 30 –38 minutes under full load. As battery begins

to reach the end of its life cycle, full charge runtime will drop to about 80% of the original

time.

Replace batteries with BlowHard battery pack only. Please contact factory with your fan

serial number for assistance.

BlowHards want to Blow Hard!

Seriously, every two weeks. Turn it on and let it blow until it stops, then plug it in and let it fully

charge. A happy BlowHard Blows Hard, a dead BlowHard sucks!

BH-20 Operations Manual v2.2

OPERATING PROCEDURES

STEP 1 - BATTERY OPERATION:

The LED should be OFF and the battery CHARGED. Turn the Power Knob to the right until it

clicks ON. Do not turn the knob past the 90 degrees position where the fan will start. The LED

should turn to Steady GREEN.

NOTE: If the LED turns Steady RED, then the battery is BAD and must be replaced. The fan

can still be used in AC Mode if no damage has been done to the BMS. If the BMS is BAD then

the fan will not work at all. See TROUBLESHOOTING and call for service.

Continue to turn the Power Knob to vertical position and the fan will start when passed the

dead-band. The dead-band is the position of the Power Knob designed to check the GREEN

LED power status without turning on the fan; it is inherent in the variable-speed control.

The following are conditions for Variable Speed settings:

The fan can be started at maximum speed for PPV Operation by directly turning the

Power Knob fully clockwise. The Electronic Speed Controller (ESC) will ramp-up the fan

to maximum speed without causing any power surge.

To set the fan at speed other than maximum, the fan can be started at maximum speed,

and then dialed down, or start at minimum speed and quickly dialed up. The ESC will

control and prevent any power surge.

The minimum speed is factory preset to provide light ventilation, is useful for rehab

situations, and will significantly extend the battery usage.

STEP 2 - AC OPERATION: Plug in the AC cord. Three conditions exist:

While the Power Knob is in OFF position: The BMS will automatically charge the battery

with available power from the AC power supply. The LED will show Slow Blinking

GREEN.

While charging as in the above condition: Turn the Power Knob to ON and start the Fan.

The BMS will shut down the charging and redirect the AC power to run the fan. The LED

will show Steady GREEN.

While the fan is running in Battery Mode as in STEP 1: The BMS will automatically

switch the power to AC and conserve battery power.

NOTE: If the power cord is disconnected while the fan is running on AC, the BMS will

automatically switch back to Battery Power and fan continues to run until the battery is

discharged and fan stops.

BH-20 Operations Manual v2.2

Operating Environment

The BH-20 has an ingress rating of IP-66 (No ingress of dust; complete protection against

contact. Water projected in powerful jets against the enclosure from any direction shall have no

harmful effects.) Ensure electrical extension cords are not operating in standing water.

The surface temperature will generally get 40ºF (4.5ºC) higher than the ambient temperature.

The BH-20 should operate “normally” in ambient temperatures ranging from -40º F (-40º C) to

110º F (43º C). The internal temperature will operate at 150º F (65ºC).

The following is a quick reference chart of Operating Modes, LED Status, and Performance

Specs

OPERATING MODES

BATTERY

While Fan is OFF

While AC Unplugged

Power Knob ON to Variable

While Fan is OFF

Plug in AC Outlet

Power Knob ON to Variable

AUTO SWITCH

While Fan is ON

Plug in or Unplug AC

Power Knob ON to Variable

CHARGING

While Fan is OFF

Plug in AC Outlet

Power Knob OFF

LED STATUS

No LED

Battery is charged, no maintenance

needed. (or Nothing Works)

Power Knob OFF

AC/BATT

Steady GREEN

AC or Battery Power is available

Power Knob ON

AC/BATT

Slow Blinking GREEN

Pre-charge, Final Charge, Battery

Maintenance.

Power Knob OFF

Fast Blinking GREEN

Fast Charge

Power Knob OFF

Blinking RED

Battery Low, Cell Low –Needs

Recharge

Power Knob

ON/OFF

BATT

Steady RED

No Battery, Bad Cell, Bad BMS

Power Knob OFF

AC/BATT

Blinking GREEN/RED

BMS attempting to recover weak

cells prior to Pre-charge

Power Knob

OFF

PERFORMANCE

PPV MODE

4000 RPM Max

Setting

11,000 CFM

30 Min. on Battery Unlimited on

VENTILATION

MODE

2000 RPM Low

Setting

6,000 CFM

180 Min. on Battery Unlimited on

BH-20 Operations Manual v2.2

PRODUCT SPECIFICATIONS

The BH-20 is a Portable Fully Integrated AC/DC Electric High Speed PPV/Ventilation/Industrial

Fan System.

LIFEPO4 BATTERY TECHNOLOGY

38.4V 10Ah LiFePO4 Battery, up to 2000 recharge cycles. High Capacity Battery 10C

Discharge. It is safe from over charging, over discharging, puncture, or high operating

temperature 150ºF (65º C). Iron phosphate is safer than other lithium chemistries like Cobalt

oxides, Nickel/Cobalt Oxides and Manganese Oxides. No memory effect like NiCad or NiMH

(metal hydride). Exceptionally low self-discharge rate.

AC POWER

The Dual-Power BH-20 also runs on standard 110 - 240VAC outlet powering the 1000W

48VDC-20A AC-DC Switching Power Supply with integrated safety features.

The fan consumes only 7A from 110VAC outlet. We have successfully operated three fans from

one 110VAC-15A circuit with no power surge or additional issues.

BATTERY MANAGEMENT SYSTEM (BMS)

The proprietary BMS automatically protects batteries from over charging and over discharging.

Onboard the BMS is an integrated charging circuit which eliminates the need for external battery

charger. This will automatically charge the battery when the fan is not in operation.

Another BMS feature is the Automatic Power Switch. This switches over to AC power operation

to conserve battery power when AC is available. Automatically switches over to battery

operation when AC power is interrupted. The BMS also does maintenance on the battery while

the fan is in the “off”position and plugged in.

FAST CHARGING INTEGRATED CIRCUIT

No external charger to buy

Recharges to 80% in just 60 Minutes

No memory effect from early recharging

BMS manages Trickle Charge with no negative impact

ELECTRONIC SPEED CONTROLLER (ESC)

The Integrated ESC maintains constant high speed of the Brushless DC (BLDC) motor to provide

consistent air flow and pressure. The Software is programmable and upgradeable motor control and

protection proprietary firmware.

NEODYMIUM MAGNET BLDC MOTOR

The fan motor is a highly compact and robust 2000W 2.7hp, as used in aerospace and unmanned

reconnaissance aerial vehicles (UAV).

BH-20 Operations Manual v2.2

ADVANCED PROPELLER DESIGN

Super lightweight, 20 inch two-bladed wood propeller designed for highest efficiency. This narrow

propeller is designed to match the very high rotation speed of the BLDC motor and provide exceptionally

higher pressure air flow than conventional fat and slow propellers.

HIGH CAPACITY

10,500 CFM, Tested per AMCA standards. Higher dynamic pressure outperforms 15,000 cfm rated

competition fan in independent tests.

VARIABLE SPEED CONTROL

Matching propeller design to motor design allows the fan to operate at high 4,000 RPM PPV Mode and

low 2000 RPM in Ventilation mode.

The variable control will allow the fan to operate at the optimum range between 2,000 rpm –4,000 rpm.

RUN TIME PERFORMANCE

30 - 38 Minutes Battery Run Time on PPV (high) Speed.

180 Minutes Battery Run Time on Ventilation (low) Speed.

Unlimited Run time at any speed when operating on 110-240VAC-48VDC Switching Power

Supply 1000W.

LIGHT WEIGHT AND COMPACT IN SIZE

Total system weight including Integrated Battery and Charging Circuit, 59lbs.

MULTI-PURPOSE FAN

Fire and Rescue PPV Fan

Smoke and Hazardous Chemical Ventilation

Confined Space Air Source

Firefighter heat stress rehabilitation

Athletics Ventilation

Commercial and Industrial process and product cooling

Space Cooling and Air Circulation for Factories and Farms

Cinematic Special Effects

Fan Banks and Fan Matrix can be used for dust control

Commercial Aircraft Brake Cooling

ATTACHMENTS

The center of the fan grill is a metallic hub to which attachments may be connected including the

popular multipurpose Misting Ring. See your distributor for details.

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